splicing welding cable 1

[Tmoose]

I need to cut the hot and ground cables on my old Lincoln welder to adapt a Hi Frequency arc stabilizer. Those extruded aluminum splicer reducers that clamp the bare cable with a large round nose set screw look appropriate. The package says Max 1/0 STR (stranded?) and minimum 14 AWG. The welder's cables are 4, finely stranded, with 3 or 4 twisted bundle. The Thomas and Betts site is useless for tech info. I think I ought to solder the last 5/8 inch of the cable to turn the fine strands into a lump. Or is it really correct to just crush those fine strands, so that only about half of them are making firm contact with one another and the connector ID?

 

[metengr]

I would contact Lincoln.

 

[fegenbush]

I have hooked up a HF Arc Stabilizer to my Miller Thunderbolt to weld aluminum. You are making this much harder than it needs to be.

From your description of 4 AWG leads that are fixed to the machine, I will assume you are using an AC-225.

If you were to cut the leads approximately 1 ft from the face of the machine, you could attach female Lenco LC10 connectors to the machine via those short sections. Then, attach male LC10 connectors to your leads. This would allow you to selectively hook up your HF unit.

Another option is to open the machine and switch out the connected leads for a socket connector. Hook up the male socket connector to your leads, and you're good to go. The result is a cleaner finished product, but it takes more time to do.

Whatever you do, you should contact your local welding supplier to get the proper connectors for welding. While other commercial electrical items may work, you can't beat the expertise of the staff at a welding shop and the safety of devices specifically made for welding.

 

[Tmoose]

This says the Lencos also would connect to my cables with a single oval point screw, just like the aluminum splicer.

http://www.usweldingsupply.com/lenco-connector-lc-10.html

The $10.51 /cable set is more palatable than the $20-$40/ sets elsewhere, since I'm going to need at least 4 even if I harvest the plugs off the HFAS.

The old AC/DC 225/125 with one lead snipped short looks a lot like HellBoy.

Dan T

 

[fegenbush]

The Lencos connectors are a little more involved than a single screw. They have instructions with them, but the general theme is that the molded exterior is connected to a piece of wire twisted around the *outside* of the cable so you don't risk the insulation receeding and having exposed copper. Additionally, there is a piece of sheetmetal (for some reason I think it's tin, but I can't remember for sure) that wraps around the braided conductor to keep the bundle together.

Maybe it hasn't gotten you yet, but you sure can't beat 50 ft (or more) of ground cable. Much easier to move yourself than to move the machine. Be sure to check the standard literature from Miller or Lincoln as to the cable size to use, if you decide to lengthen it.