H01N2-D Welding Cable

H01N2-D Welding Cable
  • Cable Type: H01N2-D
  • Voltage: 100/100 V
  • DIN VDE 0282 part 6
  • CE & RoHS compliant

H01N2-D welding cable is used for transmission of high currents from the electric welding machine to the welding tool.

H01N2-D welding cable is highly flexible thus suitable for applications in the automobile industry, shipbuilding, transport and conveyor systems, tool making machinery, welding robots, etc.

H01N2-D welding cable retains high flexibility even under the influence of ozone, light, oxygen, protective gases, oil, and petrol.

It features cold resistant, UV resistant, flame retardant and highly flexible.So it is ideal for outside installation in dry, moist and wet areas.

Conductor Size/mm²Sheath Thickness/mmOverall Diameter/mmMax. Resistance at 20 ℃
mm²Wire NO./mmMIN.MAX.Bare Copper
10320/0.202.07.79.71.910
16512/0.202.08.811.01.160
25800/0.202.010.112.70.758
351120/0.202.011.414.20.536
501600/0.202.213.216.50.379
702240/0.202.415.319.20.268
953024/0.202.617.121.40.198
120614/0.512.819.224.00.157
150765/0.513.021.226.40.125
185944/0.513.223.128.90.102

Conductor: extra flexible copper wire

Synthetic or paper separator over the core

Sheath: Polychloroprene rubber (neoprene) jacket EM5

Color of sheath: Black

Working voltage: 100/100 volts

Test voltage: 1000 volts

Minimum bending radius:

12xOverall diameter (H01N2-D)

10xOverall diameter (H01N2-E)

Moving application operation temperature: -25℃ to +80℃

Fixed application operating temperature: -40℃ to +80℃

Flame retardant: IEC 60332-1

The Ultimate Buying Guide of Welding Cable

h01n2-d welding cable

What is Welding Cable?

Welding cables are usually defined as a pair of electrical cables which supplies power to different welding machines and functions towards the materials being welded.

The welding cable leads are attached to the welding machine. Here, one lead connects the machine with the electric holder. The other lead then connects to the welding machine to work.

Welding cable is basically a portable cord with a single conductor stranded for flexibility. It comes in sizes ranging from 6 AWG to 500 MCM. Welding cables are known to serve as the electrical conductor where the welding power/current flows.

These cables include copper strands enclosed inside of a durable, non-conductive jacket made from synthetic rubber, which, by the way, comes with a variety of colors.

It’s copper strands make the cable more flexible compared to other electrical insulating jackets and conductors. This is mainly because it resists from extreme impact coming from external factors.

It’s also designed to withstand high heat in order to overcome repeated movement over jaggy surfaces while operating. The insulating jacket comes with excellent protection from oils, coolants acids, ozone, tearing flame, abrasion, and other chemicals.

Like any conductor, welding cables can carry both AC and DC power. So, whether you’re using an AC or DC, welder matters more for figuring out what sort of electrode to use and affects what type of weld you get. As long as the cable can handle the number of amps being generated at a certain voltage (not exceeding 600 volts), it’ll work.

There are different types of welding cable, such as 0361TQ, H01N2-D, H01N2-E, etc. The H01N2-D welding cable is heat and oil resistant. It’s a Flame Retardant HOFR) flexible cable. It is used for high current transmission from the electric welding machine to the welding tool.

These cables are highly flexible and suitable for use under critical conditions like in machine tool applications, shipbuilding, motor car manufacturing, etc. You can also use these cables for non-welding applications like flexible tails on the power supply, busbar connections, and earthing return leads.

H01N2-D Special Characteristics:

  • Highly flexible
  • Heat resistant to +85 °C
  • Cold resistant
  • UV resistant
  • Retains good flexibility under the influence of general gases and oils

Welding Cable Applications

Often used in high-end applications, welding cable is a secondary voltage-resistance cable for various welding tools. It also works as a power cable which is attached to industrial machinery and generators.

For instance, electric arc-welding tools usually depend on two separate cables for operation:

  • One that acts as the main power source for the device
  • One that supplies a secondary power source

Welding cable might not power the generator, but it’s required for the electrode.

Welding cables are approved for use in power supply applications where the voltage doesn’t exceed 600 volts. Having an EPDM or neoprene jacket makes this sort of cable the most appropriate choice when it comes to tight battery applications.

