Automotive Catalog
Content
Automotive Cables
The Global Cable Solutions Company
Automotive Cables
600V (UL), 1000V c(UL), power drop for weld controllers, AC transformers and Tri-pack weld controls. RHH-RHW, Type TC-ER, Type R90. GM Class 2 cable.
Index
Weld Primary Cable – WPCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2000V (UL), 1000V c(UL), primary power connections to transformers and Trans-Guns. RHH-RHW, Type TC-ER, Type R90. GM Class 2 cable.
Weld Primary Cable – WPCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Weld Primary Cable – WPCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2000V (UL), 1000V c(UL), power connections for transformers and weld controllers. RHH-RHW, Type TC-ER, Type R90, GM Class 3 cable.
Weld Primary Cable – WPCS Flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
600V (UL), 1000V c(UL), flat power drop for transformers and weld controllers. RHH-RHW, Type TC-ER, Type R90. GM Class 2 cable.
Trans-Gun Assembly – WPCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Highly flexible cable assembly for Trans-Gun welding equipment. GM Class 4 cable.
Trans-Gun Immobilization Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Immobilization bracket for use with 90° Trans-Gun cable assemblies.
Tiger-Flex Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2000V, multi-conductor flexible power cable for continuous flexing and twisting applications. Type W, Type TC. 6 AWG to 4/0
Robotic and Manual Welding Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 16
600V, flexible power cables for a wide range of robotic and welding applications.
Robotic and Manual Welding Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2000V, flexible power cables for a wide range of robotic and welding applications.
Cables for Toyota . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
600V to 2000V, cables specially designed for Toyota Motors.
Cables for DaimlerChrysler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2000V, portable cables to meet DaimlerChrysler specifications.
DLO Flexible Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2000V, single conductor. Diesel locomotive cable. EP/CPE, RHH, RHW-2
Lower Installed Costs
See Page 2
El Dorado, Arkansas
AmerCable believes the information presented throughout this catalog to be reliable and current. All information is subject to change without notice. The information listed is approximate, and is presented only as a guide for product selection. We make no claims or warranties for the suitability of any product for any particular application.
Made in America
© 2006, AmerCable Incorporated
Our Commitment to the Automotive Industry
Tough operating environments require cables engineered for longer service life and increased productivity
AmerCable has a automotive cable productivity solution for you. Our innovatively engineered and manufactured Automotive Cable Family is designed for your toughest conditions. As a leading producer of automotive cables in North America, AmerCable is dedicated to producing: highly flexible and reliable cables cables that last longer in harsh automotive environments cables designed to help provide greater levels of safety and productivity
Cable Innovation
Designing insulating and jacketing materials that are more flexible with greater resistance to abrasion and moisture Cable constructions that last longer – providing reduced down time for increased productivity New product development that addresses environmental, safety and cost reduction issues specific to your application.
Operating Excellence
On-time delivery backed by our industry leading shipment percentage of 99%+ for the past 36 months. For our current on-time delivery rate, visit our website at www.amercable.com Standard lead-time of 6 to 8 weeks Urgent response shipment capability of 2 to 4 weeks AmerCable is an ISO-9001 certified manufacturer
Hands-on Field Support
Our experienced field application engineers are available for on-site evaluation and solutions. They also conduct education and training sessions that address safety, splicing and cable handling issues.
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e-mail: [email protected]
1
TC-ER for Fast, Economical Cable Installation
Your Challenge: The plant manager directs you to develop a plan to install a new production line. His only directions are to do it faster and for less money than the last change. Your First Thought: How is this going to be possible without compromising installation quality? The AmerCable Solution: Exposed run cables for fast, economical installation.
Type TC-ER cables are permitted to extend for an unlimited distance. Because of this increased out-of-tray cable length, the use of -ER rated cables can reduce the need for conduit and the overall cost of the installation.
AmerCable Exposed Run Cables
This new rating for tray cables – TC-ER – was created by changes in NEC and UL standards. If the basic UL cable type meets additional crush and impact requirements, UL permits the manufacturer to add the -ER suffix to the basic listing on the cable. The -ER signifies that it has met the physical toughness requirements that permit it to be installed as exposed wiring in certain applications. Such wiring, i.e. wiring that is installed outside of a tray, conduit or other raceway, is sometimes also called open wiring. With the -ER suffix printed on the cable, the responsible electrical inspector is able to verify that the cable meets Code requirements for use as exposed wiring.
UL Type TC-ER APPROVED!
Formerly “Open Wiring”
Lower Installed Cost!
UL Type TC tray cables are permitted in cable trays by the NEC. However, tray cables without the -ER suffix that extend from the tray for more than 1.8 meters (6 feet) to connect to a motor or other electrical device must be installed in conduit or other type of raceway. Tray cables with the -ER suffix can extend much further in certain applications if given adequate protection and support.
2005 National Electrical Code® Excerpt Type TC Cables Article 336.10 (7) In industrial establishments where the conditions of maintenance and supervision ensure that only qualified persons service the installation and where the cable is continuously supported and protected against physical damage using mechanical protection, such as struts, angles or channel, Type TC tray cable that complies with the crush and impact requirements of Type MC cable and is identified for such use with the marking Type TC-ER shall be permitted between a cable tray and the utilization equipment or device. The cable shall be secured at intervals not exceeding 1.8m (6ft). Equipment grounding for the utilization equipment shall be provided by an equipment grounding conductor within the cable.
Source: National Electrical Code 2005
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Manufactured by AmerCable Incorporated • (870) 862-4919 • (800) 643-1516 • Fax (870) 862-9613
Installation Cost Comparison
60 Amp Drop
Conduit Installation 6AWG RHW + 8AWG RHW gnd.............. $241.00 1" Rigid Conduit + Fittings ........................ 270.00 Labor (24 Hours)....................................1,200.00 Total....................................... $1,711.00 Open Wiring Installation AmerCable Power Cable 6AWG + gnd .... $440.00 (AmerCable Part #: 37-849-067) Cable Supports ........................................... 90.00 Labor (8 Hours)........................................ 400.00 Total ......................................... $930.00 Savings Conduit Installation.............................. $1,711.00 Open Wiring Installation ........................... 930.00 Cost Difference ......................................... 781.00
Automotive Cables
Installation Description: Bus Drop from bus plug to safety switch or control panel; 120 foot total cable run; 30 foot vertical drop
100 Amp Drop
Conduit Installation 2AWG RHW + 8AWG RHW gnd.............. $516.00 1-1/4" Rigid Conduit + Fittings.................. 373.00 Labor (24 Hours)................................... 1,200.00 Total....................................... $2,089.00 Open Wiring Installation AmerCable Power Cable 4AWG + gnd .... $526.00 (AmerCable Part #: 37-849-058) Cable Supports ........................................... 90.00 Labor (8 Hours)........................................ 400.00 Total....................................... $1,016.00 Savings Conduit Installation...............................$2,089.00 Open Wiring Installation .........................1,016.00 Cost Difference .......................................1,073.00
Total Savings ........................... 46%
Total Savings ........................... 51%
200 Amp Drop
Conduit Installation 3/0AWG RHW + 6AWG RHW gnd........ $1,115.00 2" Rigid Conduit + Fittings ........................ 519.00 Labor (32 Hours) ....................................1,600.00 Total ....................................... $3,234.00 Open Wiring Installation AmerCable Power Cable 2/0AWG + gnd ................................... $1341.00 (AmerCable Part #: 37-849-060) Cable Supports ..........................................140.00 Labor (16 Hours)...................................... 800.00 Total ....................................... $2,281.00 Savings Conduit Installation.............................. $3,234.00 Open Wiring Installation ........................ 2,281.00 Cost Difference ......................................... 953.00
400 Amp Drop
Conduit Installation 600 kcmil RHW + 1/0AWG RHW gnd .. $3,623.00 4" Rigid Conduit + Fittings ......................1,527.00 Labor (48 Hours) ....................................2,400.00 Total ....................................... $7,550.00 Open Wiring Installation AmerCable Power Cable 400 kcmil + gnd................................. $3,371.00 (AmerCable Part #: 37-849-063) Cable Supports ......................................... 210.00 Labor (24 Hours) ................................... 1,200.00 Total ....................................... $4,781.00 Savings Conduit Installation ............................. $7,550.00 Open Wiring Installation......................... 4,181.00 Cost Difference ...................................... 2,769.00
Total Savings ........................... 29%
Total Savings ........................... 37%
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37-849
Weld Primary Cable • WPCS 2000 Volts (UL) • 1000 Volts c(UL)
Type RHH/RHW • Type TC-ER • Type R90 • 90°C Conductors
Flexible tinned copper
Insulation
90°C ethylene-propylene rubber (EPR). Phase identified by color code
Application
Primary power connections to transformers Main power drops Feeders to hard automatics and Trans-Guns Temporary feeders (4/0 single conductor)
Separator
A suitable separator providing easy stripping of insulation
Separator
A suitable separator providing easy stripping of jacket
Features
Suitable for continuous operating conductor temperature of 90°C Extremely flexible stranding used for increased flexibility and ease of installation Insulated with EPR meeting the requirements of ICEA S-75-381 Heavy-duty jacket offers excellent protection against abrasion, impact, heat, oil, flame, ozone, alkali and acids. Suitable for extra hard usage Rated by GM as Class 2 cable, suitable for periodic flexing
Jacket
Mold-cured thermoset with cable identification via permanent marking (1/C is CV-Cured)
Reinforcement
Synthetic yarn over assembly
Ratings & Approvals
UL Type RHH/RHW UL Type TC-ER (Multi-Conductor) c(UL) Type TC (Multi-Conductor) c(UL) Type R90 Flame Resistance: FT1 (Single Conductor) Flame Resistance: FT4 (Multi-Conductor) CSA: -40°C UL 44: Thermoset-Insulated Wires and Cables
UL Type TC-ER APPROVED!
