[Oscar]

2 gauge cable over total of 100ft @ 210A DC will suffer a ~30% voltage drop(!) at the electrode. No Good.

A 50ft extension on 10awg cable using 240V AC/30A input will lose ~3V at the end of the extension cord, for about 237V, so not too bad.

 

[Oscar]

I do have a inverter stick welder Mmm well what about 100ft of 12\3 on 110v? What's the math

If you only draw 20A into the welder, then yeap about ~6V drop, so the 110V would go down to about 103V at the machine. But then again, not you're not talking about stick welding anywhere near 210A DC. 103V @ 20A = 2060W of power. If your welder runs @ 25V welding voltage, you would be able to do roughly ~80A DC. I hope you only plan on running 3/32" 7018, or 1/8" 6010 only.

 

[Oscar]

120v-6v= 114v



Engine drive should have 120v.

If it is only 110v, machine needs check up

True, but you never know. You can consider it a worst-case scenario

If I had to work 200' from the power source often , I'd build something like Oscar did in this thread.


You would then have 120 & 240v at the place you need it.

http://weldingweb.com/showthread.ph...41-Who-sells-the-best-220v-Welding-extension-chord-for-the-best-price-25-amp-50

There's no way I'd make it 200 feet though! It's heavy enough as it is!. I haven't weighed it, but it seems every time I need to pick it up, it gains 10lbs, lol.

BUT, using Electron Beam's 6 awg cable, which really measures 16.6 mm² (more like 5 awg "standard), a 200 foot run of 6awg only drops from 240 down to ~230V AC, with 50A draw. Not too shabby. But it will weigh 150 lbs, lol.

 

[Oscar]

Unless I am reading this incorrectly, Lincoln says you are good to go with 2 gauge leads up to 150 feet.

http://www.lincolnelectric.com/en-u...en-us/support/welding-solutions/Pages/selecting-proper-size-welding-cables.aspx

The only issue I have with that chart, is that it doesn't show you the voltage drops at the end of the cable, right at the stinger. See, there will ALWAYS be a voltage drop (power loss) unless you have access to a room-temperature superconductor. The REAL question here is: just how much loss is acceptable??? It doesn't matter if you just barely struck an arc or have been welding near that specified 60% duty cycle. The voltage drop (and thus power loss) will be there from the very beginning, regardless of what chart anyone references. Charts can't change the laws of physics. Don't get me wrong, I'm sure there is some truth and validity to that chart, but I feel it's a little too "allowing".

 

[Oscar]

I am going to assume that one of THE premier welder manufacturers was comprehensive enough to include voltage loss in their recommendations. I mean they know their welders and their welding rods and what it takes to complete a good weld. No offense Oscar, but I will trust them over your math any day.

No offense taken, since I'm not dis-crediting that article altogether. It's just not to my "liking".