It makes an excellent alternative to the battery cable. You can also use it in marine applications. However, the insulation requires to be water and oil resistant as to not become overly saturated.

Below are some of the applications where welding cable is used:

  • Battery Cables
  • Arc-welding
  • Battery Charger Lead wires
  • Electrode holder
  • Entertainment or stage lighting cables
  • Electroplating leads
  • Lighting and sound systems
  • Bus welding boxes
  • Communication vans
  • Portable lighting
  • Solar Power
  • Lift truck cables
  • Welding ground leads
  • Ground connections to arc welders
  • Welding Electrode leads
  • Battery charger lines
  • Power supply applications

How to Choose the Right Size of Welding Cable

welding cable size specification

Welding cable sizes are usually measured with an amperage rating. This rating is the highest number of current which can be delivered safely via the cable.

Other than size, the temperature ratings and length of the material can factor into the cable size you choose.

Even if the welding cable is the same diameter, one with a much shorter length can carry power more than a larger one.

The copper in the cable produces some resistance heating. Once you have the right size, you can expect your cable to be warm to the touch when it’s been used.

However, if you do end up pushing way too much current through a smaller cable, it will inevitably overheat. This will not only ruin the cable but will also cause a fire hazard.

While not hazardous, using a welding cable that is too big can be inefficient. Longer and larger amounts of cable cost more bucks due to having more copper strands.

All of that boils down to why you should choose the right size welding cable. It is indeed safer and cost-effective.

When buying a welding cable, one must know the total length of their welding circuit. This is mainly the entire path that current travels when you’re welding, including your welding gun, welding machine, or stick electrode, electrode holder, or wire, work cable and the work clamp.

You need to know about the maximum amperage which you plan on using with your welding machine and ultimately the cable. You can usually find the output on the machine.

And finally, you need to figure out the capacity rating. It’s a percentage of a 10-minute time period. It measures how much electricity can be used before the welding cable overheats and shuts down completely. You will find it either on the side of your machine or the owner’s manual.

Once noted the above information, it’s time to choose the right cable for your job. The sizes are typically measured by an American Wire Gauge (AWG) size.

In the metric system, welding cable size is expressed in square millimeters (mm2). This represents the cross-sectional part of the cable.

Cable Size (AWG)Equivalent Size (mm2)Standard Int’l Size
613.310mm2
516.816mm2
421.125mm2
326.725mm2
233.635mm2
142.450mm2
1/053.550mm2
2/067.470mm2
3/085.095mm2
4/0107.2120mm2

How Does Welding Cable Differ from Other Cables?

Welding cables are made to be extremely flexible and durable. Arc-welding requires you to move the electrode around the shop and along the joints being welded.

Therefore, it’s important to have a flexible welding cable which will allow the ease of movement. A high strand count arranged concentrically, and rubber insulation can help boost the flexibility of the cable.

A durable welding cable is crucial due to welding often taking place in industrial environments where cuts, burns from sparks, abrasions, and water and oil exposure can wear out a weaker cable quickly.

1. Welding Cable vs Battery Cable

Battery cable is a single conductor bare copper cable in an XLPE or PVC insulation. It has thicker copper strands, and they aren’t that tightly compacted in the PVC sleeving, which makes it less flexible compared to other types of cable. It’s offered in sizes ranging from 6 AWG to 4/0 AWG.

These cables are best when it comes to a simple connection and protection. However, battery cable becomes stiff and quite difficult to work with in cold weather.

This is because of the already limited flexibility. You can find battery cables in standard battery circuit cable black and red.

When comparing battery cable to welding cable, however, it’s easy to see that although battery cable has fewer strands of copper per conductor than the exact gauge size of welding cable, grounding cable aka welding cable is definitely a better choice for applications where usability and flexibility are above all.

It’s also known that the number of copper per foot of welding cable is higher than that of battery cable which enables it to handle high voltage applications.

Even though battery cables are difficult to work with compared to welding cables, especially in colder climates, they both perform quite similarly in that environment.

2. Welding Cable vs OFC

OFC — optical fiber cable, is an assembly just like an electrical cable. However, it contains one or more optical fibers which are used to carry light.

The elements here are individually coated with plastic layers and then contained in a protective tube that’s suitable for the environment where the OFC cable will be deployed.

