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Insulation on Welding Wire

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dfritzj(at)yahoo.com
Guest

Posted: Sun May 17, 2009 8:23 am Post subject: Insulation on Welding Wire

All,

 I'm getting ready to buy my main battery cables and would like some advice on which insulation to choose.  I've read the discussions that say welding cable is good to use for its flexibility and durability, but should I be worried about the temperature range of the insulation?  The choices seem to be neoprene welding cable (good to 90C), thermoplastic rubber welding cable (good to 105C), PVC battery cable (good to 80C), and "SGX" battery cable (good to 125C).  Any ideas/insight into which of these is the most desirable?  The application is a 24V system in a Velocity (batteries in the front, engine in the back).  Should I consider using some of the stiffer battery cable for the run from the batteries to the firewall-mounted starter contactor and then welding cable from the contactor to the starter motor?

  

 Also, Waytek has some pretty good prices on these, but only sell in quantities greater than 100ft, does anyone know a good source that won't break the bank?

  

 Thanks,

 Dan



           [quote][b]

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jaybannist(at)cs.com
Guest

Posted: Sun May 17, 2009 8:50 am Post subject: Insulation on Welding Wire

Dan,

 

 I got my welding cable (~30') at Grainger for what I thought was a very reasonable price.

 

 Jay Bannister

 

   

 

   

 

 --

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larry(at)macsmachine.com
Guest

Posted: Sun May 17, 2009 8:55 am Post subject: Insulation on Welding Wire

Hi Dan,

I think welding wire is a better product for the heavy cable at the 

batteries. It's easy to join with silver solder and cupped ring ends. 

It's flexible and doesn't

get brittle because of the fine wires.



*January 15 *The order for cable terminals from Wicks came in so the 

battery contactor to starter was stripped, inserted and was crimped 

once. Flanges were filed off. Silver solder was added to join cable and 

terminal and shrink-wrap was added. After refastening it to the 

contactor, tie-ties reattached the cable to bus support structures 

through the plane. The instrument panel was removed to the worktable and 

switches were placed thru the switch template panel to keep them in 

order. Wires were revisited to shorten them, provide bundled protection, 

and minimize motion.

see link:

http://www.macsmachine.com/images/electrical/full/chargebatteryconnection.gif



Larry McFarland 601HDS at www.macsmachine.com



D Fritz wrote:

 	  Quote: 	
		   All,

 I'm getting ready to buy my main battery cables and would like some 

 advice on which insulation to choose.  I've read the discussions that 

 say welding cable is good to use for its flexibility and durability, 

 but should I be worried about the temperature range of the 

 insulation?  The choices seem to be neoprene welding cable (good to 

 90C), thermoplastic rubber welding cable (good to 105C), PVC battery 

 cable (good to 80C), and "SGX" battery cable (good to 125C).  Any 

 ideas/insight into which of these is the most desirable?  The 

 application is a 24V system in a Velocity (batteries in the front, 

 engine in the back).  Should I consider using some of the stiffer 

 battery cable for the run from the batteries to the firewall-mounted 

 starter contactor and then welding cable from the contactor to the 

 starter motor?

  

 Also, Waytek has some pretty good prices on these, but only sell in 

 quantities greater than 100ft, does anyone know a good source that 

 won't break the bank?

  

 Thanks,

 Dan

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dfritzj(at)yahoo.com
Guest

Posted: Tue May 19, 2009 7:45 am Post subject: Insulation on Welding Wire

Thanks for the replies Larry and Jay.  Has anyone else got any input on the material of the insulation?  Particularly, would I be buying into excessive risk using the "Thermoplastic Rubber" insulated welding wire that's rated at 80C or do I need to consider going to the 105C or 125C rated materials?  I don't intend to have an electrical fire, but I like to plan for the worst and hope for the best..

