WesBell Welding Cable is flexible and rated for 600 volts and 90°C. It's used as secondary voltage resistance welding leads and power supply applications not exceeding 600 volts. It comes in black or red as standard colors AWGs 6 through 500 MCM. It’s the most basic type of single conductor portable cord in the industry since it has the least amount of approvals, protection and in-depth design.
Welding Cable Construction
It all starts with 30 AWG bare copper strands (Class K) wound together to form each different size ranging from 6 AWG to 500 MCM. As the cable size increases the amount of 30 AWG coppers strands do as well. For example, 6 AWG cables have 259 strands and 4 AWG cables have 374 strands. These small copper strands keep the flexibility of the cable loose and portable for welding applications.
Next comes the black or red EPDM jacket that has good flexibility, abrasion resistance and good color retention. Welding cable is designed to be flexible so that users can coil it when they aren’t using it, but unravel it when they need to reach different areas of their shop or garage location. Electrical cables are the opposite, it costs less money to create a less flexible cable with bigger copper strands, but it’s only attractive to buy if the cable is installed forever in a single location.
Welding Cable Approvals
Since this is the most basic single conductor portable cord product on the market, approvals aren’t as important as construction. It’s RoHS compliant and meets 600 volts and a temperature range of -40°C to 90°C. Any application that requires more voltage or higher temperature must review the approvals of another cable. The amount of AMPS each gauge size carries depends on the length of the cable, so when reviewing the AMPS listing in our charts, be sure to remember that a voltage drop needs to be considered. Otherwise, the AMPS are based on a 250’ continuous run.
Welding Cable Applications
Generally, single conductor portable cord is used in applications that require handling the cable on a regular basis. Sure, it’s easier to install a flexible cable, but if it’s never being touched again there’s no need to pay additional money for the design and manufacturing process. Also, less flexible cables are easier to install in conduit when they are stiff since they need to be pushed through long lengths of conduit or raceway. Secondary voltage resistance welding leads and power supply applications not exceeding 600 volts AC are the most common applications.
Welding Cable Manufacturers
Several manufacturers are involved in the industry of designing and manufacturing welding cable because it doesn’t require the UL and CSA approvals that most other cables do. In fact, those manufacturers that are first entering the industry will start with welding cable and work their way into more intense multiconductor portable cord cables. Therefore, you might judge the capabilities of a manufacturer based on their extensive line of cables which, in turn, describes their growth initiatives as a company. It wouldn’t make sense to start with the most difficult cable and work your way to easier cables.
Welding Cable Lugs
WesBell is an ISO 9001 certified company that cuts single conductor cord products, strips the ends off, and crimps Burndy® lugs to either end. Many of our customers request this service so we have it simplified on or website during the checkout process. Simply choose the size of your cable, the size of your lug, and make notes as to any specific dimensions and strip lengths. We can also add a 2” piece of heat shrink tubing to cover the connection point of the cable and lug for less exposed copper and a cleaner look.
- Secondary voltage resistance leads
- Portable Power
- Welding Machines