JTS C#I338 90 MM 4933608 0083105 2 mw “JIS JAPANESE INDUSTRIAL STANDARD UDC 621.315,22.027.6:621.791.763.1.03-182.3, Water-cooled secondary cables for portable spot welding machines JIS C 9318-»» Translated and Published by Japanese Standards Association —{ Printed in Japan lsJIS Cx9328 90 Ml 4933608 0083206 4 mm In the event of any doubt arising, the original Standard in Japanese is to be final authority. Cope by the lspanese neural senda un hug 12 075980 2007JIS Cx93U8 90 ml 4933608 0083207 & mm UDC 621,315,22,027,5:621.791.763.1.03-182.3, JAPANESE INDUSTRIAL STANDARD JIS e Water-cooled secondary cables for portable spot C 9318-1990 welding machines 1. Scope . ‘This Japanese Industrial Standard specifies the water-cooled secondary cables with low reactance and in single-connector type to be used mainly to connect the welding transformer of JIS C 9317 portable gun, hereafter referred to as "cables Remarks 1. Applicable Standards to this Standard are shown in the following. JIS C 9305-General Rule for Resistance Welding Machines JIS © 9317-Welding Transformers for Portable Spot Welding Machines e 2. The units and numerical values given in { } in this Standard are based on the traditional units and are cutrently: the ceiteria in force, 2 f Terms ‘The definitions of main terms to be used in this Standard are as follows. (2) ow reactance cable Flexible water-cooled cable, in which the conductors ‘in two Toutes Insulated electrically with each other, set in one hose to make the reactance small, (2) single-conductor cable Flexible water-cooled cable in which each of go- Sie-round pach Conduetors have been see in one nose. (3) nominal sectional area Area obtained by summing the sectional areas of every wire of conductors in every route, e (4) cable length Length between reference lines shown in Fig. 1. Tig. Cable Lengtt (a) Low Reactance Cable Reference Reference Line Ceble length ——o Reference Standard: ISO DP8205-Resistance welding equipment-low impedance wires for resistance @ welding Copyment by the Tapanese neuer Sandan un hug 12 075980 2007JIS Cx9318 50 MH 4933608 0083108 8 mm 2 © 9318-1990 (>) Single Conductor Cable Mone Cable_length ae pram) Notes (1) AA" is the central line of 4 bolt holes. (2) BBY is the end tine of threaded part. 3. Classification The classification of low reactance cables and single conductor cables shall be defined by the nominal sectional area and cable length as shown Table 1. Classification of Cable: Low reactence cable ‘Single conductor Rosipal —|howtnal Claseiti-|Seetion-|Longt [clase iti sectlon-| Length cation areree | y leation [al area | yy is0-10) 150 | 10 |8150-06) 150] 06 K1s0-15 1s |s1s0-10 10 150-20 20 |sisv-15 15 K150-24 24 |8150-20 20 K160 25 |siso a6 26 ‘kago-10) 10 | 10 |sia0-06) 160 wa 20 fsinoas eos 24 fesmnao aoe 2s [eines r) opment by the lapmnese Indust un hug 12 075980 2007 sendaJIS #9326 90 MM 4933608 0063109 7 a 3 © 9318-1990 Remarks: The symbols shown in columns of classification are as follows. First character K: low reactance S: single-conductor type Initial numerical characters Nominal sectional area of conductor Numerical characters at the end Length of cable Informative Reference: The numerical characters in the table are appended . specially basing upon 180 DP8&205, Standard Using State The using state of cables shall comply with 3. of JIS C 9305. 5, Cooling Water 5.1 Water Temperature ‘The water temperature of cooling water to be used for cablés shall be 30°C or under at feed water opening. 5.2 Water Quality The water quality of cooling water to be used for cables @ shar bo the industrial water o that ‘conforming to this 6, Characteristics 6,1 Blectrical Characteristics 6.1.1 Insulation Resistance _ The insulation resistance between wires of low reactance cable shall be I M9 or over when measured by the method of 8.1.1. 