Formerly “Open Wiring”
UL 1277: Electrical Power and Control Tray Cables with Optional Optical-Fiber Members CSA C22.2 No. 38: Thermoset Insulated Wires and Cables ASTM B33: Tinned Soft or Annealed Copper Wire for Electrical Purposes ASTM B172: Standard Specification for Rope-Lay-Stranded Copper Conductors having Bunch-Stranded Members, for Electrical Conductors ASTM B173: Standard Specification for Rope-Lay-Stranded Copper Conductors Having ConcentricStranded Members, for Electrical Conductors These cables meet the requirements of General Motors Corporation Resistance Welding Equipment WS-2, Section C: Primary Cables Specification.
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Manufactured by AmerCable Incorporated • (870) 862-4919 • (800) 643-1516 • Fax (870) 862-9613
Automotive Cables
37-849 • Weld Primary Cable • 2000 Volts (UL) • 1000 Volts c(UL)
Number of Part No. Size Power 37-849- AWG Cond. 053 055 050
1
1 Min. Nominal Min. Nominal 1Nominal DC 1 WPCS Wires Insulation Ground Wires per Ground Outside Approx. Resistance Part per Thickness Size Ground Insulation Dia. Weight Ohms/mft Cond. AWG Cond. Thk. in. (in.) Lbs/mft @ 75°C 2Ampacity No. in.
BOC Cross Jacket Ref. Color
2/0 2/0 4/0
2 3 1
323 323 532
0.090 0.090 0.090
2 2 NA
259 259 NA
0.070 0.070 NA
1.677 1.890 0.917
2184 2764 908
0.101 0.101 0.0626
271 237 405
2X20X2X BOC-33 Black 3X20X2X BOC-38 Black 1X40XXX BOC-18 Yellow
Cable dimensions, weights and dc-resistances are subject to manufacturing tolerance. Consult factory for exact tolerances. Ampacity is listed with a 90°C conductor temperature and 30°C ambient air, free air installation, per 2005 NEC.
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37-849
Weld Primary Cable • WPCS 600 Volts (UL) • 1000 Volts c(UL)
Type RHH/RHW • Type TC-ER • Type R90 • 90°C
Application
Conductors
Flexible tinned copper
Separator
A suitable separator provides easy stripping of insulation
Insulation
90° ethylene-propylene rubber (EPR). Phase identified by color code
Separator
A suitable separator providing easy stripping of jacket
2/C 4/0 Plus 1/0 Ground Main power drop to a single-phase weld controller from a bus plug Power drop from a weld controller to a conventional AC transformer Power drop from a weld controller to a junction box for automatics 3/C 4/0 Plus 1/0 Ground Feeders for Tri-pack weld controls
Reinforcement
Synthetic yarn over assembly
Jacket
Mold-cured thermoset with cable identification via permanent marking
Features
Suitable for continuous operating conductor temperature of 90°C Extremely flexible stranding used for increased flexibility and ease of installation Phase conductors insulated with EPR meeting the requirements of ICEA S-75-381 Heavy-duty jacket offers excellent protection against abrasion, impact, heat, oil, flame, ozone, alkali and acids Innovative design reduces diameter and weight Rated by GM as Class 2 cable, suitable for periodic flexing Suitable for extra hard usage
Ratings & Approvals
UL Type RHH/RHW UL Type TC-ER c(UL) Type TC c(UL) Type R90 Flame Resistance: FT4 CSA: -40°C UL 44: Thermoset-Insulated Wires and Cables
Formerly “Open Wiring”
UL Type TC-ER APPROVED!
UL 1277: Electrical Power and Control Tray Cables with Optional Optical-Fiber Members CSA C22.2 No. 38: Thermoset Insulated Wires and Cables ASTM B33: Tinned Soft or Annealed Copper Wire for Electrical Purposes ASTM B172: Standard Specification for Rope-Lay-Stranded Copper Conductors having Bunch-Stranded Members, for Electrical Conductors These cables meet the requirements of General Motors Corporation Resistance Welding Equipment WS-2, Section C: Primary Cables Specification.
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Manufactured by AmerCable Incorporated • (870) 862-4919 • (800) 643-1516 • Fax (870) 862-9613
Automotive Cables
37-849 • Weld Primary Cable • 600 Volts (UL) • 1000 Volts c(UL)
Number of Part No. Size Power 37-849- AWG Cond. 051 054
1
1 Min. Nominal DC Min. Nominal 1Nominal WPCS Wires Insulation Ground Wires per Ground Outside 1Approx. Resistance Part per Thickness Size Ground Insulation Dia. Weight Ohms/mft Cond. (in.) Lbs/mft @ 75°C 2Ampacity No. AWG Cond. Thk. in. in.
BOC Cross Jacket Ref. Color
4/0 4/0
2 3
532 532
0.080 0.080
1/0 1/0
266 266
0.055 0.055
1.825 2.033
2962 3770
0.0626 0.0626
361 316
2X4010X BOC-31 Black 3X4010X BOC-36 Black
Cable dimensions, weights and dc-resistances are subject to manufacturing tolerance. Consult factory for exact tolerances. Ampacity is listed with a 90°C conductor temperature and 30°C ambient air, free air installation, per 2005 NEC.
2
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37-849
Weld Primary Cable • WPCS 2000 Volts (UL) • 1000 Volts c(UL)
Type RHH/RHW • Type TC-ER • Type R90 • 90°C Conductors
Flexible tinned copper
Application
Primary power connections to transformers (2/C plus ground) Main power drop to a three-phase weld controller from a bus plug (3/C plus ground)
Separator Core Binder
Synthetic yarn over assembly A suitable separator provides easy stripping of insulation
Features
Suitable for continuous operating conductor temperature of 90°C Extremely flexible stranding used for increased flexibility and ease of installation Insulated with EPR meeting the requirements of ICEA S-75-381 Serrated insulation and special length of lay to insure long flex life Heavy-duty jacket offers excellent protection against abrasion, impact, heat, oil, flame, ozone, alkali and acids Jacket extruded into cable core interstices to ensure durability Suitable for extra hard usage Rated by GM as Class 3 cable, suitable for continuous duty flexing service at moderate speeds with extensive high count flex life and moderate amounts of torsional stress
Insulation
90° ethylene-propylene rubber (EPR) serrated to ensure long flex life. Phase identified by color code
Reinforcement
Two (2) servings of synthetic yarn applied between jacket layers
Jacket
2-pass, integral fill, mold-cured thermoset with cable identification via permanent marking
Ratings & Approvals
UL Type RHH/RHW UL Type TC-ER c(UL) Type TC c(UL) Type R90 Flame Resistance: FT4 CSA: -40°C UL 44: Thermoset-Insulated Wires and Cables
Formerly “Open Wiring”
UL Type TC-ER APPROVED!
UL 1277: Electrical Power and Control Tray Cables with Optional Optical-Fiber Members CSA C22.2 No. 38: Thermoset Insulated Wires and Cables ASTM B33: Tinned Soft or Annealed Copper Wire for Electrical Purposes ASTM B173: Standard Specification for Rope-Lay-Stranded Copper Conductors Having Concentric-Stranded Members, for Electrical Conductors ASTM B174: Standard Specification for Bunch-Stranded Copper Conductors for Electrical Conductors These cables meet the requirements of General Motors Corporation Resistance Welding Equipment WS-2, Section C: Primary Cables Specification.
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Manufactured by AmerCable Incorporated • (870) 862-4919 • (800) 643-1516 • Fax (870) 862-9613
Automotive Cables
37-849 • Weld Primary Cable • 2000 Volts (UL) • 1000 Volts c(UL)
Number of Part No. Size Power 37-849- AWG Cond. 048 056 057
1
1 Min. Nominal Min. Nominal 1Nominal DC 1 WPCS Wires Insulation Ground Wires per Ground Outside Approx. Resistance Part per Thickness Size Ground Insulation Dia. Weight Ohms/mft Cond. AWG Cond. Thk. in. (in.) Lbs/mft @ 75°C 2Ampacity No. in.
BOC Cross Jacket Ref. Color
2 2 4
3 2 2
259 259 259
0.070 0.070 0.070
2 2 4
259 259 259
0.070 0.070 0.070
1.453 1.330 1.225
1793 1347 1039
0.201 0.201 0.321
152 174 130
3XX2X2X NA Black 2XX2X2X BOC-39 Yellow 2XX4X4X BOC-40 Yellow
Cable dimensions, weights and dc-resistances are subject to manufacturing tolerance. Consult factory for exact tolerances. Ampacity is listed with a 90°C conductor temperature and 30°C ambient air, free air installation, per 2005 NEC.
