Air Cooled Jumper Cables

Air - Cooled Sub / Jumper Cable

Product description:

An extra flexible rope type secondary conductors with connectors swage formed on each end for maximum flexibility and cooling. Each cable or secondary shunt is dedigned & built to perform with maximum efficienct and economy in its intended application, Air Cooled jumpers are required to electrically connect diatant points which move in relation to each other.

Such as

1. The movable gun-arm of certain types of welding guns to the Cables

2. On multiple Spot Welding Machines

These cables are immensely used in welding applications and highly demanded in the market. Offered products are manufactured using premium quality raw material and modern techniques keeping in mind the defined industry standards. Available in different specifications, the offered products can be purchased at meager costs.

Features:

Durability

Smooth finish

High tensile strength

Specification:

Advantages of using Air Cooled Cables

• Added Flexibility using Stranded Copper Rope in comparison to single strand of copper with same cross section

• Extremely long flex life, with especially strong demand in the use of moving parts in equipment and heavy machinery

• Improved Mechanical Strength. Due to highly calibrated designs with sufficient flexibility, Air Cooled Cables also provide good mechanical strength and an ability to withstand severe electrical stress

• Excellent Conductivity is obtained by using copper stranded ropes, providing highly efficiency transmission of current

• High Purity of Stranded Copper Cables provides protection from voltage drops and issues in conductivity

Industrial Applications of Air Cooled Cables

• Switchgears

• Transformer and Rectifiers

• Connecting moveable gun-arms of certain types of welding guns to power cables

• Spot welding machines

• Fuel Cells

• Electrolytic Processes

• Furnaces, Induction Furnaces (Glass, Metal Melting)

• ISO-Phase Bus-ways

• Plating Processes

• Resistance Welding

Air Cooled Jumper Sizing

Use the following method to determine what size cable should be used for your application. First you use the Conversion Factor chart to determine your “Continuous Duty Current”; then you read the correct size cable off the second chart. An example is worked out below.

Step 1: Lay one side of a straight edge across the graph at the six cycles of current “one time” point (the left hand vertical scale of the conversion factor chart).

Step 2: Pivot the other end of the straight edge across to line up with the “60 welds per minute” on the far right vertical scale.

Step 3: At the intersection of your straight edge with the diagonal conversion factor scale line, you should be able to read a conversion factor of .32 off the lower 1/2 of the line.

Step 4: Multiply the required current (10,000 amps) by the conversion factor (.32) to get the “continuous duty current” of 3,200 amps. Now proceed to the Air Cooled Jumper Selection Chart to read complete the selection.

Step 5 : Line up your straight edge on the 3200 continuous duty amp mark, and find the intersection with your desired length line (from below).

Step 6 : Any cable whose line is above this point may be safely used, since the load it would carry will be within its thermal capacity. In this example a 1200 MCM cable can be used and stay within design tolerances.

Example Data:

6 cycles of current “on time” per weld

60 welds per minute

10,000 amps per weld

10 inch cable Length

Installation Guidelines

Good Working shapes for Air Cooled Cables

Air cooled jumpers should be installed in such a manner that the mechanical stresses at the terminals will be reduced to a minimum. This may be accomplished by installing the jumper with a little slack, which will allow the jumper to flex freely.

Bend radii should not be sharp, and should be distributed throughout as much of the jumper as possible, in order to distribute the frictional wear over the greatest possible area. See the below charts for suggested minimum bend radii.

Recommended Minimum Bend Radii:

500 MCM and Below: 2″

600 MCM – 1500 MCM: 3″

Minimum Distance from the end of the hose to the point where the bend radii should start is:

350 MCM – 600 MCM: 2″

750 MCM: 2-1/2″

1000 MCM: 3″

1200 MCM: 3-1/2″

1500 MCM: 4″

More Specifications

D.C. Resistance of Single Conductor Water Cooled

(and Water Cooled) Cables

Each air cooled cable is manufactured with completely silver plated terminals, which can be manufactured up to 3-7/8" long for special applications.A chart for sizing the correct gauge cable is on the right of the page, as well as guidelines for installation.

To order an air cooled cable, you need to know several specifications for that cable. The following will walk you through this process

Step 1: Select Styles of Terminal Ends

End Combinations: The first “DJ” stands for Dry Jumper.The part number after this describes the two ends.

