Is9857:1990

Indian Standard ( First Revision )

( Reallimed 2005 ( Reaffirmed1995 ) )

WELDING CABLES - SPECIFICATION

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Second Reprint JANUARY 1998 UDC 621’315’21 : 621’791’03

@ BIS 1990

BUREAU
MANAK

OF INDIAN
BHAVAN,

STANDARDS
ZAFAR MARG

9 BAHADUR SHAH NEW DELHI 110002

July 1990

Price Chomp 4

In this standard. and IS 10810 : 1984 ‘Methods of test for cables’. of this standard. a need was felt to have a separate standard for welding cables. British Standards BS 638 : 1966 Specification Institution ( UK). The number of significant places retained in the rounded off value should be the same as that of the specified value in this standard. The limitations of aluminium as a conductor for welding cables have been given in Annex A. expressing the result of a test or analysis. IS 6386 : 1984 ‘Elastomeric insulation and sheath of electric cables (f. IEC Pub 245-6 Rubber ( arc welding electrode insulated cables of rated voltage up to and including 450/750 volts cables ). The requirements of welding cables were earlier covered in IS 434 ( Parts 1 and 2) : 1964 and ( revised). ETD 9 FOREWORD This Indian Standard ( First Revision ) was adopted by the Bureau of Indian Standards on 23 Tanuarv 1990.Power Cables Sectional Committee. The details given in Tables 2 to 7 are for information In the preparation only. for insulated electric cables and flexible cords (jkrt rezkion )‘. observed or calculated. . the requirement for cables with copper as well as aluminium conductors have been specified. assistance has been derived from the following: for arc welding plant. IS 434 ( Part 2 ) : 1964 ‘Rubber insulated cables: Part 1 With copper conductors Part 2 With aluminium conductors ( revised)’ at the time of revision of these standards. shall be rounded off in accordance with IS 2 : 1960 ‘Rules for rounding off numerical values (mired)‘. International Electrotechnical Commission ( IEC) .st rmisiun )‘. This separate standard ( IS 9857 ) This revision is brought out to align it with IS 8130 : 1984 ‘Conductors was published in 1981. equipment and accessories. after the draft finalized by the Power Cables Sectional Committee had been approved by the Electrotechnical Division Council. For the purpose of deciding whether a particular requirement of this standard is complied with. the final value.

which might change the performance characteristics. 2 REFERENCES 2.1 The material shall be dry paper. 8130 : 1984 10810 (Part 44) : I984 3 TERMINOLOGY 3. 3.1 The fo!lowing Indian standards sary adjuncts to this standard: are necestype of compound rests SECTION 2 MATERIALS 4 CONDUCTOR Conductor 4. The conductor formation shall be according Table 4 of IS 8130 : 1984.IS9857:1990 lndian Standard WELDING CABLES .4 Type Teats Tests required to be made before supply on a general commercial basis on a type of cable in order to demonstrate satisfactory performance characteristics to meet the intended application. b) 90°C for heat resisting oil resisting flame retardant ( HOFR ) normal duty elastomeric compound.1 Thir standard covers the requirements and tests for single core flexible cables used in welding circuits. NOTE . conductors The conductor shall be composed of aluminium wires complying with IS 8130 : 1984. 5 SEPARATOR 5.2 Acceptance Test 6.1 For the purpose of this standard.2 The heat resisting.1 Circular Copper Conductor Tests carried out on samples taken from a lot for the purpose of acceptance of the lot.3 Routine Tests Tests made by the manufacturer on all finished cable lengths to demonstrate the integrity of the cable. oil resisting and flame retardant ( HOFR ) normal duty elastomeric compound shall be Type SE 3 conforming to the requirements of IS 6380 : 1984. they need not be repeated unless changes are made in the cable materials design. insulation electric cables (Jirst reurjion ) Specification for conductors for insulated electric cables and flexible cords ( jirst revision) Methods of test Part 44 Spark test for cables: 6 COVERING 6.These tests are of such a nature that after they have been made. 1885 (Part 32 ) : 1971 Ztle Electrotechnical vocabulary: Part 32 Cables. The selection of the with the purchaser.SPECIFICATION ( First Revision ) SECTION 1 SCOPE 1.1 The general service normal duty elastomeric compound shall be Type SE1 conforming to the requirements of IS 6380 : 1984.2 Aluminium Conductor 1s ?fQ.1 Copper The conductor shall be composed of plain or tinned annealed high conductivity copper wires complying with IS 8130 : 1984. 1. and normal duty 1 GENERAL 3. 4. to 1 . the following definitions in addition to those given in 1s 1885 ( Part 32 ) : 1971 shall apply. and accessories for electricity SUPPlY Methods for random sampling 4905 : 1968 6380 : 1984 Specification for elastomeric and sheath of . SECTION 3 CONSTRUCTION 7 CONDUCTOR 7.2 The cables covered in this standard are suitable for use where combination of ambient tern erature and the temperature due to load resti P in a steady conductor temperature ts not exceeding: a) 60°C for general service elastomeric compound. polyester tape or any other suitable material. 3.