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37-849
Weld Primary Cable • Flat • WPCS 600 Volts (UL) • 1000 Volts c(UL)
Type RHH/RHW • Type TC-ER • Type R90 • 90°C
Application
Conductors
Flexible tinned copper
Separator
A suitable separator provides easy stripping of insulation
Main power drop from bus plug to single-phase weld controller Power drop from weld controller to conventional AC transformer Power drop from weld controller to junction box for automatics
Insulation Reinforcement
Synthetic yarn over assembly 90° ethylene-propylene rubber (EPR). Phase identified by color code
Features
Suitable for continuous operating conductor temperature of 90°C Extremely flexible stranding used for increased flexibility and ease of installation Phase conductors insulated with EPR meeting the requirements of ICEA S-75-381 Heavy-duty jacket offers excellent protection against abrasion, impact, heat, oil, flame, ozone, alkali and acids Innovative design reduces diameter and weight Rated by GM as Class 2 cable, suitable for periodic flexing Suitable for extra hard usage
Jacket
Mold-cured thermoset with cable identification via permanent marking
Ratings & Approvals
UL Type RHH/RHW UL Type TC-ER c(UL) Type TC c(UL) Type R90 Flame Resistance: FT4 CSA: -40°C UL 44: Thermoset-Insulated Wires and Cables
Formerly “Open Wiring”
UL Type TC-ER APPROVED!
UL 1277: Electrical Power and Control Tray Cables with Optional Optical-Fiber Members CSA C22.2 No. 38: Thermoset Insulated Wires and Cables ASTM B33: Tinned Soft or Annealed Copper Wire for Electrical Purposes ASTM B33: Tinned Soft or Annealed Copper Wire for Electrical Purposes ASTM B172: Standard Specification for Rope-Lay-Stranded Copper Conductors having Bunch-Stranded Members, for Electrical Conductors These cables meet the requirements of General Motors Corporation Resistance Welding Equipment WS-2, Section C: Primary Cables Specification. Manufactured by AmerCable Incorporated • (870) 862-4919 • (800) 643-1516 • Fax (870) 862-9613
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Automotive Cables
37-849 • Weld Primary Cable • 600 Volts (UL) • 1000 Volts c(UL)
Number of Part No. Size Power 37-849- AWG Cond. 052
1
1 Min. Nominal DC Min. Nominal 1Nominal WPCS Wires Insulation Ground Wires per Ground Outside 1Approx. Resistance Part per Thickness Size Ground Insulation Dia. Weight Ohms/mft Cond. (in.) Lbs/mft @ 75°C 2Ampacity No. AWG Cond. Thk. in. in.
BOC Cross Jacket Ref. Color
4/0
2
532
0.080
1/0
1050
0.055
1.1x 2.131
2516
0.0626
361
2X4010F BOC-19 Black
Cable dimensions, weights and dc-resistances are subject to manufacturing tolerance. Consult factory for exact tolerances. Ampacity is listed with a 90°C conductor temperature and 30°C ambient air, free air installation, per 2005 NEC.
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11
37-449
WPCS Trans-Gun Cable Assembly Durable • Highly Flexible
Power cable for automotive assembly welding robots
Molded Connector
90° integral molded polyurethane with 11⁄2" NPT and integral strain relief.
Conductors
Also Available: Straight integral molded polyurethane with 11⁄2" NPT and integral strain relief.
#2 or #4 soft or annealed copper, extra-flexible stranding specifically designed and manufactured for maximum flex life.
Separators
Non-adhering, easy to strip. Opaque for easy identification.
Application
Primary power connections to transformer on integral Trans-Gun welding equipment. Designed and manufactured to withstand the continuous flexing of automotive assembly welding robots.
Jacket
Continuous flex polymer with an 11,000,000 flex design life. Extremely high abrasion and cut-through resistance. Color: Black
Insulation
Continuous flex polymer. 1000V
Special Order
Contact factory for details
25 Feet
Color Code:
• 1/C Black • 1/C Red • 1/C Green
Ratings & Approvals
WPCS 2XX2X2A/B WPCS 2XX4X4A/B 90°C Design Life – 11,000,000 flexes on robotic welding equipment UL and c(UL) AWM Listed; CSA 22.2, 210.2 Class 2, Group B; UL 758
WPCS Part No. WPCS 2XX2X2B WPCS 2XX4X4B WPCS 2XX2X2A WPCS 2XX4X4A AmerCable Part No. 37-449-822ANGL 37-449-824ANGL 37-449-822STRT 37-449-824STRT Description 90,° 2 AWG, 3/C 90,° 4 AWG, 3/C Straight, 2 AWG, 3/C Straight, 4 AWG, 3/C
Construction Options
Because all Trans-Gun assemblies’ strain reliefs must be immobilized to ensure proper operation, AmerCable offers an immobilization bracket for use exclusively with AmerCable 90° Trans-Gun assemblies. See Catalog sheet for Trans-Gun Immobilization Bracket P/N 37-449-BRKT2 or consult Factory for details.
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Manufactured by AmerCable Incorporated • (870) 862-4919 • (800) 643-1516 • Fax (870) 862-9613
37-449-BRKT2
AmerCable Trans-Gun Immobilization Bracket
Automotive Cables
Because all Trans-Gun assemblies must be immobilized to ensure proper operation, AmerCable is pleased to offer an immobilization bracket for use exclusively with AmerCable 90° Trans-Gun assemblies. The immobilization bracket is designed to immobilize the molded connector of AmerCable’s Trans-Gun robotic welding cable assemblies. It is for use exclusively with WPCS 2XX2X2B – 90° Version Only and WPCS 2XX4X4B – 90° Version Only.
The immobilization bracket is designed to fit the following Roman Transformers:
TRy74X TRy77X TRy78X TRy79X TRy80X TRy82X TRy81X
The immobilization bracket consists of the following:
1 – Tapping plate 2 – Opposing brackets 4 – 1/4-20 x 1" long hex cap screws with flat and lock washers 8 – 3/8-16 x 3/4" long hex cap screws with flat and lock washers All bolts are grade 5 or better Installation procedures are available from AmerCable upon request 1 – Pivot Ring
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37-430TF/431TF/432TF
Tiger-Flex Power Cable Flexible • 90°C • 2000 Volts
Conductors
Specially designed and manufactured for maximum flex life.
Application
Tiger-Flex Power Cable is designed for use in continuous flexing, twisting applications and harsh physical environments where flame, abrasion, chemicals, moisture, impact-tearing and temperature extremes are considerations. Applications include: portable power, robotic welding, power tracks, cable tenders, hoists, spring and motor driven reels, festoon systems, cable tracks and cranes. Tiger-Flex 8000 is also suitable for indoor or outdoor use on: magnet cranes, barges, mining machines and mining equipment. This cable is suitable for installation in water, including aerator ponds.
Separator
Non-adhering, easy to strip. Opaque for easy identification.
Insulation Reinforcement
Synthetic yarn over assembly Specially formulated flexible thermoset EP per ICEA S75-381 and UL 44. Serrated and lubricated to ensure long flex life. Phase identified by color code
Jacket
Oil, chemical and heat resistant yellow thermoset extra heavy-duty chlorinated polyethylene
Features
Special lay length and lubrication to ensure long flex life. Core-wrapped with high tensile binder to maintain flexing geometry. Single color coded for easy identification Singles serrated to ensure long flex life.
Ratings & Approvals
UL listed as Type W c(UL) listed as Type TC c(UL) listed as Type W Flame Resistance: FT-4, FT-5 MSHA Approved
ASTM B-33: Standard Specification for Tinned Soft or Annealed Wire for Electrical Purposes UL 44: Thermoset-Insulated Wires and Cables ICEA S-75-381/NEMA WC-58: Portable and Power Feeder Cables for Use in Mines and Similar Applications
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Manufactured by AmerCable Incorporated • (870) 862-4919 • (800) 643-1516 • Fax (870) 862-9613
Automotive Cables
37-430TF/431TF/432TF • Tiger-Flex Power Cable • 2000 Volts
Minimum Number of Wires 133 133 133 259 259 259 259 259 259 259 259 259 266 266 266 342 342 342 418 418 418 532 532 532 Nominal Insulation Thickness in. 0.060 0.060 0.060 0.060 0.060 0.060 0.060 0.060 0.060 0.080 0.080 0.080 0.080 0.080 0.080 0.080 0.080 0.080 0.080 0.080 0.080 0.080 0.080 0.080 Nominal Jacket Thickness in. 0.131 0.148 0.141 0.144 0.163 0.161 0.180 0.160 0.186 0.178 0.171 0.187 0.171 0.191 0.185 0.181 0.181 0.189 0.191 0.197 0.197 0.201 0.201 0.213 Approx. Weight lbs. per 1,000 ft. 531 659 735 704 980 1168 1084 1325 1688 1410 1731 2180 1628 2070 2549 1962 2465 3099 2310 2940 3677 2810 3555 4517 Ampacity 90°C Ambient Temp 99 99 87 130 130 114 174 174 152 202 202 177 234 234 205 271 271 237 313 313 274 361 361 316
Part No. 37430006TF 431006TF 432006TF 430004TF 431004TF 432004TF 430002TF 431002TF 432002TF 430001TF 431001TF 432001TF 430010TF 431010TF 432010TF 430020TF 431020TF 432020TF 430030TF 431030TF 432030TF 430040TF 431040TF 432040TF
Size AWG 6 6 6 4 4 4 2 2 2 1 1 1 1/0 1/0 1/0 2/0 2/0 2/0 3/0 3/0 3/0 4/0 4/0 4/0
Numbers of Conductors 2 3 4 2 3 4 2 3 4 2 3 4 2 3 4 2 3 4 2 3 4 2 3 4
Nominal Finished Diameter 0.931 1.020 1.114 1.028 1.170 1.270 1.269 1.350 1.480 1.439 1.518 1.681 1.527 1.650 1.790 1.649 1.754 1.931 1.769 1.894 2.074 1.927 2.044 2.265
• Ampacity is based on a 90°C conductor temperature and 30°C ambient air, per 2005 NEC, Table 400-5 (b) • 3/C and 4/C ampacities based on one non-current carrying conductor in the cable.
