All about welder extension cords (viewer request)

In this episode we tackle extension cords so you dont waste money

0:00:00 Intro and overview
0:03:03 Basics of cords and what to look for
0:12:20 Conclusion

#welding #welders #howtoweldforbeginners #tigwelding #migwelding #stickwelding

[makingmistakeswithgreg]

For clarification: if you’re running a 200 amp class inverter welder you can use a #8 wire extension cord. They tend to not pull over 35 amps on 240v. National electrical code says #8 is rated to 40amps so you are in the clear. If you have a 220+ amp welder or a 200+ amp transformer welder and plan on maxing it out, you will likely pull over 40 amps and should be using a #6 wire.

To make matters more confusing the 30 and 50 amp welder outlets look identical. National electrical code says you can run 8ga on a 50amp outlet for a welder circuit, because of the duty cycle. That’s fine, until you put a 250+ amp welder on it and have to deal with voltage loss on the 8ga wire due to resistance. The smartest way to go is 6ga wiring on a 50 amp breaker if you plan on running a bigger welder. If all you have is a 200amp inverter #8 on a 30 will be fine. I know this is confusing but the simple way to look at it is being slightly oversized is better than under if you have a bigger welder and expect to use it 😀

[christinamoneyhan]

As a retired electrician everything you said is spot on. Very good. The 8 gauge is good for 40 amperes.

[scotthansen]

GREAT INFORMATION !!!
Thank you for taking the time before your workday to make and post this video !!!

[jessealanis]

If you drop it you're getting more than a tickle, that's to funny. Really appreciate the little humor thrown in there and of course the educational content. Thank you.

[unclebob]

Appreciate the overview. I needed a voice of reason as what I perceived as lawyer speak when my welder Prohibited Extension cord use. -thx

[thenetwerx]

I have the same heavy blue extension cord from Amazon and it was MFer to unplug the welder from it! I cut the end off and used a 4” metal work box with 1” knockouts, an aluminum “Chinese finger lock” strain relief from McMaster Carr, and a 6-50 outlet and cover plate. Super duty and easy to grip when unplugging. I have pics I can share.

[xanatax]

Previously noted, “Tuny cheapo Stick Welder” has a number, but we’re not sure how accurate that is: I bought a $20 amp-clamp, as you suggested, Thank You! 💜👍 Very interesting to meter a few things around the house. It arrived just after a storm knocked out the electricity for a day, so I’d kinda been thinking, “How much power does ____ need?” while running the generator. 😅

[Ron-FabandBuild]

Thank you for putting this out there. Solid information.

[melgross]

8 ga = 40 amps. I use the same extension for my ESAB 205 and ThermalArc 40 amp. No problem with the cable. I’ve had it for 6 years. I made a box it plugs into with two 50 amp outlets so I can have both the welder and plasma connected. The box is mounted on my welder cart. No one uses the equipment but me, so no chance of both used at once. I prefer very tight connections. It’s tough to remove, but not as hard as you’ve experienced.

[MrObsvenchilde]

If you're looking for the regular 6-50R end then Pass & Seymour D0653 from Menards comes to mind. Just prepare for jaw drop when you see the price. There are 50 amp twist locks as well. A lot are various models of (non-NEMA) California Standard plugs. I believe the only 50 amp, three prong NEMA connector is the SS 1-50 plug

[fitch]

Your advice on extension cords is excellent. That said, I can say from personal experience that a 25' #8 extension (which should be rated for 40A) works just fine for a home welder. The duty cycle of any home welder which is operated so it's drawing more than 40A of input current is going to be so short the heating of the cord is the least of one's problems. Few if any of the new inverter welders draw more than 40 amps. I made an extension using #8-3 with ground for my Lincoln AC 225 Tombstone over fifty years ago. So did several of my friends. It worked just fine. I bought one like your blue one off Amazon but got lucky and don't have the sticky plug problem.

