1、raising standards worldwideNO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAWBSI Standards PublicationWater-cooled secondary connection cables for resistance weldingPart 3: Test requirementsBS EN ISO 8205-3:2012National forewordThis British Standard is the UK implementation of EN
2、 ISO 8205-3:2012. It supersedes BS EN ISO 8205-3:1997 which is withdrawn.The UK participation in its preparation was entrusted to Technical Committee WEE/29, Resistance welding.A list of organizations represented on this committee can be obtained on request to its secretary.This publication does not
3、 purport to include all the necessary provisions of a contract. Users are responsible for its correct application. The British Standards Institution 2012.Published by BSI Standards Limited 2012 ISBN 978 0 580 78102 5 ICS 25.160.30Compliance with a British Standard cannot confer immunity from legal o
4、bligations.This British Standard was published under the authority of the Standards Policy and Strategy Committee on 30 November 2012.Amendments issued since publicationDate Text affectedBRITISH STANDARDBS EN ISO 8205-3:2012EUROPEAN STANDARD NORME EUROPENNE EUROPISCHE NORM EN ISO 8205-3 October 2012
5、 ICS 25.160.30 Supersedes EN ISO 8205-3:1996English Version Water-cooled secondary connection cables for resistance welding - Part 3: Test requirements (ISO 8205-3:2012) Cbles secondaires refroidis par eau, pour le soudage par rsistance - Partie 3: Spcifications pour les essais (ISO 8205-3:2012) Wid
6、erstandsschweien - Wassergekhlte Sekundranschlusskabel fr das Widerstandsschweien - Teil 3: Prfanforderungen (ISO 8205-3:2012) This European Standard was approved by CEN on 14 October 2012. CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for g
7、iving this European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the CEN-CENELEC Management Centre or to any CEN member. This European Standard exists in three o
8、fficial versions (English, French, German). A version in any other language made by translation under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC Management Centre has the same status as the official versions. CEN members are the national standards bodies
9、 of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spai
10、n, Sweden, Switzerland, Turkey and United Kingdom. EUROPEAN COMMITTEE FOR STANDARDIZATION COMIT EUROPEN DE NORMALISATION EUROPISCHES KOMITEE FR NORMUNG Management Centre: Avenue Marnix 17, B-1000 Brussels 2012 CEN All rights of exploitation in any form and by any means reserved worldwide for CEN nat
11、ional Members. Ref. No. EN ISO 8205-3:2012: EBS EN ISO 8205-3:2012EN ISO 8205-3:2012 (E) 2 Contents Page Foreword 3BS EN ISO 8205-3:2012EN ISO 8205-3:2012 (E) 3 Foreword This document (EN ISO 8205-3:2012) has been prepared by Technical Committee ISO/TC 44 “Welding and allied processes“ in collaborat
12、ion with Technical Committee CEN/TC 121 “Welding” the secretariat of which is held by DIN. This European Standard shall be given the status of a national standard, either by publication of an identical text or by endorsement, at the latest by April 2013, and conflicting national standards shall be w
13、ithdrawn at the latest by April 2013. Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights. CEN and/or CENELEC shall not be held responsible for identifying any or all such patent rights. This document supersedes EN ISO 8205-3:1996. Acc
14、ording to the CEN/CENELEC Internal Regulations, the national standards organisations of the following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, German
15、y, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United Kingdom. Endorsement notice The text of ISO 8205-3:2012 has been approved by CEN as a EN ISO 8205-3
16、:2012 without any modification. BS EN ISO 8205-3:2012Water-cooled secondary connection cables for resistance welding Part 3: Test requirements1 ScopeThis part of ISO 8205 specifies test procedures for single- and double-conductor secondary connection cables used for resistance welding and allied pro
17、cesses. It stipulates the requirements regarding the electrical, mechanical, and cooling characteristics of these cables.2 Normative referencesThe following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated
