Welder Extension Cord

[ToolBoxTavern]

Buddy of mine had a 50 foot 8/3 gauge wire and gave it to me. I put a male plug on one end and two female plugs on the other. One for the welder and the other for the plasma cutter. Of course you cannot use both units at the same time.

Does anyone see a issue with this?

 

[KennyG]

Looks like a real good idea to me. Just be careful how you restrain the wire where it enters the receptacle boxes. They really aren't designed to have movement and you need to be sure you aren't getting any unseen abrasion or wear on the insulation. Personally, I would rather have non-metallic boxes because of the potential for getting a hot short to the box itself. If this is a three wire 220 circuit, the boxes may not be grounded to protect you.

 

[ToolBoxTavern]

Looks like a real good idea to me. Just be careful how you restrain the wire where it enters the receptacle boxes. They really aren't designed to have movement and you need to be sure you aren't getting any unseen abrasion or wear on the insulation. Personally, I would rather have non-metallic boxes because of the potential for getting a hot short to the box itself. If this is a three wire 220 circuit, the boxes may not be grounded to protect you.

So would it work if I ran a short jumper wire from the ground on the plug to a screw on the box?

 

[J_J]

What source are you plugging the #8 extension into? It would have to be a #8 also, with an 80 A breaker.


Here is a voltage calculator.

http://www.csgnetwork.com/voltagedropcalc.html

Your cable will carry the current, with a slight voltage drop.

On my Lincoln Pro-Cut -55, they state 60 amps input current at 208 v. at max cutting amps.

Output cutting amps at 25-60A

Breaker size 80 A, and #8

http://www.lincolnelectric.com/assets/servicenavigator/lincoln2/SVM140A.pdf

Page A2

 

[grsthegreat]

Personally Ive done the same thing in the past, but i have the female plugs on back to back steel boxes with the individual receptacles. Even though most welders are rated at 50 amps, if you ever put a tester to them in operation the 50 amp pulse only last for a second, then they drop to about 30 amps on average.

Another thing you can do to make it even easier is to have the same 50 amp male cord on both welder and plasma cutter. Just replace one of them. Then you only need 1 receptacle. Theres no law that says you cant increase the cord and plug size on th plasma cutter. YOU simply have to have the cord rated for the plug (in this case #6 wire and a 50 amp male plug).

 

[deereman75]

he could plug that thing into a 115v 15 amp circuit if he wanted to, you can always use a wire thicker then needed, but never thinner. I used to have my welder plugged into a 30 amp circuit, with a 25 foot 4/3 cord, thats way better than the 10/3 needed, much less voltage drop.

 

[ToolBoxTavern]

What source are you plugging the #8 extension into? It would have to be a #8 also, with an 80 A breaker.


Here is a voltage calculator.

Voltage Drop Calculator

Your cable will carry the current, with a slight voltage drop.

On my Lincoln Pro-Cut -55, they state 60 amps input current at 208 v. at max cutting amps.

Output cutting amps at 25-60A

Breaker size 80 A, and #8

http://www.lincolnelectric.com/assets/servicenavigator/lincoln2/SVM140A.pdf

Page A2

Thanx for the links.

I have a 100 amp sub panel with a dedicated 50 amp breaker that this will be plugged into. I also intend for the females ends to be mounted on the cart and the box, female ends and male ends of equipment to never move.

O and I am pretty sure I have to go look but to the sub panel and from the breaker to the plug I think is #6 wire....maybe #4, but for sure #6. I don't remember. Been a while since we put it in.

 

[ToolBoxTavern]

Personally Ive done the same thing in the past, but i have the female plugs on back to back steel boxes with the individual receptacles. Even though most welders are rated at 50 amps, if you ever put a tester to them in operation the 50 amp pulse only last for a second, then they drop to about 30 amps on average.

Another thing you can do to make it even easier is to have the same 50 amp male cord on both welder and plasma cutter. Just replace one of them. Then you only need 1 receptacle. Theres no law that says you cant increase the cord and plug size on th plasma cutter. YOU simply have to have the cord rated for the plug (in this case #6 wire and a 50 amp male plug).

My female plugs are back to back. I bolted boxes together. The welder and plasma come with the plugs that I need already. I set boxes to match the tools.

 

[ToolBoxTavern]

he could plug that thing into a 115v 15 amp circuit if he wanted to, you can always use a wire thicker then needed, but never thinner. I used to have my welder plugged into a 30 amp circuit, with a 25 foot 4/3 cord, thats way better than the 10/3 needed, much less voltage drop.

Thanx for the reply.

 

[J_J]

he could plug that thing into a 115v 15 amp circuit if he wanted to, you can always use a wire thicker then needed, but never thinner. I used to have my welder plugged into a 30 amp circuit, with a 25 foot 4/3 cord, thats way better than the 10/3 needed, much less voltage drop.

If your welder doesn't draw more than 30 A, he is OK, but I think he is talking about a larger welder and plasma cutter.

Did you see the Lincoln data sheet for the Pro-Cut -55?


ToolBoxTavern,

How many amps does your welder and plasma cutter draw at full potential?

