HOW TO - make a 220V extension cord

[fredf]

Tony

If you only need 220v (2 hots + ground) you can use 3 wire SO cord, It would be a good idea to mark the white wire with paint, tape or shrink tubing, although it is often not done. As always Green is Ground the World around . . . NEVER use the green wire to carry current. if you need 110 /220 use 4 wire and use the white for a neutral. If you used the green and the wire failed, you would end up with 110 on the case of your tool(s)!!!!! It could ruin you whole day.

I don't have the particulars in front of me, but it is possible to used undersized conductors for welders and other equipment that doesn't operate continuously at full load (duty cycle) if you go with the continuous ratings, however you cant go wrong

[thenrie]

Yeah. I could have used 10-3, but I already had the hardware and it was all 4-wire. Since I wanted to split off a 110v outlet, I figured I'd go ahead with 4-wire, so I would have a common AND a ground. I figured a little extra safety on a extension cord wouldn't hurt.

I think your point about the white as common is important for folks to know, as long as they understand that on a 3-wire cable for 220v the white IS HOT, but on a 4-wire cable it is the common. The green is ground ALWAYS. Recoloring the HOT WHITE is always a good idea. Make it black or red.

Your last point is also a good one, and a cost saver. You can run a dedicated circuit for particular tools/appliances using smaller than normal cabling, but it has to be a dedicated circuit to pass code. I don't know what the particulars are either, right off-hand. My dedicated welder circuit is #6 THHN on a 60 Amp breaker right now, but I may move up to a 100 amp breaker to allow me to use the full potential of my Maxtron 300. My welder's manual indicates that is appropriate sized cable for my welder. Otherwise I'd be running 1/0 copper cable. Very expensive! I'll still have to check with the county to make sure my set up meets code, though.

Be safe. Do things right.

[yesindeed]

Originally Posted by MAC702

You have one of the fragile blue boxes on the end of a cord? No, if on the end of a cord, you'll need a steel box with a strain relief. The blue plastic boxes are for not for independent use and their only designed strain relief is stapling the cable to the same framing member that the box is attached to.

Or are we picturing different blue boxes?

I know this is not very responsive, but I just made a bracket mounted to my welding cart to coil the 30 foot of wire when not using it and attached the "2 gang receptacle "outlet box on the end of wire right to my welding cart (which started life as a red metal Sears rolling tool cart). one receptacle is 220v for my welders, and plasma cutter, and the other is 110v for my old stick welder or grinders, etc. that might be needed. For noobs I used the red, black and ground for the 220v recept. and the white black and ground for the 110v recept.The other end plugs into my 220v outlet that i mounted in my driveway last month.

[jimcolt]

I have one plasma on a CNC machine, and a Hobart Mig at my welding table. Neither operate at the same time....I fabricated a heavy steel box out of 1/8" steel.....put in two receptacles for single phase, 240 volt, 50 Amp use. The receptacles are recessed for protection.....the cord is a 4 wire, #10awg S/O type cable, 50' long that plugs into a receptacle at my main panel.

Jim

[specter]

Nice construction on that electrical box extension cord

[Hybrid Welder]

Hey guys.. I know, old thread!

I have a Hobart 220 Welder and it has the 6-50P.

My garage has a pre-existing 220V 50AMP circuit (even marked "Welder" in the fuse box).. however it is a 10-50R.

Can I do this with a 10-50P on one end... and a 6-50R on the other? Just hook up same color to same color? Thanks guys! Just wanted to check before I blow myself up.

[Sandy]

Originally Posted by Hybrid Welder

Hey guys.. I know, old thread!

I have a Hobart 220 Welder and it has the 6-50P.

My garage has a pre-existing 220V 50AMP circuit (even marked "Welder" in the fuse box).. however it is a 10-50R.

Can I do this with a 10-50P on one end... and a 6-50R on the other? Just hook up same color to same color? Thanks guys! Just wanted to check before I blow myself up.

