Welding Cable

What is Welding Cable?

Welding cable is designed for use in electric arc-welding machines to power an electrode, a specially designed metal rod, that conducts a charge. The charge carried by the electrode is needed to produce an electric arc, the heat source, between the electrode and the metals being welded.

Welding cable is made to be extremely durable and flexible. Arc-welding requires a person to move the electrode around the shop and along the joints being welded, so it is essential to have a flexible welding cable that allows for ease of movement. A high strand count and rubber insulation help increase the cable's flexibility.

A durable cable is important in industrial environments where abrasions, cuts, burns from sparks, and oil and water exposure can quickly wear out a weaker cable.

TEMCo's Welding Cable is highly flexible stranded No. 30 bare copper conductor insulated with high grade black EPDM. A paper separator is utilized to enhance stripability. Maximum conductor operating temperature is 105°C in circuits not exceeding 600 volts. Minimum temperature rating -50°C. View our guide below to learn more about welding cable sizing and applications. Our full product line is also available below.

what is welding cable TEMCo Welding Cable

Sizing & Applications

This guide is meant to inform and support you in the proper selection and use of welding cable. We always recommend that you consult a licensed and competent electrician to help you with the sizing and selection of parts for your particular application.

Sizing

For welding applications, specifications to consider are:

Ampacity: The ampacity refers to the maximum amount of current your cable can handle safely. For more information, view the section on welding cable ampacity.

Length: Your cable should be long enough to reach every corner of the space you will be welding in. You will need to keep in mind (1) one cable connects from the welder to the elctrode and (2) another cable will connect from the welder to the piece that is being welded (also known as the work clamp or ground lead).

Gauge: The longer and thinner the welding cable, the lower the ampacity, so if you require a long cable, you may want to look at thicker sizes to compensate for the length and to prevent damage to your machine.

Insulation: Welding cable insulation is commonly made of neoprene, EPDM, or PVC. Both neoprene and EPDM jackets are flexible, resistant to harsh weather, abrasion, moisture, and water. However, they are not well suited for exposure to gas or other petroleum based liquid. PVC is less flexible but has high resistance to cuts and tears.

Flexibility: The higher the strand count, the more flexible the cable.

Color: You may want additional insulation colors to distinguish between different cables.

Gauge Max Amps Nomnial OD (in.) Conductor Diameter (in.) Conductor Stranding
6 AWG 115 0.303 0.2 260/30
4 AWG 150 0.331 0.228 364/30
2 AWG 205 0.413 0.3 624/30
1 AWG 240 0.481 0.343 767/30
1/0 285 0.526 0.373 975/30
2/0 325 0.564 0.426 1196/30
3/0 380 0.621 0.465 1547/30
4/0 440 0.686 0.56 1950/30

Applications

Arc-welding: For welding applications, two cables are required: one connects the machine to the electrode, while the other connects the machine to the workpiece that is being welded, and these two cables form a complete circuit.

Other uses: Welding cables are durable and flexible and are a popular choice for entertainment or stage lighting cables, lighting and sound systems, and communication vans. They can also function as battery cables for cars, inverter cables, and as a more cost-effective alternative to pendant (or reeling) cable on hoists and cranes.

This Portable Welder Instructables Tutorial is a great example of how you could use TEMCo welding cable for your own personal projects. This particular project uses 50 feet of 1/0 welding cable to create a connection cable from the batteries/vehicle to the welder.

Instructable for Portable welder using 1/0 welding cable

Ampacity

The ampacity, or amperage capacity, is the maximum amount of electrical current that the welding cable can conduct safely. Different welding cable running on the same voltage will have different amp ratings depending on several factors, which include: cable length, wire size (gauge), insulation temperature rating, and the type of machine the cables are connected to.

What affects welding cable ampacity?

Electrical resistance (in ohms) & insulation temperature rating: The more amps you run through your cable, the hotter it gets. The higher the resistance rating of the welding cable, the fewer amps you can safely run without overheating it. Overloading your welding cable will over heat it, which leads to damage to the insulation.

Cable size & length: Ampacity ratings decrease as the cable is longer and thinner.

