Welding Cables

 

  • Choice of Black, Orange, Red or Yellow jacket, single & double insulated.
  • SQ MM sizes (European style) 10 sq mm to 240 sq mm and  AWG sizes (North American style)  6 Awg to 500 MCM
  • With sequential  foot / meter marking
  • Conforming to international standards IS 9857, BS 6700, IEC 60245, HD 22.6, DIN VDE 0282, BS 6007, ISRI 1926, SABS 1507, IS 473, AS 1995, AS/NZS 5000.1
  • Wide temperature range: -55°C to 105°C
  • Flexible & durable cable with excellent  resistance to oil, grease, solvents & chemicals, cuts, tears and abrasion, ozone & weather
  • For secondary connection from welding machine to electrode holder for hand or automatic metal-arc welding in machine tool and motor car manufacturing, ship building, on assembly lines and for spot welding machines.
  • Also suitable for power supply applications not exceeding 600 Volt AC for heavy duty portable supply in dry, wet and oil environment like connection of motors, generators, transformers, earthing / return leads, power feeds to electrolytic plating process, busbar connection, aircraft servicing equipments, hoists, cranes, switchgear wiring, internal wiring or open jumper leads in restricted access areas requiring flexible connections etc.
  • Conductor : High purity electrolytic grade bright annealed flexible bunched bare copper conductor according to international standards like IS-8130, BS-6360, IEC-228 & VDE-0295
  • Sheath / Jacket : Oil & Water Resistant Heavy Duty Elastomer Compound of Black , Orange, Red or Yellow color ( single & double insulated )

Welding Cables

Cross -
sectional area 		Max.
conductor
resistance
at 200C 		Nom.
thickness
of
sheath 		Overall
diameter 		Max.
overall
diameter 		Current ratings
welding application
duty cycle(%) 		Non welding
application
          100 85 60 30 20  
mm2 ohm/km mm mm mm amp amp amp amp amp amp
10 1.91 2 8.6 10 105 115 135 190 235 110
16 1.21 2 9.7 11.5 135 145 175 245 302 138
25 0.78 2 11.1 13 180 195 230 330 402 187
35 0.554 2 12.5 14.5 225 245 290 410 503 233
50 0.386 2.2 14.3 17 285 310 370 520 637 295
70 0.272 2.4 17.1 19 355 385 460 650 794 372
95 0.206 2.6 19.5 21.5 430 470 560 790 961 449
120 0.161 2.8 21.5 24 500 540 650 910 1118 523
150 0.129 3 23.9 26 580 620 740 1040 1297 608
185 0.106 3.2 26.3 29 660 715 850 1200 1476 690
240 0.0801 3.4 29 32 710 770 916 1296 1587 744
300 0.0641 3.6 32.6 35 800 850 1035 1450 1790 840
400 0.0486 3.8 37 39 925 1000 1195 1690 2070 970

Note:
Insulation thickness, Sheath thickness and overall dimensions are nominal values. The number of wires is approximate and strand diameter is nominal; they shall be such as to satisfy the requirements of conductor resistance as per IS 8130/1984, BS-6360, IEC-60228 & VDE-0295 .

Current Rating

The maximum current ratings of flexible welding cables for different duly cycles are based on an ambient
air temperature of 250C and a maximum conductor temperature of 900. The percentage duly cycles given
in the table are based on a cycle time of 5 minutes. The typical duly cycles for various welding processes
and applications are as follows

1 Automobile Welding : upto 100
2 Semi-automatic welding : 30% to 85%
3 Manual Welding : 30% to 60%
4 Very intermittent or Occasional Welding : upto 20%

Voltage Drop

When total cable lengths in excess of 15 Mtrs are involved, It may be necessary to use cables of larger cross section to ensure that the voltage drop is not excessive and welding currents are maintained at adequate levels.

Rating factors for variation in ambient temperature

Ambient temperature °C 20° 25° 30° 35° 40° 45° 50° 55° 60° 65°
Rating factor 1.04 1 0.96 0.91 0.87 0.82 0.76 0.69 0.64 0.57