Air Cooled Jumper Cables

Each air cooled cable is manufactured with completely silver plated terminals, which can be manufactured up to 3-7/8" long for special applications.

A chart for sizing the correct gauge cable is at the bottom of the page, as well as guidelines for installation.

To order an air cooled cable, you need the length measured from the bolt hole centers at each end of the cable on straight or 45 degree terminals. It is measured from the extreme ends of 90 degree terminals. On terminals with two holes, measure from the centers of the outer holes. The following information should be provided:

1. Select Styles of Terminal Ends:

2. Taking Cable Measurements:

Length of the Cable = L (distance between hole centers)
Terminal Face Width = W (1.250, 1.375, 1.500)
Terminal Face Width = T ( on dependent on the terminal face width, and the gauge of the cable, as outlined in the table below.)

Notes:
- The standard terminal width is 1-1/4". If a 1-3/8" or 1-1/2" wide terminal is desired, please be sure to specify this.
- If you are unsure of what MCM your application requires, you can size the correct cable yourself.

3. More Cable Options:

Isolated Conductor Cables with isolated, individually wrapped conductors increase cable life by preventing common failure points: Eliminated Frictional wear between adjacent copper ropes by encasing them in rubber tube. Reduces the number of friction points for wear  between strands from 36 to 9, in the rope  cross section. Reduced strand failure at the rear terminal by adding a Stabilizer flare. Increased flexibility due to the fact that a standard lapped cover is not required. Note: Thermal tests have indicated that the operating temperatures of this style is virtually identical to that of standard jumper using a lapped cover.
Stabilizer Collar Increased strand life at the cable terminal is the advantage of a stabilizing collar. It slightly increases the minimum flex radius for the jumper, reducing over flexing.
Extra Flexible 36 AWG copper rope stranding and an extra flexible protective cover are used to create an extra flexible jumper. The result is a jumper that is over twice that of a regular jumper. This makes it ideal for robotic applications and where limited space makes standard cables a hard fit. The DJ-XF is available in 750, 1000, and 1200 MCM. Other options include a perforated cover or a special Hypalon high temperature cover, able to withstand 300°F to -30°F.

Air Cooled Jumper Sizing

Use the following method to determine what size cable should be used for your application. First you use the Conversion Factor chart to determine your "Continuous Duty Current"; then you read the correct size cable off the second chart. An example is worked out below.

Step 1
Lay one side of a straight edge across the graph at the six cycles of current "one time" point (the left hand vertical scale of the conversion factor chart).

Step 2
Pivot the other end of the straight edge across to line up with the "60 welds per minute" on the far right vertical scale.

Step 3
At the intersection of your straight edge with the diagonal conversion factor scale line, you should be able to read a conversion factor of .32 off the lower 1/2 of the line.

Step 4
Multiply the required current (10,000 amps) by the conversion factor (.32) to get the "continuous duty current" of 3,200 amps.

Conversion Factor & Duty Cycle Chart

Step 5
Line up your straight edge on the 3200 continuous duty amp mark, and find the intersection with your desired length line (from below).

Step 6
Any cable whose line is above this point may be safely used, since the load it would carry will be within its thermal capacity. In this example a 1200 MCM cable can be used and stay within design tolerances.

Air Cooled Jumper Selection Chart

More Specifications

D.C. Resistance of Single Conductor
Air Cooled (and water cooled) Cables