Ambient temperature: Electrical resistance increases at higher temperatures. Ambient temperature affects the cable's ability to dissipate heat. Multiple cables lying too close or on top of each other dissipate less heat.


AWG Size Chart

Welding cable size is measured by the American Wire Gauge (AWG) standard. AWG sizes will have three numbers, for example, "2 AWG 625/30." This means that the welding cable has a total cross sectional area of 2 AWG and is made from 625 strands of 30 AWG wire.

View the AWG reference table below for dimensions and sizing of welding cable.

AWG Diameter (in.) Diameter (mm) Circular Mil
4/0 0.4600 11.6840 211593.92
3/0 0.4096 10.4038 167767.34
2/0 0.3648 9.2659 133075.22
1/0 0.3249 8.2525 105556.98
1 0.2893 7.3482 83692.09
2 0.2580 6.5532 66562.09
3 0.2290 5.8166 52439.49
4 0.2040 5.1816 41614.80
5 0.1820 4.6228 33123.05
6 0.1620 4.1154 26250.70
7 0.1443 3.6648 20817.56
8 0.1285 3.2639 16511.78
9 0.1144 2.9058 13086.98
10 0.1019 2.5883 10383.31
11 0.0907 2.3038 8226.25
12 0.0808 2.0523 6528.45
13 0.0720 1.8288 5183.85
14 0.0641 1.6281 4108.69
15 0.0571 1.4503 3260.32
16 0.0508 1.2903 2580.57
17 0.0453 1.1506 2052.03
18 0.0403 1.0236 1624.04
19 0.0359 0.9119 1288.77
20 0.0320 0.8128 1023.97
21 0.0285 0.7239 812.23
22 0.0253 0.6426 640.07
23 0.0226 0.5740 510.75
24 0.0201 0.5105 404.00
25 0.0179 0.4547 320.40
26 0.0159 0.4039 252.80
27 0.0142 0.3607 201.63
28 0.0126 0.3200 158.76
29 0.0113 0.2870 127.69
30 0.0100 0.2540 100.00
31 0.0089 0.2261 79.21
32 0.0080 0.2032 64.00
33 0.0071 0.1803 50.41
34 0.0063 0.1600 39.69
35 0.0056 0.1422 31.36
36 0.0050 0.1270 25.00
37 0.0045 0.1143 20.25
38 0.0040 0.1016 16.00
39 0.0035 0.0889 12.25
40 0.0031 0.0787 9.61


Product Selection

TEMCo Welding Cable
TEMCo Welding Cable
TEMCo Welding Cable
TEMCo Welding Cable

Conductor: Fully annealed stranded bare copper per ASTM B-172
Jacket: High Grade EPDM
Great flexibility
Resistant to cuts, tears, abrasion, and moisture.
For secondary voltage resistance welding leads and power supply applications not exceeding 600 volts AC.

6 AWG

Conductor Stranding: 259/0.01 in.
Nominal Outside Diameter (in.): 0.32
Max Amps: 115

Length
(ft.)
Color
(Model No.)
Black Red Black & Red
5 WC0081 WC0161 -
10 WC0082 WC0162 WC0199
15 WC0083 WC0163 -
20 WC0084 WC0164 WC0200
25 WC0096 WC0165 -
30 WC0085 WC0166 WC0201
35 WC0086 WC0167 -
40 WC0473 WC0474 WC0449
50 WC0087 WC0168 WC0202
60 - - WC0450
65 WC0391 WC0436 -
75 WC0088 WC0169 -
80 - - WC0451
85 WC0392 WC0437 -
100 WC0089 WC0170 WC0203
125 WC0393 WC0438 -
150 WC0090 WC0171 WC0204
175 WC0394 WC0439 -
200 WC0091 WC0172 WC0205
225 WC0395 WC0440 -
250 WC0092 WC0173 WC0206
300 WC0093 WC0174 WC0207
400 WC0094 WC0175 WC0208
500 WC0095 WC0176 WC0209
1000 WC0448 WC0441 WC0447

