I'm looking to extend the distance from the transformer to the welder head and would like to do it by attaching an extension bar to the cable. Is this possible? If so what material should I use for this modification?

-- Jason Rathfelder (bitsdoo@yahoo.ca), June 05, 2001

Answers

Hi--

You won't be able to get as good of an electrical connection, because of resistance losses in the additional connection and added cable length. Maybe an electrical engineer can chime in on how much would be lost-- but it would help to know from you the current and desired size (MCM) and length-- as well as how much current you plan on putting through the connection.

You have three options that I can think of: 1. Get a new cable that is long enough for the whole run 2. Add a copper "buss bar" type shunt 3. Add another cable inline

Both 2 and 3 are "shortcut" methods-- they are what one of my engineering professors would call "redneck engineering". In other words, they are not the correct things to do, and while they may work they may also get you into deep trouble.

Also-by using method 2 or 3 you may be breaking the national electrical code.

Have you priced a cable for the entire job? You would want something similar to what is on: http://www.tjsnow.com/supplies/cables_shunts_connectors/index.htm

Sam

-- Sam Snow (2snows@mailandnews.com), June 06, 2001.

As Sam stated the more common practice is to replace dry jumpers with one piece cable of sufficient length for the project.

However, it is common for resistance welding designers to use high conductivity copper buss or 110 Copper of sufficient size to extend secondary buss connections long distances. It should also be noted that the connection surfaces are machined with a minimum 63 finish and silver plated. Much of the time the copper is water cooled at least at the connection areas. Again this is best left to an Electro- mechanical designer, who understands the relationship of the losses and gains of copper geometry to current flow densities, and where insulation or close proximity’s to other electrical current carrying members or magnetic materials will affect the efficiency of the circuit.

-- Bob Balla (bobballa@tjsnow.com), June 07, 2001.