test immersion test ) e) Static test flexibility 120t *For copper conductor only. or A layer of heat resisting oil resisting flame retardant (HOFR ) normal duty elastomeric compound in accordance with 6. rhall be black.1 Type Tests The following Tests shall consist of one of over the conductor and the the OF TESTS shall constitute type tests: Test M&ad ( Purr No.2 9. it may be obtained by using two small cables in parallel instead of one equivalent larger cable.1 The conductor shall be covered with a separator (M 5. The covering shall be so applied that it fits closely on the taped conductor.1 4) Oil resistance test 5) Hot set test voltage d) High ( water. NOTE-Where greater flexibility is required.5 The colour of the covering shall be The conductor formation shall be according Table 5 of IS 8130 : 1984. The separator tape shall be so applied as to give complete coverage of the conductor. 9 COVERING SECTION 4 TESTS 10 CLASSIFICATION 10. 9.1).2. resistance test. test ( water immersion . 8 SEPARATOR 8. IS 6380: 1984 7 Table 1 Thickness of Covering Nominal Thickaammof Covering (2) Nominal Cromm-8ccdoaal ArerofConductor (1) IS6380: 1984 11 Under PIcparation 31 30 45 mm’ 16+ 25 35 50 70 95 mm 2'00 2'00 2'00 2'20 2'40 2'60 2'80 IS 6380.3 Tolerance on Thickness of Covering Acceptance Tests The smallest of the measured values of the thickness of covering shall not fall below the nominal value ( fc in mm) specified in Table 1 by more than 0’10 mm + 0’15 tc.4 54 53 f ) Flammability test 10.3 11.1): test. b) 4 4 2 Conductor. and test ). 9. of IS 10810 ) Rsquirmmts 9.2 Thickness The average of Covering thickness of the covering shall be not less than the nominal value (4 ) specified in Table 1.4 Application of Covering The following ( requirements Annealing a> shall constitute acceptance tests and tests methods as in 10.1.: 1984 IS 6380 : 1984 IS 6380 : 1984 11. a) Tests on conductor: 1) Annealing test IS 8130: 1984 1 5 6 2) Conductor resistance test b) Test for thickness of covering c) Physical tests for covering (as applicable) 1) Tensile strength and elongation at break 2) Ageing oven 3) Ageing bomb in air in air IS 8130 : 1984 Table 1 9. 11.189S57:1999 7. applied in two or more layers. The covering.1 The covering following applied separator: 4 b) A layer of general service normal duty in accordance elastomeric compound with 6.2 Circular Aluminium Conductor to unless applied by extrusion method. tFor aluminium conductor only. Test for thickness High voltage of covering.

