Welding Cable vs. Battery Cable: Can You Substitute One For The Other?
Welding and battery cables are often compared because of their similar ampacity. 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 that were originally created for the welding leads. They are equipped with a stranded copper conductor. Today, welder’s cables with a RHH/RHW double rating are quite versatile and used in many applications, including industrial uses and other demanding environments. If you wish to learn more about welding lead wire applications, read this blog on the topic.
Battery cables are designed to connect batteries with their starter. 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 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, which makes it easy to install welder’s cables in batteries in the same way battery cables are installed.
Welding cables have excellent high-heat resistance. With EPDM insulation, their temperature range is -50℃ - 105℃, which is perfect for batteries. In fact, welding cables rank higher than battery cables when it comes to 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 in that regard.
Welding lead wire with EPDM insulation performs way better than PVC-insulated battery cables in freezing temperatures; therefore, you might consider using welding cables if your batteries are often exposed to cold. If the battery wire has an XLPE insulation instead, this comparison is not relevant as it is not likely to stiffen in the cold.
It makes sense to choose welding cables for large battery banks because they come in a bigger size range than different types of battery cables.
Note that in order to comply with the National Electrical Code Standard, welding cable needs 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.
Can I use a battery cable for welding arcs?
While welding cable is suitable for 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.
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.
Some say that welding cables are too expensive to replace cheaper battery cables in car applications, while others prefer to use them in car batteries and car 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.
Foreword
Properly rated welding cables can replace battery cables, but not vice versa. While it is not necessary to replace battery cables with welder's, 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 the high-quality wire and cable in the industry thanks to the access to special rates from our suppliers.