Passes General Motors EHS-221 Robotic Application Durability Test (4 AWG, 3 conductor).
Tiger ® Brand is a registered trademark of AmerCable Incorporated
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15
37-829/849
Robotic and Manual Welding Power Cable 90°C • Flexible • 600 Volts
Application
Conductors
Flexible tinned copper
Separator
A suitable separator provides easy stripping of insulation
Insulation
90° ethylene-propylene rubber (EPR). Phase identified by color code
AmerCable robotic and manual welding cables are suitable for a wide range of applications in robotic and manual welding operations in harsh industrial environments. Applications include temporary feeders from bus plugs, primary power drops from weld controllers, interconnects from weld controllers to transformers and bus drop feeders.
Separator
A suitable separator providing easy stripping of jacket
Features
Flexible and easy to install Heat and chemical resistant thermoset jacket Suitable for continuous operating conductor temperature of 90°C
Reinforcement
Synthetic yarn over assembly
Jacket
Mold-cured thermoset with cable identification via permanent marking
Ratings & Approvals
UL listed c(UL) listed MSHA approved Flame Resistance: FT1 (Single Conductor) Flame Resistance: FT4 (Multi-Conductor) CSA: -40°C UL 44: Thermoset-Insulated Wires and Cables CSA C22.2 No. 38: Thermoset Insulated Wires and Cables
16
Manufactured by AmerCable Incorporated • (870) 862-4919 • (800) 643-1516 • Fax (870) 862-9613
Automotive Cables
37-829/849 • Robotic and Manual Welding Power Cable •600 Volts
Nominal Nominal Nominal Min. Min. Wires Outside Wires Insulation Ground per Ground Ground Conductor Number Dimensions of Power Thickness Size per Size Part No. Conductor Insulation in. Thk. in. Conductors Conductor in. AWG AWG 37829000SDL 849-001 849-002 849-003 849-004 849-008 849-006 849-058 849-059 4/0 4/0 2/0 2 4/0 2/0 2/0 4 2/0 2/0 250 250 400 262 262 1/0 6 2 2 2 3 3 3 3 3 2 3 2 3 3 2 3 3 3 532 532 323 259 532 323 323 133 323 323 627 627 999 646 646 266 133 0.080 0.080 0.080 0.080 0.080 0.080 0.080 0.060 0.080 0.080 0.095 0.095 0.095 0.095 0.095 0.080 0.060 1/0 1/0 4 7 (X2) 1/0 3 4 (X2) 8 1/0 6 1/0 1/0 3 1/0 1/0 6 8 1050 266 133 133 266 133 133 133 266 133 266 266 259 266 266 133 133 0.045 0.080 0.060 0.060 0.80 0.060 0.060 0.060 0.080 0.060 0.080 0.080 0.060 0.080 0.080 0.060 0.060
Typical Applications
BOC #
1.10 x 2.10 Power Drop to 19 Flat Controller, XFMR, J Box 1.95 Power Drop to 31 Diameter Controller, XFMR, J Box 1.66 Diameter 1.50 Diameter 2.34 Diameter 1.940 Diameter 1.940 Diameter 1.190 Diameter 1.685 Diameter 1.744 Diameter 2.034 Diameter 2.370 Diameter 2.745 Diameter 2.120 Diameter 2.425 Diameter 1.665 Diameter 1.130 Diameter Power Drop & Feeder Power Connections Feeder to Controllers Power Drop Power Connections Power Drop Power Drop Power Drop Power Drop Power Drop Power Drop Power Drop Power Drop Power Drop Power Drop 33 34 36 38 35 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
UL Type TC-ER APPROVED
849-060 849-061 849-062 849-063 849-064 849-065 849-066 849-067
UL Type TC-ER APPROVED!
• Cable dimensions and weights are subject to manufacturing tolerances. Consult factory for exact tolerances.
Formerly “Open Wiring”
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17
37-809/849
Robotic and Manual Welding Power Cable 90°C • Flexible • 2000 Volts
Application
Conductors
Flexible tinned copper
Separator
A suitable separator provides easy stripping of insulation
Insulation
90° ethylene-propylene rubber (EPR). Phase identified by color code
AmerCable robotic and manual welding cables are suitable for a wide range of applications in robotic and manual welding operations in harsh industrial environments. Applications include temporary feeders from bus plugs, primary power drops from weld controllers, interconnects from weld controllers to transformers and bus drop feeders.
Separator
A suitable separator providing easy stripping of jacket
Features
Flexible and easy to install Heat and chemical resistant thermoset jacket Suitable for continuous operating conductor temperature of 90°C
Reinforcement
Synthetic yarn over assembly
Jacket
Mold-cured thermoset with cable identification via permanent marking
Ratings & Approvals
UL listed c(UL) listed MSHA approved Flame Resistance: FT1 (Single Conductor) Flame Resistance: FT4 (Multi-Conductor) CSA: -40°C UL 44: Thermoset-Insulated Wires and Cables CSA C22.2 No. 38: Thermoset Insulated Wires and Cables
18
Manufactured by AmerCable Incorporated • (870) 862-4919 • (800) 643-1516 • Fax (870) 862-9613
Automotive Cables
37-809/849 • Robotic and Manual Welding Power Cable • 2000 Volts
Nominal Nominal Min. Min. Wires Wires Insulation Ground per Ground Ground Conductor Number Insulation of Power Thickness Size per Size Part No. Conductor Thk. in. Conductors Conductor in. AWG AWG 37809-040 4/0 1 532 0.090 NA NA NA 849-007 849-000 2 2 2 2 259 259 0.080 0.080 2 6 259 133 0.080 0.070 Nominal Outside Diameter in. 0.930 1.355 1.310
Typical Applications Temporary Feeder Power Connections Diameter Power Connections Diameter
BOC # 18 37 32
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19
37-431/432/445
Automotive Cables for Toyota Flexible • 2000 Volts • 90°C
Conductors
Flexible tinned copper
Application
Separator
A suitable separator providing easy stripping of insulation
Insulation
90°C ethylene-propylene rubber (EPR)
These 600 Volt and 2kV flexible cables are specially designed and manufactured to meet requirements of Toyota Motor Company. These cables are suitable for use in the harsh environment of automotive assembly operation and meet applicable UL and Canadian listings.
Features
Flexible and easy to install Gray jackets to meet Toyota requirements UL and c(UL) listed as appropriate
Reinforcement
Synthetic yarn over assembly
Jacket
Mold-cured thermoset with cable identification via permanent marking
Ratings & Approvals
UL 1277: Electrical Power and Control Tray Cables with Optional Optical Fiber Members CSA C222 No. 96: Portable Power Cables ASTM B33: Tinned Soft or Annealed Copper Wire for Electrical Purposes Flame Resistance: FT4 CSA: -40°C
Formerly “Open Wiring”
UL Type TC-ER APPROVED!
Part No. 37445-002TOY 445-010TOY 431-002GRY 432-002GRY 431-010GRY 432-010GRY 432-040GRY
Conductor Number of Power Size Conductors AWG 2 1/0 2 2 1/0 1/0 4/0 3* 3* 3 4 3 4 4
Voltage 600 UL/1000 c(UL) 600 UL/1000 c(UL) 2000 2000 2000 2000 2000
Nominal Outside Diameter in. 1.205 1.465 1.346 1.500 1.665 1.810 2.260
Approx. Weight lbs. per 1,000 ft. 1416 1682 1246 1622 1967 1396 4376
UL Listing TC-ER TC-ER W W W W W
c(UL) Listing R-90 R-90 W, TC W, TC W, TC W, TC W, TC
*This cable also contains a #6 AWG insulated ground.
20
Manufactured by AmerCable Incorporated • (870) 862-4919 • (800) 643-1516 • Fax (870) 862-9613
37-431/430/119/809
Automotive Cables for DaimlerChrysler Flexible • 2000 Volts • 90°C
Conductors
Flexible tinned copper
Application
Separator
A suitable separator providing easy stripping of insulation
Insulation
90°C ethylene-propylene rubber (EPR)
These 2000 Volt portable power cables are manufactured to meet a variety of DaimlerChrysler cable specifications. These cables are suitable for use in a wide range of applications in the harsh environment of automotive assembly plants.
