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WELDING CABLES
 

At present Copper and Aluminium welding cables are covered under IS : 9857-1990.The earlier IS : 434, covered only VIR covering. Whereas,the present specification coversWelding Cables under two categories.
1.    Cable with General Purpose Rubber compound covering (GPR)
2.    Cable with Heat Resistant,Oil Resistant ,Fire Retardant compound covering (HOFR).

Construction
(a) Conductor:

(I)    Copper Conductor : The conductor shall be composed of plain or tinned annealed high conductivity copper wires complying with IS :8130.The conductor formation           shall be according to class 6 (Table 4) of IS :8130.

(ii)   Aluminium Conductor : The conductor shall be composed of Aluminium wires complying with IS : 8130. The conductor formation  shall be according toTable 5 of IS        :8130.

(b)  Separator :
The separator shall be of polyester tape/dry paper, or any other suitable material. The conductor shall be covered with a separator.The separator tape shall applied on conductor to give complete coverage over the conductor.
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(c)  Covering :GPR/HOFR

The general purpose rubber compound shall comply with requirements of type SE1 to IS : 6380.The heat resistant normal duty
Heat Resistant, Oil Resistant , Fire Retardant (HOFR) compound covering compound shall comply with the requirement ofType
SE 3 to IS :6380.The covering shall consist of one of the following applied over the conductor and separator.

(a)   A layer of general purpose normal duty rubber compound. or
(b)   A  layer  of   Heat  Resistant, Oil  Resistant  , Fire  Retardant  (HOFR)  compound  covering  normal  duty.

 
 
 

Equivalent rating to
IS : 434 at
20% DC Converted at
40°C ambient air temperature (Amps.)

 

New Section to IS : 9857 size

 

Maximum Diameter of Wire in the bunch

New Rating at 40°C ambient GP Typw (60°C Class*)

New Rating at 40°C ambient
HOFR type (85°C class)

 

Theread of covering

 

Rating at
20% DC**

 

Rating at
60% DC**

 

Rating at
100% DC**

 

Rating at
20% DC**

 

Rating at
60% DC**

 

Rating at
100% DC**

GP

HOFR

(Sq.mm)

(mm)

(Amps.)

(Amps.)

(Amps.)

(Amps.)

(Amps.)

(Amps.)

(mm)

Copper Conductor

 

150

16

0.21

179

103

80

261

151

117

2.0

150

230

25

0.21

230

133

103

351

203

157

2.0

230

400

35

0.21

288

166

129

438

253

196

2.0

400

600

50

0.31

373

215

167

550

320

248

2.2

600

800

70

0.31

458

264

205

691

390

309

2.4

800

1000

95

0.31

561

324

251

836

482

374

2.6

Aluminium Conductor

 

150

25

0.31

179

103

80

273

157

122

2.0

150

230

35

0.31

230

133

103

340

196

152

2.0

230

400

50

0.31

288

166

129

438

253

196

2.2

400

600

70

0.31

358

206

160

534

308

239

2.4

600

800

95

0.31

434

250

194

651

375

291

2.6

800

1000

120

0.31

510

294

223

758

437

339

2.8

 
 

*60°C  &  85°C  Class  - The  maximum  conductor  temperature  attained  for  the  duty  cycles  specified  for  the  welding  cables.
*DC  : Duty  Cycle, GP  : General  Purpose Type, HOFR  :  Heat  Resistant, Oil  Resistant  , Fire  Retardant Type.

 
 
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