Welding Extension Cord failure

[OnlyStihl]

I had a 40' 40Amp (8awg) extension cord fail on me. Nothing plugged into the wall but the cord, and it pops the breaker. I replaced both terminal ends and it still pops the breaker. The welder plugged into the wall is fine. It's just the cord. I stripped off the outer protective sheathing and can see nothing wrong. Nothing, and everything ohms out well, as expected.

I'm thinking poor quality copper, but really have no way to test that, and I think it is the copper only because I cannot imagine what else might be the problem.

Anybody, know what might be going on. I did order a new cord, 25' 6awg.

 

[srcarr52]

Sounds like the cord is shorted out internally or you mixed up and put a line on the ground pin.

 

[misterhandyman]

Check for continuity between wires and look for a single stray strand of wire touching another terminal/wire at the plug ends. Does the breaker blow when you plug the cord in then the welder or just the cord by itself?

 

[OnlyStihl]

Check for continuity between wires and look for a single stray strand of wire touching another terminal/wire at the plug ends. Does the breaker blow when you plug the cord in then the welder or just the cord by itself?

Just the cord by itself. Meter shows no continuity between pins with the old cord. New cord showed up and breaker is stable. If this cable fails over time I'm going to get longer leads to replace the 6' at the welder and leave extension cords out of the mix.

 

[Dustin4185]

Just the cord by itself. Meter shows no continuity between pins with the old cord. New cord showed up and breaker is stable. If this cable fails over time I'm going to get longer leads to replace the 6' at the welder and leave extension cords out of the mix.

How big is your shop/garage? We used 6/3 SOOW cord and a festooning kit to keep it up off the floor. Best decision ever.

 

[OnlyStihl]

How big is your shop/garage? We used 6/3 SOOW cord and a festooning kit to keep it up off the floor. Best decision ever.

This is what I ordered. If weight is any indication then this a quality cord. 25' just gets me thru the garage so I can weld in the open air (barely).

​

https://primeweld.com/products/heavy-duty-welder-extension-cord

I'll be testing it out this weekend. Doing some welding on a neighbors Kubota.

 

[Boomer2230]

Driving over those cables kill them quick

 

[OnlyStihl]

Problem solved. It was the breaker. Old breaker powered a Jacuzzi, which is long gone. Repurposed for the welder and plasma cutter, worked for a year. Not being able to test what exactly went wrong, I'm blaming the GFCI. I installed a new 2 Pole 50Amp breaker, and with everything plugged in and on, the breaker is holding. I'll weld in a week or so, but I'm calling it FIXED.

 

[isaaccarlson]

I don't even bother with extension cords unless its really far. I have 40 ft power cords on both my welders and 25 ft cords on power tools. Sometimes I need an extension, but usually not. People see the long cords on stuff and start asking why they are so long.....I just smile and wave.

I keep several hundred feet of air hose too, so I can reach a flat tire or work in the house.

 

[OnlyStihl]

I don't even bother with extension cords unless its really far. I have 40 ft power cords on both my welders and 25 ft cords on power tools. Sometimes I need an extension, but usually not. People see the long cords on stuff and start asking why they are so long.....I just smile and wave.

I keep several hundred feet of air hose too, so I can reach a flat tire or work in the house.

I don't get it. What's the gain in having all your equipment with long power cords, vs a single extension cord for all? Seems like an occasional convenience at the expense of having a constant cord tripping hazard.

Most of my power tools are fine with 6' of cord, and the few times I need an extension it is very convenient to just reach overhead and pull as much cord as I need, and it is self winding when I'm done.

My only problem with the overhead cord is mine is rated for 15 amps, but 90% of the time that is enough.

I have been looking for a similar setup for 6 or 8 AWG 50amps, which is hard to find and can break the bank.

 

[isaaccarlson]

I have a 40x80 shop. I use multiple tools at a time, and unplugging to switch tools is a pain. I work on different sized projects and a long cord on the tool usually means not even thinking of an extension cord. I have some 25, 50, and 100 ft cords, and they get used, but not every day.

Good luck finding a retractable 50 amp cord. The power cord on my big welder is at least an inch in diameter and is VERY heavy. It gets coiled up on the side of the welder. Having a retractable spool would be nice, but the contacts would be massive and ANY connection issues would spell disaster.

I would be hesitant to use more than an angle grinder on a retractable cord reel. They may be rated for 10 or 15 amps, but most ratings are momentary max and have voltage drop. I have done what I can to reduce or eliminate voltage drop at my place. The service line coming in is 800/1200 amp, and the transformer is located centrally to ensure short runs to my buildings. I don't have huge breaker boxes, but I have plenty of clean power when I need it, with lots of room for upgrades when needed, which is also a big deal if we ever decide to sell/move.

Good water and good power are important. Don't skimp on either.

 

[Lnk]

Just the cord by itself. Meter shows no continuity between pins with the old cord. New cord showed up and breaker is stable. If this cable fails over time I'm going to get longer leads to replace the 6' at the welder and leave extension cords out of the mix.

You need to measure that cord with a meggar. Which will test the integrity of the internal insulation. I bet the cord was run over at one time and two of the wires have breaks in the insulation, would be a short to higher voltage, but not the 9vdc of your meter.

 

[OnlyStihl]

You need to measure that cord with a meggar. Which will test the integrity of the internal insulation. I bet the cord was run over at one time and two of the wires have breaks in the insulation, would be a short to higher voltage, but not the 9vdc of your meter.

And you'd be wrong. I say it was not run over. But if you're sure of it, then I must have, right?

And since a brand new cable had the exact same problem, and a new breaker fixed the problem THEN maybe I ran over the breaker. Yeah, that must be it.

 

[Lnk]

And you'd be wrong. I say it was not run over. But if you're sure of it, then I must have, right?

And since a brand new cable had the exact same problem, and a new breaker fixed the problem THEN maybe I ran over the breaker. Yeah, that must be it.

Wow, such hostility towards someone trying to assist you. If I came across as anything other than trying to help, it wasn't my intention. I won't try to help you again.

 

[OnlyStihl]

Wow, such hostility towards someone trying to assist you. If I came across as anything other than trying to help, it wasn't my intention. I won't try to help you again.

Good. Helpful you are not, even attempting.

 

[Lnk]

Good. Helpful you are not, even attempting.

What a dik. Gfy

 

[OnlyStihl]

What a dik. Gfy

You too. GFY!

 

[bogieboy]

Wow, such hostility towards someone trying to assist you. If I came across as anything other than trying to help, it wasn't my intention. I won't try to help you again.

And its not hostile to claim that the OP is wrong and did drive over the cord, when 2.5 months ago it was stated that a new cord did not fix the issue, but the breaker was the original issue? Read the dang thread before you reply and make yourself look like an idiot...

 

[Bill G]

I hope when you replaced the breaker you also replaced the cord.