6.1.2 Resistance and Impedance The resistance of low reactance cables and single-conductor cables, shall be the values of Table 2 or under in the value of resistance converted to 25°C when measured by the method of 8.1.2 (1). However, this resistance value shall be the value of sum of those in go-and-return path. Table 2, Resistance Values of Cables Unit: #9. temperature 25°C mes] 10 vs |ao| a4 25|o6| 10] 15 | 20| 2s too [aw pow [smo oes fom | ws Jamo om | ae | i — | 245 | sar | 0 | s90 fo] —|— | | — | — 200 | iss | 25 | 90 | azo | 40 | a0 | 195 | 293 | 90 | 50 350 [ass | 28 | ato | #15 | a0 | os | 155 | 25 | a10 | 0 ‘is _[ 1s | v0,| 20 | 0 | 300 | — Informative Reference: ‘The nominal sectional areas and lengths shown with slender characters in the Table ate appended specially conforming to ISO P8205. Copyment by the fapanese ndusnal Sandan un hug 12 075980 2007JIS Cx9328 50 MM 4933608 0083110 b mm 4 © 9818-1990 The impedance of low reactance cable shall be the values of Table 3 or under in the value of impedance converted to 25°C when measured by the method of 8.1.2 (2). Table 3. Impedance Values of Cables Unit: pa, temperature 25°C teers —— 0"! ao | as | a0 | 24 | as 150 foc] estan) rss | sy | OC) 1co [asta | soca | ca) |exocns | cocoa 200 | asian) | atoca | atoczo | sss) |s8(52) 250 | isco) | axoca | ssocau | soca) | 0.40) ais 135,040) | 00(205) | 265,270) | 315(805) | 360(40) Remarks: ‘The values of impedance shall be those for 50 Hz power source and values in (—) are those for 60 Hz power solirec. Informative Reference: The nominal sectional areas and lengths shown with slender characters are appended specially conforming to ISO DP8205, 6.1.3 Temperature Rise The temperature rise of cable having been measured by tho mothéd-of B-1-3 shall be represented by the difference of inlet temperature and exit temperature of the cooling water and its value shall not exceed 45 K, 6.2 Mechanical Characteristics 6.2.1 Water Pressure Resistance The water prossure resistance of cable shall be tested by the method of 8.2.1 and at this test, there shall be no bursting of hose cover and no leakage in any form at every connecting part. 6.2.2 Water Flowing The water flowing of cable shall be measured by the method Of 8:22 and When the cooling water is flowed in 7 ¢/min in the Case of low reactance cable and in 3 ¢/min for every wire in the case of single- conductor cable, the pressure loss in cable shall be 69 kPa {0.7 kgt/em2} or under. 6.2.3 Flexibility (Apply only to the Low Reactance Cables) ‘he flexibility of cables shall be nieasirel by the method of B23, The value of bending force in each shall be as agreed between the parties concerned with delivery. 6.2.4 ‘Twisting (Apply only to Low Reactance Cables) The twisting of cables shall Be mousuted by the method of 8.2.4, The value of twisting force shall be as agreed between the parties concerned with delivery, 6.3 Endurance The endurance of cables shall be tested by the method of 8.3. ‘The necessary enduring times shall be as agreed hetween the parties ean- cerned with delivery. opment by the lspanese neural Bandas un hug 12 075980 2007VIS Cx93L8 90 MM 4933608 0083211 8 mm © 9218-1990 7. Structure Tel Low Reuclance Cables 7.1.1 Construction The cable shall he constricted with cable part consist ing at least go-and-return conductors, separator, hose cover ete. and cable . terminals attached to both ends. An example of section of cable part is shown in Fig. 2. Fig. 2. Example of Form of Section ee oeoling water Cofduetar Hosé cover 7.1.2 Conductors The conductor is the intertwisted copper fine wires and shall be excellent in floxibility. Further, its sum of sectional areas shall be the nominal sectional area or over. 7.1.8 Hose Cover The hose cover shall be excellent in flexibility and in- sulation and its external surface shall be abrasion resistant. ant and abrasion resistant e 7 7.1.4 Separators The separator shall be heat resis and shall be excellent in flexibility and insulation. 