Correct Wire Ga. for 225 Amp,Miller AC Welder?

[fordy]

............I finally procured an older Miller 225 Amp A\C crackerbox welder ! The 240 volt plug is smaller than any 240 volt plug I have ever seen before . It has both flat spade elements for each hot leg and the round , ground plug on top . Plus , the cord is only about 6 feet long , way to short for my needs .
............I've decided to rewire the plug , with a standard size 4 prong , 240 volt plug............it looks like I'll have to connect the ground to the neutral connector as well . So , my question is........IF I want to make the cord say 25 feet long , can I use 10 Gauge stranded wire without incurring to much voltage drop ? Thanks , fordy

[sammyd]

.it looks like I'll have to connect the ground to the neutral connector as well

Why would you have to do that?
If the machine only requires 2 hot legs and a ground and you have a 4 prong plug, just leave the neutral prong unconnected.
You'd have to check the nameplate as to the current required to run that welder. voltage drop might be less of a problem than overcurrent and heat....
What size is the wire in the cord on the machine now?

[fordy]

Originally Posted by sammyd

Why would you have to do that?
If the machine only requires 2 hot legs and a ground and you have a 4 prong plug, just leave the neutral prong unconnected.
You'd have to check the nameplate as to the current required to run that welder. voltage drop might be less of a problem than overcurrent and heat....
What size is the wire in the cord on the machine now?

............It's either 10 or 12 ! I have 2 , 3 conductor , 8ga.-30 amp RV extension cords......I'm thinking since I only need 3 conductors I'll just use one of those cords and install the correct 240vac male plug , and wire the other end into the welder . Besides , they're made to use in the weather . You saved me some $$$ ,.....now I can just use the wire I already have . thanks , fordy

[farminghandyman]

run the wire that is capable of supporting the rating on the plug, and for future possibilities I would wire it for 50 to 60 amps, with a 50 amp receptacle, as that is what most old buzz box welders call for,

if your going with a "dryer type plug, that would be for 30 amps,

what I am trying to say is if your going to wire, I would wire for the standard OLD buzz box welder, you can always make a short adapter and reconfigure it, for different plugs, on 220/240

if you ever need a 50 amp plug in you have it, and it will all ways run lesser needs,
the breaker is not for machine protection it is for the protection of the wire,

if the plug is factory and not been messed with in the past, then why change it look on the welder name plate and wire it accordingly,

My two cents

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most likely the manual is on the miller web site, look It up and see what it says,

[oneokie]

What is the orientation of the flat spade lugs on the end of the power cord that is now on the welder?
The amp rating of the plug/machine determines the orientation of the hot lugs.

[fordy]

Originally Posted by oneokie

What is the orientation of the flat spade lugs on the end of the power cord that is now on the welder?
The amp rating of the plug/machine determines the orientation of the hot lugs.

..............They are flat , one at 9 , one at 3 , the gnd is at 12 ! But , one spade is smaller than the other and the whole plug is smaller than anyone I have ever seen on any crackerbox . The seller must have cut this plug off some other 220vac something and wired into this Miller a\c welder . I'm going to rewire the machine with a new , 50 amp rv , 4 conductor cord and 4 prong plug . It's cheaper to add length to the power cord than buy longer leads . , fordy

[simi-steading]

I'd imagine you'd be fine with 8ga wire, but will you be able to fit them in the terminal blocks or what ever the connection point in the welder?

Can you tell I've been there and fought that battle?

[fordy]

Originally Posted by simi-steading

I'd imagine you'd be fine with 8ga wire, but will you be able to fit them in the terminal blocks or what ever the connection point in the welder?

Can you tell I've been there and fought that battle?

............Yes , I can ! I've got to take the back off the welder and see what the connections look like . It's a real PITA to manhandle this bugger around cause it must weigh 120 lbs . It does have wheels , but they don't function to well here in the Rocky Road RV park where I live . Guess I'll disassemble it on the F150 tailgate . , fordy

[Awnry Abe]

Originally Posted by simi-steading

I'd imagine you'd be fine with 8ga wire, but will you be able to fit them in the terminal blocks or what ever the connection point in the welder?

Can you tell I've been there and fought that battle?

No kidding. I ran #6 in my barn for the outlet and made an extension coord out of 8. Neither was fun.

[unioncreek]

If the welder requires a 50 amp breaker you will ne #6.

Bob