Everyone from beginners to experts in welding should be aware of what to keep in mind when choosing the right welding cable. First of all, what is welding cable? It’s the electrical conductor that is used to carry a current. It is usually made up of fine copper strands (copper is the best material to use as an electrical conductor), and an insulating jacket. This combination of materials allows for the best possible conducting ability, while also protecting the copper from the outside environment, as well as keeping it flexible and durable.

Why Welding Cable Size Is Important

Selecting the correct welding cable size is vital because the size you need relies on the level of current that is being conducted. Current is measured in amperage (also referred to as amps), and as the current increases, the diameter of the welding cable needs to increase as well. This is because as the diameter of the cable increases, so does the number of copper wires inside it, which allows for a greater ability of conductivity. This is important to pay attention to because if you are conducting more electricity than the welding cable is designed to handle, the cable can overheat and can become a fire hazard.

So, how do you choose the right size? First, you need to find out the length of your welding circuit. All that means is that you need to know how long the path of electricity will be traveling when you are doing your welding. This includes everything used within your welding process as well. And secondly, you need to be aware of your maximum amperage (the highest level of current that may be conducted) that you will be using for you welding machine and welding cable. This information is usually provided upon purchase of a welding machine. Once you have this information, it’s time to actually pick out your cable size. Welding cables are measure by Gauge.. The smaller the actual diameter of the welding cable, the higher the Gauge it will have.

How To Extend The Life Of Your Welding Cable

First, you need to make sure you have chosen the best welding cable for the environment that you’ll be using it in. If you’re going to be putting it through some sort of harsh environment (abrasion, high temperatures, exposure to chemicals, flexing, etc.) then make sure the welding cable you choose is designed for those extreme conditions. Secondly, as mentioned earlier, pay attention to cable size!

You also should take the proper precautions to prevent unnecessary damage to your welding cable. In particular, you should try to avoid kinking or twisting the wire during the installation. Avoid extra tension, and keep the wire from being crushed or pressed in any form (this may damage the jacket, which will prevent the copper from being properly insulated). Definitely keep the wire away from any elements that it is not designed to be near or in, particularly pay attention to keeping your welding cable away from open flame. Also, work to adjust your cable reel. A good tip is to switch your ends periodically, particularly if one end is more susceptible to a certain harsh environment, the welding cable won’t deteriorate on one end.

You should also take care to make the proper repairs on your wire when needed. This means frequently inspecting the full length of the cable to ensure there is no damage, and make repairs before you are forced to replace the entire welding cable. Also, you should remove any cut (or even crushed) wire before it develops into a potentially unsafe or harmful environment. You should also keep spare cable handy in case you need a temporary fix to avoid damage to machinery.

Another great thing to keep in mind is to keep records of your welding cable, as well as all your electrical and wiring. If you record when it was installed, you can be aware of the expected deterioration rate and when it is suggested to replace it. You should also keep track of any fixes you’ve made so that if it develops into a reoccurring problem with your welding cable, you can be better prepared when trying to determine an underlying problem. And, if you’re analyzing your welding cable performance, then you will be well informed when it comes to replacing it if you need to make changes.

Do you have any questions about our products or services? Or do you need a consultation on what size welding cable would work best for your project and machines? Contact us today and let us help you with all your cable and wire needs!