7.1.8 Cable Terminals The dimensions of connecting part of cable terminal shall be, in general, as shown in Fig. 3. Further, the polarity identifying symbols to discriminate the two hoses shall be indicated clearly on the corresponding both cable terminals. Copyment by the fapanese neuer Sandan un hug 12 075980 2007JTS Cx9338 90 mm 4933608 008322 T mm 6 © 9918-1990 Fig, 8 Cable Terminals (Low Reactance Cable) e Unit: mm. Woter cooled holo’ 7.2, Single Conductor Cables 1 Construction ‘The cable shall be constructed with the cable part © consisting of at Teast conductors and hose cover and the cable terminals attached to both ends. 7.2.2 Conductors ‘The conductor is the intertwisted copper fine wires and shall be excellent i Flexibility. Further, ite cum of sectional aroas shall be the nominal sectional area or over. 7.2.38 Hose Cover The hose cover shall be excellent in flexibility and in- sulation and Its external surface shall be abrasion resistant. 7.2.4. Cable Terminals ‘The dimensions of connecting parts of cable terminals shall be as shown in Fig. 4 (1) for terminal in transformer side and Fig, 4 (2) for terminal in gun side. Fig. 4, Cable Terminals (Single Conductor Cable) unit: mm * (1) Transformer side (2) Gun side (a) Form of (>) Dimensions of terminal threaded part fle d ee ics - ata ee Soole Morse taper Nowa ss as sous ers 2 7 9400 opment by the lapanese Indust un hug 12 075980 2007 SoJTS C1348 90 MM 4933608 0083233 1 am 7 ¢ 9918-1990 Note (3) ‘Thé thread shall be left hand thread and its number of ridges shall be 14 ridges per 25.4 mm. The basic thread profile and dimensions shall comply with Fig. 4 (2) (D). 8 Tests 81 Tests of Electric Characteristics 8.1.1 Ingulation Resistance Test This test shall be conducted under the state where There is 110 waler in the cooling route of cable and the insulation resistance between go-and-return conductors shall be measured by the insulation resistance, tester of d.c. voltage 48 V or over. 8.1.2, Test of Resistance and Impedance (1) Measurement of Resistance of Cable Measure the resistance of low Feactance cable between the positions of reference lines of terminals e shown in Fig. 1 (a) for each single wire and the resistance of single wire reciprocating type cable between the positions of reference lines of terminal shown in Fig. 1 (b). As for the measurement, let flow dic. current(*) of 10 A between terminals of cable to measure the voltage(*) between the side surfaces at positions of reference lines of cable terminals and determine the value of resistance according to the following furmula. ve Rag a where, Rt value of resistance of cable to be determined (us) Vt measured d.c. voltage (nV) Note-(*) The precision of d.c. ammeter and d.c. voltmeter for measurement shall be grade 0.5 or over. In the case of low reactance cable, measure in each single wire e@ and determine their sum to take as the value of reciprocating, In the case of single wire reciprocating type, double the measured value to take as the reciprocating value. Further, flow water in cable as shown in Pig. 5, measure in the state being cooled and indicate the value converted to Zo°U of the obtained value. Use the following formula for conversion. R Ro TAOS)” tt) where, R,+ value of resistance determined by formula (1) (ua) 1 + water temperature at the time of measurement (°C) Ret value of resistance converted to 25°C (uO) ‘As for ¢, measure the water temperature at exit side. Copyment by the fapanese meusnal Sandan un hug 12 075980 2007VIS CX9318 90 MH 4933608 0083224 3 mm 8 © 9918-1990 Hig. 5. Measuring Method of Keststance Prossure gaige [lonstant carrot ae] p-————— power scurce {dics thormonater _ feurrent 104) a» oe eg EY atte tow aonrea Topiteting eter “ ec. voltmeter (2) Measurement of Impedance of Cable “Measure the. impedance of cable In the state where the cable 1s being cooled. The measuring method is shown in Fig. 6. Short-clreuit the end of one side by the method using pure copper bolt shown in Fig. 7. @ (b) Apply to two ends of cable a.c, voltage of frequency 