AWG Size Options

All of the compression lugs come in a wide variety of sizes. For the short barrel one hole compression lugs there is a range of sizes starting from 6 AWG all the way to 500 MCM size. This gives customers the ability to use almost any size welding cable they have. These lugs also come in both a flexible and a non-flexible form. Also each AWG sized lug has options that customers can pick the size of the bolt they want to use. The range of sizes available to customers also gives them the freedom to use the lugs to attach to almost any welding machine.

Bolt Size Options

The size of the bolt a customer uses to attach the compression lug to the welding machine is very important. There are different bolt size options for each size of compression lug. Generally the bigger the compression lug and the cable being used the larger the bolt will need to be to keep a strong connection.  The size of the bolt can also be determined by the machine you are attaching too. If the welding machine moves shakes a lot you may want a bigger bolt to make the connection stronger and last longer.

Flexible vs. Non-Flexible

This is referring to the kind of cable being used here. A flexible cable used a different lug than a non-flexible cable. This is because the copper strands of the flexible cable will start to fray to a bigger O.D. when the insulation is removed. So a flexible cable needs to use a flexible lug. Meanwhile a solid copper cable will be able to use a solid compression lug. Just know that as the cables get larger though it’s more likely that they are going to only come in the flexible option. This is because larger gauges of wires and cables with solid conductors do not bend or move well.

Compression lugs by Burndy are rated to be able to handle between 600 volts and 35,000 volts of electricity. The lugs also are approved for temperatures reaching as high as 90°C. They also have both UL and CSA approvals on them. The fact that the compression lugs come in a variety of sizes with the options of having different size bolts as well as options for flexible and solid conductors just proves that this product is versatile. These compression lugs are going to be great for any customer who needs them.

Written by: WesBell Wire and Cable

SOOW & SJOOW Cables

These cables are very similar. The SOOW and SJOOW cables are almost identical except for the voltage level each of them can handle. The SOOW cable is approved to be able to handle up to 600 volts of electricity, while the SJOOW cable is only approved to be able to handle 300. They are both used in control circuits, machine tools, heavy industrial, and processing and construction equipment. These cables are extra flexible and are super abrasion resistant. And they are made with a Neoprene rubber jacket around them.

Type W Cable

The Type W portable cord is approved to be able to handle 2,000 volts of electricity, and have the same neoprene rubber jacket around them. The cords are better suited for outdoor use and can handle the outdoor environment better than the SOOW cables. This cord can also withstand exposure to oils, acid, alkalies, heat moisture and most chemicals, making this the perfect cord for industrial applications. This cord is intended to be used in heavy duty service as power supply, and even in mobile and portable electronic equipment. Because of these uses the cords need to be very rugged and durable.

Type G and G-GC Cable

The Type G and  G-GC cords are very similar to the Type W cords. The only main difference is that the Type G and the G-GC cords have additional ground wires that the Type W cords do not have.  They are made with the same Neoprene rubber jacket again. And the cords have just about identical uses and applications that the Type W cables have.  These cords are also rated to be able to handle temperatures between -40°C and up to 90°C.

Tray Cable

Tray cable has a number of smaller conductors inside of it. The cords start off with a PLTC cable, and then it gets two or three conductors added to it. However these cords can have up to five conductors in it. It can either be shielded or unshielded. Most of the options for tray cables are approved for 300 volts of electricity. The tray cables are made to endure extreme conditions such as extreme heat, weathering, moisture, and even sunlight. The extreme durability of the cords allows it to be used in industrial applications.

Higher Voltage Cable

For even higher voltage cord options you could look at a MV-105 power cable. These cable options are a little different. They are usually made from a combination of ethylene propylene rubber and cross linked polyethylene. The cables are usually rated to be able to handle voltages around 5kV to 35kV. These cables are generally only used for either industrial or commercial uses. The cords are made to last and can provide customers with long term service. Customers need to be careful of which cord they purchase and need to be sure they know what they are doing before buying a high voltage MV-105 cable.

As a customer you need to make sure that you have done your research before you go right ahead and buy one of these cables. Each one is a little bit different. They do all however have very similar uses, and are made out of fairly similar materials. It is important that as a customer you know what you’re doing when doing electrical work. The SJOOW & SOOW cords are more basic and more commonly used. The Type W, G and G-GC cords are more for industrial uses than uses around the home. Same goes for the Tray cables and the High voltage cables.

