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Answers to common questions about the lead that carries welding current from the machine to the electrode holder.
Look over the whole lead each day before you start. The HSE says the insulation on the cables, plugs, clamps and electrode holder should be undamaged, and that connectors should be clean, undamaged and correctly rated for the current.Check the full length of the cable for cuts, crushed sections, bare copper or bulges. Check that the holder handle and jaw insulation is intact and that the plug fits snugly and is not discoloured by heat. Report any defect straight away rather than carrying on.
Replace it when the insulation is cut, cracked or worn through, when copper is showing, when the holder or plug is damaged or has overheated, or when the connection will no longer hold tight. HSE says the insulation on welding cables, plugs, clamps and the electrode holder should be undamaged, so a lead that fails that check should be taken out of use and marked clearly so nobody picks it up by mistake.A damaged lead is an electric shock risk as well as a fire risk, so do not wrap it in tape and carry on. Follow the manufacturer's instructions and your own risk assessment.
Some warmth in use is normal, but a lead that becomes too hot to hold points to a problem. The usual causes are a loose or dirty connection, a cable or connector that is too small for the current, or damaged cable with broken strands. Each of these adds electrical resistance, and resistance produces heat.The HSE says connectors should be clean, undamaged and correctly rated for the current. Switch off, let everything cool, then check the plug, the holder end and the cable. If heating continues, replace the damaged part or move up to a larger lead, and check the rating in the holder and welder manuals.
Cable size is given as the conductor cross-section in mm2. It depends on the welding current you will use, how much of each ten minutes you are actually welding, and the total length of the circuit, which means the electrode lead plus the work lead.The higher the current or duty cycle, or the longer the leads, the larger the cable usually needs to be. If you are in doubt, going one size larger is generally the safer choice. The welder's manual normally gives recommended sizes for its maximum output, so check there first.