50 Hz or 60 Hz as sinusoidal as possible and let flow the secondary current of 100 A to 500 A in the cable through the welding transformer. (©) Measure the voltage and secondary current between two terminals in inlet side of cable, Purthor, at tho time of moasuremont, let flow tho water at 7 ¢/min or over to protect the cable from temperature rise. Fig. 6. Measuring Method of Impedance . Pas Flow Fegulating- Flow valve rover cin Autotrans- Kolding formar" Eranstorser Trerneneter F Cable to be re we Short-cireuit Ler bolt CCopyngtt by the Tapanese neuer Sandan un hug 12 075980 2007JIS #9318 90 MM 4933608 0083115 5 mm 9 © 9318-1990 (d) Determine the impedance of cable at the time of measurement accord- ing to the following formula, Kx ig 7 2=-fexi0e 6) where, + impedance of cable at the time of measurement (wa) Yat voltage between two terminals in inlet side of cable (V) 4, : secondary current (A) Informative Reference: Determine the power’ factor of cable (o0s@) according lo Ure following formula. — eno =F where, %, Impedance converted to 29°C (ui) Ret value of resistance of cable determined by formula (2) of 8.1.2 (1) (a) At the determination of Zs, the conversion of resistance component is conducted by formula (2) of & Further, for the value of water temperature at the time of measure~ ment in this case, apply the water temperature at exit side, Fig. 7. Short-Circuiting Method of Cable Terminal Assembly drawing unit: mom Cebie torninel fa) oy fed (a) Round nut (bd) Short-circuit nut — 22 CCopymet by the Tapanese neuer Sandan un hug 12 075980 2007JTS Cx9338 90 MM 4933608 008321 7 am | 10 © 9312-1990 Fig. 7. (Continued) (ce) Washer ‘Unit: mm. iO. 4 a 4 8. 3 Temperature Test Indicate the methods of feed water and load dis- patching im Cie tenperatare test in Fig. 8," In the temperature test of cable, let flow the cooling water at 7 ¢/min for low reactance cable and at 3 ¢/min for single wire for single-conductor cable, let flow the electric current” as sinusoidal 8 possible given in Table 4 and measure the water temperatures at inlet and exit, Fig, 8, Methods of Feed Water and Load Dispatching in ‘cumperature Test @ Pressure gouge 1 oa Goo wm momar HT eertrans a ‘Lind plug Table 4. Continuous Currents for Nominal Sectional Areas Unit: A. Low rosctance able ‘Single conductor cable Nominal Length) sections, Ym | 10 | 15 | 20 | 24 | 25 | 06 | 10 | 15 | 20 | 25 Informative Reference: The nominal sectional areas and length in slender characters in the table are appended specially conform- ing to ISO DP8205. CCopyngnt by the Tapanese neuer Sandan un hug 12 075980 2007IS C*9338 90 MM 4933608 0083117 9 u © 9918-1990 8.2 Mechanical Characteristic ‘Tests 8.2.1 Water Pressure Resistance Test As shown in Fig, 9, shut the water~ way in downstream side of cable, Teed water from upper stream side, ascertain that the cable has been filled with cooling water sufficiently, then shut the dis- charge channel in upper stream side and supply the water pressure 735 kPa {7.5 kgf/cme} for 6 min, Fig. 9, Water Pressure Resistance Testing Method (Example in the case of low reactance cable) Pressure ange 7354 a For 6 xin _fsuied ste Cable to bo noacured e orind poo "suing pve 8.2.2 Water Flowing Test As shown in Fig. 10, rogulate by the flow rogulat ing valve the coollig water quantity to 7 z/min for low reactance cable and to 3.4/min for single-conductor cable and then measure the pressure loss by the pressure gauges at inlet side and exit side. Fig. 10. Waler Plowing Testing Method (Example in the case of Low Reactance Cable) OL — se A Cable to’ be moasured Pressure ‘gauge Flow regulating vatve e * ‘This test must be conducted in the case of following 2 kinds. - Straight line state (Fig. 11 (al ~Bended state (Big. 11 (b)] [ar Copyment by the Tapanese meusnel Sandan un hug 12 075980 2007JIS (#9328 90 MM 4933608 008328 0 mm 12 © 9318-1990 Fig, 11, Water Iowing Testing Methods Units mm, (b) Bended State (a)’ Straight Line