Written by: WesBell Wire and Cable

One Hole

This is the basic kind of compression lug. A one hole compression lug is simply just that. There is one hole in the lug so that there is one bolt that can attach the lug to the welding machine. This does not however give the most secure connection. This lug is the least expensive out of all the options.

Short Barrel

These compression lugs are also pretty basic. Again it’s just what it sounds like a short barrel lug. The barrel on the lug is short so there is only room for one crimp onto the welding cable. This gives a good connection between the two but it does not however provide the best connection. The short barrel compression lug is the more basic option when comparing it to the long barrel lug.

Two Hole

The two hole compression lugs give a better hold onto the welding machine. That’s because there is room for two bolts. The two bolts obviously give a better connection than just the one bolt does. If you have a welding machine that vibrates a lot you may want to consider buying a two holed compression lug. The two bolts give the connection more strength and a better hold compared to when there is only one bolt.

Long Barrel

The long barrel lugs offer a better grip onto the welding cable than the short barrel lugs do. This is because there is room for two crimps onto the welding cable rather than just the one. This will also offer a longer connection not only between the compression lug and the welding cable, but also between the compression lug and the welding machine as well.

Depending on the manufacturer the lugs can have both UL and CSA approvals. The compression lugs are all made of copper. They all have a beveled entry and are electro tin plated. Depending on the size of the barrel of the lug it can be crimped either once or twice the higher number of crimps there are the stronger the hold the lug has on the welding cable itself. The number of holes the compression lug has also dictates the number of bolts that can be used to secure the lug to the welding machine.

Written by: WesBell Wire and Cable

Polyolefin

This is the most basic form of heat shrink tubing. It is also the least expensive form. This kind of tubing is still all purpose and can satisfy a variety or demanding needs and different applications. The polyolefin tubing won’t burn or support flames. The tubing is thermally stable and can be used as a multi-purpose insulator. And the tubing is resistant to chemicals as well as solvents. Meaning that not only can this tubing help to fix breaks in a wire or cable but it also can increase the protection of the wire.

Adhesive Lined

This tubing has a thin layer of glue on the inside. So now when the tubing is heated to shrink the glue also melts. Once it is dry it has formed an even more solid bond between the tubing and the wire or cable it has been shrunk around. The adhesive also helps to create a corrosion resistant seal. The adhesive lined tubing is still flexible so it won’t interfere with the wire or cables flexibility. It is also offers the wire more moisture protection. Because of the added protection and the adhesive lining this variation of the tubing is going to be more expensive. It is however worth the money for the added protection and the better hold it will have on the wires.

PVC

PVC stands for polyvinyl chloride. This tubing is slightly more expensive. That is because it has a more glossy feeling to it that the other kinds of tubing. This version of tubing has a lower shrinking temperature than the others do. It also has superior strength to it once it has been shrunk down to size. The PVC tubing is also highly flame resistant. And in addition to being resistant to chemicals and moisture, they are also resistant to oils, sunlight and fungus. The PVC tubing pretty much has the same characteristics as PVC coated wire.

Tubing can be very helpful. They all come in a variety of colors so that each wire can easily be identified. They are great for organizing as well as fixing broken wires. The tubing no matter what kind you get can also be great for bundling multiple wires together. Each material that the heat shrink tubing can be made out of each has its own set of unique characteristics. As a customer you should look at each kind of tubing to see which one will best fit your needs.

Written by: WesBell Electronics, Inc. 

The literal reason for THHN THWN electrical wire being less flexible is due to the size of the copper strands. When the diameter of two copper cables is the same it means they have the same AWG size and, therefore, offer the same amount of power. However, when one of the two cables has smaller strands of copper it will make it much more flexible.

For instance, a 6 AWG THHN wire has 19 copper strands while a 6 AWG welding cable has 259 strands. They both meet the same diameter and offer the same amount of power but the welding cable will be much more flexible due to the use of smaller strands.

Another reason for the flexibility difference is due to the insulation. Thermoplastic High Heat Nylon insulation uses stiff PVC and a nylon coating similar to the clear piece at the end of a shoe lace. You can imagine how the clear nylon piece over the entire length of the wire will deem it less flexible. Welding cable uses a rubber EPDM insulation designed to be flexible because a welder will be using the cable daily instead of just installing it.

