Kickless Cable, Kickless Cable Assembly Process, Water Cooled Kickless Cable, Hose Crimping for Kickless Cable, Mumbai, India
Water Cooled Furnace Power Cable
Water Cooled Kickless Cable
Water Cooled Jumper Cables
Air Cooled Jumper Cable
Weld Gun Arm, Shank, Electrode, Cap, Tip
Spot Welding Machines
Projection Welding Machines
Seam Welding Machine
Resistance Welding Transformers
Heating Machines
Laminated Copper Shunts
'BYSTRONIC’ Spare parts
‘TRUMPF’ Spare parts
CLOOS Schweisstechnik GmbH

Kickless Cable

 

 
Kickless Cable Assembly Process Alternate Polarity separated by Separator
Kickless Cable Assembly Process Alternate Polarity separated by Separator
 
Hose Crimping for Kickless Cable Resistance Checking of the Kickless Cable Resistance Checking of the Kickless Cable
Hose Crimping for Kickless Cable Resistance Checking of the Kickless Cable  
Specification of Water Cooled Kickless Cable :
1. Design of Cable as per Customers Specification with very less tolerance.
2. Special type of rubber hose with the High flexibility, more than 10 Kg/cm2
Capacity and to protect to high temperature water for safe operation. Excellent cooling effect even in continued welding operation.
3. Copper wire size is 33 Gauge for 300 MCM & 400 MCM as per standard of RWMA.
4. Accurate copper straight lugs or copper bend lug with 99% conductivity of Electrolytic Copper. Little Impedance & little Reactance drop.
5. Fantastic water testing units with Pressure 10 to 12 Kg/cm2, each and every Cable are tested.
6. Good Quality product with Long Life and very competitive rate. Long cable life reduces cable cost per weld - the true measure of cost cable.
7.

We have good team of engineers with more than 10 Years experience in same field.

8. Strict Quality Control during production, delivery as per schedule.
9. Easy for check & replacement & maintenance.
10. We have own Quality Assurance Plan of our products.
Maximum current available with different cable on different Transformer:
CABLE SELECTION CHART-MCM
      Amperes continuous duty current.
Duty Multiplier LEANTH            
Cycle   MCM 300 400 500 600 650 800
100% 1.00 3ft 10720 12400 13700 15200 15800 17620
90% 0.95 4ft 9300 10890 12000 13100 13550 15220
80% 0.90 5ft 8350 9700 11400 11570 12200 13420
70% 0.84 6ft 7660 8800 9800 10800 11100 12480
60% 0.78 7ft 7060 8100 9100 9900 10300 11550
50% 0.71 8ft 6600 7700 8500 9100 9680 10720
40% 0.63 9ft 6210 7100 8000 8700 9160 10400
30% 0.55 10ft 5900 6800 7640 8300 8650 9650
20% 0.45 11ft 5560 6500 7250 7920 8250 9100
10% 0.32 12ft 5350 6200 6950 7620 7920 8700
5% 0.22 13ft 5160 6200 6650 7300 7600 8400
3% 0.17 14ft 5000 5570 6420 7000 7300 8130
2% 0.14 15ft 4800 5400 6200 6800 7100 7780
    16ft 4650 5150 6000 6560 6820 7620
    17ft 4500 5050 5850 6360 6640 7400
    18ft 4420 5050 5670 6100 6460 7100
    19ft 4300 4950 5540 6000 6270 7000
    20ft 4200 4850 5380 5840 6110 6820
EMC : Eletromech kickless cable
First numeral : Normal sectional area of conductor.
Second numeral : Length of cable
• a) With a sub-cable 150 mm2 × 650 mm long + 1200 mm electrical Throat Depth × 200 mm Throat Gap gun
        + kickless cable.
•  Tip to tip current is given.
 
Unique Technical Features:
Extra operations on each end of Electromech Kickless Cable.
These operations are necessary where wires are crimped in an exclusive male and female pattern to position the wires to achieve the best alternate polarity design. This ultimately results into less Kick in Kickless Cable without any shorting of inside wires while in weld operation and hence increases the life by two to three months.
Operation 1 & 2 : Copper strip using for Wire crimping in Hydraulic press & then soldering on both end lugs.
Operation 3 & 4 : Blanking of Non magnetic S.S. sheets - 2 times (One Male & One Female).
Operation 5 & 6 : Forming of straight Pipe (male) and taper Pipe (female)
Operation 7 & 8 : Spot Welding straight pipe (male) and taper Pipe (female)
Operation 9 & 2 : Crimping into male type and other into female type.
Operation 11 : Covering the male pipe with high quality imported heat shrink sleeve.
 
Secondary Welding Cable (300 MCM) Technical Parameter Chart :
Specification Length 150 mm2 (300 mcm) Remark
Impedance At 25OC 50 Hz
2.0 mtr
2.4 mtr
515 +/- 15 Micro Ohms)
(600 +/- 15 Micro Ohms )
 
       
D.C Resistance At 25O C
2.0 mtr
2.4 mtr
(490 Micro Ohms)
(590 Micro Ohms)
 
       
Reactance
2.0 mtr
2.4 mtr
(85 Micro Ohms)
(90 Micro Ohms)
 
       
Power Factor
2.0 mtr
2.4 mtr
(0.96)
(0.96)
 
       
Coolant Flow Rate
2.0 mtr
2.4 mtr
More Than 7 Liters / min
More Than 7 Liters / min
Pressure Loss
0.5 kg / cm2
       
Temp Rise of Coolant
2.0 mtr
2.4 mtr
40-44o C at 5600 A
40-44o C at 5600 A
At Coolant Flow Rate of 7 Liters / Min
       
Weight
2.0 mtr
2.4 mtr
10.150 Kg.
12.300 Kg.
 