State 8.2.3 Flexibility Test Conduct the test necessarily in two kinds (1) 90° End Bending Force Test ‘of Fig. 12 (a) parpendienlar direction and Fig. 12 (b) parallel direction, attach the cable horizontally on the board with smooth surface, draw the terminal part by spring balance or the like and read out the bending force when 9" has been reached, Measure the values in L dimensions from 200 mm up to 500 mm by increasing by 100 mm in each, 90° End Bending Force Test Methods (a) Perpendicular Direction to (b) Parallel Direction to Terminal Terminal Plane Plane Fig. 12. Spring baience ‘or the Like oF sho Tike. ar b+ Fixing port xing part (2) 180° Central Part Dending Porce Test As for the test, attach horizon- tally the cable to the board With siooth surface, bend the cable by 180° as shown in Fig, 13 and measure the bending force of central part by spring balance or the like. Measure the values in R dimensions from 100 mm up to 200 mm by increasing by 50 mm in each. Copy by the lspanese neural Bandas un hug 12 075980 2007JIS Cx9328 90 MH 4933608 0083219 2 mm 13 c 9318-1990 Fig. 13. 180° Central Part Bending Force Test Method Fixing pert: Spring balance or the Like 8.2.4 Torsion Test Set the cable as shown in Fig. 14, rotate up to 180° in clockwise’ and in-anticlockwise alternatively and measure the torsion force in every 30° by spring balance or the like, Fig. 14. Torsion Test Method a Unit: mm e pron or the Like ; — Fixing gi x yf anti Clockwise ‘clockwise: rotation Fotation 83. Endurance Test (1) For Une endurance test for low reactance cable, as shown in the test, device of Fig. 15, connect the one end of cable with the secondary terminal of welding transformer for portable spot welding machine specified in JIS C 9317, fasten tightly the other end at defined position of test device by bolt and short-circuit to carry out the test. Regulate the e conditions shown in Table according to nominal sectional area of cable. Make the cooling water quantity 7 ¢/min, Table 5. Regulation of Endurance Test Conditions Weatnal 68° ourrene] CUTSPE ] Tinos por ain | WARING] Wolding cycle in fonel a Ken) passing ‘ine ore ine 150 | 16200 | 12 cycles 8 50 46 10 (04 cycles) (48) 19000 | 20 cycles 8 a3 46 (24 cycles) (63) Remarks: The values of current passing time and working ratio are defined for 60 Hz power source and those shown in (~ ) are for 60 Hz power source, e Informative Reference: The nominal sectional areas described with slender characters in the Table are appended specially con- forming to ISO DP8205, opment by the apanese meusnel Sandan un hug 12 075980 2007JIS Cx9318 90 MH 4933608 008320 9 mm | iy c-9318-1990 (2) Test Cycles of Endurance Test Set the Lest cycle as follows. Take one Teal eyale WS 2 i 25 F and include the following actions in every test cycle. (a) Forward motion of truck trom starting position defined In Table 6 by truck moving distance defined in Table 7 or over: one time. (b) Motion of forward twist of 90° or over and backward twist to return to the original position: 15 times in each. (c) Motion of forward oscillation in 90° or over and backward oscillation to return to the original position: 10 times in each. (d) Current application: 30 times. (e) Backward motion of truck to retum to original position: one time. ‘Table 6, Truck Starting Positions Cable length 10) 20 Truck starting position an] — distance trom canter of: Goising trensforner 250 Informative Reference: ‘The cable length in slender characters is appended specially conforming to ISO DP8205. Table 7. Truck Moving Distances Truck moving dietence am [| — | 0 | 50 | 450 | 450 (tron starting position? Informative Reference: The cable length in slender characters is appended specially conforming to ISO DP&205, (3) A chart of one test cycle 1s indicated in ig. 16. ‘The biginning of test cycle is the time of truck starting for forward motion and the end of test cycle is the time whon: tho truck has returned to the original