Features
Flexible and easy to install Heat and chemical resistant thermoset jacket Suitable for continuous operating conductor temperatures of 90°C
Reinforcement
Synthetic yarn over assembly
Jacket
Mold-cured thermoset with cable identification via permanent marking
Ratings & Approvals
Ratings and Approvals for these cables can be found on the appropriate AmerCable catalog page: Type W – Pages 14-15 DLO – Pages 22-23 BOC-18 – Pages 18-19
Conductor Size Part No. AWG 37431-002TF 430-002 431-002 430-010 119-205 119-207 119-209 119-210 119-211 119-212 809-040 2 2 2 1/0 6 4 2 1 1/0 2/0 4/0
Number of Power Conductors
Nominal Outside Diameter in. 1.350 1.280 1.340 1.560 0.365 0.460 0.534 0.623 0.664 0.704 0.930
Approx. Weight lbs. per 1,000 ft. 1287 1045 1295 1464 124 198 261 400 468 561 968
*DaimlerChrysler Specification NPM Code M/C Type W / 27-795-1023 M/C Type W / 27-795-2150 M/C Type W / 27-795-2155 M/C Type W / 27-795-2800 NPEY-121 / 27-795-5004 NPEY-121 / 27-795-5006 NPEY-121 / 27-795-5008 NPEY-121 / 27-795-5012 NPEY-121 / 27-795-5014 NPEY-121 / 27-795-5016 NPEY-121 / 27-795-5020
DaimlerChrysler Part No. 37-431-002TF 37-430-002 37-431-002 37-430-010 10060-C 10070-C 10090-C 10100-C 10110-C 10120-C 10140-C
Cable Type Type W Type W Type W Type W DLO DLO DLO DLO DLO DLO BOC-18
3 2 3 2 1 1 1 1 1 1 1
*CPE Jacket is standard on all NPEY-121 cables • Customized legends are available upon request.
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21
37-119
Flexible Power Cable • DLO 2000 Volts • 90°C
Diesel Locomotive Cable • EP/CPE • RHH, RHW-2 Conductors
Flexible-stranded, tinned, annealed coated copper
Application
AmerCable’s 2000V Diesel Locomotive Cable (DLO) is a single conductor Portable Power Cable suitable for use in industrial applications needing great flexibility, excellent wearability and a good flex life. Applications include locomotive and car equipment, motor and generator leads, battery leads, shipyards, telecommunications power, heavy earth moving equipment and other heavy duty flexing applications.
Separator Jacket
Flame retardant, oil and sunlight resistant Chlorinated Polyethylene (CPE) Jackets are available in: • black (standard) • red • blue • green Suitable separator tape provides easy stripping of insulation
Insulation
Ethylene-Propylene rubber (EPR)
Features
A two layer composite of flame retardant, oil and sunlight resistant Chlorinated Polyethylene (CPE) outer layer and Ethylene-Propylene rubber (EPR) inner layer. The composite design provides significant diameter reductions compared to designs using full thickness jackets. Suitable for continuous operating temperatures of 90°C, wet or dry Rated RHH, RHW-2; 2/0 – 1000 kcmil listed and marked “for CT use” UL listed as Sunlight Resistant UL listed as Marine Shipboard Cable (4/0 and larger) – Special order only Insulation and jacket meet hazardous waste regulations, per Code of Federal Regulations 40 Section 261 (40CFR261) for characteristic lead content Flame Resistance: FT-4/IEEE1202 for 2/0 and larger, and UL VW-1 Meets smoke release and other requirements of Vertical Cable Tray Test UL 1685 and is marked “LS” for 2/0 and larger Extremely flexible stranding used for increased flexibility and ease of installation Jackets also available in red, blue and green
DaimlerChrysler Approved Supplier for 6AWG-2/0
Ratings & Approvals
ICEA S- 95-658/ NEMA WC-70: Nonshielded Power Cables Rated 2000 Volts or Less for the Distribution of Electrical Energy UL Standard 44: Thermoset Insulated Wires & Cables, Types RHH, RHW-2. UL VW-1 UL Standard 1685: Vertical Tray Fire propagation and Smoke Release Test for Electrical and optical Fiber Cables. (UL, LS) ASTM B-33: Standard Specification for Tinned Soft or Annealed Copper Wire for Electrical Purposes ASTM B-172: Standard Specification for Rope-LayStranded Copper Conductors having Bunch-Stranded Members, for Electrical Conductors MSHA P-184
22
Manufactured by AmerCable Incorporated • (870) 862-4919 • (800) 643-1516 • Fax (870) 862-9613
Automotive Cables
37-119 • Single Conductor Portable Power Cable • DLO
Nominal Insulation Thickness in. 0.045 0.045 0.045 0.055 0.055 0.055 0.055 0.065 0.065 0.065 0.065 0.065 0.075 0.075 0.075 0.075 0.090 0.090 0.090 0.090 0.115 Nominal Jacket Thickness in. 0.015 0.015 0.015 0.030 0.030 0.030 0.030 0.045 0.045 0.045 0.045 0.045 0.065 0.065 0.065 0.065 0.065 0.065 0.065 0.065 0.095 Nominal Outside Diameter in. 0.214 0.233 0.257 0.349 0.365 0.460 0.534 0.623 0.664 0.704 0.789 0.839 0.973 1.029 1.110 1.181 1.284 1.368 1.488 1.640 1.800 Approx. Weight lbs. per 1,000 ft. 31 41 58 86 124 198 261 400 468 561 725 888 1048 1227 1436 1691 2034 2395 2837 3448 4304
Part No. 37-119201 202 203 204 205 207 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223
Size AWG/ kcmil 14 12 10 8 6 4 2 1 1/0 2/0 3/0 4/0 262 313 373 444 535 646 777 929 1111
Minimum Wires per Conductor 19 19 27 37 61 105 147 224 266 323 418 532 646 777 925 1110 1332 1591 1924 2318 2745
*Ampacity 90°C 35 40 55 80 105 140 190 220 260 300 350 405 467 522 591 652 728 815 904 1005 1119
* Ampacity is calculated with a 90°C conductor temperature and 30°C ambient air, per 2005 NEC, Table 310-17 • Cable diameters and weights are subject to +/- 5% manufacturing tolerance
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23
Trans-Gun Quick Disconnect Assemblies
Factory prepared cable assemblies are a reliable way to lower your overall cable connectivity costs through enhanced reliability, reduced handling and lower installation time.
24
Contact factory for details
www. amercable.com • e-mail: [email protected]
Automotive Cables
Type W Cables 600-2000 Volts Motor Lead Cable • 90°C 1-6 Conductor
AmerCable’s Type W cables deliver great flexibility and durability. Applications include heavy duty or temporary power supply service, AC or DC, to motor or generators, portable and stationary heavy duty equipment, cranes, conveyors and other mobile equipment. Also recommended for payout and retractable reels, festoons, suspended loops and power tracks. Some of our Type W’s also carry a UL Type TC-ER listing.
VFD Power Cable Shielded • 2000 Volts 3 Conductors + 3 Grounds + Ground Check(s)
AmerCable’s flexible, braid and foil shielded, 2kV power cable specifically engineered for use in variable frequency AC motor drive (VFD) applications.
Ask your rep for more details about these, and other, AmerCable industrial cables
Specially engineered cable design produces a longer cable life in VFD applications. Overall braid and foil shield provides 100% coverage containing VFD EMI emissions. Symmetrical insulated ground conductors reduce induced voltage imbalances and carry common mode noise back to the drive. High strand count conductors and braid shield design is much more flexible, easier to install and more resistant to vibration than Type MC cable. 2kV insulation thickness resists the repetitive 2x voltage spikes from 600V VFDs and reduces drive over current trip problems due to cable charging current.
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25
Automotive Cables
AmerCable manufactures high quality jacketed electrical cables for the automotive industry and other specialized industrial applications. AmerCable is an ISO 9001 certified cable manufacturer that combines leading-edge technology, proven manufacturing techniques, and high quality service to deliver the finest automotive cable products available. AmerCable serves a worldwide customer base from our manufacturing facility in El Dorado, Arkansas. Our professional field engineering and sales force work in partnership with our network of independent distributors to identify and fulfill your specific cable requirements.
AmerCable’s manufacturing facility and corporate headquarters in El Dorado, Arkansas.
What can you expect from AmerCable?
High Quality Cable On Time Delivery (99%+ in the last 36 months)* Professional Sales, Support and Service Strategic Inventory Locations Operational Excellence Short Lead Times
* Check www.amercable.com for our most current on time delivery record
El Dorado, Arkansas
Made in America
AmerCable Industrial Cable Products
Industrial Automotive Reeling
For complete product information visit our website! www.amercable.com
For complete product information visit our web site!
Room & Pillar Surface
Longwall
© 2006, AmerCable Incorporated
350 Bailey Road • El Dorado, Arkansas USA (870) 862-4919 • (800) 643-1516 • Fax (870) 862-9613 e-mail: [email protected] • www.amercable.com
5/06
The Global Cable Solutions Company
Automotive Cables
600V (UL), 1000V c(UL), power drop for weld controllers, AC transformers and Tri-pack weld controls. RHH-RHW, Type TC-ER, Type R90. GM Class 2 cable.
Index
Weld Primary Cable – WPCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2000V (UL), 1000V c(UL), primary power connections to transformers and Trans-Guns. RHH-RHW, Type TC-ER, Type R90. GM Class 2 cable.
Weld Primary Cable – WPCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Weld Primary Cable – WPCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2000V (UL), 1000V c(UL), power connections for transformers and weld controllers. RHH-RHW, Type TC-ER, Type R90, GM Class 3 cable.
