Copper Electrical Cable Differences

Copper electrical cable is very expensive, but the real differences in price actually comes down to the insulation type more than the copper. Copper is the conductor of electricity in all copper electrical cables and the price of copper changes everyday. However, Romex 6/3® has the same amount of copper as UFB 6/3, so why is the price different?

A 6 awg wire is a 6 awg wire whether it’s in a Romex NMB® jacket or a tough underground PVC jacket. That means each 6 awg wire would be the same price if they were both stripped of all insulation. A UFB underground insulation was manufactured to be used without conduit. So the jacket needed extra protection in order to last as long as an electrical cable in conduit.

In order of the amount of protection Romex® comes first, MC cable second and UFB cable third for electrical cables. Even though each of these cables have different levels of protection they all still have THHN THWN as the wire conductor insulation, so what changes the fact that some have more restrictions?

Romex® cable has a bare copper uninsulated ground wire, but lacks a strong enough jacket to protect it outdoors or in conduit. Moisture, gas, solvents and other fluids can puncture the jacket and hit the bare ground wire leaving it only available for wiring indoors.

MC cable is manufactured with all THHN wires and a THHN insulated green ground wire. That allows MC electrical cables to be used outdoors and in conduit because it resists all water, moisture oils and gases without an uninsulated ground wire in the way.

UFB cable is manufactured as an underground electrical cable which is also known as direct burial in the wire and cable industry. It still has an uninsulateed ground wire but the PVC jacket is engineered tough enough to protect all of the wires even when used directly underground.

In order to find the cheapest cable possible you’ll want to first speak to an electrician to let you know the awg size of the cable you need. This will prevent you from getting a size too big and paying more money than you need to. The second thing you want to do is make sure you’re not getting too much insulation that you may not need. Getting UFB cable when you’re using conduit anyways is a waste of money. You should get MC cable which is cheaper and manufactured for use in conduit.

We offer exact cut lengths on all of our electrical cables and THHN wire because in the contractors, engineers and installers like to have the exact length they need to avoid waste of small lengths at the end of each spool. We also offer free shipping on orders over $250 so that you don’t have to negociate deals with trucking companies to get spool of wire or cable.

Please call us if you need any type of wire, cable or heat shrink tubing as we’ve been a stocking distributor for over 25 years.

WesBell Electronics Inc
(800) 334-8400

Welding Cable Pricing and Specifications

We’ve been buying and selling welding cable for over 20 years and learning a lot about it along the way. There are two main types of welding cable and many similar types of flexible single conductor power cables.

Welding cable is manufactured as a single conductor wire only and usually comes in black or red. If you need a different color then most manufacturers will make it with a minimum run quantity. The second type of welding cable is much stronger, more flexible and only comes in the color orange.

It’s most commonly used on welders and power supply applications needing a 600 volt single conductor cable. It’s made with flexible 30 awg copper strands making it much more flexible than THHN electrical wire. It also has a rubber EPDM insulation which is more flexible and durable than THHN as well.

This basic welding cable comes in black or red and has a high temperature rating of 105°C. It’s rated for 600 volts and the amps for each gauge size are listed on our website to help you understand which size you need for your particular application. The sizes range from 6 awg to 500 mcm with each larger size carrying more power than the last.

The 6 awg is the smallest carrying about 75 AMPS and weighing 140 pounds per 1000 feet. THHN wire is a single conductor electrical wire and only weighs 98 pounds per 1000 feet which means the PVC insulation is much lighter than the rubber insulation because they both have the same amount of copper in them. The 500 mcm welding cable carries 695 AMPS and weighs 1960 pounds per 1000 feet. The rest of the awg sizes range in between those giving a wide range of power options.

Welding cable costs more than electrical wire because it has the rubber jacket that can withstand higher impact and a higher temperature rating. It also has more flexible copper strands that are more difficult to manufacture. THHN 6 awg has 19 strands which makes it a stiff conductor in order to push it through conduit much easier. Welding cable 6 awg has 259 strands making it more flexible to move around with the welder and coil up easily when you’re finished.

We cut each size of THHN and welding cable by the foot so that you can buy whatever you need for the job you’re doing. We also offer free shipping on orders over $250 and ship from the tax free state of New Hampshire which should each help you save money on each job.

WesBell Electronics Inc
(800) 334-8400

Electrical Wire Questions and Answers

We get a lot of phone calls and emails with questions about many different types of electrical wire and cable. Since some of them are repeated we’re going to put them on our website so that people can find the answer before they need to make a phone call.