Different types of OFC are used for different applications, such as long-distance telecommunication, providing a high-speed broadband connection between different parts of a building, etc.

As far as copper content goes, it’s all OFC. So, the strand/size count is going to be a major difference. Welding cable is usually going to have fewer strands, and therefore, it will be a little less flexible. However, that’s never been a concern of most.

Welding Cable Ampacity

Ampacity, otherwise known as amperage capacity, amp ratings, or current capacity, refers to the maximum amount of current that a cable can conduct safely.

Amperage, aka current, is a measure of the amount of charged particles (coulombs) moving past a fixed point in 1 sec. Another way to put it is that amperage is the measure of the volume charged particles moved per second relative to a fixed point or the volumetric flow rate via conductor.

Different welding cables running on a similar voltage (e.g., 600V) will have different amp ratings based on a number of factors. This includes insulation temperature rating, cable length, gauge, and what type of machine it’s connected to.

Factors Which Affect Welding Cable Ampacity Are:

1. Electrical Resistance and Insulation Temperature Rating

Three of the main factors to consider in terms of the electrical system are resistance, amperage, and voltage. Similar to how friction is the resistive force of motion between two objects (unless, of course, an object is moving through a vacuum), the force that resists the electric charges flow passing via an object is called electrical resistance.

What this means is that you’ll now have more energy losses in welding cables with greater ohm ratings while transferring electric power as energy is wasted to overcome resistance in the welding cable.

Moreover, like what happens with friction, the energy used to bypass electrical resistance turns into heat. Essentially, this indicates that the more amps conducted through your welding cable, the hotter your wires will get.

The greater the ohm ratings of the cable, the fewer amps you’ll be able to run safely without overheating the welding cable. Ampacity also depends on insulation material temperature ratings.

The copper wire itself will handle the high temperatures generated through higher amperages. However, the insulation protecting the copper wires can melt long before the wires themselves sustain any critical damage.

2. Ambient Temperature

Higher temperatures boost electrical resistance. As mentioned, the copper wire can get much hotter than the ambient temperature — wire charts are typically listed with 30° C ambient and 105° C conductor temperature ratings. But, ambient temperature can affect the ability of the welding cable to dissipate heat into its surrounding environment.

3. Cable Length, Shape, Cross-Sectional Area, and Material

All these factors directly affect how much electrical resistance you’ll have in your circuit.= Welding cable consists of stranded copper wires and is typically round in shape. What affects your cable ampacity is cable gauge, which rates the cross-sectional part in stranded wires, and length.

4. Using Several Cables In Close Proximity

Like the reasoning for ambient temperature, several cables lying close to or on top of each other can dissipate less heat than those with extra space around them.

Welding Cable Specifications

There are many leading companies that offer a wide range of high Voltage Welding Cables. They have a team of proficient laborers that design such products using superior quality insulators and conductors. These are processed under high-end technologies with the guidance of professional experts.

You can consider the following specifications for welding applications:

  • Ampacity — refers to the maximum number of current your welding cable can safely handle.
  • Insulation — the welding cable insulation is made of neoprene, PVC or EPDM. Both EPDM and neoprene jackets are flexible and resistant to harsh weather, moisture, abrasion, and water. But, they aren’t well suited for exposure to a gas or any other petroleum based liquid. Also, PVC is less flexible but has high resistance to tears and cuts.
  • Length — the welding cable should be large enough to reach each corner of the space that you’ll be welding in. You’ll, however, need to keep in mind two things: one cable connects from the welder to the electrode, and the other one will connect from the welder to the piece that’s being welded (also referred to as the ground lead or work clamp).
  • Gauge — the larger and thinner your welding cable is, the lower its ampacity will be. So, if you need a long cable, you may also want to look at thicker sizes in order to compensate for the length. This will also prevent damage to your welding machine.
  • Flexibility — the higher the strand count is, the more flexible the cable will be. Make sure the cable is flexible enough.
  • Color — Black, Orange, Blue, Red
GaugeMax AmpsNominal OD (in.)Conductor Diameter (in.)Conductor Stranding
6 AWG1150.3030.2260/30
4 AWG1500.3310.228364/30
2 AWG2050.4130.3624/30
1 AWG2400.4810.343767/30
1/02850.5260.373975/30
2/03250.5640.4261196/30
3/03800.6210.4651547/30
4/04400.6860.561950/30

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