 

[dstig1]

So would it work if I ran a short jumper wire from the ground on the plug to a screw on the box?

Yes, required by code to ground all metal bits, plus a very good idea.

JJ, #8 is used for ~50A circuits, not 80A. This is a standard welder extension cord. I can buy the exact cord with the 50A M&F plug ends on it from Hobart at the Fleet Farm store here. For home use, it is hard to get something that really needs more than 50A, and even harder to drive a welder hard enough to max that out. Home welders just don't run that hot and heavy. Not many interstate bridges built in home garages...

 

[JB4310]

Yup, I ran my buzz box for years on a 40 amp breaker, never popped it once.

I've got a legit 50 amp circuit now.
I've got a 6ga 4 wire 50 ft extension cord, that can be used for welder or 10kw generator feed. Pretty heavy though.

JB.

 

[deereman75]

If your welder doesn't draw more than 30 A, he is OK, but I think he is talking about a larger welder and plasma cutter.

Did you see the Lincoln data sheet for the Pro-Cut -55?


ToolBoxTavern,

How many amps does your welder and plasma cutter draw at full potential?

My welder draws 50 amps at max output, so I just dont turn it up all the way. My 4/3 cable would be fine for almost any single phase welder, you could run a lincoln idealarc 300 at max amperage, and it would still be within code. The cable bairly fit in the outlet I was using, the wires are almost as thick as a pencil, and the whole cable is about 1 inch in diameter. According to my outdated canadian electrical code book (1995), 4 gauge cable is good for up to 100 amps, and anything lower.

 

[ToolBoxTavern]

If your welder doesn't draw more than 30 A, he is OK, but I think he is talking about a larger welder and plasma cutter.

Did you see the Lincoln data sheet for the Pro-Cut -55?


ToolBoxTavern,

How many amps does your welder and plasma cutter draw at full potential?

The welder is an Hobart Iron Man 230 and the future plasma cutter will be Hobart Airforce 700i. Both require a 50 amp breaker. I am not sure how to answer your question because I have more than one answer, but I think this may shed some light on it.

 

[ToolBoxTavern]

Yes, required by code to ground all metal bits, plus a very good idea.

JJ, #8 is used for ~50A circuits, not 80A. This is a standard welder extension cord. I can buy the exact cord with the 50A M&F plug ends on it from Hobart at the Fleet Farm store here. For home use, it is hard to get something that really needs more than 50A, and even harder to drive a welder hard enough to max that out. Home welders just don't run that hot and heavy. Not many interstate bridges built in home garages...

Thanx. I'll add the ground to the box.

 

[ToolBoxTavern]

Yup, I ran my buzz box for years on a 40 amp breaker, never popped it once.

I've got a legit 50 amp circuit now.
I've got a 6ga 4 wire 50 ft extension cord, that can be used for welder or 10kw generator feed. Pretty heavy though.

JB.

Great info. Thanx.

 

[ToolBoxTavern]

My welder draws 50 amps at max output, so I just dont turn it up all the way. My 4/3 cable would be fine for almost any single phase welder, you could run a lincoln idealarc 300 at max amperage, and it would still be within code. The cable bairly fit in the outlet I was using, the wires are almost as thick as a pencil, and the whole cable is about 1 inch in diameter. According to my outdated canadian electrical code book (1995), 4 gauge cable is good for up to 100 amps, and anything lower.

Mine is 8/3 wire. I am assuming in my situation I should be fine. What is your opinion?

 

[grsthegreat]

Mine is 8/3 wire. I am assuming in my situation I should be fine. What is your opinion?

Number 8 is technically only rated for 40 amps, but it will probably work just fine. Like i said an average residential buzz box is realistically only running between 20-30 amps at full output. There rated at 50 amps for the initial current draw only. If you have a clamp on meter you can verify your units output to be sure.

Another way to check it would to simply do a welding job then go feel the wire. If its real hot..you best think about scrapping that idea. If its cool to the touch..your home free. Just make sure the outlet its plugged into IS 50 amp with #6 wire as you don't want the permanent wiring to be damaged by heat.

My welder has a 50 foot cord thats #6. But i got this wire real cheap from a temporary power supply off of a job

 

[ToolBoxTavern]

Number 8 is technically only rated for 40 amps, but it will probably work just fine. Like i said an average residential buzz box is realistically only running between 20-30 amps at full output. There rated at 50 amps for the initial current draw only. If you have a clamp on meter you can verify your units output to be sure.

Another way to check it would to simply do a welding job then go feel the wire. If its real hot..you best think about scrapping that idea. If its cool to the touch..your home free. Just make sure the outlet its plugged into IS 50 amp with #6 wire as you don't want the permanent wiring to be damaged by heat.

My welder has a 50 foot cord thats #6. But i got this wire real cheap from a temporary power supply off of a job

Thanx for the input.

 

[ToolBoxTavern]

My buddy I got the wire off of owns games on the carnival and the wires are always getting ran over, stepped on, etc. Heavily abused. This one was almost new that he gave me so I am confident in the durability of the wire so everyones helps trying to get this thing right is sure appreciative. I believe it will last a long time. Just trying to make sure.

Thanx again everyone and keep the comments coming please.