Extension Cord for welder

[sandman2234]

Hmmm, just for thought...one cord has a slightly higher resistance than the other, which leads to a restriction, or heat buildup, thereby causing more resistance in that wire than the other, which in turn causes the other one to have to handle more amperage, heating it up more, causing more resistance, amperage flips back to the other... oh heck, a person could drive themselves crazy (or in my case, crazier) trying to figure that one out from a technocol aspect. No wonder electricians make so much money, lol, as they have to content with all of our "can we do it cheaper another way" ideas.
Trust me, I understand limited budgets, but learned many years ago not to scrimp on wire when it is carrying voltage to a welder (or anything else). Do what you can with what you have, but when it comes to the right wire for the job, save up till you can do it right. That is one of the times when doing it over a second time is a bad idea, because you could be sifting the ashes of a home from an electrical fire instead of just buying a length of larger wire.
David from jax

 

[Groo]

any wire can be screwed up and have only a partial connection, heat up, and start a fire. At least with an extension cord, you are right there when it is in use.

 

[undercut]

I'd be a bit more concerned about the custom pigtails. The heat buildup may or may not cause a fire - given how much current is being used and the duty cycle where it might allow the cord to cool down but the pigtails would certainly be an electrocution hazard if only one cable was plugged into one side but the other side had both cables plugged in. Somewhere along the line, one end has exposed terminals. (think about it). Using two extension cords should be be considered a theoretical exercise as opposed to a recommendation.

 

[Groo]

not getting what you are getting at at all.

 

[undercut]

The poster was wondering if he could use two extension cords but still be able to use them for conventional use. If he does that, he would need to make two pigtails, one for each side. Each pigtail would need to combine two extension cords. One pigtail to the 220v outlet. One pigtail to the welder. If one extension cord is only plugged in one end, there will be a male plug somewhere in the setup that potentially would be live and its blades exposed.

 

[Groo]

The poster was wondering if he could use two extension cords but still be able to use them for conventional use. If he does that, he would need to make two pigtails, one for each side. Each pigtail would need to combine two extension cords. One pigtail to the 220v outlet. One pigtail to the welder. If one extension cord is only plugged in one end, there will be a male plug somewhere in the setup that potentially would be live and its blades exposed.

If the welder was blasting away while someone pulled the plug, yes I could see how 110 might potentially hit someone, but even then, it would only be a danger for the instant it was opened (after that, the welder would shut down, wouldn't it?), but extension cord could be as dangerous in that instant. I've been shocked before unplugging a normal cord

 

[grsthegreat]

This is all foolishness. a 6/3 SO rated cord is about $ 2.80/foot at my supply house. So a 50 foot length of proper sized welder cord will cost a whopping $140.00.. This cord is heavy duty, work rated wire that can have trucks drive over it, wood fall on it, etc and keep working 24/7.

It not some patched together extension cords that can fray and crack in cold weather, or short out if someone drives over it.

This wire will last 50 years and be hassle free.

I have such a wire on my welder. It was on my old welder that finally wore out after nearly 20 years of use. i kept the wire and threw out the welder. The wire still looks new.

so lets forget about all the ways to get around the proper materials

 

[undercut]

This is all foolishness. a 6/3 SO rated cord is about $ 2.80/foot at my supply house. So a 50 foot length of proper sized welder cord will cost a whopping $140.00.. This cord is heavy duty, work rated wire that can have trucks drive over it, wood fall on it, etc and keep working 24/7.

It not some patched together extension cords that can fray and crack in cold weather, or short out if someone drives over it.

This wire will last 50 years and be hassle free.

I have such a wire on my welder. It was on my old welder that finally wore out after nearly 20 years of use. i kept the wire and threw out the welder. The wire still looks new.

so lets forget about all the ways to get around the proper materials

I agree. I should have known better than to get into a theoretical discussion when it comes to safety.

 

[AmericanTractorDriver]

Is the local electrical distibutor also the best place for the cable ends? Any reason not to use ends compatible with normal interior (i.e. clothes dryer) 220 plugs? I purchased a used AC225 Lincoln welder and plan to replace the 6' pigtail as well as make an extension cord. Thanks!

 

[patrick_g]

You may pay a little more buying from a welding specialty shop but my experience with 220VAC receptacles from Lowes and the like has been marginal at best. The cheap plastic plugs and receptacles are fine for hooking up a water heater every 20 years but for extension cord use and abuse??? The best luck I have had is to use a metal J-box to enclose what was intended to be a wall mount receptacle. The receptacles intended for extension cord use (not enclosed in metal) just don't last getting dropped on the floor, stepped on etc. regardless their source.

Good luck to you on your welding adventure,

Pat