Select the wire conductor material, either copper or aluminum.The smaller, the better, but the limit is 5% to keep devices working properly. Input what percentage voltage drop is allowable.Enter a value for the source voltage, e.g., 12 V.That means the calculator can be a simple DC wire size calculator, all the way up to an AC three-phase tool. Either DC/AC Single-phase or AC Three-phase. Select which electrical system you will be using.For welding cable, these may include SAE J1127 (battery), NFPA 70/NEC Article 630, UL 558 and 583 (and others), and CA Prop 65.ĭirect Wire’s Flex-A-Prene® and Ultra-Flex® premium welding cables meet or exceed the SAE J1127 standard, which requires minimum copper amounts per gauge (i.e., guaranteed copper contents), appropriate sizing for specific applications, and testing for mechanical and performance characteristics.įLEXIBILITY: Fine copper stranding and a high-quality outer insulation/jacket layer provide welding cable with increased flexibility, smoother pulling across various surfaces, and ease-of-movement on the job site.ĬOLOR & MARKINGS: Colored welding cable and customized markings can be used for various applications, including ownership and identification, accurate footage (or sequential) markings, industry standards and approvals, physical and mechanical characteristics, branding, and more.Here is a step-by-step guide on how to use the wire size calculator: STANDARDS & APPROVALS: Welders should look for key industry standards and approvals, ensuring quality and performance while protecting against substandard manufacturing. Superior flexibility, durability, and resistance properties are also vital to a welding cable’s ability to perform in a range of demanding applications and environments. An improper gauge size will not carry the anticipated current, which can cause excessive heat absorption (melting and fire hazard), failure, and damage to equipment.ĬONSTRUCTION: Welding cable construction uses a multi-stranded single conductor insulated (or jacketed) by a single layer of EPDM or neoprene thermoset with a temperature rating of -50☌ (-58☏) to 105☌ (221☏). If a longer cable is needed, the user should consider thicker gauge sizes. A longer, thinner welding cable will carry lower ampacity. GAUGE SIZE: It is critical to select the proper gauge size for the given welding application. It is essential to keep in mind (1) ampacity ratings decrease as length increases due to additional resistance, and (2) welding cable should be spread apart to allow heat to dissipate during use. LENGTH: Welding cables should be long enough to provide the user with adequate length to reach all work areas-without becoming a hazard. ![]() Specifications that should be considered when selecting welding cable include:ĪMPACITY: Welding cable ampacity (also known as current-carrying capacity or current rating) refers to the maximum amount of current (in amperes) that a cable conductor can continuously and safely carry without exceeding the operating temperature rating. This information is for reference only, and it is highly recommended the user consult a licensed electrical engineer for a particular welding application.įor welding applications, using the proper cable gauge size is critical to ensure high-quality welds and protect the user and their welding equipment. Direct Wire’s welding cable ampacity chart intends to support and guide welding professionals toward the proper cable gauge and length.
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