Manufacturers understand each application and how beneficial certain characteristics can be for the user or for the connection. In this case, they understand that installers want their THHN wire to be stiff in order to push it through conduit and snake it through walls. They also know that welders coil and uncoil their cable daily along with dragging it around the shop throughout the day. Flexibility is a big attribute to give welding cable due to the daily use of it.

The last step is for the engineers to actually create the electrical wire. Sure, it needs to resist water, but how? With what materials? I’ll leave that for them to explain but beware that there are more than just the cost of materials involved in pricing these electrical cables. Speak to your wire and cable supplier if you’re unsure of exactly what you need for your application. They might even save you a few dollars by recommending a similar cable.

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PTFE 22 AWG hook up wire will not have a set price which you will quickly find out as you start you search. A supplier of PTFE wire could have bought their inventory within the last 6 months which means their cost could have been up to 15% lower or higher depending, literally, on the day they bought it. Copper could have been high on that particular day, silver could’ve been high and the demand for PTFE compound has been rising as well.

Copper is the first component in PTFE hook up wire because the strands are manufactured with copper as the conductor of electricity. Copper jumped in price about 3 years ago and has steadily increased since then. If the price of copper-per-pound goes up then it raises the price suppliers will have to pay for it. If copper goes up 10% the price of the wire will not go up 10% because there are other factors such as silver and insulation compounds.

Silver is the second factor to consider when buying PTFE wire. Silver is used to coat the copper to help limit corrosion and to help the conductivity of the wire. Since silver is a better conductor of electricity the added silver will make a clearer connection than the bare copper without silver. PTFE insulation is used for higher temperature applications which can corrode the copper so the silver helps limit that.

A common type of PTFE compound is a brand name called TEFLON®. TEFLON® is a group of elements used in PTFE insulation that help it withstand high temperatures. It also helps create a non-stick outer insulation which you’ll notice when you handle it. It has a slippery feeling almost as if it were wet.

Speak to your wire and cable supplier about 22 AWG hook up wire to make sure that PTFE wire is right for you. It can be very expensive, as explained, compared to a basic PVC hook up wire used in appliances, electronics and wire harness assemblies.

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Since a solid rod of 2/0 isn’t flexible enough and a 19 strand 2/0 wire isn’t flexible enough what do you need? You need something with more than 19 strands. Portable cord products are those that are manufactured with a rubber insulation rather than PVC insulation with a nylon coating. So moving into the portable cord industry might be right for you.

First, understand that contractors, electricians and installers like to have a stiff 2/0 wire to push through conduit and snake up walls of homes and buildings. Having a wire that holds its form is more useful to them during the installation process. Even though that’s the case they still wouldn’t be able to work well with a solid strand of 2/0 but having the wire still is the goal for that industry.

Welding cable is a single conductor wire that comes in 6 AWG through 500 MCM which includes a 2/0 size. While building wire is installed and forgotten about, welding cable is installed and used day to day. Commonly, welders will uncoil the wire in order to use it around the shop for welding jobs which definitely promotes flexibility. Once the jobs are completed for the day they will coil it back up and store it in a corner of the room which also promotes flexibility.

Most portable cord products are very similar to welding cable in that they are used day to day rather than installed and forgotten. Another type of portable cord is a simple extension cord you have at your home. This is the same scenario as the welding cable where you will need to uncoil it and coil it back once you’re finished. It also might need to be run out a door and around a corner in order to connect to the application which wouldn’t be as easy with a stiff electrical wire 2/0.

There are many more flexible types of electrical wire on the market that should be referred to as portable cord in the future. Mentioning “electrical wire” will most likely lead you in the wrong direction.

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1. TFFN = Thermoplastic Flexible Fixture Nylon

2. THHN = Thermoplastic High Heat Nylon

3. THWN = Thermoplastic Heat and Water resistant Nylon

The acronyms above each have specific letters that represent specific characteristics of the particular wire you’re looking to buy. If the “N” is missing from the acronym (THW wire) then the nylon coating will be missing as well. Since the beginning of the 2000’s these types of electrical wire have been dual or tri-rated in order to minimize inventory for large manufacturers. You’ll commonly find an electrical wire with THHN/THWN/THW markings on it which means all of the approvals above have been met in the same wire. It can be called a universal THHN wire.