position, The angles of forward twist and forward oscillation, shall comply with the agreement between the parties concerned with delivery. During the period of test, measure the impedance at all baffing points and draw necessarily the graph of relation of impedance and number of lol cycles. Evaluate the test by the number of times of test cycles at the time when the water leakage or breaking of cable has occured or the defined value of impedance agreed between the parties concerned with delivery has been reached, opment by the lapanese neural Benda un hug 12 075980 2007JIS Cx9318 90 Ml 4933608 008312) 0 mm , 15, 9318-1990 Fig. 15. Endurance Test Device Units mm Wording ans ormer . ‘Cable to be Saatea Tustin ; Te oscitating Soir y part Ak fl e H notion, - h ! Braelion Foryerd and —1—~ “Fy = iaonet == foving' truck} FY 7 L___t2e9 Track visreing Hig. 16, Chart of ‘Test Cycle ‘Truck “+ Truck advance |= ‘Truck retreat e Twisting ‘Forward twist © Backward twist Oselllation \ Forward oscillation] 7 Backward oscillation uurrent. application] 1 Truck y Sera te | 0] (ORCA OaI ROR OO ROROR ORO ORUR VICAR CRCRCRCRORVROLCRVRVROEG! Osetiiation| 4 \ # NON2= 3000 —Sase Een current Spplication 14.6 ¢ (wolding eyele) 4.6 6. 2 min 25 ¢ (test cyclo) Copyment by the Tapanese meusnal Sandan un hug 12 075980 2007JIS C9928 90 MH 4533608 0083122 2 mm | 16 © 9818-1990 9. Inspections 9.1 Type Inspection(®) The type inspection shall be conducted according to 8 on’ the same product in the following sequence, and the tést samples shall comply with the specifications of 6. to 7. (1) Insulation resistance test (2) Water pressure resistance test (3) Water flowing test (4) Flexibility test (5) Torston test (6) Temperature test (7) Resistance and impedance test e (8) Endurance test: Note () The type inspection designates the inspection to Judge whether the qualities of product comply with all characteristics shown in design or not. 9.2 Delivery Inspection(*)_ ‘The delivery inspection. shall be conducted by the motiiod of 22 and shall Comply with the specification of 6.2.2." However, this may be abridged by the agreement between the parties concerned with delivery. Note (*) The delivery inspection designates the inspection to Judge whether the characteristics recognized as necessary are complied with or not at the time of delivery of products same in design and manu- facture as that accopted already by type inspection. 10. Designation of Products @ The products shall be designated by the type of cable, nominal sectional area and length of cable and shall be as follows. (Symbol of type of cable) [Nominal sectional area (mm2)] - [length of cable (decam)] Example: ‘The designation of low reactance cable with nominal sectional area 150 mm2 and length of cable 2.4 m is K 160-24. 11, Marking The cable shall be inscribed with the following items in the easily visible place or shall be appended with lavel indicating these. (1) Designation (2) Classification e (3) Power factor (frequency) opment by the lspanese Incusal Bandas un hug 12 075980 2007JIS C#9328 90 MM 4933608 0083323 4 mm 17 © 9818-1990 (4) Nominal sectional area (mm?) (5) Length (m) (6) Year of manufacture (7) Manufacturer's name 12, Shipping Conditions ‘The cable shall be shipped by adequately protecting the terminal parts and water cooled holes specially. opment by the lspanese neural Bandas un hug 12 075980 2007JIS Cx9328 90 MM 4933608 0083224 6 mm © 9318-1990 Edition 1 Japanese Text Bstablished by Minister of Internati al Trade and Industry Date of Bstablishment: 1972-03 mn Date of Revision: 1990-10-01 1990-10-04 e Date of Public Notice in Official Gazette: Investigated by: Japanese Industrial Standards Committes Divisional Council on Electricity ‘This English translation is published by: Japanese Standards Association 1-24, Akasaka 4, Minato-ku, ‘Tokyo 107" Japan © ISA, 1991 e Printed tn Tokyo by Hohbunsha Co,, Lid Copy by the lapanese Indu un hug 12 075980 2007 saneares