4 AWG

Conductor Stranding: 364/0.01 in.
Nominal Outside Diameter (in.): 0.348
Max Amps: 150

Length
(ft.)
Color
(Model No.)
Black Red Black & Red
5 WC0113 WC0145 -
10 WC0114 WC0146 WC0188
15 WC0115 WC0147 -
20 WC0116 WC0148 WC0189
25 WC0117 WC0149 -
30 WC0118 WC0150 WC0190
35 WC0119 WC0151 -
40 WC0475 WC0476 WC0452
50 WC0120 WC0152 WC0191
60 - - WC0453
65 WC0385 WC0430 -
75 WC0121 WC0153 -
80 - - WC0454
85 WC0386 WC0431 -
100 WC0122 WC0154 WC0192
125 WC0387 WC0432 -
150 WC0123 WC0155 WC0193
175 WC0388 WC0433 -
200 WC0124 WC0156 WC0194
225 WC0389 WC0434 -
250 WC0125 WC0157 WC0195
300 WC0126 WC0158 WC0196
400 WC0127 WC0159 WC0197
500 WC0128 WC0160 WC0198
1000 WC0390 WC0435 WC0446

2 AWG

Conductor Stranding: 624/0.01 in.
Nominal Outside Diameter (in.): 0.42
Max Amps: 205

Length
(ft.)
Color
(Model No.)
Black Red Black & Red
5 WC0097 WC0129 -
10 WC0098 WC0130 WC0177
15 WC0099 WC0131 -
20 WC0100 WC0132 WC0178
25 WC0101 WC0133 -
30 WC0102 WC0134 WC0179
35 WC0103 WC0135 -
40 WC0477 WC0478 WC0455
50 WC0104 WC0136 WC0180
60 - - WC0456
65 WC0379 WC0424 -
75 WC0105 WC0137 -
80 - - WC0457
85 WC0380 WC0425 -
100 WC0106 WC0138 WC0181
125 WC0381 WC0426 -
150 WC0107 WC0139 WC0182
175 WC0382 WC0427 -
200 WC0108 WC0140 WC0183
225 WC0383 WC0428 -
250 WC0109 WC0141 WC0184
300 WC0110 WC0142 WC0185
400 WC0111 WC0143 WC0186
500 WC0112 WC0144 WC0187
1000 WC0384 WC0429 WC0445

1 AWG

Conductor Stranding: 780/0.01 in.
Nominal Outside Diameter (in.): 0.503
Max Amps: 240

Length
(ft.)
Color
(Model No.)
Black Red Black & Red
5 WC0216 WC0233 -
10 WC0217 WC0234 WC0250
15 WC0218 WC0235 -
20 WC0219 WC0236 WC0251
25 WC0220 WC0237 -
30 WC0221 WC0238 WC0252
35 WC0222 WC0239 -
40 WC0479 WC0480 WC0458
50 WC0223 WC0240 WC0253
60 - - WC0459
65 WC0374 WC0419 -
75 WC0224 WC0241 -
80 - - WC0460
85 WC0375 WC0420 -
100 WC0225 WC0242 WC0254
125 WC0376 WC0421 -
150 WC0226 WC0243 WC0255
175 WC0377 WC0422 -
200 WC0227 WC0244 WC0256
225 WC0378 WC0423 -
250 WC0228 WC0245 WC0257
300 WC0229 WC0246 WC0258
400 WC0230 WC0247 WC0259
500 WC0231 WC0248 WC0260
1000 WC0232 WC0249 WC0261

1/0

Conductor Stranding: 988/0.01 in.
Nominal Outside Diameter (in.): 0.533
Max Amps: 285

