Cable Construction
| Conductor | 16mm² to 95mm²: Class 6 extra flexible copper conductor according to BS EN 60228 (previously BS 6360) 120mm² and above: Class 5 flexible copper conductor |
| Insulation | EPR (Ethylene Propylene Rubber) Type GP4 according to BS 7655 |
| Bedding | PET (Polyester Type) |
| Sheath | HOFR (Heat and Oil Resistant and Flame Retardant) Type EM5 according to BS EN 50363 |
Dimensions - Type 0361TQ - Plain Copper Conductors
| Conductor Class | Nominal Cross Sectional Area mm² | Total Radial Thickness of Covering mm | Nominal Overall Diameter mm | Nominal Weight kg/km |
|---|---|---|---|---|
| 6 | 16 | 2 | 9.7 | 215 |
| 6 | 25 | 2 | 11.2 | 305 |
| 6 | 35 | 2 | 12.4 | 400 |
| 6 | 50 | 2.2 | 14.3 | 587 |
| 6 | 70 | 2.4 | 16.3 | 775 |
| 6 | 95 | 2.6 | 18.6 | 1040 |
| 5 | 120 | 2.8 | 20.3 | 1256 |
| 5 | 150 | 3 | 22.6 | 1360 |
| 5 | 185 | 3.2 | 24.7 | 1875 |
| 5 | 240 | 3.4 | 27.8 | 2534 |
Class 6 Flexible Copper Conductors for Single Core and Multi-Core Cables
| Nominal Cross Sectional Area mm² | Maximum Diameter of Wires in Conductor mm | Maximum Resistance of Conductor At 20ºC |
|---|---|---|
| Plain Wires ohms/km | ||
| 16 | 0.21 | 1.21 |
| 25 | 0.21 | 0.78 |
| 35 | 0.21 | 0.554 |
| 50 | 0.21 | 0.386 |
| 70 | 0.21 | 0.272 |
| 995 | 0.21 | 0.206 |
Class 5 Flexible Copper Conductors for Single Core and Multi-Core Cables
| Nominal Cross Sectional Area mm² | Maximum Diameter of Wires in Conductor mm | Maximum Resistance of Conductor At 20ºC |
|---|---|---|
| Plain Wires ohms/km | ||
| 120 | 0.51 | 0.161 |
| 150 | 0.51 | 0.129 |
| 185 | 0.51 | 0.106 |
| 240 | 0.51 | 0.0817 |
Duty Cycle and Current carrying Capacity
The current carrying capacity of a welding depends on the length of the duty cycle. The duty cycle is the length of time in which a loaded current passes through the cable over an operation period time of 5 minutes, indicated as a percentage of that period. For example, if the current is flowing for the whole 5 minutes, the duty cycle is 100% and if the current is only flowing for 1 minute, the duty cycle is 20%.
As conductor temperature differs according to the in use as well as current, ratings displayed are given as a guide.
The permissible loading of the cable for duty cycles other than those displayed in the table can be calculated using the following formula:
I = I100 x √100/F
Where:
I = the maximum permissible loading current for the required duty cycle
I100 = the maximum permissible loading current for a duty cycle of 100%
F = the required duty cycle calculated as a percentage of the 5 minute operation period
Typical guidance values for different welding processes are as follows:
Fully Automatic Welding 100%
Semi-Automatic Welding 65-85%
Manual Welding 30-60%
Very Infrequent or Occasional Welding 20%
Current Carrying Capacity
The below table is in accordance with Table A.5 of BS 638 Part 4
| Nominal Cross Sectional Area mm² | Current Rating for Single Cycle Operation Over a Maximum Period of 5 Minutes Amps | |||
|---|---|---|---|---|
| 100% | 85% | 60% | 35% | |
| 16 | 135 | 145 | 175 | 230 |
| 25 | 180 | 195 | 230 | 300 |
| 35 | 225 | 245 | 290 | 375 |
| 50 | 285 | 305 | 365 | 480 |
| 70 | 355 | 385 | 460 | 600 |
| 95 | 430 | 470 | 560 | 730 |
| 120 | 500 | 540 | 650 | 850 |
| 150 | 580 | 630 | 750 | 980 |
| 185 | 665 | 720 | 860 | 1120 |
| 240 | 780 | 850 | 975 | 1250 |
De-Rating Factors
The below table is in accordance with Table A.7 of BS 638 Part 4
| Ambient Temperature °C | 25 | 30 | 35 | 40 | 45 |
| DE-RATING FACTOR | 1.0 | 0.96 | 0.91 | 0.87 | 0.82 |
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