Weld Primary Cable – WPCS Flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
600V (UL), 1000V c(UL), flat power drop for transformers and weld controllers. RHH-RHW, Type TC-ER, Type R90. GM Class 2 cable.
Trans-Gun Assembly – WPCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Highly flexible cable assembly for Trans-Gun welding equipment. GM Class 4 cable.
Trans-Gun Immobilization Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Immobilization bracket for use with 90° Trans-Gun cable assemblies.
Tiger-Flex Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2000V, multi-conductor flexible power cable for continuous flexing and twisting applications. Type W, Type TC. 6 AWG to 4/0
Robotic and Manual Welding Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 16
600V, flexible power cables for a wide range of robotic and welding applications.
Robotic and Manual Welding Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2000V, flexible power cables for a wide range of robotic and welding applications.
Cables for Toyota . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
600V to 2000V, cables specially designed for Toyota Motors.
Cables for DaimlerChrysler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2000V, portable cables to meet DaimlerChrysler specifications.
DLO Flexible Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2000V, single conductor. Diesel locomotive cable. EP/CPE, RHH, RHW-2
Lower Installed Costs
See Page 2
El Dorado, Arkansas
AmerCable believes the information presented throughout this catalog to be reliable and current. All information is subject to change without notice. The information listed is approximate, and is presented only as a guide for product selection. We make no claims or warranties for the suitability of any product for any particular application.
Made in America
© 2006, AmerCable Incorporated
Our Commitment to the Automotive Industry
Tough operating environments require cables engineered for longer service life and increased productivity
AmerCable has a automotive cable productivity solution for you. Our innovatively engineered and manufactured Automotive Cable Family is designed for your toughest conditions. As a leading producer of automotive cables in North America, AmerCable is dedicated to producing: highly flexible and reliable cables cables that last longer in harsh automotive environments cables designed to help provide greater levels of safety and productivity
Cable Innovation
Designing insulating and jacketing materials that are more flexible with greater resistance to abrasion and moisture Cable constructions that last longer – providing reduced down time for increased productivity New product development that addresses environmental, safety and cost reduction issues specific to your application.
Operating Excellence
On-time delivery backed by our industry leading shipment percentage of 99%+ for the past 36 months. For our current on-time delivery rate, visit our website at www.amercable.com Standard lead-time of 6 to 8 weeks Urgent response shipment capability of 2 to 4 weeks AmerCable is an ISO-9001 certified manufacturer
Hands-on Field Support
Our experienced field application engineers are available for on-site evaluation and solutions. They also conduct education and training sessions that address safety, splicing and cable handling issues.
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1
TC-ER for Fast, Economical Cable Installation
Your Challenge: The plant manager directs you to develop a plan to install a new production line. His only directions are to do it faster and for less money than the last change. Your First Thought: How is this going to be possible without compromising installation quality? The AmerCable Solution: Exposed run cables for fast, economical installation.
Type TC-ER cables are permitted to extend for an unlimited distance. Because of this increased out-of-tray cable length, the use of -ER rated cables can reduce the need for conduit and the overall cost of the installation.
AmerCable Exposed Run Cables
This new rating for tray cables – TC-ER – was created by changes in NEC and UL standards. If the basic UL cable type meets additional crush and impact requirements, UL permits the manufacturer to add the -ER suffix to the basic listing on the cable. The -ER signifies that it has met the physical toughness requirements that permit it to be installed as exposed wiring in certain applications. Such wiring, i.e. wiring that is installed outside of a tray, conduit or other raceway, is sometimes also called open wiring. With the -ER suffix printed on the cable, the responsible electrical inspector is able to verify that the cable meets Code requirements for use as exposed wiring.
UL Type TC-ER APPROVED!
Formerly “Open Wiring”
Lower Installed Cost!
UL Type TC tray cables are permitted in cable trays by the NEC. However, tray cables without the -ER suffix that extend from the tray for more than 1.8 meters (6 feet) to connect to a motor or other electrical device must be installed in conduit or other type of raceway. Tray cables with the -ER suffix can extend much further in certain applications if given adequate protection and support.
2005 National Electrical Code® Excerpt Type TC Cables Article 336.10 (7) In industrial establishments where the conditions of maintenance and supervision ensure that only qualified persons service the installation and where the cable is continuously supported and protected against physical damage using mechanical protection, such as struts, angles or channel, Type TC tray cable that complies with the crush and impact requirements of Type MC cable and is identified for such use with the marking Type TC-ER shall be permitted between a cable tray and the utilization equipment or device. The cable shall be secured at intervals not exceeding 1.8m (6ft). Equipment grounding for the utilization equipment shall be provided by an equipment grounding conductor within the cable.
Source: National Electrical Code 2005
2
Manufactured by AmerCable Incorporated • (870) 862-4919 • (800) 643-1516 • Fax (870) 862-9613
Installation Cost Comparison
60 Amp Drop
Conduit Installation 6AWG RHW + 8AWG RHW gnd.............. $241.00 1" Rigid Conduit + Fittings ........................ 270.00 Labor (24 Hours)....................................1,200.00 Total....................................... $1,711.00 Open Wiring Installation AmerCable Power Cable 6AWG + gnd .... $440.00 (AmerCable Part #: 37-849-067) Cable Supports ........................................... 90.00 Labor (8 Hours)........................................ 400.00 Total ......................................... $930.00 Savings Conduit Installation.............................. $1,711.00 Open Wiring Installation ........................... 930.00 Cost Difference ......................................... 781.00
Automotive Cables
Installation Description: Bus Drop from bus plug to safety switch or control panel; 120 foot total cable run; 30 foot vertical drop
100 Amp Drop
Conduit Installation 2AWG RHW + 8AWG RHW gnd.............. $516.00 1-1/4" Rigid Conduit + Fittings.................. 373.00 Labor (24 Hours)................................... 1,200.00 Total....................................... $2,089.00 Open Wiring Installation AmerCable Power Cable 4AWG + gnd .... $526.00 (AmerCable Part #: 37-849-058) Cable Supports ........................................... 90.00 Labor (8 Hours)........................................ 400.00 Total....................................... $1,016.00 Savings Conduit Installation...............................$2,089.00 Open Wiring Installation .........................1,016.00 Cost Difference .......................................1,073.00
Total Savings ........................... 46%
Total Savings ........................... 51%
200 Amp Drop
Conduit Installation 3/0AWG RHW + 6AWG RHW gnd........ $1,115.00 2" Rigid Conduit + Fittings ........................ 519.00 Labor (32 Hours) ....................................1,600.00 Total ....................................... $3,234.00 Open Wiring Installation AmerCable Power Cable 2/0AWG + gnd ................................... $1341.00 (AmerCable Part #: 37-849-060) Cable Supports ..........................................140.00 Labor (16 Hours)...................................... 800.00 Total ....................................... $2,281.00 Savings Conduit Installation.............................. $3,234.00 Open Wiring Installation ........................ 2,281.00 Cost Difference ......................................... 953.00
400 Amp Drop
Conduit Installation 600 kcmil RHW + 1/0AWG RHW gnd .. $3,623.00 4" Rigid Conduit + Fittings ......................1,527.00 Labor (48 Hours) ....................................2,400.00 Total ....................................... $7,550.00 Open Wiring Installation AmerCable Power Cable 400 kcmil + gnd................................. $3,371.00 (AmerCable Part #: 37-849-063) Cable Supports ......................................... 210.00 Labor (24 Hours) ................................... 1,200.00 Total ....................................... $4,781.00 Savings Conduit Installation ............................. $7,550.00 Open Wiring Installation......................... 4,181.00 Cost Difference ...................................... 2,769.00
Total Savings ........................... 29%
Total Savings ........................... 37%
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3
37-849
Weld Primary Cable • WPCS 2000 Volts (UL) • 1000 Volts c(UL)
Type RHH/RHW • Type TC-ER • Type R90 • 90°C Conductors
Flexible tinned copper
Insulation
90°C ethylene-propylene rubber (EPR). Phase identified by color code
Application
Primary power connections to transformers Main power drops Feeders to hard automatics and Trans-Guns Temporary feeders (4/0 single conductor)
Separator
A suitable separator providing easy stripping of insulation
Separator
A suitable separator providing easy stripping of jacket
Features
Suitable for continuous operating conductor temperature of 90°C Extremely flexible stranding used for increased flexibility and ease of installation Insulated with EPR meeting the requirements of ICEA S-75-381 Heavy-duty jacket offers excellent protection against abrasion, impact, heat, oil, flame, ozone, alkali and acids. Suitable for extra hard usage Rated by GM as Class 2 cable, suitable for periodic flexing
Jacket
Mold-cured thermoset with cable identification via permanent marking (1/C is CV-Cured)
Reinforcement
Synthetic yarn over assembly
Ratings & Approvals
UL Type RHH/RHW UL Type TC-ER (Multi-Conductor) c(UL) Type TC (Multi-Conductor) c(UL) Type R90 Flame Resistance: FT1 (Single Conductor) Flame Resistance: FT4 (Multi-Conductor) CSA: -40°C UL 44: Thermoset-Insulated Wires and Cables
UL Type TC-ER APPROVED!
