It is normal for a properly sized welding cable to feel warm to the touch after prolonged welding. Therefore, some amount of resistance heating will occur in the cable. Note that while copper is an excellent conductor of electricity, it still has a degree of resistance to the flow of electrons through it. Multiple cables should be slightly spread apart. In addition, several cables packed tightly together can also have a reduction in their ability to dissipate heat. Higher ambient temperatures can reduce their ability to dissipate heat into the surrounding environment, and thus reduce their ampacity. Welding cables are also often rated for an ambient temperature of 30☌ (86☏). While the copper wire itself can handle the high temperatures generated by higher amperages before sustaining damage, the insulation protecting them would melt. Welding cable is often rated with a conductor temperature of 75☌ (167° F), 90☌ (194⁰F) or 105☌ (221☏). Shorter cables can carry more current than longer cables of the same diameter. Besides the cross sectional area, other factors that impact the ampacity of welding cable are its length, ohm rating (i.e., resistance rating), temperature ratings of the insulation material and the ambient temperature. Welding cable “ampacity”, also known as current capacity or amperage rating, refers to the maximum amount of electrical current that a cable can safely conduct. You use a smaller hose to water your garden, while the fire department uses a much larger hose to fight fires. A larger diameter hose is needed in order to carry a greater volume of water. The concept is similar to the flow of water through a hose. As the current level increases (measured in amperage or amps), the diameter of the welding cable and resulting cross sectional area of the copper stranding needs to increase. The fine copper strands give welding cable more flexibility than other types of electrical conductors and the insulating jacket is designed to hold up to repeated movement over rough surfaces. It consists of a series of fine copper strands wrapped inside a non-conductive, durable jacket (typically some type of synthetic or natural rubber of various colors). Welding cable is the electrical conductor for the welding current. I have seen some reference charts, but would like an explanation on how to use them. I need to order some welding cable for our shop, but am not sure the correct size to get.
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