The manual shows 250ft total for both leads if you use 3/0 cable and want to run 200A...no reason that shouldn't work. Even though the manual stops there you could almost certainly go longer if you went with bigger cables...if there isn't too much voltage drop the welder won't care, but it would get expensive.

I had one briefly and it came with 120ft of leads (total) that were 1/0....worked fine.

 

Thanks! you run same length on both?

 

On that machine they were the same length, but that was how I got them. A lot of people will run the required heavier wire for most of the length, and then add something like a 10-15' whip at the end for the stinger using lighter wire and a quick connect fitting to join the two. That gives your stinger a little more reach, which can be handy, and you're not holding the weight of the heavier cable off the ground so it's easier to manage. You obviously don't want to go too light, but dropping a couple of sizes shouldn't cause any problems since it's such a short run.

 

Stinger cable is usually a little longer. Often times you can hook the thing-a-majig clamp (because there's so much confusion on what to call it) closer than where you are actually welding.

 

Or worse case tack on a piece of rebar, to extend your lead thingy. Just don't put it on the ground.

 

I was thinking same to M J D and WelderDave. Have used rebar for said purpose already on my tombstone. Just wanted to make sure Thanks

 

:laugh::laugh::laugh: This shtuff is just too funny!

But seriously, it makes no difference which lead has which length, as long as you don’t exceed the limit length. If they recommend 200 feet of 1/0 lead and your welding on a high rise building, you can have a 10’ negative to the building steel and 190’ positive to your stinger.

For your Hobart, just get what you need. I would suggest 50’ of each in 1/0, if it was me.

 

But would the one attached to the building be a ground lead, or a negative work lead? Because you know we can't have a lot of negativity...

 

Thanks everyone!
Will be welding a weld up building possibly.

thinking of the following

150' 2/0
15'' 1 = whip
75' 2/0

 

Don't think you need 2/0 for a Hobart Champion 16. 1/0 would be plenty. Unless you're going to be using lots of 5/32" or bigger rods a #2 stinger is lighter and more flexible.

 

I agree with Welder Dave, I wouldn't get 2/0 for that welder. I would go with 50' sections of 1/0. The majority of work is probably going to be 150A or under, I am guessing. For higher amperage work, do it closer to the welder. I have a Lincoln Commander 500A, 100% duty cycle. I have 100' of each lead in 2/0, and I regularly air arc with 5/16" carbons.

 

Yep, just get what you need. In an emergency situation you can get a bunch 20 foot sticks of rebar and weld them together as you go for extra length use at least a 1/2 inch weld bead between sticks and use a number 4 bar for up to 150 amps and a number 6 bar should work up to 200 amps