Formerly “Open Wiring”
UL 1277: Electrical Power and Control Tray Cables with Optional Optical-Fiber Members CSA C22.2 No. 38: Thermoset Insulated Wires and Cables ASTM B33: Tinned Soft or Annealed Copper Wire for Electrical Purposes ASTM B172: Standard Specification for Rope-Lay-Stranded Copper Conductors having Bunch-Stranded Members, for Electrical Conductors ASTM B173: Standard Specification for Rope-Lay-Stranded Copper Conductors Having ConcentricStranded Members, for Electrical Conductors These cables meet the requirements of General Motors Corporation Resistance Welding Equipment WS-2, Section C: Primary Cables Specification.
4
Manufactured by AmerCable Incorporated • (870) 862-4919 • (800) 643-1516 • Fax (870) 862-9613
Automotive Cables
37-849 • Weld Primary Cable • 2000 Volts (UL) • 1000 Volts c(UL)
Number of Part No. Size Power 37-849- AWG Cond. 053 055 050
1
1 Min. Nominal Min. Nominal 1Nominal DC 1 WPCS Wires Insulation Ground Wires per Ground Outside Approx. Resistance Part per Thickness Size Ground Insulation Dia. Weight Ohms/mft Cond. AWG Cond. Thk. in. (in.) Lbs/mft @ 75°C 2Ampacity No. in.
BOC Cross Jacket Ref. Color
2/0 2/0 4/0
2 3 1
323 323 532
0.090 0.090 0.090
2 2 NA
259 259 NA
0.070 0.070 NA
1.677 1.890 0.917
2184 2764 908
0.101 0.101 0.0626
271 237 405
2X20X2X BOC-33 Black 3X20X2X BOC-38 Black 1X40XXX BOC-18 Yellow
Cable dimensions, weights and dc-resistances are subject to manufacturing tolerance. Consult factory for exact tolerances. Ampacity is listed with a 90°C conductor temperature and 30°C ambient air, free air installation, per 2005 NEC.
2
v4.06.1
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5
37-849
Weld Primary Cable • WPCS 600 Volts (UL) • 1000 Volts c(UL)
Type RHH/RHW • Type TC-ER • Type R90 • 90°C
Application
Conductors
Flexible tinned copper
Separator
A suitable separator provides easy stripping of insulation
Insulation
90° ethylene-propylene rubber (EPR). Phase identified by color code
Separator
A suitable separator providing easy stripping of jacket
2/C 4/0 Plus 1/0 Ground Main power drop to a single-phase weld controller from a bus plug Power drop from a weld controller to a conventional AC transformer Power drop from a weld controller to a junction box for automatics 3/C 4/0 Plus 1/0 Ground Feeders for Tri-pack weld controls
Reinforcement
Synthetic yarn over assembly
Jacket
Mold-cured thermoset with cable identification via permanent marking
Features
Suitable for continuous operating conductor temperature of 90°C Extremely flexible stranding used for increased flexibility and ease of installation Phase conductors insulated with EPR meeting the requirements of ICEA S-75-381 Heavy-duty jacket offers excellent protection against abrasion, impact, heat, oil, flame, ozone, alkali and acids Innovative design reduces diameter and weight Rated by GM as Class 2 cable, suitable for periodic flexing Suitable for extra hard usage
Ratings & Approvals
UL Type RHH/RHW UL Type TC-ER c(UL) Type TC c(UL) Type R90 Flame Resistance: FT4 CSA: -40°C UL 44: Thermoset-Insulated Wires and Cables
Formerly “Open Wiring”
UL Type TC-ER APPROVED!
UL 1277: Electrical Power and Control Tray Cables with Optional Optical-Fiber Members CSA C22.2 No. 38: Thermoset Insulated Wires and Cables ASTM B33: Tinned Soft or Annealed Copper Wire for Electrical Purposes ASTM B172: Standard Specification for Rope-Lay-Stranded Copper Conductors having Bunch-Stranded Members, for Electrical Conductors These cables meet the requirements of General Motors Corporation Resistance Welding Equipment WS-2, Section C: Primary Cables Specification.
6
Manufactured by AmerCable Incorporated • (870) 862-4919 • (800) 643-1516 • Fax (870) 862-9613
Automotive Cables
37-849 • Weld Primary Cable • 600 Volts (UL) • 1000 Volts c(UL)
Number of Part No. Size Power 37-849- AWG Cond. 051 054
1
1 Min. Nominal DC Min. Nominal 1Nominal WPCS Wires Insulation Ground Wires per Ground Outside 1Approx. Resistance Part per Thickness Size Ground Insulation Dia. Weight Ohms/mft Cond. (in.) Lbs/mft @ 75°C 2Ampacity No. AWG Cond. Thk. in. in.
BOC Cross Jacket Ref. Color
4/0 4/0
2 3
532 532
0.080 0.080
1/0 1/0
266 266
0.055 0.055
1.825 2.033
2962 3770
0.0626 0.0626
361 316
2X4010X BOC-31 Black 3X4010X BOC-36 Black
Cable dimensions, weights and dc-resistances are subject to manufacturing tolerance. Consult factory for exact tolerances. Ampacity is listed with a 90°C conductor temperature and 30°C ambient air, free air installation, per 2005 NEC.
2
v4.06.1
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7
37-849
Weld Primary Cable • WPCS 2000 Volts (UL) • 1000 Volts c(UL)
Type RHH/RHW • Type TC-ER • Type R90 • 90°C Conductors
Flexible tinned copper
Application
Primary power connections to transformers (2/C plus ground) Main power drop to a three-phase weld controller from a bus plug (3/C plus ground)
Separator Core Binder
Synthetic yarn over assembly A suitable separator provides easy stripping of insulation
Features
Suitable for continuous operating conductor temperature of 90°C Extremely flexible stranding used for increased flexibility and ease of installation Insulated with EPR meeting the requirements of ICEA S-75-381 Serrated insulation and special length of lay to insure long flex life Heavy-duty jacket offers excellent protection against abrasion, impact, heat, oil, flame, ozone, alkali and acids Jacket extruded into cable core interstices to ensure durability Suitable for extra hard usage Rated by GM as Class 3 cable, suitable for continuous duty flexing service at moderate speeds with extensive high count flex life and moderate amounts of torsional stress
Insulation
90° ethylene-propylene rubber (EPR) serrated to ensure long flex life. Phase identified by color code
Reinforcement
Two (2) servings of synthetic yarn applied between jacket layers
Jacket
2-pass, integral fill, mold-cured thermoset with cable identification via permanent marking
Ratings & Approvals
UL Type RHH/RHW UL Type TC-ER c(UL) Type TC c(UL) Type R90 Flame Resistance: FT4 CSA: -40°C UL 44: Thermoset-Insulated Wires and Cables
Formerly “Open Wiring”
UL Type TC-ER APPROVED!
UL 1277: Electrical Power and Control Tray Cables with Optional Optical-Fiber Members CSA C22.2 No. 38: Thermoset Insulated Wires and Cables ASTM B33: Tinned Soft or Annealed Copper Wire for Electrical Purposes ASTM B173: Standard Specification for Rope-Lay-Stranded Copper Conductors Having Concentric-Stranded Members, for Electrical Conductors ASTM B174: Standard Specification for Bunch-Stranded Copper Conductors for Electrical Conductors These cables meet the requirements of General Motors Corporation Resistance Welding Equipment WS-2, Section C: Primary Cables Specification.
8
Manufactured by AmerCable Incorporated • (870) 862-4919 • (800) 643-1516 • Fax (870) 862-9613
Automotive Cables
37-849 • Weld Primary Cable • 2000 Volts (UL) • 1000 Volts c(UL)
Number of Part No. Size Power 37-849- AWG Cond. 048 056 057
1
1 Min. Nominal Min. Nominal 1Nominal DC 1 WPCS Wires Insulation Ground Wires per Ground Outside Approx. Resistance Part per Thickness Size Ground Insulation Dia. Weight Ohms/mft Cond. AWG Cond. Thk. in. (in.) Lbs/mft @ 75°C 2Ampacity No. in.
BOC Cross Jacket Ref. Color
2 2 4
3 2 2
259 259 259
0.070 0.070 0.070
2 2 4
259 259 259
0.070 0.070 0.070
1.453 1.330 1.225
1793 1347 1039
0.201 0.201 0.321
152 174 130
3XX2X2X NA Black 2XX2X2X BOC-39 Yellow 2XX4X4X BOC-40 Yellow
Cable dimensions, weights and dc-resistances are subject to manufacturing tolerance. Consult factory for exact tolerances. Ampacity is listed with a 90°C conductor temperature and 30°C ambient air, free air installation, per 2005 NEC.
2
v4.06.1
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9
37-849
Weld Primary Cable • Flat • WPCS 600 Volts (UL) • 1000 Volts c(UL)
Type RHH/RHW • Type TC-ER • Type R90 • 90°C
Application
Conductors
Flexible tinned copper
Separator
A suitable separator provides easy stripping of insulation
Main power drop from bus plug to single-phase weld controller Power drop from weld controller to conventional AC transformer Power drop from weld controller to junction box for automatics
Insulation Reinforcement
Synthetic yarn over assembly 90° ethylene-propylene rubber (EPR). Phase identified by color code
Features
Suitable for continuous operating conductor temperature of 90°C Extremely flexible stranding used for increased flexibility and ease of installation Phase conductors insulated with EPR meeting the requirements of ICEA S-75-381 Heavy-duty jacket offers excellent protection against abrasion, impact, heat, oil, flame, ozone, alkali and acids Innovative design reduces diameter and weight Rated by GM as Class 2 cable, suitable for periodic flexing Suitable for extra hard usage
Jacket
Mold-cured thermoset with cable identification via permanent marking
Ratings & Approvals
UL Type RHH/RHW UL Type TC-ER c(UL) Type TC c(UL) Type R90 Flame Resistance: FT4 CSA: -40°C UL 44: Thermoset-Insulated Wires and Cables
Formerly “Open Wiring”
UL Type TC-ER APPROVED!