       

Flexibility of Rubber Hose and Star separator is 48 to 50 Sour A. Over all finished Cable flexibility check by the Coiling around Wooden Former.

Secondary Welding Cable (400 MCM) Technical Parameter Chart :
Specification Length 200 mm2 Remark
Impedance At 25OC 50 Hz
2.0 mtr
2.4 mtr
(360 +/- 20 Micro Ohms)
(455 +/- 20 Micro Ohms )
 
       
D.C Resistance At 25O C
2.0 mtr
2.4 mtr
(350 Micro Ohms)
(440 Micro Ohms)
 
       
Reactance
2.0 mtr
2.4 mtr
(85 Micro Ohms)
(95 Micro Ohms)
 
       
Power Factor
2.0 mtr
2.4 mtr
(0.97)
(0.97)
 
       
Coolant Flow Rate
2.0 mtr
2.4 mtr
More Than 7 Liters / min
More Than 7 Liters / min
Pressure Loss
0.5 kg / cm2
       
Temp Rise
2.0 mtr
2.4 mtr
40-44o C at 6500 A
40-44o C at 5900 A
At Coolant Flow Rate of 7 Liters / Min
       
Weight
2.0 mtr
2.5 mtr
12.300 Kg.
15.900 Kg.
 
       

Flexibility of Rubber Hose and Star separator is 48 to 50 Sour A. Over all finished Cable flexibility checked by the coiling around wooden former.

 

Secondary welding cable Parameter chart :
Specification Length 180 mm2 (360 mcm) Remark
D.C Resistance At 25O C
1.0 mtr
1.5 mtr
Below 110 micro ohms
Below 165 micro ohms
 
       
Coolant Flow Rate
1.0 mtr
1.5 mtr
More than 3 lit/ min
More than 3 lit / min
Pressure Loss
0.5 kgf / cm2
       
Temp Rise of Coolent
1.0 mtr
1.5 mtr
460 c at 6600 amp count.
470 c 5700 amp count
At Coolant Flow Rate of 7 Liters / Min
       
Weight
1.0 mtr
1.5 mtr
3.5 kg. approx
4.75 kg. approx.
 
       

 

• Little impedance and little reactance drop.
• High flexibility for good working efficiency.
• High resistance to repeating kicks and bending caused by electro-magnetic force  induced by welding current and welding operation, and accordingly long life.
• Excellent cooling effect even in continued welding operation.
• Easy check, replacement, and maintenance.
• Covering of good pressure resistance, heat resistance, and wear resistance.
• The kickless cable is consumable part and required to be inexpensive.
• Long cable life reduces cable cost per weld - the true measure of cable cost.

Secondary cables for portable Spot Welding Machine
 
1. This specification consult to JIS C 9318

2. Ours secondary cable mainly include Kickless cable and single conductor cable.
1) Kickless cable: A low-reactance water cooled flexible cable composed of 2 separate conductors insulated mutually and braided into a single hose.
2) Single conductor cable: A water cooled flexible,in which each of go-and-return path conductors is braided into a hose,usually making a set. 

3. Specifiction

ITEM

CABLE SIZE

300 MCM (2X150MM2)

400 MCM (2X200MM2)

2.0M

2.4M

3.0M

2.0M

2.4M

3.0M

RESISTANCE (μΩ)

460

550

680

330

400

495

IMPEDANCE (μΩ)

465±10

556±10

686±10

333±15

404±15

500±15

REACTANCE (μΩ)

68

81

90

45

57

71

COOLING WATER FLOWING

6L/MIN

Dia. Of bare copper wire

φ 0.25mm

LIFE TIME

About 600000 spot welding at 12000A,10CYCLE(NORMALLY 4 MONTHES)

4. Cable Model:
 
A. Kickless cable model:
Usually,we have 3 kinds of cross section 150sqmm*2, 160sqmm*2and 200sqmm*2,the satandard length is 2.4m.Also,we can make different length cable accroding to clients’ needs.
 
B. Single conductor cable,Aid cable:
We have 150/160/180/200/250sqmm cross section cable, the length is according to customers' needs.

HTRF Cover Hose

MCM
Size

Outer
Diameter

Terminal
Diameter

300

2″

1-7/16″

400-450

2-1/4″

1-11/16″

500

2-7/16″

1-7/8″

650

2-9/16″

1-7/8″

The HTRF Cover hose was developed to combat the primary cause of water-cooled cable failure: wear through of the outer cover. Often a hose wears through due to abrasion on the welding equipment or production components. WATTEREDGE-UNIFLEX has developed a super high abrasion compound which can outlast other materials 40 to 1 against failure due to abrasion. This compound is integrated into the HTRF cover hose, which is available for all kickless cables and also for water cooled jumpers up to 600 MCM in size.
Also available is a high abrasion thin wall sleeve, which can be mounted over the standard kickless cable hose.
 
DC Cable / 500 and 650 MCM
Opposed polarity cables for high amperage, direct current applications.
These heavily reinforced, two conductor water cooled cables are primarily used on heavy duty spot welding stations for joining aluminum panels. This cable is designed to operate at welding currents typically in the range of 45,000 to 55,000 amps D.C.
Several design features maximize cable life and are exclusive to these WATTEREDGE-UNIFLEX cables:
Stranding is press welded to the terminal to provide the lowest possible electrical resistance properties and a virtually indestructible bond. (Patent # 4,640,982)
Opposed polarity for optimum efficiency.
High strength, high temperature teflon reinforced retaining rings throughout the entire cable length.
High pressure, impact resistant cover hose.
1/2″ or 3/8″ NPT water port
21/32″ diameter mounting hole

 
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