What size or guage electrical cable do I need if I am installing a 50Amp Breaker in panel and going 100' to run a 220 volt welder?
Wiring – Installing a 50 Amp breaker for 220 circuit, using a direct burial cable for 100′ for use of electric 220 welder
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The calculator you referenced is only appropriate for voltage drop and makes the disclaimer that the results of the calculation do not account for current specs or NEC. Any circuit fused for 30 amps must use a minimum of 10 ga copper or 8 ga alu. Longer runs may require an upgrade of wire size. In your case, use at least 10 copper for your welder regardless how far it is from the breaker panel. I'm sure one of my buddies here will have a NEC ref for ya.
Wiring from garage panel to welder
NEC 630.11(A) may be of interest.
National Electric Code 2008
ARTICLE 630 Electric Welders
II. Arc Welders
630.11 Ampacity of Supply Conductors.
(A) Individual Welders. The ampacity of the supply conductors shall be not less than the I1eff value on the rating plate. Alternatively, if the I1eff is not given, the ampacity of the supply conductors shall not be less than the current value determined by multiplying the rated primary current in amperes given on the welder rating plate by the factor shown in Table 630.11(A) based on the duty cycle of the welder.
Also take a look at 630.12 Overcurrent Protection.
The Owners manual (PDF) seems to contain the answer.
Wiring from service panel to sub panel
If we look at 110.14(C) in 2008 NEC, it says:
National Electrical Code 2008
ARTICLE 110 Requirements for Electrical Installations
I. General
110.14 Electrical Connections.
(C) Temperature Limitations. The temperature rating associated with the ampacity of a conductor shall be selected and coordinated so as not to exceed the lowest temperature rating of any connected termination, conductor, or device. Conductors with temperature ratings higher than specified for terminations shall be permitted to be used for ampacity adjustment, correction, or both.
Which means we'll have to check the breakers temperature rating, and the subpanel terminals temperature rating. Then we'll have to look at table 310.16 (Table 310.15(B)(16) NEC 2011), so we can determine the wire size we should use.
In this example image you can see if we're using copper, we'll use 60°C. Once we look at the table, we'll see that for 50A @ 60°C we need 6 AWG copper wire. (50A @ 75°C = 8 AWG).
110.14(C)(1)(a) basically says that if the temperature is not listed, use 60°C for circuits less than 100A. 110.14(C)(1)(b) says if the temperature is not listed, use 75°C for circuits over 100A. However, in the real world 75°C is often used for both.
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Best Answer
A welder is defined as a non continuous load so the wire can be sized at 100% of the listed nameplate per table 630.11.A. But a 50 amp breaker you would need at least #6 copper. I would upsize a bit and put a sub panel in so more could be done than the welder only.