18、references, the latest edition of the referenced document (including any amendments) applies.ISO 8205-1, Water-cooled secondary connection cables for resistance welding Part 1: Dimensions and requirements for double-conductor connection cablesISO 8205-2, Water-cooled secondary connection cables for
19、resistance welding Part 2: Dimensions and requirements for single-conductor connection cables3 Tests3.1 GeneralAll the tests are type tests.Figure 1 gives an example of the water supply to the cable for the tests requiring this.When the tests are carried out, there shall be no trace of water at the
20、various connections.Key1 pressure reducing valve 4 pressure gauge2 valve 5 cable3 flow meter 6 sealFigure 1 Example of water supply to the cableINTERNATIONAL STANDARD ISO 8205-3:2012(E) ISO 2012 All rights reserved 1BS EN ISO 8205-3:2012ISO 8205-3:2012(E)3.2 Leak tightness and pressure resistance of
21、 the water circuitSupply the water circuit, sealed downstream of the cable (e.g. by closing the valve on the right-hand side of Figure 1), under a pressure of 750 kPa (7,5 bar), e.g. by adjusting pressure-reducing valve 1, for 6 min.3.3 Water flowCarry out this test successively: with the cable laid
22、 flat out straight on a horizontal surface see Figure 2 a); with the cable placed on a horizontal surface but bent with a radius of curvature of 300 mm see Figure 2 b).With the water circulating in the cable, e.g. by opening both valves (labelled 2) shown in Figure 1, adjust the pressure loss to 70
23、kPa (0,7 bar) for an upstream pressure greater than or equal to 100 kPa (1 bar).Measure the water flow using a suitable flow transducer see Figure 1, item 3.3.4 Verification of flexibility at ends3.4.1 GeneralCarry out this test on a low-reactance cable with a cross-sectional area of 200 mm2and leng
24、th of 2 500 mm, considered to be representative of cables of the same design with a cross-sectional area or length as specified in ISO 8205-1 and ISO 8205-2.3.4.2 Fixing of the cableFix the cable by one of its end lugs to a device fitted with horizontal and vertical graduated rules for measuring the
25、 coordinates of a point, in such a way that its other end hangs free see Figure 3.Carry out the test for each of the two ends of the cable.3.4.3 Measurements to be takenUsing the two graduated rules, measure the ordinate y at each of the points A, B and C with x equal to 0 mm, 150 mm, and 300 mm, re
26、spectively. The origin A of the coordinates is the point of intersection of the axis of the fixing hole in the end lug with its median plane; points B and C are located on the axis of the cable see Figure 3.3.4.4 Interpretation of resultsDetermine the arc of the circle passing through the three poin
27、ts A, B, and C by geometrical construction. The radius of the arc shall be regarded as the radius of curvature see Figure 3 b).NOTE If the ordinate of point C is greater than 0,30 m, the radius of curvature is regarded as being less than 0,30 m provided that the ordinate of point B is different from
28、 0.3.5 Torsion3.5.1 GeneralCarry out this test on low-reactance cable with a cross-sectional area of 200 mm2and length of 1 250 mm, regarded as being representative of cables of the same design having a cross-sectional area and length as specified in ISO 8205-1.3.5.2 Test rigSee Figure 4.2 ISO 2012
29、All rights reservedBS EN ISO 8205-3:2012ISO 8205-3:2012(E)Suspend the cable vertically, with the end lug by which it is suspended, immobilized as regards rotational and translational motion. Apply a force of 500 N 50 N to the lower lug of the cable by means of a rotating fork coupling and a pressure
30、 cylinder. Fill the cable with water at a pressure of 150 kPa (1,5 bar).3.5.3 Measurement to be takenMeasure the torque required to effect a 180 rotation in each direction of the lower lug.3.6 Measurement of insulation resistanceMeasure the insulation resistance of a new dry cable following applicat
31、ion of a d.c. voltage of 48 V for 1 min.3.7 Determination of the impedance of the cable (only for cables in accordance with ISO 8205-1)Determine the impedance of the cable at 30 C by applying to its terminals an alternating voltage, as sinusoidal as possible, of frequency 50 Hz or 60 Hz, r.m.s value