That said, I agree a 50' extension for a 240V welder should have #6 gage wire.  I wouldn't recommend an extension longer than 50' for a welder. If a hundred foot cord is absolutely heeded, I'd recommend 4/3 SO which is around $6/foot so it's a $600 extension cord plus tax and end fittings (and maybe the cost of a safe to keep it in given the frequency of copper thefts). The problem is voltage drop as the cord gets longer and longer.

[CALDues]

Glad you had some time before work! It cleared up a few things. Thanks

[jacobwrona]

This was this video I've been looking for. I bought a 50ft primeweld extension cord and I'm pretty happy, 6ga and the insulation isn't stiff when cold about $200 after the first time customer discount.

[VEAEA]

I usually make them to my own needs. For 50 amp circuits, SEOOW 6/4 wire is my choice for making 25-50ft 240v extension cords. Its black rubber jacket is nice and flexible and 6/4 means you have a neutral in there so you can use it for generator duty or welder duty with the right end. Hubble or Leviton twist locks wired up depending on the configuration needed. Perfect setup for backup generator duty.

[ls]

Interesting subject/video. For years, I've used bigger Millers (stick, tig, & mig) in my shop, using a 25ft 240v (50a breaker) connection. Using a long extension cord recently became of greater interest, after purchasing an ArcCaptain MIG200 (which I would highly recommend so far), mostly because of the abilities. The initial reviews on YT (see @NBSWelding) showed the machine with a 120v male plug, with a female 120v/male 240v adapter. I watched another review where "On Fire Welding" was complaining about how dangerous he thought it needed to change that (the plug orientation). Unfortunately, the safety nazis won, & I received a machine that had been changed to a male 240v male, with a 240v female/120v male adapter. While bad things could happen for a dunce not paying attention (plugging a 120v tool into an extension cord carrying 240v); the initial design would have been a lot handier for portability and using away from the shop.

I certainly have the ability to make an adapter for an extension it's just frustrating that it was a change made for liability, over functionality.

[Justforfun-eket]

Wow, it’s as if you are reading my mind. I just installed 240 receptacle in my garage a few months ago and want to move further away from the outlet so I can use my homemade extraction fan to blow the smoke out my door. A homemade extension cord would be quite helpful.

[JonathanEleini]

Help needed: I have a 110V TOOILIOM 135A Inverter welder. I don't have any 30A breakers in my house, but I do have a outside 125V 30A RV connector. My welder has a standard 3 prong household grounded male plug like you would find on a coffee maker. I am planning on using the outside RV plug, with an extension cord. Where can I find a 10 gauge extension cord that has the male RV plug on one side and a standard 110V female plug on the other side (to plug in my welder)? Thanks

[sebastianleicht]

Thanks for that Video! When it comes to voltage-drop by long or poor wiring, the PFC of the newer weldinmachines can also start to fight you because it draws more amperage the more the voltage drops. Maybe it is worse for us in
Germany because we have higher voltage in standard (230v 1-phase and 400V 3-phase) and according to this thinner wire and weaker breakers (commonly 16A or just 10A in households - depending designation of the circuit). Weld 7cm continuously then run 200m to fix the breaker... 😂 At one certain point i Was tired of running and wearing and redid the whole wiring to my garage...

[mlafi]

Had an 10Awg 1ft to a 8awg 30ft to another 10awg 1ft from a dryer outlet rated at 30amps but my 110 harbor freight flux woudnt run but runs if welder goes straight to a 20amp outlet

[hubertrobinson]

I use only 10 and 12 gauge extension cords 12 ga for grinders and chop saw the 10ga I run my little inverter 160amp welder from the 240v outlet that one I built solely for the welder 100ft long I also carry 150ft of store bought of 10ga cords a 50ft and a 100ft after see your video I'm now thinking on getting a 100ft of 8ga built for the inverter welder I use it if I need to go beyond the 60ft of leads on my Lincoln Ranger on my truck might be expensive but better safe than sorry thanks for the information