What type of electrical cable do I use to run electricity to my barn or garage?

If it’s above ground or in conduit you can use SER (Service Entrance Cable). Talk to an electrician first to check the gauge of the cable you’ll need. The electrician will do a calculation based on the length of the cable, the amount of amps you need and the voltage.

If you want to run the cable directly underground then you need to use UFB cable or Tray cable. UFB cable is an underground feeder that has added protection to be used underground. If you need something bigger than 6 awg then you’ll need to use tray cable which can also be used directly underground. Tray cable gets as big as 750 mcm with 4 conductors plus a ground wire.

Can I use Romex wire if it’s only going to be outdoors for 10 feet?

No matter how long I work for a wire and cable company I know this question will continue to come up. Romex can NOT be used outdoors because the jacket insulation isn’t manufactured with enough protection to resist any moisture, gas, oil or solvents. Anything that penetrates the jacket could hit the bare copper ground wire and short the connection.

Can I use THHN as dog fence wire?

Only if you keep the wire above ground. Usually dog fence wire is buried in the ground so you’ll need a wire that has enough protection to be used directly underground. THHN wire is used indoors, outdoors and in conduit only. The manufacturer states that THHN can not be used underground so that’s the message we pass along.

What type of wire do I use if I need high temperature?

Standard PVC hook up wire is rated for 105C with a few different voltage ratings available. If you need higher temperature then you should use teflon wire which is rated up to 200C. It’s silver plated copper with a PTFE insulation and it’s getting more expensive by the minute. Copper is rising, silver is rising and PTFE compound is also rising to give teflon wire 3 possible inceases each day.

Please email or call us with any questions you might have about electrical wire and cable.

WesBell Electronics Inc
(800) 334-8400

Tray Cable – Underground Multi-Conductor Electrical Wire

Tray cable has become a very big seller over the past year for WesBell Electronics. We started selling all types of electrical wire over 5 years ago to compliment our already booming electronic line. Tray cable has been a very easy sell for many reasons in the electrical industry.

Our type TC-ER tray cable is manufactured with THHN wire conductors and a PVC water tight jacket which makes it available for direct burial in the ground. It’s round with a black jacket and all black conductors that are numbered for easy installation. It ranges in awg sizes from 18 to 750 mcm with up to 4 conductors and a ground wire.

The reason it’s such an easy sell is that it has all the bells and whistles with out the outragous pricing. Copper still weighs heavily on the price because it’s so high right now but other cables manufctured for the same undergound use have a higher expense.

Type MC cable is slightly cheaper because it can only be used in conduit. If you want an MC cable that can be direct buried you’ll need the additional PVC jacket over the metal clad armour. That makes for a very expensive cable but it can also be used in concrete which tray cable cannot.

Many of our customers call and want to use Romex® for their application. Then they say it’s only going outside for a few feet so it should be fine for this situation. Well that’s not true. Romex® doesn’t have the protection that UFB cable and tray cable have because it’s only made to be used for indoor applications. That’s why it’s cheaper and that’s probably why they want to is it over the more expensive cable, but getting tray cable first is better than replacing the Romex® later.

WesBell Electronics Inc
(800) 334-8400

Indoor Outdoor and Underground Copper Electrical Wire

Electrical wire comes with all different types of insulation, but they all have the common denominator of copper or aluminum stranding. The insulation changes the expense of the wire or cable based on the environment you need to place it in.

Indoor Wire and Cable

THHN wire is the most common type of single conductor electrical wire. It’s manufactured with a dual rating of THHN and THWN so that it’s all water resistant. It can be used indoors and in conduit only.

Using your copper wire and cable indoors requires the least amount of protection on the insulation because there isn’t much that can hurt it. There isn’t any moisture, oil or solvents effecting the life of the insulation so it can be made for less money. Romex cable is the most common type of indoor electrical wire which uses THHN wire conductors.

Outdoor Wire and Cable

THHN is still the single conductor wire used outdoors and in conduit because the THWN rating can resist water, oil, gases and solvents. However, running 3-4 single wires can be difficult for the installer because they’ll have to run each one individually or tie all 3 together and try to run them as one.

Romex will not work outdoors OR in conduit so you’ll have to upgrade in quality and price to an MC Cable. It’s manufactured with THHN wires and a Metal Clad jacket for easy installation in conduit. The ground wire in MC cable is also a THHN wire rather than a bare copper ground wire so the cable remains moisture and solvent resistant.