The nylon coating adds value to the wire in a few ways starting with the resistance of moisture, chemicals, oils and solvents. It’s also a glossy smooth finish helping with the installation process. The nylon coating almost provides a lubricant which helps it slide through the conduit installations.

THHN and THWN electrical wires are used in homes and buildings to run power from the electrical box to the lights, outlets and appliances. You might even see the THHN wires within a cable format in such cables as MC cable, Romex® NMB cable and UFB underground cables. Each cable has a different jacket over the wires to protect it against the environment it is most commonly used in. UFB is the most expensive cable with the highest amount of engineering to protect the copper from direct burial use.

Underneath the nylon coating is a thermoplastic, or PVC, insulation. PVC is a common type of insulation for electronic and appliance wire used indoors. UL1015 16 AWG hook up wire is a standard type that’s cut to length and used in wire harnesses that are then used in appliances to make multiple connections at once. There are many colors available for harnesses that require 15 to 20 wires in it.

Speak to your wire and cable supplier to see which type of wire is best for your application. They will provide you with some insight about each type of hook up wire for you to make the final decision.

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A 4 AWG wire is considered a 4 AWG wire when it falls into a certain outer diameter bracket which is a very small tolerance. The thickness of the insulation cannot be included in the outer diameter because the insulation is there for completely different reasons than the copper.

So, you have a solid tinned copper strand of wire without insulation and you need it to be more flexible. Obviously a 10 AWG solid tinned copper strand would bend easier than a 4 AWG correct? Even better, a 30 AWG wire would easily wrap around your finger so that would be the most flexible option. Any time you see a 4 AWG wire on the market using 30 AWG strands you’ll also notice that it takes 374 of those strands wound together to equal the same outer diameter as the single 4 AWG strand of tinned copper.

We sell both types of tinned copper electrical wire because we like to offer the available options to our customers. The single strand of solid tinned copper 4 AWG is used as a grounding wire so there’s no need for it to be flexible. There are also industries that like less flexible wires for installations in conduit and in walls of homes and buildings. A flexible wire would just bunch up when trying to push it through conduit creating many headaches.

Bus bar wire is another term for tinned copper. The process is that of using bare copper first and coating it with a layer of tin. It seeps through the copper making it look like silver or aluminum so if you’re unsure of the type make sure you consult an electrician or metal expert to examine it for you.

Please call us if you have questions about flexibility or the different types of insulation that can cover a 4 AWG tinned copper wire. Different types of insulation protect the copper against temperature and environmental conditions such as moisture, gasses, oils and chemicals.

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Class K stranding refers to the use of 30 AWG copper strands which is already much more flexible than a standard THHN electrical wire. A 2/0 welding cable with class K stranding will need a total of 1248 strands to meet the outer diameter requirement of a 2/0 wire. This cable weighs about 487 pound per 1000 feet, it’s rated for 600 volts and has a temperature rating of 90ºC.

Class M stranding refers to the use of 34 AWG copper strands which makes this an extra flexible welding cable called Super Vu-Tron. A 2/0 Super Vu-Tron welding cable needs a total of 3300 copper strands to meet the outer diameter requirement of a 2/0 wire. A super Vu-Tron welding cable is UL, CSA, MSHA and RoHS compliant while the class K cable is only RoHS compliant.

The Super Vu-Tron welding cable also has a much more rugged insulation to deal with more impact throughout the day. It’s more commonly used on industrial job sites to bring power to portable tools and machines. It’s still a single conductor portable power cable rated for 600 volts and 90ºC but it can handle a lot more impact than the class K cable.

Since the class M stranded cable has a thicker insulation it can also handle a higher amount of power travelling through it. Class M welding cable can handle 300 AMPS while class K cables can handle 223 AMPS. Be careful when choosing a cable yourself because the amount of AMPS is calculated partly by the distance the power is travelling. The calculations on websites and in catalogs are based on a 250 foot run only. If your installation is longer or shorter than that then you should most definitely speak to an electrician about the size of cable you need.

If you’re not sure about the stranding option you need then speak to your electrical wire and cable supplier and they will walk you through the similarities and differences so you can make the decision yourself. Suppliers deal with different situations every day so they have probably already had a similar application requirement as yours.

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