Terminal Thickness

Step 2: Taking Measurements

Length of the Cable = L

Terminal Face Width = B

To get L, measure from the center of one set of mounting holes to the center of the second set.

The secondary measurement, B, is the face width.

The terminal thickness is dependent on the terminal face width, and the gauge of the cable, as outlined in the table on the right.

Notes: The standard terminal width is 1-1/4". If a 1-3/8" or 1-1/2" wide terminal is desired, please be sure to specify this. If you are unsure of what MCM your application requires, you can size the correct cable yourself.kness

Step 3: More Cable Options

DJ-IC

Isolated Conductor

Cables with isolated, individually wrapped conductors increase cable life by preventing common failure points:

• Eliminated Frictional wear between adjacent copper ropes by encasing them in rubber tube.

• Reduces the number of friction points for wear between strands from 36 to 9, in the rope cross section.

• Reduced strand failure at the rear terminal by adding a Stabilizer flare.

• Increased flexibility due to the fact that a standard lapped cover is not required.

Note: Thermal tests have indicated that the operating temperatures of this style is virtually identical to that of standard jumper using a lapped cover.

DJ-SC

Stabilizer Collar

Increased strand life at the cable terminal is the advantage of a stabilizing collar. It slightly increases the minimum flex radius for the jumper, reducing over flexing.

DJ-sXF

Extra Flexible

36 AWG copper rope stranding and an extra flexible protective cover are used to create an extra flexible jumper. The result is a jumper that is over twice that of a regular jumper. This makes it ideal for robotic applications and where limited space makes standard cables a hard fit.

The DJ-XF is available in 750, 1000, and 1200 MCM. Other options include a perforated cover or a special Hypalon high temperature cover, able to withstand 300°F to -30°F.

A wide variety of high current air cooled power cables ideal for many different industries and applications including resistance welding, resistance heating and bus bar systems.

Each cable and jumper is designed and built to perform with maximum efficiency and economy, providing longer cable life and greater flexibility over standard jumpers.

Our in-house engineering team can manufacture high current air cooled power cables and jumpers to customer specification or we can assist with custom design concepts and fabrication.

Air Cooled Cable Specifications

Our air cooled cables are designated as type DJ (dry jumpers).

Made from non-insulated copper wire ranging from 400 to 2000 MCM

Cable end termination options:

Crimped lugs, compression terminals

Press welded compression terminals.

Air Cooled Cable Options:

Air Cooled Cable with Isolated Conductor

DJ-IC Air Cooled Jumper

Isolated Conductor type dry jumpers are identified by “IC,”

The Air Cooled Jumpers increase cable life by correcting the common causes of failure as indicated in the following:

Eliminates frictional wear between adjacent ropes by the use of rubber tubing.

Reduces frictional wear between strands of adjacent bunches within a rope by reducing “wear points” from 36 to 9 within the rope cross section.

Reduces strand failure at rear of terminal, resulting from the added Stabilizer Flare.

Increases flexibility and versatility because of an improved insulation method, not requiring the standard lapped hose cover.

Air Cooled Cable with Stabilizer Collar

DJ-SC Air Cooled Jumper

Increases dry jumper life by reducing strand failure at the cable terminal; this is accomplished by a slight increase in the minimum flex radius which in turn reduces overstressing.

Extra Flexible Air Cooled Cable

DJ-XF - Extra Flexible Air Cooled Jumper

The Extra Flexible type Dry Jumper increases cable life by the use of 36 AWG copper rope stranding and an extremely flexible protective cover specifically designed for this application.

The combination of the strand and cover increases the flexibility of the DJ-XF to over double that of the standard dry jumper. (DJ)

This increased flexibility makes it ideal for all robotic applications or where limited space makes installation of standard flexes a problem.

Tthe Extra Flexible Air Cooled Jumper is currently available in 750 MCM, 1000 MCM and 1200 MCM.

Terminal dimensions and ordering specifications are identical to the standard dry jumper (DJ).

Ideal for these Air Cooled Cable and Jumper Applications:

Air and Water Cooled Jumpers are required to electrically connect distant points which move in relation to each other and ideal for: