dual welder setup for 2 types of wire, worth it?

[CPOM]

I have a Miller 210 I have been very happy with most of the time running .030 wire and argon/co2.

I "inherited" a 120V lincoln "weld pak" set up for flux core.

I often do exhaust and sheet metal work and like using the .023 wire for that. Changing out the wire is kindof a bitch so I was thinking of converting the fluxcore lincoln weldpak setup to run .023 MIG all the time.

What I was thinking was building an extension cord with a 220 and 120 outlet built-in. The one cord would power both welders. Then put the 120V on top of the Miller, get some type of gas line splitter to have one bottle and regulator feed both welders.

So I would need , a MIG liner, gas hose, gas solenoid, gas tip and wire feed tip, is that it? I could even tie the ground cables together to use one ground clamp if I wanted to get crazy.

So think this is a good idea? How will the little 120V welder work compared to the MM210 for exhaust and sheet metal stuff?

[CrustyJeep]

I think that sounds like a great setup.

I'd be surprised if that little welder didn't do better on exhaust type stuff than the 210...

[ihojeff]

Should work great for lighter sheet metal and exhaust work. Most Home Depot's or Lowes that sell these weldpaks will also sell the gas conversion kit as well as any other welding store.

[jasonmt]

I have a 175 I bought to keep spooled with 0.023" hardwire so I think it is a great idea but I am wondering how you were planning on wiring the 120/240V?

[45acp]

For thin stuff, neither one is going to work any better than the other. Both are (i believe) 30 amps at the lowest setting. So, with that said, put the 23 and gas on the Lincoln and leave the Miller setup for the big stuff.

[ihojeff]

I have a 175 I bought to keep spooled with 0.023" hardwire so I think it is a great idea but I am wondering how you were planning on wiring the 120/240V?

I'm not an electrician but I think you pull power off of only one leg of the 240 volt to get the 120 you need. I could be wrong but I think this is how its done.

[AthlonAJ]

I'm not an electrician but I think you pull power off of only one leg of the 240 volt to get the 120 you need. I could be wrong but I think this is how its done.

Yup exactly. So there would only be one 220 cord going to the welder, split it off from there. One big advantage of having the smaller welder setup for that is the gun size is smaller and easier to get into tighter spaces.

[CPOM]

For thin stuff, neither one is going to work any better than the other. Both are (i believe) 30 amps at the lowest setting. So, with that said, put the 23 and gas on the Lincoln and leave the Miller setup for the big stuff.

I was just hoping that the little Lincoln would not be WORSE at the thin sheet metal than the Miller as it is a lower priced and lower quality welder. If they are dead equal on thin stuff than this will work great! It's a weldpak3200HD and already set up for gas, i just have to get the gas copper tip, the .025 tips, and the adapter to run 8" spools.

Anyone know where I can get that 8" spool adapter? I suppose I can just make something.

[jasonmt]

I'm not an electrician but I think you pull power off of only one leg of the 240 volt to get the 120 you need. I could be wrong but I think this is how its done.

Yup exactly. So there would only be one 220 cord going to the welder, split it off from there. One big advantage of having the smaller welder setup for that is the gun size is smaller and easier to get into tighter spaces.




It was a loaded question, how are you going to protect a 120V/20A machine with a 240V/40A/2 pole circuit breaker?

As well there is the problem with having current flow in the grounding conductor if you are using a 3 wire receptacle such as a 6-50R.

[blahblahblah]

I'm not an electrician but I think you pull power off of only one leg of the 240 volt to get the 120 you need. I could be wrong but I think this is how its done.

You would need a 4 wire hookup for this. Both 110v legs, neutral and ground. To get 110 you pull from one leg and neutral, a typical 220v welder hookup only has the two legs and ground. If you can figure out a way to protect the 110v properly....

[xjmark]

I have a Miller 210 with .035 wire for the heavy stuff, and a Miller 130 with .023 wire for the thinner stuff and tight areas. Each are on their own carts, but currently have one tank. I use the 210 about 90% of the time, but roll the 130 over to it and swap regulators when it's time to use that one.
Each has it's purpose.

Mounting the two units on one cart and splitting the regulator line will work fine, but get a dedicated power supply for each unit. It's only a matter of extension cords.

[rusted]

I'm mainly replying to thank you for the idea on the extension cord. I don't know why I dint think of that.

Second, I bet your 210 would actually be better on thin sheet metal :D I bet the Lincoln still kicks butt though, and you'll have a great setup.

[300sniper]

You would need a 4 wire hookup for this. Both 110v legs, neutral and ground. To get 110 you pull from one leg and neutral, a typical 220v welder hookup only has the two legs and ground. If you can figure out a way to protect the 110v properly....


maybe an extension cord to small sub panel located at the welders. one (or more) 110 breaker and a 220 breaker. you could even "hard wire" in the welders to the panel to eliminate the plugs and excess wire.