Too Big a Welder

I agree with tcmtech's comment.

I am curious... what is it that is limiting you to a 40 feed for the welder?

I think your quote sort of explains the likely problem. Limited service capacity.

He could be using his electric range circuit. Those are typically 40A. Still, like I said, as guest (forgot to sign in), he would only have a problem if he was trying to weld at full amperage. When I referred to my 180A Hobart, I was plugged into my dryer's outlet and that was only 30A. Still, I never had a problem with tripping it. I have since wired a dedicated 50A circuit, though.

I concur. Unless you are welding heavy stuff you probably won't have a problem.

If you do, follow the advice of tcmtech.

Happy Beads.

I agree with TCMTech, just run it as normal and find what amperage setting trips the breaker. The welder is rated at 65A input at the 235A output. Its only going to draw 65 amps when welding balls to the wall at 235A. I've found that, unless you are tring to weld 1/2' thick steel in a single pass, you never use anywhere near the welder's max current. What are you welding? Is this a commercial shop operation or just a home hobby use welder? My Hobart Stick only draws 37 amps, 240V at full tilt (180A). Still, I found, in my home hobby work, I have never needed more than 140A. That was when I was welding 1/4" steel.

I agree with all and have this to add:

Unless you are running your welder off a small generator, I would almost bet you have at least a 100 amp service at your home or shop. If so; you can add a dedicated circuit to your service panel or an outboard disconnect protected by 40 amp breakers.

I wouldn't use resistors on the supply for they will create a voltage drop. If you want extra electrons for demand surges from the welder you would want giant capacitors.

I think he should be fine. Because as others have pointed out, he probably will not be running this machine anywhere near full output. The duty cycle of the machine will probably never be reached under most welding requirements.

He could also look at installing a d curve circuit breaker or fit motor start fuses they will handle the initial current when striking an arc a lot better than standard fuses we have had a lot less incidental tripping of our welders since changing from standard fuses and circuit breakers