1、 Manufacturing StandardsFord Motor Company199110 SPECIFICATIONS AND REQUIREMENTS FOR WELDING TRANSFORMER WK4XPRIMARY SERVICE CABLEEngineering Standards & Printed copies are uncontrolled.Systems Engineering (ESSE) Page 1 of 5Two conductor type W round cables (without grounding conductors), andsingle
2、conductor cables.1. SCOPE:1.1 The purpose of this specification is to assure purchasers ofobtaining neoprene jacketed cables of superior quality, for weldingtransformer primary service and portable power cables, that arereliable, dependable, and designed and manufactured in accordancewith accepted i
3、ndustry standards.1.2 This specification covers the construction of round type (W) twoconductor and single conductor portable power cables designed for600 volt service. Cables covered within this specification shallconform to the construction and engineering recommendations of theInsulated Power Cab
4、le Engineers Association (IPCEA). SpecificationsS-19-81.2. GENERAL:2.1.1 The copper used for the conductors shall be of electrolyticquality and 99.8% pure. Each strand within all conductorsshall be annealed dead soft copper and tinned. The physicaland electrical properties shall be equal to or excee
5、d therequirements of the American Society for Testing Materials(ASTM) standard B-3.2.1.2 The copper wires used in the makeup of the stranded conductorsmay be bunched concentric lay or rope lay as required. Thesize and number of the individual wires in each conductor, whenstranded together, shall hav
6、e a circular mil area equal to thecircular mil area of each conductor size specified based onAmerican Wire Gauge (AWG) sizes.2.1.3 The minimum stranding for all cables shall be in accordancewith the following Table I:TABLE IMinimum MinimumAWG Size Stranding AWG Size Stranding8 133 1 2596 133 1/0 259
7、4 133 2/0 2593 133 3/0 2592 259 4/0 427Manufacturing StandardsFord Motor Company199110 SPECIFICATIONS AND REQUIREMENTS FOR WELDING TRANSFORMER WK4XPRIMARY SERVICE CABLEEngineering Standards & Printed copies are uncontrolled.Systems Engineering (ESSE) Page 2 of 52.1.4 The ampacity or current carrying
8、 capacity of the cables in thisspecification shall be in accordance with Table II whenoperating with a copper temperature of 70 C (158 F) and anambient air temperature of 40 C (104 F).TABLE IIAWG Size Amperes Amperes AWG Size Amperes Amperes1 Cond. 2 Cond. 1 Cond. 2 Cond.8 60 50 1 170 1406 85 65 1/0
9、 200 1704 110 90 2/0 235 1903 130 105 3/0 275 2252 150 120 4/0 315 2602.2 INSULATION:2.2.1 The individual electrical conductors for all cables shall beinsulated with a heat and moisture resistant synthetic rubberconsisting of at least 40% neoprene. The insulation shall becapable of withstanding a co
10、nductor temperature of 70 C (158 F)and an ambient air temperature of 40 C (104 F) while inoperation, and meet the requirements of ASTM-D 1352 and IPCEAS-19-81, Section 3.16.2.2.2 There shall be no cotton or paper separator between the powerconductor and the rubber insulation.2.2.3 The test voltage a
11、nd thickness of the insulation on all powerconductors shall be in accordance with IPCEA recommendations,shown in Table III.TABLE IIIInsulation ThicknessAWG Size in 64ths Test Voltage8 4 6,0006 4 6,0004 4 6,0003 4 6,0002 4 6,0001 5 7,5001/0 5 7,5002/0 5 7,5003/0 5 7,5004/0 5 7,500Manufacturing Standa
12、rdsFord Motor Company199110 SPECIFICATIONS AND REQUIREMENTS FOR WELDING TRANSFORMER WK4XPRIMARY SERVICE CABLEEngineering Standards & Printed copies are uncontrolled.Systems Engineering (ESSE) Page 3 of 52.2.4 The color of the insulation of all power conductors shall be inaccordance with the followin
13、g Table IV:TABLE IVSingle Cond. & Type W Cables Color CodeNo. of Cond. Black White1 12 1 12.2.5 The insulation on conductors covered by this specificationshall have a tensile strength of not less than 1,000 lbs. persquare inch.2.3 OUTER JACKET:2.3.1 The outer jacket on all cables shall consist of a
14、heavy wall ofnonflammable black neoprene compound containing a minimum of65% new neoprene. It shall be moisture, oil, acid, and Alkaliresistant. The jacket shall be applied directly over theconductor assembly reinforcement, and shall meet allrequirements of IPCEA standards S-19-81 and ASTM-D-752, Se
15、ction7.6.20 (heavy-duty jacket).2.3.2 The outer jacket on all cables covered in this specificationshall be mold cured, lead cured, or by a Ford approvedalternate method.2.3.3 All cables made in accordance with this specification areflame-resistant as required by the U.S. Bureau of Mines. Asevidence
16、of full compliance with these requirements, the symbolP*-BM or *BM (*MFRS Approval Number) shall appear as apart of the permanent marking on the outer surface of thecable.2.3.4 Embossed or debossed marking molded into and an integral partof the jacket shall show the following information: TradeName,
17、 Type, Cable, Size, Number of Conductors, Voltage, Numberof Strands, and Mines Approval Number (P*BM or *BM).2.3.5 The marking described in 2.3.4 shall appear every 3 feet orless.2.3.6 The original tensile strength of the jacket on all cablescovered in this specification shall be no less than 2,500
18、PSI.Manufacturing StandardsFord Motor Company199110 SPECIFICATIONS AND REQUIREMENTS FOR WELDING TRANSFORMER WK4XPRIMARY SERVICE CABLEEngineering Standards & Printed copies are uncontrolled.Systems Engineering (ESSE) Page 4 of 53. SINGLE CONDUCTOR CABLE:3.1 CONDUCTOR ASSEMBLY:3.1.1 The cable conducto
19、r assembly (conductor and insulation lessjacket, see sketches) shall have an open twine braid overallfor added protection and added strength. The reinforcementshall be applied with a tension that will permit the conductorto move freely when the cable is flexed.3.1.2 The overall diameter of single co
20、nductor cables shall bewithin the limits as shown in the following Table V:TABLE VOverall DiameterAWG Size Min. Max.8 .39 .496 .46 .564 .52 .623 .58 .682 .61 .711 .69 .791/0 .72 .822/0 .77 .873/0 .82 .924/0 .88 .984. TYPE W TWO CONDUCTOR CABLE:4.1 CONDUCTOR ASSEMBLY:4.1.1 The insulated power conduct
21、ors of type W cables, shall becabled together with a length of lay or twist of the conductorsdesigned to provide maximum flex life in all types ofapplications within the design limits of the cable.4.1.2 Suitable moisture and heat resisting fibrous or rubber fillersshall be placed in the valleys or i
22、nterstices between thetwisted conductors, within type W cable to form a firm compactconcentric cable assembly.4.1.3 Open twine braid shall be applied in the same manner as listedin paragraph 3.1.1.Manufacturing StandardsFord Motor Company199110 SPECIFICATIONS AND REQUIREMENTS FOR WELDING TRANSFORMER
23、 WK4XPRIMARY SERVICE CABLEEngineering Standards & Printed copies are uncontrolled.Systems Engineering (ESSE) Page 5 of 54.1.4 The overall diameter of round type W two conductor cable shallbe within the limits as shown in the following Table VI.TABLE VIOverall DiameterAWG Size Min. Max.8 .76 .866 .88 .984 1.03 1.133 1.12 1.222 1.22 1.321 1.39 1.491/0 1.47 1.572/0 1.57 1.673/0 1.72 1.824/0 1.87 1.97