32、, U, and measuring, by means of a calibrated toroid, the intensity, I, of the current circulating in the cable. The impedance, Z, is then given byZUI=3.8 Determination of the resistance of the cableDetermine the resistance of the cable at 30 C and with no water in the cable, by applying to its termi
33、nals a permanent voltage, U, and measuring the intensity, I, of the current circulating in the cable. The resistance, R, is then given byRUI=Dimensions in millimetresa) Straight cable b) Curved cableFigure 2 Verification of water flow ISO 2012 All rights reserved 3BS EN ISO 8205-3:2012ISO 8205-3:201
34、2(E)Dimensions in millimetresa) Test device b) Determination of radius of curvatureFigure 3 Measurement of radius of curvatureKey1 cable2 elastic proving device3 cylinder tensile load, 500 NFigure 4 Rig for torsion test4 ISO 2012 All rights reservedBS EN ISO 8205-3:2012ISO 8205-3:2012(E)3.9 Calculat
35、ion of cos (only for cables in accordance with ISO 8205-1)The value of cos for the cable can then be calculated by using the values obtained in 3.7 and 3.8 as follows:cos =RZ3.10 Endurance test3.10.1 PrincipleEstimation of the life of a type of low-reactance cable and the variation in time of its el
36、ectrical resistance.The cable is fixed to a test device which enables the displacements, tilting and twisting likely to occur in normal service to be reproduced and is supplied by a welding transformer and cooled. It is then subjected to a series of cycles comprising a fixed number of the various po
37、ssible movements and pulse currents (referred to below as welding duration and current).This type test shall be carried out on the length stated in Table 1.Table 1 Adjustment parameters for 2 500 mm long cablesCross-sectional area of cableCurrentDuration of application of currentNumber of current pu
38、lses per minuteDuty ratioDuration of one welding cycleDuration of test cyclemm2kA s % s s160 16 0,24 13 5,2 4,6 145200 19 0,4 13 8,6 4,6 145250 19 0,4 15 10 4 127315 24 0,5 10 8,3 6 1873.10.2 Test apparatusFigure 5 gives an example of the test apparatus.3.10.3 Adjustment parametersThe test shall be
39、carried out on a 2 500 mm long cable. The adjustment parameters given in Table 1 for the various cross-sectional areas shall be used.The cooling circuit shall be adjusted so as to obtain a pressure loss of 70 kPa (0,7 bar).3.10.4 Test cycleEach test cycle shall have the duration specified in Table 1
40、 and shall comprise: one forward movement of the carriage over a distance of 700 mm; 15 torsional cycles consisting of a 90 twist in one direction, return to the initial position, a 90 twist in the opposite direction, and return to the initial position; 10 forward tilting movements over an angle of
41、90 followed by tilting in the opposite direction to return to the initial position; 30 applications of current for the duration specified in Table 1; one backward displacement of the carriage returning it to its initial position. ISO 2012 All rights reserved 5BS EN ISO 8205-3:2012ISO 8205-3:2012(E)T
42、he beginning of the cycle is defined as the start of forward motion of the carriage and the end of the cycle is defined as the return of the carriage to its initial position.Figure 6 gives a chart of a test cycle.3.10.5 Test procedure and durationDetermine the impedance of the cable every 2 000 cycl
43、es and plot the curve Z = f(N), where N is the number of cycles.Halt the test at the first sign of failure, e.g. escape of water or rupture of the cable. Note the number of cycles carried out and the nature of the failure.3.11 Test reportThe test report shall include the following information:a) a r
44、eference to this part of ISO 8205 (ISO 8205-3:2012);b) an identification of the cable tested;c) the results of the tests;d) any circumstances affecting the results.Dimensions in millimetresa) Front view b) Front view leftKey1 transformeraRotation by 90.bTilting.cForward.dReturn.Figure 5 Example of t
45、est apparatus for testing the endurance of a low-reactance cable6 ISO 2012 All rights reservedBS EN ISO 8205-3:2012ISO 8205-3:2012(E)KeyC carriage Carriage forward Carriage returnT torsion Forward torsion Reverse torsionB tilting Forward tilt Reverse tiltI current Figure 6 Chart of test cycle ISO 20
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