HeyHybrid, folks my be shying away from this because of the "color-to-color" thing. That's always a bit scarry without knowing exactly what you've got or plan on using. There are the Black/White/Green vs Black/Red/White and other combinations that seem to get thrown into the mix that can be a real blind side blow.

Basically on the 6-50's you've got the two straight blades that are the two 120 volt hots and the round or inverted U that is the ground. On the 10-50 you've got the two angled blades generally labeled X & Y that are the two 120 volt hots and the the straight up n down blade labeled W that is the nuetral/ground. Match those up and you're good to go.

Really what you're doing is making an adapter instead modifying the garage receptacle or the welders' plug and yes is very doable. Play color blind and mate the hots to the hots and ground to the nuetral/ground and you've got it made. A volt/ohm meter would help you verify a steap at a time as you go.

Have fun.

[Hybrid Welder]

Thanks for your reply Sandy! Just finished wiring up my 50' cord.. plugged it in.. flipped on the Hobart and it fired right up! Now on to welding!

[farmersamm]

Sandy, did you say neutral/ground??????????????

I am vindicated

GROUND IT TO NEUTRAL

[GCJEEPING]

Hi, just a quick question on making a extension cord for my 220 welder to a 220 plug on a generator. The 8k Gen has a 4 prong twist lock receptacle and the welder has a standard 3 prong plug. I've read through this thread and just wanna make sure I get it right. I know what plug/receptacle and wire. Just want to make sure of wiring. I know the two hots, big/small blade on welder, will go to BL/R on gen. My question is should the Grnd from the welder go to Grng or W on the Gen?

Thanks
Dave

http://i120.photobucket.com/albums/o...eping/plug.jpg

[Broccoli1]

Hey dave,

http://i210.photobucket.com/albums/b...4-20to6-50.jpg


and the end result

http://i210.photobucket.com/albums/b...s/IMG_7753.jpg

[GCJEEPING]

Originally Posted by Broccoli1

Hey dave,

http://i210.photobucket.com/albums/b...4-20to6-50.jpg


and the end result

http://i210.photobucket.com/albums/b...s/IMG_7753.jpg

Thanks, but I need to know where the grnd wire from the welder end receptacle goes to at the gen end plug. Does it go to the grnd or the w(neut) pin at the gen plug. I read thru this thead and it kinda says either. Just want to know.

Thanks

[Broccoli1]

Originally Posted by GCJEEPING

Thanks, but I need to know where the grnd wire from the welder end receptacle goes to at the gen end plug. Does it go to the grnd or the w(neut) pin at the gen plug. I read thru this thead and it kinda says either. Just want to know.

Thanks

The first pic has the wiring .

Green= Ground to Ground.

As I wrote on the Pic the cord you buy will only have 3 wires and they will be Black, White and Green.

In This case you use the Black for Hot and the White for Hot
Green=Ground is Ground.

[GCJEEPING]

Originally Posted by Broccoli1

The first pic has the wiring .

Green= Ground to Ground.

As I wrote on the Pic the cord you buy will only have 3 wires and they will be Black, White and Green.

In This case you use the Black for Hot and the White for Hot
Green=Ground is Ground.

Thanks. Sorry bout that. Some reason I thought the first pic you posted was mine and didnt even open it. Its late here on the east coast.

Thanks

Dave

[jag8243]

just throwing this out there 10 for 30amp 8 for 40amp 6 for 50amp per code

[jag8243]

over 100 feet would be a concern for voltage drop then you would have to up size the wire

[ak4130]

found this on harbor freight

it just says 30amp but im assuming its 10 gauge

probably gonna pick it up

http://www.harborfreight.com/general...ord-66122.html

[fredf]

note that it is probably 110v connectors at 30 amp, and wont work without changing connectors. check HD for a 10 gage extension with reg (15a) ends, think it might be a bit cheaper, probably better quality wire too . . .