Stud welding offers several advantages to manufacturers across different industries. Not only is it a powerful fastening system that can connect studs to a surface with clean, quick results, but stud welding also has many welding units designed for portability. These units can be moved throughout a work site with ease using cables reaching even beyond 200 ft. The majority of handheld stud welding tools can be used as portable systems, but units like the HBS IT 2002 for arc welding and the TRUWELD ACE-P100 for capacitor discharge (CD) pins are specifically designed to be used on work sites where multiple locations require weld fastening operations. These tools and others often work with long cables that need their own management systems to ensure electrical safety and reduce trip hazards. If you’re working with portable units on multiple job sites, you can find all the supplies you need at Northland Fastening Systems (NFS). We offer a comprehensive selection of stud welding equipment, including tools for rent or purchase, studs for drawn arc and CD operations, welding accessories, and our own expertise.
Cables for Stud Welding Equipment
Whether you’re working on an active job site with a portable unit or in-house facilities with permanent systems, choosing the correct type of cable that meets a range of specifications is key. Without the correct welding cable, tools are, at best, operating at poor capacities, and at worst, posing a risk to worker safety.
Specifications for Stud Welding Equipment
There are several technical specifications to take into account when choosing the correct cable for your stud welding equipment. Basics include:
- Length: On a job site or in your routine facility layout, your cable needs to be long enough to reach a weld point without stretching. This often means you’ll need to account for extra length as you move around a space to reach multiple weld points on a part. Each welding cable will need to be long enough to reach the weld point, safely connect to the unit for power supply, and accurately ground the system.
- Gauge: Welding cable is available in a range of gauges. The thinner and the longer the cable is, the lower the available amperage. Longer cables reaching several hundreds of feet will need to be thicker in gauge to account for lost power supply.
- Power: With length and gauge taken into account, you should make sure you are operating at the right ampacity. Cables will each have specific amp levels they can safely handle. Operating with the wrong power supply can damage a welding unit, making it hazardous to workers.
- Insulation: There are several materials welding cables may be insulated with. Choosing the right insulation depends on your work site conditions. For example, neoprene (synthetic rubber) and EPDM (ethylene propylene diene terpolymer or monomer) insulation is flexible and resistant to weather, but they should not be used when gas and petroleum based liquids are exposed. PVC (Polyvinyl Chloride), on the other hand, is stiffer but more resistant to tearing or cuts.