Welder lead size?

[DangerousDan55]

I won on auction, a Lincoln AC/DC 225 amp welder(tombstone). It doesnt have any leads.
Question. What size/gauge leads is required for this welder?

 

[Jason280]

It really depends on how long you want the leads to be. I believe they came from the factory with #2 (may even be #4), and were typically around 10-15' in length (can't remember the exact specs). If you are staying under 20', you should be able to get away with #2.

 

[Zrexxer]

They really cheaped out on the leads they supplied with those models. As Jason said I think some of them were shipped with #4. I'd probably go with a #2 or #1. I found that even after shipping, buying bulk lead from www.weldingsupply.com was cheaper than getting it locally, sometimes by half.

 

[DangerousDan55]

Thanks, now looking for a good price on cable.
I already have a cart to put the welder on along side my MIG unit.
So, I can go with shorter cables.

 

[CWP1616L]

 

[Zrexxer]

p.s. the Lincolns originally come from the factory with the leads lugged inside the machine. A popular retrofit is to put about a foot of lead on the original terminals, then put a female Tweco or Lenco quick-connect on it. You can then put the male Tweco on the main part of the leads, and disconnect them and roll them up when you're not using them.

 

[DangerousDan55]

Really great info guys. I pick the welder up tomorrow. Got it without inspecting it. But the school that had it indicated that its good. They kept the long leads that were on it.
Got it for $ 150.
I'll try the supply site & craigslist for cables.
Again Thanks!

 

[zkling]

Be careful buying used leads. Check them over carefully for burn marks and the like.

I have ordered cable from this place before. Good quality cable at what was a reasonable price. Not sure how they compare these days though.

weldingsupply.com

They also carry the rod holder, ground clamps and quick disconnect connectors if you need them. Try to stick with a quality name brand cable. I have some Excelene cable that is real nice and flexible.

I would probably put #2 on that machine just to be safe. I had an OLD AC225 (same model as yours without the rectifiers for DC) that had #1 on it. Dang near a bullet proof machine.

 

[Steroblan]

I have the same welder. It has #5 leads on it with a Tweco stinger and quick disconnects.

 

[All]

I have the same welder. To give it reach around my yard, I changed the input cord as well. Higher voltage travels better and carries more power with less loss for longer distances.

The power lines on the poles are high voltage up top to carry power to the neighborhood, and stepped down with transformers on the second tier for delivering power to the houses.

Applying the same principle to the welder, I changed the input cord to 8/3 SOOW for 25 feet or 50 feet. Forget which, as I use a larger DC welder now. I changed the "low voltage" work leads also, to something along the lines of the chart posted, following a step higher. But the key for me in making that AC tomb stone reach the corners of my property was the high voltage (240V) INPUT cord.

I also made a 50 foot extension cord out of some 4/4 SOOW copper cable that came from dismantling a production facility. That very heavy and fat cable is what plugs into the wall first, then the 25 foot 8/3 from the welder. I have another 50 foot of 8/3 extension cord made up, but I haven't needed to use it yet.

The main point here is that for a tombstone, putting the length into the input cord, not the work leads, keeps the power integrity up, as well as makes it easer to adjust the output on the tombstone as it doesn't have a control input for a remote.

 

[sberry]

Yes you make a good point about cost, a number 10 cord is cheap compared to lead. I have a Maxstar and as handy as it is I also got a 25 ft lead, so useful when hopping around on construction/trailer type work with welds all over. shouold have bought it before a shelf job, saves moving machine.
I have hanging leads for my DC buzzer though, do not move the machine. Its really a convenience deal for working on machinery, moving a machine with short leads gets old in a hurry.
Mine is such an issue its got 2 ground leads, hooked to grounded benches and 2 stingers with stuff that reaches outside. The welder has a "home" and connected to a loom of sorts.

 

[sberry]

The most you will use is about 115A @30%. A 4 will work a 2 lets you work a little distance where the machine dont know its there. Heat, v drop isnt an issue at all. Can add 50 ft to the machine and leave it right on.

 

[sberry]

Actually is trimmed and fit in its home in the last pic. It could be disconnected and rolled out but it isnt. There is a stinger that reaches the booth and the benches and another set of connected leads serve the general shop floor or outdoor on apron.

I added pic, you can see when door is open you can grab a ground and stinger and reach out.

 

[sberry]

You can see what a catch all in pic 2 it was with leads hung on itself. I finally parked it in pic 4, also never in the sun, only a couple steps difference in use but so much more out of the way when not.

 

[All]

Since I just learned how to post pics here today, I thought I'd follow SBerry's "lead" (puns are always intended) and post a pic of my upgraded primary wire (input side) of my 40 year old AC tombstone.

View media item 30754