A P P E N D I X A9

Industrial Cables for Special Applications

Conductor

W E L D I N G CABLES
to BS 638, Part 4 : 1 9 7 9

Tinned copper
or aluminium
(multi-bunched)

Insulation
8 5 C rubber

Main application: low voltage

leads for connection to automatic
or hand-held metal arc welding
electrodes and for the earthing
return leads

~ ~ , , .

",,L~

'

Tape

Paper
separating
tape

Protect ion]
85C HOFR rubber

Table A9.1 Range and dimensions

Conductor
size
(ram 2)

Diameter

Approximate weight

Minimum
(mm)

Maximum
(mm)

16
25
35
50
70

8.8
10.0
11.0
13.0
15.0

11.5
13.0
14.5
17.0
19.5

225
320
430
590
820

230
325
440
600
830

95
120
185

17.0
19.0
23.0

22.0
24.0
29.0

1090
1350
2030

1110
1370
2050

25
35
50
70
95

10.0
11.0
13.0
15.0
17.0

13.0
14.5
17.0
19.0
21.5

165
210
285
370
480

170
215
295
385
500

120
150
240

19.0
21.0
26.0

24.5
26.5
33.0

620
740
1150

640
760
1180

Copper conductor

Designa
(kg/km)

0361T

A l u m ~ m conductor

Designa
(kg/km)

0361TQ

0361T (A1)

0361TQ(A1)

aT signifies 85C rubber insulation; TQ signifies 85C rubber insulation and 85C
HOFR covering.
877

Electric Cables Handbook

878
I WELDING CABLES
to BS 638, Part 4:1979

Table A9.2 Resistance and volt drop

Conductor
size
(mm2)

Maximum resistance
(f~/km) at 20C
Tinned

Plain

Voltage drop - d.c.

(V/100 A/10 m of cable)
20C

60C

85C

Copper conductor
16

1.24

1.21

1.24

1.43

25
35
50
70

0.795
0.565
0.393
0.277

0.780
0.554
0.386
0.272

0.80
0.57
0.39
0.28

0.92
0.65
0.46
0.32

1.56
1.00
0.71
0.49
0.35

95
120
185

0.210
0.164
0.108

0.206
0.161
0.106

0.21
0.16
0.11

0.24
0.19
0.13

0.26
0.21
0.14

1.248
0.886
0.616
0.440
0.326

1.25
0.89
0.62
0.44
0.33

1.45
1.03
0.72
0.51
0.38

1.58
1.12
0.78
0.56
0.41

0.254
0.208
0.126

0.25
0.21
0.13

0.30
0.24
0.15

0.32
0.26
0.16

Aluminium conductor
25
35
50
70
95
120
150
240

Notes
(a) Excessive voltage drop may occur if long lengths o f cable are required. Under
such circumstances much larger conductors are required than dictated by rating
but for flexibility the final length to the electrode m a y revert to the size a p p r o p r i a t e
to rating.
(b) The corresponding voltage drops when using a.c. m a y be much higher depending
on the configuration of the cables.

Industrial Cables for Special Applications

WELDING CABLES
to BS638, Part 4:1979

879

Table A9.3 Current ratings for repeat cycle operation

based on 5 minute period
Conductor
size
(mm2)

Duty cycle
100%
(A)

85%
(A)

60%
(A)

20%
(A)

Copper conductor (tinned)

10
16
25
35
50
70

100
135
180
225
285
355

101
138
186
235
299
375

106
148
204
260
336
426

143
212
305
400
529
682

95
120
185

430
500
665

456
532
619

523
613
826

850
1006
1374

Alum~iumconductor
25
35
50
70
95

140
175
225
275
335

143
180
234
288
353

153
196
257
322
399

218
289
389
502
633

120
150
240

390
455
600

412
482
640

469
552
742

755
869
1228

Notes
(a) The above ratings are based on an ambient temperature of 25C and a maximum
conductor operating temperature of 85C.
(b) High operating temperatures make the cable too hot to handle and reduce the
expected service life. Under severe conditions, if a long service life is not expected,
e.g. because of the possibility of mechanical damage, or where a high surface
temperature can be tolerated, the current ratings for 25C ambient may be used up
to 40C.

Rating factors
Ambient temperature (C)
Rating factor

25
1.0

30
0.96

35
0.91

40
0.87

45
0.82

880

Electric Cables Handbook

Duty cycle
Current ratings have to be related to the period of the operating cycle, defined as the
percentage time per 5 minute period that the cable is operated. The classification of
duty cycles adopted is as follows:
Automatic
Semi-automatic
Manual
Intermittent or occasional

up to 100%
30%-85%
30%-60%
up to 30%