1、April 2013 Translation by DIN-Sprachendienst.English price group 8No part of this translation may be reproduced without prior permission ofDIN Deutsches Institut fr Normung e. V., Berlin. Beuth Verlag GmbH, 10772 Berlin, Germany,has the exclusive right of sale for German Standards (DIN-Normen).ICS 2
2、5.160.30!$L2“1974115www.din.deDDIN EN ISO 8205-3Water-cooled secondary connection cables for resistance welding Part 3: Test requirements (ISO 8205-3:2012);English version EN ISO 8205-3:2012,English translation of DIN EN ISO 8205-3:2013-04Wassergekhlte Sekundranschlusskabel fr das Widerstandsschweie
3、n Teil 3: Prfanforderungen (ISO 8205-3:2012);Englische Fassung EN ISO 8205-3:2012,Englische bersetzung von DIN EN ISO 8205-3:2013-04Cbles secondaires refroidis par eau, pour le soudage par rsistance Partie 3: Spcifications pour les essais (ISO 8205-3:2012);Version anglaise EN ISO 8205-3:2012,Traduct
4、ion anglaise de DIN EN ISO 8205-3:2013-04SupersedesDIN EN ISO 8205-3:1997-02www.beuth.deDocument comprises 12 pagesIn case of doubt, the German-language original shall be considered authoritative.03.13DIN EN ISO 8205-3:2013-04 2 A comma is used as the decimal marker. National foreword The text of IS
5、O 8205-3:2012 has been prepared by Technical Committee ISO/TC 44 “Welding and allied processes” and has been taken over as EN ISO 8205-3:2012 by Technical Committee CEN/TC 121 “Welding” (Secretariat: DIN, Germany). The responsible German body involved in its preparation was the Normenausschuss Schwe
6、ien und verwandte Verfahren (Welding and Allied Processes Standards Committee), Working Group NA 092-00-12-06 AK Fertiungsmittel zum Widerstandsschweien (DVS AG V 3.8). The DIN Standards corresponding to the International Standards referred to in this document are as follows: ISO 8205-1 DIN EN ISO 8
7、205-1 ISO 8205-2 DIN EN ISO 8205-2 Amendments This standard differs from DIN EN ISO 8205-3:1997-02 as follows: a) the standard has been editorially revised and normative references have been updated; b) the impedance of the cable can alternatively be determined at a frequency of 60 Hz (3.7); c) the
8、principle of the endurance test has been given in more detail (3.10.1); d) the description of the test cycle has been rendered more precise (3.10.4). Previous editions DIN EN ISO 8205-3: 1997-02 National Annex NA (informative) Bibliography DIN EN ISO 8205-1, Water-cooled secondary connection cables
9、for resistance welding Part 1: Dimensions and requirements for double-conductor connection cables DIN EN ISO 8205-2, Water-cooled secondary connection cables for resistance welding Part 2: Dimensions and requirements for single-conductor connection cables EUROPEAN STANDARD NORME EUROPENNE EUROPISCHE
10、 NORM EN ISO 8205-3 October 2012 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
11、les essais (ISO 8205-3:2012) 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 condit
12、ions for giving 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
13、in three official 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 standa
14、rds bodies 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, Slov
15、enia, Spain, 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 f
16、or CEN national Members. Ref. No. EN ISO 8205-3:2012: EDIN EN ISO 8205-3:2013-04 EN ISO 8205-3:2012 (E) 2 Page Foreword 3 1 Scope 4 2 Normative references 4 3 Tests 4 3.1 General 4 3.2 Leak tightness and pressure resistance of the water circuit 5 3.3 Water flow .5 3.4 Verification of flexibility at
17、ends .5 3.4.1 General 5 3.4.2 Fixing of the cable .5 3.4.3 Measurements to be taken 5 3.4.4 Interpretation of results 5 3.5 Torsion 5 3.5.1 General 5 3.5.2 Test rig 5 3.5.3 Measurement to be taken 6 3.6 Measurement of insulation resistance 6 3.7 Determination of the impedance of the cable (only for
18、cables in accordance with ISO 8205-1) .6 3.8 Determination of the resistance of the cable 6 3.9 Calculation of cos (only for cables in accordance with ISO 8205-1) 8 3.10 Endurance test .8 3.10.1 Principle 8 3.10.2 Test apparatus .8 3.10.3 Adjustment parameters .8 3.10.4 Test cycle 8 3.10.5 Test proc
19、edure and duration 9 3.11 Test report 9 Foreword This document (EN ISO 8205-3:2012) has been prepared by Technical Committee ISO/TC 44 Welding and allied processes” in collaboration with Technical Committee CEN/TC 121 “Welding” the secretariat of which is held by DIN. This European Standard shall be
20、 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 withdrawn at the latest by April 2013. Attention is drawn to the possibility that some of the elements of this document may
21、 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. According to the CEN/CENELEC Internal Regulations, the national standards organisations of the following countries are bound
22、to implement this European Standard: 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,
23、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 8205-3:2012 without any modification. “ DIN EN ISO 8205-3:2013-04 EN ISO 8205-3:2012 (E) 3 1 ScopeThis part of ISO 8205 specifie
24、s test procedures for single- and double-conductor secondary connection cables used for resistance welding and allied processes. It stipulates the requirements regarding the electrical, mechanical, and cooling characteristics of these cables.2 Normative referencesThe following referenced documents a
25、re indispensable for the application of this document. For dated references, only the edition cited applies. For undated 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: Di
26、mensions and requirements for double-conductor connection cablesISO 8205-2, Water-cooled secondary connection cables for 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
27、supply to the cable for the tests requiring this.When the tests are carried out, there shall be no trace of water at the various connections.Key1 pressure reducing valve 4 pressure gauge2 valve 5 cable3 flow meter 6 sealFigure 1 Example of water supply to the cableDIN EN ISO 8205-3:2013-04 EN ISO 82
28、05-3:2012 (E) 4 3.2 Leak tightness and pressure resistance of 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 Wa
29、ter flowCarry out this test successively: with the cable laid 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 (l
30、abelled 2) shown in Figure 1, adjust the pressure loss to 70 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-r
31、eactance cable with a cross-sectional area of 200 mm2and length 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 w
32、ith horizontal and vertical graduated rules for measuring the 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 p
33、oints A, B and C with x equal to 0 mm, 150 mm, and 300 mm, respectively. 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 resultsD
34、etermine the arc of the circle passing through the three points 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
35、,30 m provided that the ordinate of point B is different from 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 s
36、pecified in ISO 8205-1.3.5.2 Test rigSee Figure 4.DIN EN ISO 8205-3:2013-04 EN ISO 8205-3:2012 (E) 5 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
37、 of a rotating fork coupling and a pressure 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 resis
38、tance of a new dry cable following application 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 possibl
39、e, of frequency 50 Hz or 60 Hz, r.m.s value, 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 w
40、ater in the cable, by applying to its terminals 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 flowDIN EN ISO 8205-3:2013-
41、04 EN ISO 8205-3:2012 (E) 6 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 testDIN EN ISO 8205-3:2013-04 EN ISO 8205-3:2012 (E) 7 3.9 Ca
42、lculation 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
43、its electrical 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 vari
44、ous possible 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 curr
45、ent pulses 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 sha
46、ll be 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 T
47、able 1 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 ang
48、le of 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.DIN EN ISO 8205-3:2013-04 EN ISO 8205-3:2012 (E) 8 The beginning
49、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 cycles 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
