Length Of Power Cord To Welder

[tttmex]

I just bought a Lincoln AC225 for a house construction project in Mexico. I need to do some welding at about 50 meters from our power supply. The Lincoln manual says I need to use a #4 cable for this distance. Is this correct or would the machine work satisfactorily with a lighter cable??
50 meters of #4 cable ( times 2 cables) will cost twice as much as the machine itself!!!

Thank you,
Paul

[duaneb55]

Well Paul, I have to believe you realize Lincoln (or any manufacturer) lists the power supply cable size requirement for a reason - the ability to get full performance out of the machine. You could run a 10ga cord to it but about the only thing you'll power up is the fan at 50m.

Any chance you have or have access to a generator with a 230V, 50-60A outlet? Depending on how much welding you need to do, that may be an economical option.

BTW, welcome to the forum.

[bigb]

Any idea how many amps you will be welding with?

Where abouts in Mexico?

[tttmex]

Hello BigB

Thank you for your reply.

Just bought the AC225 a couple days ago and am not at all familiar with it yet.. I used to have and use quite frequently a Lincoln up in the real world many years ago. So not having used the AC225 yet, I don't know where I will have to set the amps. I would imagine from mid-range and up.

I am in Chapala. A town on Lake Chapala in Jalisco. About 30 miles south of Guadalajara.

Paul

[bigb]

Well if you could get some scrap of the size you intend to weld, along with a clamp on amp meter we might be able to determine your amp needs and therefore see if you can use a smaller extension cord for those particular settings. But like suggested earlier, a generator would be a viable option.

Ocassionally it is possible to obtain lenghths of #2 aluminum triplex (used) from the utility. I had several hundred feet hanging around for a year, I finally gave it away. When they change out overhead services they will give it to you if you ask, however probably not in Mexico. Besides, the average service in MX is only 30 amps.

I frequent the fishing villages along the Sea of Cortez.

[duaneb55]

Originally Posted by bigb

Ocassionally it is possible to obtain lenghths of #2 aluminum triplex (used) from the utility.

OK, now there's a thought. I would have to be in a real spot to do this myself but I know a guy that used aluminum service cable for weld lead extensions rather than on the power supply side of things. Cut the current welder leads a few feet from the front of the welder, install Tweco (or similar QDs) on the pigtails and remaining lenghts original leads, do the same to the aluminum service cable and strike away. Just trying to think outside the 'buzzbox'.

Any chance you can borrow/rent some 150', 2/0 leads? Or 100', 1/0 leads and get a 50' 8/3, NEMA 6-50 extension cord http://cgi.ebay.com/ws/eBayISAPI.dll...263602_263622?

[Broccoli1]

Regarding a genset for that Buzzbox:

You'll need at least a 12,500watt generator to power the Transformer welder.

The Buzz boxes don't work the same as a Mig Machine where you can get away with running the machine off of a lower powered Circuit/ genset and turning the welder amps down.


Your best bet is looking for an Engine drive welder.

[duaneb55]

I've still got an older 6.5 Kohler, 4 cylinder gas generator with 27A main breaker that I used to run an AC225 off of in my service van that would run fine at 90-125A. Of course it would trip the breaker in short order at 175A+ and occassionaly in between depending on how long I was running a bead.

But then there's probably twice the copper in that old Kohler as there is in any newer unit you can get today of 'equal' output.

Just the same, I agree 100% with Ed on needing a 12K genny for full output from the 225 but failed to point that out so it would boil down to what you'll be needing for maximum output as bigb indicated.

[justsam]

Originally Posted by tttmex

I just bought a Lincoln AC225 for a house construction project in Mexico. I need to do some welding at about 50 meters from our power supply. The Lincoln manual says I need to use a #4 cable for this distance. Is this correct or would the machine work satisfactorily with a lighter cable??
50 meters of #4 cable ( times 2 cables) will cost twice as much as the machine itself!!!

Thank you,
Paul

What are the limits of the "power supply" that you are 50 meters from? I do mission work in Zacatecas and my experience is that few "homes" have 220v. Most are only 110v unless the owner has demonstrated a need and applied for a 220v service. We use a welder/generator combination, which we can load and unload in a trailer. Not a cheap solution if you do not have need for both however.

Is there a way you can move the work closer to your source of power? Rent a generator perhaps?

[Norcal01]

Originally Posted by bigb

Well if you could get some scrap of the size you intend to weld, along with a clamp on amp meter we might be able to determine your amp needs and therefore see if you can use a smaller extension cord for those particular settings. But like suggested earlier, a generator would be a viable option.

Ocassionally it is possible to obtain lenghths of #2 aluminum triplex (used) from the utility. I had several hundred feet hanging around for a year, I finally gave it away. When they change out overhead services they will give it to you if you ask, however probably not in Mexico. Besides, the average service in MX is only 30 amps.

I frequent the fishing villages along the Sea of Cortez.

Triplex is not safe to use for a extension cord, not made to be dragged across the ground nor for the flexing common to extension cords, IMO that is being too clever for ones own good.

[bigb]

No I suppose you are right, but it could still be used strung up on poles to the work area. It is questionable in the first place if the OP even has an electrical service that would meet the demands of the machine.

[dougspair]

....yes, you're gonna need #4 wire for a 50 meter run..as that 150+ feet.....any transformer/stick type machine needs pretty sturdy input power......