3 Static Flexibility Test Maximum Distance Between Two Plumb The following code shall be used for designating the cable: Constituent Code Letter Aluminium Elastomeric NOTE -No conductor. and the conductor. The values corresponding to cables with aluminium conductor are under consideration.2 Cable Identification Cables with HOFR compound shall be identified throughout the length by legend ‘HR 90’ on a tape placed inside the cable or by printing. indenting or embossing on the cable. The distance between any two consecutive printings. A covering code letter is required R for copper Nominal CrossSectional Area Line (L’) (mm) 450 450 500 500 550 600 13 PACKING AND MARKING (mm’) 16 25 35 50 70 95 13. indentations or embossings shall be not more than 1 m.3 Routine Tests The following shall constitute routine tests: test (requirement and plan for applicable only Type SE3. 10. one ).2 Spark Test The manufacturer shall be identified throughout the length of the cable by means of a tape bearing the indication of the source of manufacture being printed. Identification b) High voltage rest ( water immersion test) ( requirement and test method as in 11. d) Nominal conductor. colour identification threads in accordance with a scheme to be approved by the Bureau of Indian Standards shall be employed.1 ). 12.4 Flammability Test Period of burning after removal uf the flame shall not exceed 60 seconds snd the unaffected top clamp (uncharred ) portion from the lower edge of the shall be at least 50 mm. indented or embossed In case none of these methods on the cable. to cable with covering of SECTION 5 PACKING 12 1DENTIFICATION 12.The above values are corresponding to cables copper conductor. The test shall be made at room temperature with an ac voltage of 1000 V ( rms) at a frequency of 40 to 60 Hz. can be applied or if the purchaser so desires.1 A recommended sampling acceptance tests is given in Annex B. e) Cable code.2. of lengths than cross-sectional area of the 11.ength of cable on tile drum. AND MARKING aj Conductor resistance and test method as in 10.1 Manufacturer’s IDENTIFICATION. f) 1. with NOTE . 11. 11. The voltage shall be increased gradually and maintained at the full value for 5 minutes without breakdown. 12. reel or coil ( if more . the spark test in accordance with IS 10810 ( Part 44) : 1984 may be applied as an alternative to high voltage test of 11.1 The cable shall be either wound on reels or drums or supplied in coils packed and labelled. of the source of manufacture.3 Cable Code As a routine test. This test is g) Number 3 on the drum.1 High Voltage Test ) The voltage shall be applied after the cable has beeli immersed in water for not less than 12 hours. c) Type of cable.IS 9857 : 1990 10.1 to cables having a nominal area of conductor 50 mme and below and the spark test voltage shall be 3 5 kV ac.2 The label or the stencilling on the drum shall contain the following information: a) Reference b) Indication to this Indian Standard. 11 DETAILS OF TESTS Test ( Water Immersion 11.2).1) or spark test ( 11. reel or coil. The test voltage shall be applied between the water in which the cable is immersed which shall be earthed. 13.

Current Ratings of General Service Normal Dmty Elastomeric Compound Covered Cable with Copper Conductor ( cluuss14. j) Approximate k) Country of manufacture.)~ at the required where 11 = current rating duty cycles.1 The following are typical duty cycles for various welding processes and applications: 4 Automatic welding : : : : Up to 100 percent 30 to 85 percent 30 to 60 percent Up to 20 percent current ratings of flexible welding cables based on an ambient air temperature of 30% are given in Tables 2 and 4 for a maximum conductor temperature of 60°C and in Tables 3 and 5 for maximum conductor temperature of 90°C. Tables 6 and / showing the dc voltage drop at normal and elevated temperatures are given for guidance. m) Year of manufacture. and F = required 100 percent gross weight. The percentage duty cycles given in Tables 2. 4 and 5 can be calculated using the following formula: I1 = Ic 15 VOLTAGE 15.1 When total (10011. 3. 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. 4 and 5 are based on a cycle time of 5 minutes.1 The maximum of the drum (by IC = current rating.60°C 85% (3) A 102 136 169 214 269 342 60% (4) A 121 161 201 254 320 386 30% (5) A 172 228 285 360 453 546 20% (6) A 210 279 349 440 555 669 temperature Rating Factors for Variation (l ) C in Ambient 25 Temperature 30 35 40 45 0’71 50 Ambient Air Temperature Rating Factor 1’08 1’0 0’91 0’82 0’58 4 .Fr occasional weldIng DROP ratings for duty cycles other than those given in Tables 2.2. 3. at duty cycle. Table 2 cable lengths in excess of 15 m are involved. and duty factor expressed as a percentage.h) Direction of rotation means of an arrow ).1 ) Nc%lz of codmctor (1) mm* 16 25 $5 50 70 95 Ambient Maximum air temperature conductor Carrant c--------------* R8ting at 8 M8dmmm of --_-_-------__~ Doty cycle 100% (2) A 94 125 156 197 248 299 30°C . 14 CABLE RATINGS 14. 14.2 The current b) 4 4 Semi-automatic welding Manual welding Very intermittent . 14.