  

 Da 



         [quote][b]

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nuckolls.bob(at)aeroelect
Guest

Posted: Tue May 19, 2009 7:59 am Post subject: Insulation on Welding Wire

At 10:39 AM 5/19/2009, you wrote:

 	  Quote: 	
		  Thanks for the replies Larry and Jay.  Has anyone else got any input 

on the material of the insulation?  Particularly, would I be buying 

into excessive risk using the "Thermoplastic Rubber" insulated 

welding wire that's rated at 80C or do I need to consider going to 

the 105C or 125C rated materials?  I don't intend to have an 

electrical fire, but I like to plan for the worst and hope for the best...


	


    Don't loose any sleep over it. You're

    not going to start an electrical fire

    by heating a fat wire. Welding cable is

    just fine. It's inexpensive and a joy

    to work with. Wires that burn are the

    itty-bitty fellers that should have fuses

    and/or breakers protecting them.



    Now, the insulation on your wires might

    CONTRIBUTE to a fuel fed fire but this

    is exceedingly rare . . . and if you've

    got a gasoline or oil fed fire going, adding

    a few ounces of insulation is the least

    of your worries.

        Bob . . .



        ----------------------------------------)

        ( . . .  a long habit of not thinking   )

        ( a thing wrong, gives it a superficial )

        ( appearance of being right . . .       )

        (                                       )

        (                  -Thomas Paine 1776-  )

        ----------------------------------------

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larry(at)macsmachine.com
Guest

Posted: Tue May 19, 2009 8:15 am Post subject: Insulation on Welding Wire

Considering welding wire is subjected to temporary flame, molten hot 

metal and much abuse, I'd think it's an ideal product to carry the heavy 

currents

you'll be running thru it. The insulation doesn't want to burn unless 

you've a really hot one going. By then, I doubt you'd want to be there 

either.

I'd rate the risk as very low for welding cable insulation.



Larry McFarland 601HDS at www.macsmachine.com



D Fritz wrote:

 	  Quote: 	
		   Thanks for the replies Larry and Jay.  Has anyone else got any input 

 on the material of the insulation?  Particularly, would I be buying 

 into excessive risk using the "Thermoplastic Rubber" insulated welding 

 wire that's rated at 80C or do I need to consider going to the 105C or 

 125C rated materials?  I don't intend to have an electrical fire, but 

 I like to plan for the worst and hope for the best...

  

 Da

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Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:

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frank.hinde(at)hp.com
Guest

Posted: Tue May 19, 2009 8:21 am Post subject: Insulation on Welding Wire

Yes and think of the abuse welding cable takes on the industrial job site or ship yard..I never seen a welding cable sparking to ground in 25 years of construction!



Frank 

At 10:39 AM 5/19/2009, you wrote:

 	  Quote: 	
		  Thanks for the replies Larry and Jay.  Has anyone else got any input on 

the material of the insulation?  Particularly, would I be buying into 

excessive risk using the "Thermoplastic Rubber" insulated welding wire 

that's rated at 80C or do I need to consider going to the 105C or 125C 

rated materials?  I don't intend to have an electrical fire, but I like 

to plan for the worst and hope for the best...


	


    Don't loose any sleep over it. You're

    not going to start an electrical fire

    by heating a fat wire. Welding cable is

    just fine. It's inexpensive and a joy

    to work with. Wires that burn are the

    itty-bitty fellers that should have fuses

    and/or breakers protecting them.



    Now, the insulation on your wires might

    CONTRIBUTE to a fuel fed fire but this

    is exceedingly rare . . . and if you've

    got a gasoline or oil fed fire going, adding

    a few ounces of insulation is the least

    of your worries.

        Bob . . .



        ----------------------------------------)

        ( . . .  a long habit of not thinking   )

        ( a thing wrong, gives it a superficial )

        ( appearance of being right . . .       )

        (                                       )

        (                  -Thomas Paine 1776-  )

        ----------------------------------------

- The Matronics AeroElectric-List Email Forum -

Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:

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dfritzj(at)yahoo.com
Guest

Posted: Thu May 21, 2009 9:24 pm Post subject: Insulation on Welding Wire

Thank you all for the responses on this, I feel a lot better about welding wire now.

  

 Dan



           [quote][b]

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