Length
(ft.)
Color
(Model No.)
Black Red Black & Red
5 WC0012 WC0034 -
10 WC0013 WC0035 WC0050
15 WC0014 WC0036 -
20 WC0015 WC0037 WC0051
25 WC0368 WC0413 -
30 WC0016 WC0038 WC0052
35 WC0017 WC0039 -
40 WC0481 WC0482 WC0461
50 WC0018 WC0040 WC0053
60 - - WC0462
65 WC0369 WC0414 -
80 - - WC0463
75 WC0019 WC0041 -
85 WC0370 WC0415 -
100 WC0020 WC0042 WC0054
125 WC0371 WC0416 -
150 WC0021 WC0043 WC0076
175 WC0372 WC0417 -
200 WC0059 WC0067 WC0077
225 WC0373 WC0418 -
250 WC0022 WC0044 WC0444
300 WC0060 WC0068 WC0078
400 WC0061 WC0069 WC0079
500 WC0062 WC0070 WC0080
1000 WC0211 WC0213 WC0215

2/0

Conductor Stranding: 1235/0.01 in.
Nominal Outside Diameter (in.): 0.586
Max Amps: 325

Length
(ft.)
Color
(Model No.)
Black Red Black & Red
5 WC0001 WC0023 -
10 WC0002 WC0024 WC0045
15 WC0003 WC0025 -
20 WC0004 WC0026 WC0046
25 WC0362 WC0407 -
30 WC0005 WC0027 WC0047
35 WC0006 WC0028 -
40 WC0483 WC0484 WC0464
50 WC0007 WC0029 WC0048
60 - - WC0465
65 WC0363 WC0408 -
75 WC0008 WC0030 -
80 - - WC0466
85 WC0364 WC0409 -
100 WC0009 WC0031 WC0049
125 WC0365 WC0410 -
150 WC0010 WC0032 WC0071
175 WC0366 WC0411 -
200 WC0055 WC0063 WC0072
225 WC0367 WC0412 -
250 WC0011 WC0033 WC0443
300 WC0056 WC0064 WC0073
400 WC0057 WC0065 WC0074
500 WC0058 WC0066 WC0075
1000 WC0210 WC0212 WC0214

3/0 AWG

Conductor Stranding: 1539/0.01 in.
Nominal Outside Diameter (in.): 0.675
Max Amps: 380

Length
(ft.)
Color
(Model No.)
Black Red Black & Red
5 WC0262 WC0278 -
10 WC0263 WC0279 WC0294
15 WC0264 WC0280 -
20 WC0265 WC0281 WC0295
25 WC0266 WC0282 -
30 WC0356 WC0401 WC0442
35 WC0267 WC0283 -
40 WC0485 WC0486 WC0467
50 WC0268 WC0284 WC0296
60 - - WC0468
65 WC0357 WC0402 -
75 WC0269 WC0285 -
80 - - WC0469
85 WC0358 WC0403 -
100 WC0270 WC0286 WC0297
125 WC0359 WC0404 -
150 WC0271 WC0287 WC0298
175 WC0360 WC0405 -
200 WC0272 WC0288 WC0299
225 WC0361 WC0406 -
250 WC0273 WC0289 WC0300
300 WC0274 WC0290 WC0301
400 WC0275 WC0291 WC0302
500 WC0276 WC0292 WC0303
1000 WC0277 WC0293 WC0304

4/0 AWG

Conductor Stranding: 2014/0.01 in.
Nominal Outside Diameter (in.): 0.72
Max Amps: 440

Length
(ft.)
Color
(Model No.)
Black Red Black & Red
5 WC0305 WC0322 -
10 WC0306 WC0323 WC0339
15 WC0307 WC0324 -
20 WC0308 WC0325 WC0340
25 WC0309 WC0326 -
30 WC0310 WC0327 WC0341
35 WC0311 WC0328 -
40 WC0487 WC0488 WC0470
50 WC0312 WC0329 WC0342
60 - - WC0471
65 WC0351 WC0396 -
75 WC0313 WC0330 -
80 - - WC0472
85 WC0352 WC0397 -
100 WC0314 WC0331 WC0343
125 WC0353 WC0398 -
150 WC0315 WC0332 WC0344
175 WC0354 WC0399 -
200 WC0316 WC0333 WC0345
225 WC0355 WC0400 -
250 WC0317 WC0334 WC0346
300 WC0318 WC0335 WC0347
400 WC0319 WC0336 WC0348
500 WC0320 WC0337 WC0349
1000 WC0321 WC0338 WC0350