Is9857t1mo Table 3 Current Ratings of HOFR Normal Duty Ela~tommic Compound Covered Cable with Copper Conductor ( cluus~ 14.1) Nominal CrouSeerional Area of Conductor (1) mm’ 16 25 35 50 70 95 Ambient air temperature Maximum Rating Factors Ambient Air Temperature Rating Factor conductor for Variation ( “C ) 1’04 1’0 0’96 0’91 0’87 0’82 Dmty Cycle of ~_-_-____----_----*______--________~ 100% 85% (21 A 135 177 221 279 352 424 * 30% L= 90’ Temperature 30 35 40 carrentllatimgrtr- W? (4) A 174 228 285 360 454 547 30% (5) A 246 343 409 509 643 n4 (3) A 146 192 240 303 382 460 temperature in Ambient 25 45 50 Table 4 Current Ratings of General Service Normal Duty Elastomeric Compound Covered Cable with Aluminium Conductor ( ckurrc14.1) Ppdlt~C~~of current r-----------100% (2) A 100 123 155 196 237 283 30% 60°C Condmcter (1) mm’ 25 35 50 70 95 120 Ambient air temperature Maximum conductor for Variation ( “C ) 8i% (3) A 108 133 168 213 257 307 _--A_--‘L-_------_~ 60% (4) A 129 159 200 253 306 365 Rating Duty a Maslmum of 30% (5) A 183 225 283 358 433 517 20% (6) A 224 275 347 438 550 633 temperature _Rating Factors Ambient Air Temperature Rating Factor in Ambient Temperature 25 1’08 30 I’0 35 0’91 40 0’82 45 0’71 50 0’58 5 .

6 .1) Current Rating of Masimnm ~-----_--~ 100% (1) mms 25 35 50 70 95 120 Ambient Maximum Rating-Factors Ambient Air Temperature Rating Factor (2) A 144 176 222 280 339 404 air temperature = 30% conductor for Variation ( “C ) temperature = 90°C Duty Cycle of ----*-_-----__---~~ 85% (3) A 156 191 241 304 368 438 60% (4) A 186 227 287 361 438 522 30% (5) A 263 321 405 511 619 738 Nominal CrossSectional Area of Conductor in Ambient Air Temperature 25 1’04 30 1’0 35 0’96 40 0’91 45 O-87 50 0’82 Table 6 ‘Voltage Drop in Copper Conductors at Normal Operating Temperatures ( Clause15.1 ) (1) mm’ 16 25 35 50 70 95 (2) V 1’438 0’922 0’655 0’456 0’321 0’244 Nominal CrossDC Voltage Drop/l00 A/10 m Sectional Area of Cable at of Conductor P---------C---.--Y 20°C 60°C 90°C (1) mms 25 35 50 70 95 120 (2) V 1’23 0’901 0’634 0’445 0’334 0’256 (3) V 1.570 0’428 0’328 (3) V 1’587 1’018 0’723 0’503 0’355 0’269 NOTE .-_--_-_-~ 60°C 9o”c Table 7 Voltage Drop in Alominium Conductor at Normal and Elevated Temperature (Cluuse 15.1) Nominal CrossSectional Area of Conductor DC Voltage Drop/lOQA/lO m of Cable at . These figures shall be approximately 2 percenr lower in the case of cable with plain annealed copper conductor.Voltage drops as mentioned above are corresponding to the tinned copper conductors.18 9857 8 1990 Table 5 Current Ratings of HOFR Normal Duty Elastomeric Compowd Covered Cable with Aluminirm Conductor ( Clause 14.427 1’045 0’735 0’516 0’387 0’297 (4) V 1’574 1’153 0’811 0.