Underground Electrical Wire

THHN cannot be buried directly in the ground so you’ll have to upgrade on a single conductor to USE-2 wire. It’s used mostly on solar installations and has a rubber insulation.

If your installation is directly in the Earth instead of in conduit then you’ll have to upgrade to a UFB cable which is an underground feeder cable. It’s color coded and flat instead of round with a bare copper ground wire. The insulation covers each conductor individually to keep it water and moisture tight directly underground.

Tray cable is also an underground cable for larger sizes since UFB cable only goes as large as 6 awg 3 conductor. Tray cable goes as big as 500 mcm 4 conductor with ground. It has all black numbered THHN conductors and an overall PVC jacket. We sell it per foot on our website so that you can get the exact length you need and avoid any waste.

Those are the basics of indoor and outdoor electrical wire. There are also basics on electronic wire and cable based on heat and voltage ranges for different applications.

WesBell Electronics Inc
(800) 334-8400

Why Romex© Can’t be Used Outdoors

Romex© is a type or electrical wire used indoors only for a few reasons. We get this question a lot since it has THHN THWN wires inside it that are allowed to be used outdoors.

Yes, THHN THWN wire can be used outdoors but not directly underground. Romex©, however has a bare copper ground wire inside the cable that is NOT fully protected by the PVC jacket covering all of the conductors. So when Romex© wire is used outdoors and gets wet with water, gas, oil or any type of solvent it could penetrate the jacket and ruin the connection by getting in contact with the bare copper ground wire.

What should you use instead?

MC cable can be used indoors and outdoors because the ground wire is an insulated THHN THWN wire as well. The common use for MC cable is indoors because it can be used without conduit for a much easier installation. However, even if the metal clad jacket doesn’t fully protect the THHN THWN wires they already have the approvals alone to withstand outdoor environments. Copper and Aluminum MC cable can also be used in conduit.

Why not just run THHN THWN wires individually?

You can. Depending on the current copper prices we’ll sometimes push our customers in that direction because the cost of all 4 electrical wires are cheaper than the cable. However, sometimes the cable is cheaper as well. There’s also the added labor involved in pushing each individual wire through conduit or tying all four together to push them through as a group.

We have a highly trained staff here at WesBell Electronics and are here to help you. We’ll give you the cheaper option before you ask and help you find the correct cable by the installation it’s going in. If you have questions please ask and we’ll gladly help you through the process and explain what we’re saying to help you understand.

Toll Free – (800) 334-8400

Information and Facts on Power Cable

Power cable comes in a variety of shapes and sizes, and can look complicated to the layman. These cables can be single-conductor, multi-conductor, as well as industrial strength or for personal use. Each type of power cable has its own advantages, which make them suitable for certain types of applications.

A power cable is categorized in three classes, 1) high voltage (for applications requiring load greater than 40,000V), 2) medium voltage (for applications requiring load between 6000V and 36,000V) and 3) low voltage (for applications requiring load below 1000V). These cables are used for feeders and other heavy machinery, along with branch circuits in electrical utility, commercial and industrial applications.

Single-conductor power cable is used in various applications such as stage lighting, locomotives, DLO and for welding purposes. Each single-conductor cable, depending upon its use, has a different rating for amps, voltage, flexibility and insulation, each having a different price-level.  

There are many multi-conductor cables; extensions cords, Type G-GC, Type W, SOOW and portable cords, each encased a rubber jacket for insulation. These cables are safe and flexible and when additional flexibility is required, there is a multi-conductor cable available for this need. The SOOW multi-conductor cable is similar to the extension cord (before the plugs are attached) and is generally used to supply power generators and tools in industries.

The least-expensive power cable of this group is the welding cable. Welding cable has a rubber jacket and flexible copper fibers and is rated to 600V. DLO cable also has the rubber jacket, is rated to 2000V and has tinned copper fibers. The DLO can carry more power and therefore has a higher corresponding price.

Remember, when installing power cable, it is recommended that you consult with your electrician. And when it is time to purchase your cable, some helpful hints include knowing the operating temperature, amperage, voltage, outer diameter (cable diameter + insulation jacket). Please call WesBell at 800-334-8400 for all your cable needs.

Installing THHN cable in cold weather

When the weather is cold, you can have problems not just with your heating bills and skin, but also with your cables. For example, the THHN cable is easily vulnerable to deterioration due to cold weather.

THHN cable is Thermoplastic, High-Heat Resistance, Nylon-Coated, therefore the name- THHN. Though it is versatile cable and does not fall under any specific application category, it is mostly used under Hook-up wire class.

