Welding Cable vs. Battery Cable: Can You Substitute One For The Other?
Welding and battery cables are often compared because of their similar ampacity. However, welding cables are much more flexible compared to battery cables. Can you use welding cables in batteries, and if so, what is the best way to do it? Read this blog to find out.
Welding or Battery? Definitions and Common Applications
Welding cables are flexible and durable high-heat resistant cables, typically with an EPDM insulation initially created for the welding leads or neoprene insulation. Welding cables have a 600V voltage rating, are extremely flexible, and can withstand constant movement.
They are equipped with a stranded copper conductor with fine copper strands. The flexibility of a welding cable is achieved by having hundreds of fine cable strands. For example, a 4 AWG welding cable can have as many as 364 strands.
Modern welder cables with an RHH/RHW double rating are versatile and used in many applications, including industrial uses and other demanding environments. However, welding is still a key application of these cables.
If you wish to learn more about welding lead wire applications, read this blog.
Battery cables are designed to connect batteries with their starter. They are usually low-voltage cables with a 60V rating. They also have stranded copper conductors but with the standard number of strands.
Automotive wires are a separate group of battery cables for cars. Common general battery cables are SGT, SGX, and STX. Common automotive wires include GXL, SXL, TXL, GPT, TWP, and HDT. The battery cables usually come with PVC or XLPE insulation and have limited flexibility. However, they are perfect for typical battery applications. To learn more about the subtypes of auto battery wiring, read this blog.
Can I use a welding cable in batteries?
- Welder cables are compatible with battery applications. With most manufacturers, battery and welding cables have the same ampacity when their size is the same, making it easy to install welder’s cables in batteries in the same way they are installed. In fact, many stores will sell you welding cables as battery cables.
- Welding cables have excellent high-heat resistance. With EPDM insulation, their temperature range is -50℃ - 105℃, which is perfect for batteries. Welding cables rank higher than battery cables in terms of flame retardance because they meet the UL 1581 flame-retardancy standard. Battery cables are also flame-resistant, but the standards they meet, UL 558 and UL 553, are inferior to a welder's cable UL 1581. Both battery and welding cables are resistant to oil, grease, and harsh cuts, so they are both great for batteries.
- Welding lead wire with EPDM insulation performs way better than PVC-insulated battery cables in freezing temperatures; therefore, consider using welding cables if your batteries are often exposed to cold. If the battery wire has XLPE insulation instead, this comparison is not relevant as it is not likely to stiffen in the cold.
- Choosing welding cables for large battery banks makes sense because they come in a bigger size range than different types of battery cables.
- Note that to comply with the National Electrical Code, welding cables need to be double-rated as RHH/RHW for most uses, including batteries. Welding cables without an RHH/RHW rating can be used only in welding leads.
- Please note that the welding cable should be supported fully when used in a battery. To minimize abrasion, use corrugated cable protectors.
Can I use a battery cable for welding arcs?
While welding cable suits battery applications, this is not a two-way street. Battery cables cannot be used in welding arcs, as welding cables are the only type approved for welding arcs everywhere in the world. The open circuit voltage of welders is higher than 60 volts, and a battery cable can be used to sustain it.
Can you use a welder's cable instead of the car battery cable?
Welding lead wire can absolutely be used in vehicle batteries, but whether to use it is a matter of preference. It also can work as a jumper cable.
Some say welding cables are too expensive to replace cheaper battery cables in-car applications, while others prefer using them in car batteries and amplifiers. To some, welder cables seem easier to install than battery ones. While it is true that welding cable is more expensive, it may be especially useful if you need a cable with a rating of 600 volts or one that is very flexible. In other cases, it can be considered overkill.
Is welding cable suitable for solar batteries?
Welding cables work in a solar battery as well, as long as they are UV-resistant. Because of their flexibility, they work in solar installations where cables might need to be routed in complex configurations or over longer distances.
Why would you use a welding cable instead of a battery cable?
- For applications requiring cables to bend around tight spaces because of flexibility
- For applications calling for high current carrying capacity, including inverters and large battery banks
- For applications requiring UL 1581 flammability rating
Welding Cable vs. Battery Cable Compared
Foreword
Properly rated welding cables can replace battery cables, but not vice versa. While replacing battery cables with welders is unnecessary, it is an option if you need a flexible cable with a higher voltage than a regular battery cable. Welding lead wire works for car batteries as well.
Nassau National Cable is a go-to platform for welding cables, automotive wiring, and battery cables of all kinds. We have some of the best fares on high-quality wire and cable in the industry, thanks to the access to special rates from our suppliers.