Coilm or Reels to be Taken am Sample (2) 3 5 8 13 20 Per’p’e . B-2. A test sample is called defective if it fails in any one of the acceptance tests. the procedure given in IS 4905 : 1968 may be followed.Is9857:1990 ANNEX A ( Ref. of Drums. the lot shall be declared as conforming to the requirements of acceptance tests. cables of the same size and type manufactured under essentially similar conditions of production shall be grouped together to constitute a lot. suitable accordlengths (Clauses 8.2. ANNEX ( Clause B 102. B-2. be selected shall depend 9n co1 1 and 2 of Table 8. These test samples shall be subjected to each of the acceptance tests ( see 10. Foreword ) LIMITATIONS The following are the limitations cables compared with copper: OF ALUMINIUM CABLES of aluminium for use where flexibility is involved.2 ).1 ) No. of Drum. b) There is a reduced service life d) The cable size is large for similar electrical properties which may cause difficulties in matching with other items of equipment. Defectives (3) 0 0 0 1 1 to 25 50 26 to 51 to 100 101 to 300 301 and above 7 . and are subject to atmospheric a) Terminations have to be suitable with aluminium cable.1 ) SAMPLING OF CABLES B-l LOT B-l. Table 8 Scale of Sampling B-2.1 In order to ensure the randomness of selection.1 From each of the drums selected ing to co1 1 and 2 of Table 8.1 In any consignment. If the number of defectives is less than or equal to the corresponding permissible number given in co1 3. B-2 SCALE OF SAMPLING of test samples shall be taken. Coils or Reels Jn the Lot (1) up No.3. These samples shall be taken at random.2 and 8. B-3 NUMBER OF TESTS AND CRITERION FOR CONFORMITY B-3. c) The conductors corrosion.2.2 The number of samples to. otherwise not.1 Samples shall be taken and tested from each lot for ascertaining the conformity of the lot to the requirements of the specification.

it is taken up for revision. Copyright BIS has the copyright of all its publications. type or grade designations. a standard along with amendments is reaffirmed when such review indicates that no changes are needed. Road. HYDERABAD. This Indian Standard has been developed from Dot: No. Scheme VII M. JAIPUR.I. 1986 to promote harmonious development of . PATNA. Sector 34-A.323 94 02 Regional Offices: Central Eastern Northern Southern Western branches : Manak Bhavan. X32 7X 5X { X32 7X 91.Bureau of Indian Standards BIS is a statutory institution established under the Bureau of Indian Standards Act. Enquiries relating to copyright be addressed to the Director (Publication). marking and quality certification of goods and attending to connected matters in the country. New Iklhi . Printed hy Reprography Ilnit. in the course of implementing the standard.I. of necessary details.T. V.3233X41 337 84 99.235 04 42 { 235 15 19. NAGPUR. Andheri (East) MUMBAJ 400093 : AHMADABAD. FARIDABAD. New Delhi 110002 Telephones: 323 0 131. KANPUR. ETD 9 ( 3075 ) Issued Since Publication Text Affected Amendments Amend No. if the review indicates that changes are needed. Date of Issue BUREAU Headquarters: OF INDIAN STANDARDS Telegrams: Manaksanstha (Common to all offices) Telephone 3237617. BHUBANESHWAR. Marol. E9 MIDC. Users of Indian Standards should ascertain that they are in possession of the latest amendments or edition by referring to the latest issue of ‘BIS Handbook’ and ‘Standards Monthly Additions’.337 91 20 60 3X 43 1 60 20 25 235 02 16. X32 7X 92 Manak Bhavan.323 33 75. Campus. IV Cross Road.I. such as symbols and sizes. Review of Indian Standards Amendments are issued to standards as the need arises on the basis of comments. GHAZJABAD. GUWAHATJ. THJRUVANANTHAPURAM. BIS. BHOPAL. No part of these publications may be reproduced in any form without the prior permission in writing of BIS. This does not preclude the free use. LUCKNOW.23523 15 X32 92 95. 9 Bahadur Shah Zafar Marg.the’ activities of standardizatia. COIMBATORE.T. CHENNAl : Manakalaya. CHANDIGARH : C.P. BANGALORE. Maniktola CALCUTTA 700054 160022 600113 : SC0 335-336. 9 Bahadur Shah Zafar Marg NEW DELHI 110002 : l/14 C. PIJNE. Standards are also reviewed periodically. Ij!S.337 x5 6 1 337 86 26.

AMENDMENT NO. India .1(C)] – Substi~te ’56’ for ‘Under preparation’ at S1 No. 1 JANUARY 2007 TO IS 9857:1990 WELDING CABLES — SPECIFICATION (First Rewkion) [Page 2. (ET 9) Repmgra@y Uni\ BIS. New Delhi. (3) under the column ‘Test Method (Part No. clouse 1O. of IS 10810).

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