Strengths

THHN cable comes in a variety of strengths. And since it is made from thermoplastic material, it is easy to heat and cool this wire many times to change its shape. But there is a limit to the number of times this wire can stand heating and cooling. It has its lower and higher temperature limits and if the temperature changes cross this range, this wire can become unstable. Temperature range depends upon manufacturers.

When the THHN cable comes with ‘High Heat’ rating, it means that this wire can be used in high temperature scenarios. These wires come with various specifications, which determine the specific applications where these can be used. For example, “Nylon coated” means that a certain thermoplastic material is used in this wire.

Coming to installation of the THHN cable in the cold weather, there are some simple guidelines that you should follow. Keep this cable indoors, and not in the outdoor harsh environment. Generally, a temperature of 65°F works well.

If keeping the cable indoors is not possible, bring it inside for at least 24 hours, before you install it.

If the outside temperature is below 14°F, then do not install the THHN cable.

While installing the cable, take care that it is not dropped on the floor, as these impacts can cause cracks in the stiff cable material.

Make sure you do not bend the cable too much, because it can cause the cold and stiff cable to break.

Once you have installed it, this cable will work properly in environments with temperature higher than 14°F.

All you need to Know about High Voltage Cable

If you want to transfer large amount of electricity, then high voltage cables are your safest bet. There are various forms of these cables, and all are used for different purposes depending upon voltage of electricity and the machines for which these are used. Three types of cables are: high, medium, and low voltage cables. Out of these, high voltage cables are used when the voltage is above 1000 V. These cables are heavily insulated to prevent any risks or hazards.

• AC power cables

These cables are used to transfer up to 2000 V of electricity. The composition of these cables includes cross section of cable, polyethylene insulation, and conductive material like aluminum or copper. These cables are highly flexible and work well both in low as well as high temperatures. The cable layers are fused together to avoid air seeping in, as this can cause electrical discharge, thereby damaging the insulation.

• HVDC cables

These are specialized cables that are designed for high voltage direct currents, and thus are called HVDC cables. If you have seen a power line, then it would be easy to understand, as a power line is also an HVDC cable. These cables are helpful in carrying large loads of electricity over longer distances. After reaching the transformer, their electricity is converted to AC form. Thereon it runs with lower voltage, and is transferred to businesses and homes.

• X-ray cables

These cables are used to link other high voltage cables with X ray machines. These are also used to connect high voltage cables to other scientific equipment that require higher loads of electricity. These are highly flexible cables. They have a braided cover of copper wires, and are insulated with rubber. These are fused to high voltage cable to provide safety, and to reduce the hazards of electric shocks.

All these cables are not for home use. These are used to connect high power sources to other devices or cables. If you want to buy these cables, make sure you go for the best quality, as bad cables can lead to dangerous situations.

Using Teflon wire for High Temperatures

Wire insulated with Teflon, or Teflon wire, is very useful. If you have been using PVC hook up wire to fight insulation melt downs, then you will be pleased to use Teflon. It cannot even get affected by a soldering iron. It has been used since the 1960’s due to its excellent performance in high temperature scenarios. Some companies also use it in classification of surface electronics.

Teflon wire has got copper strands, plated with sliver. The silver plating, along with Teflon insulation helps the wire to sustain extremely high temperatures. It is much better than basic hook up wire that suffers from melt downs in high temperatures. And due to its great heat withstanding ability, Teflon wire comes expensive. But in case your needs are about wiring places with extremely high temperatures, it will be a good investment in the long run.

This wire is made by following many methods. Two of the more common methods are wrapping and extrusion. Extrusion is the most common one and is done usually in the standard sizes of 24 AWG and 22 AWG. There are also some smaller sizes, where space is an important factor. The covering comes in fused and wrapped types. Teflon is also used as the outer jacket of co-axial cables.

Teflon wires also have great resistance to moisture, flame, damage from soldering iron, and thermal aging. Apart from that, the PTFE (polytetrafluoroethylene) coating is able to resist many harsh chemicals, ozone, greases, and solvents.

You can install these wires at many places, as they are very easy to fix. It also has low degree of power loss, and thus is great for high frequency usage. Because these wires are small and slippery, they can be used almost anywhere.

PTFE or Extruded Teflon hook up wire has 3 types: Type E (most commonly used, and rated for 600 V), Type EE (having thicker Teflon jacket, and rated for 1000 V), and Type ET (having thin cover, and rated for 250 V). All 3 of them can be used for temperatures up to 200^o C