What are welding cables?

What is Welding Cable?

Welding cables are essential components in welding machines and generally belong to the rubber insulated cables. These cables are used for wiring the secondary side of the welding machine and serve as special cables for connecting the welding pliers and the welding machine.

Structure of Welding Wire

Welding machine cables are characterized by high current and low voltage, making them single-core wires. The conductors are made of oxygen-free copper, with small diameter copper wires that are stranded into strands and then into conductors. The sheath is typically made of rubber, though PVC sheaths are also used, often double-layered for safety.

Rubber materials for the sheath include:

• Neoprene
• EPDM

Note: Neoprene and PVC release toxic gases when burned, which may not be acceptable in some countries and regions.

Characteristics of Welding Wire

1. Flexibility and Bending Properties: Welding cables need to be flexible and have good bending properties due to frequent movement and twisting.
2. Tear and Abrasion Resistance: The sheath needs excellent tear resistance, abrasion resistance, and good mechanical properties because the cable is often scratched and rubbed by sharp steel components.
3. Weather, Oil, and Acid/Alkali Resistance: The cable should have good weather resistance, oil resistance, and acid and alkali resistance, especially in areas exposed to sun, mud, oil, and other harsh conditions.

Different Models and Differences of Welding Cables in Different Countries

• VDE Standard: H01N2-D, H01N2-E (Single rubber sheath 100V)
  • H01N2-E has thinner copper wire and a softer cable.
• British Standard: 0361TQ (Double sheath 100V)
• China Standard: YH, YHF Cable
• USA: Class K, Class M, Welding Cable 600V, 100V with single rubber jacket
  • TYPE K has thinner copper wire and softer cable.

*Double sheath welding cable

How to Choose and Buy the Right Size Welding Cable

Common welding cable sizes include:

• 25mm, 35mm, 50mm, 70mm, 95mm
• 4awg, 2awg, 1/0, 2/0, 4/0

Choosing the cable size depends on the current and duty cycle of the welding machine.

Duty Cycle and Current Carrying Capacity

The current carrying capacity of a welding cable depends on the length of the duty cycle. The duty cycle is the percentage of time the load current passes through the cable during a 5-minute operating period. For example, if current flows for the entire 5 minutes, the duty cycle is 100%.

Refer to the following table for guidance:

We believe that after reading this article, you now have a good understanding of welding cables. For more information, please visit our welding cables page or contact one of our experts.