UL 1277: Electrical Power and Control Tray Cables with Optional Optical-Fiber Members CSA C22.2 No. 38: Thermoset Insulated Wires and Cables ASTM B33: Tinned Soft or Annealed Copper Wire for Electrical Purposes ASTM B33: Tinned Soft or Annealed Copper Wire for Electrical Purposes ASTM B172: Standard Specification for Rope-Lay-Stranded Copper Conductors having Bunch-Stranded Members, for Electrical Conductors These cables meet the requirements of General Motors Corporation Resistance Welding Equipment WS-2, Section C: Primary Cables Specification. Manufactured by AmerCable Incorporated • (870) 862-4919 • (800) 643-1516 • Fax (870) 862-9613
10
Automotive Cables
37-849 • Weld Primary Cable • 600 Volts (UL) • 1000 Volts c(UL)
Number of Part No. Size Power 37-849- AWG Cond. 052
1
1 Min. Nominal DC Min. Nominal 1Nominal WPCS Wires Insulation Ground Wires per Ground Outside 1Approx. Resistance Part per Thickness Size Ground Insulation Dia. Weight Ohms/mft Cond. (in.) Lbs/mft @ 75°C 2Ampacity No. AWG Cond. Thk. in. in.
BOC Cross Jacket Ref. Color
4/0
2
532
0.080
1/0
1050
0.055
1.1x 2.131
2516
0.0626
361
2X4010F BOC-19 Black
Cable dimensions, weights and dc-resistances are subject to manufacturing tolerance. Consult factory for exact tolerances. Ampacity is listed with a 90°C conductor temperature and 30°C ambient air, free air installation, per 2005 NEC.
2
v4.06.1
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11
37-449
WPCS Trans-Gun Cable Assembly Durable • Highly Flexible
Power cable for automotive assembly welding robots
Molded Connector
90° integral molded polyurethane with 11⁄2" NPT and integral strain relief.
Conductors
Also Available: Straight integral molded polyurethane with 11⁄2" NPT and integral strain relief.
#2 or #4 soft or annealed copper, extra-flexible stranding specifically designed and manufactured for maximum flex life.
Separators
Non-adhering, easy to strip. Opaque for easy identification.
Application
Primary power connections to transformer on integral Trans-Gun welding equipment. Designed and manufactured to withstand the continuous flexing of automotive assembly welding robots.
Jacket
Continuous flex polymer with an 11,000,000 flex design life. Extremely high abrasion and cut-through resistance. Color: Black
Insulation
Continuous flex polymer. 1000V
Special Order
Contact factory for details
25 Feet
Color Code:
• 1/C Black • 1/C Red • 1/C Green
Ratings & Approvals
WPCS 2XX2X2A/B WPCS 2XX4X4A/B 90°C Design Life – 11,000,000 flexes on robotic welding equipment UL and c(UL) AWM Listed; CSA 22.2, 210.2 Class 2, Group B; UL 758
WPCS Part No. WPCS 2XX2X2B WPCS 2XX4X4B WPCS 2XX2X2A WPCS 2XX4X4A AmerCable Part No. 37-449-822ANGL 37-449-824ANGL 37-449-822STRT 37-449-824STRT Description 90,° 2 AWG, 3/C 90,° 4 AWG, 3/C Straight, 2 AWG, 3/C Straight, 4 AWG, 3/C
Construction Options
Because all Trans-Gun assemblies’ strain reliefs must be immobilized to ensure proper operation, AmerCable offers an immobilization bracket for use exclusively with AmerCable 90° Trans-Gun assemblies. See Catalog sheet for Trans-Gun Immobilization Bracket P/N 37-449-BRKT2 or consult Factory for details.
12
Manufactured by AmerCable Incorporated • (870) 862-4919 • (800) 643-1516 • Fax (870) 862-9613
37-449-BRKT2
AmerCable Trans-Gun Immobilization Bracket
Automotive Cables
Because all Trans-Gun assemblies must be immobilized to ensure proper operation, AmerCable is pleased to offer an immobilization bracket for use exclusively with AmerCable 90° Trans-Gun assemblies. The immobilization bracket is designed to immobilize the molded connector of AmerCable’s Trans-Gun robotic welding cable assemblies. It is for use exclusively with WPCS 2XX2X2B – 90° Version Only and WPCS 2XX4X4B – 90° Version Only.
The immobilization bracket is designed to fit the following Roman Transformers:
TRy74X TRy77X TRy78X TRy79X TRy80X TRy82X TRy81X
The immobilization bracket consists of the following:
1 – Tapping plate 2 – Opposing brackets 4 – 1/4-20 x 1" long hex cap screws with flat and lock washers 8 – 3/8-16 x 3/4" long hex cap screws with flat and lock washers All bolts are grade 5 or better Installation procedures are available from AmerCable upon request 1 – Pivot Ring
v4.06.1
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13
37-430TF/431TF/432TF
Tiger-Flex Power Cable Flexible • 90°C • 2000 Volts
Conductors
Specially designed and manufactured for maximum flex life.
Application
Tiger-Flex Power Cable is designed for use in continuous flexing, twisting applications and harsh physical environments where flame, abrasion, chemicals, moisture, impact-tearing and temperature extremes are considerations. Applications include: portable power, robotic welding, power tracks, cable tenders, hoists, spring and motor driven reels, festoon systems, cable tracks and cranes. Tiger-Flex 8000 is also suitable for indoor or outdoor use on: magnet cranes, barges, mining machines and mining equipment. This cable is suitable for installation in water, including aerator ponds.
Separator
Non-adhering, easy to strip. Opaque for easy identification.
Insulation Reinforcement
Synthetic yarn over assembly Specially formulated flexible thermoset EP per ICEA S75-381 and UL 44. Serrated and lubricated to ensure long flex life. Phase identified by color code
Jacket
Oil, chemical and heat resistant yellow thermoset extra heavy-duty chlorinated polyethylene
Features
Special lay length and lubrication to ensure long flex life. Core-wrapped with high tensile binder to maintain flexing geometry. Single color coded for easy identification Singles serrated to ensure long flex life.
Ratings & Approvals
UL listed as Type W c(UL) listed as Type TC c(UL) listed as Type W Flame Resistance: FT-4, FT-5 MSHA Approved
ASTM B-33: Standard Specification for Tinned Soft or Annealed Wire for Electrical Purposes UL 44: Thermoset-Insulated Wires and Cables ICEA S-75-381/NEMA WC-58: Portable and Power Feeder Cables for Use in Mines and Similar Applications
14
Manufactured by AmerCable Incorporated • (870) 862-4919 • (800) 643-1516 • Fax (870) 862-9613
Automotive Cables
37-430TF/431TF/432TF • Tiger-Flex Power Cable • 2000 Volts
Minimum Number of Wires 133 133 133 259 259 259 259 259 259 259 259 259 266 266 266 342 342 342 418 418 418 532 532 532 Nominal Insulation Thickness in. 0.060 0.060 0.060 0.060 0.060 0.060 0.060 0.060 0.060 0.080 0.080 0.080 0.080 0.080 0.080 0.080 0.080 0.080 0.080 0.080 0.080 0.080 0.080 0.080 Nominal Jacket Thickness in. 0.131 0.148 0.141 0.144 0.163 0.161 0.180 0.160 0.186 0.178 0.171 0.187 0.171 0.191 0.185 0.181 0.181 0.189 0.191 0.197 0.197 0.201 0.201 0.213 Approx. Weight lbs. per 1,000 ft. 531 659 735 704 980 1168 1084 1325 1688 1410 1731 2180 1628 2070 2549 1962 2465 3099 2310 2940 3677 2810 3555 4517 Ampacity 90°C Ambient Temp 99 99 87 130 130 114 174 174 152 202 202 177 234 234 205 271 271 237 313 313 274 361 361 316
Part No. 37430006TF 431006TF 432006TF 430004TF 431004TF 432004TF 430002TF 431002TF 432002TF 430001TF 431001TF 432001TF 430010TF 431010TF 432010TF 430020TF 431020TF 432020TF 430030TF 431030TF 432030TF 430040TF 431040TF 432040TF
Size AWG 6 6 6 4 4 4 2 2 2 1 1 1 1/0 1/0 1/0 2/0 2/0 2/0 3/0 3/0 3/0 4/0 4/0 4/0
Numbers of Conductors 2 3 4 2 3 4 2 3 4 2 3 4 2 3 4 2 3 4 2 3 4 2 3 4
Nominal Finished Diameter 0.931 1.020 1.114 1.028 1.170 1.270 1.269 1.350 1.480 1.439 1.518 1.681 1.527 1.650 1.790 1.649 1.754 1.931 1.769 1.894 2.074 1.927 2.044 2.265
• Ampacity is based on a 90°C conductor temperature and 30°C ambient air, per 2005 NEC, Table 400-5 (b) • 3/C and 4/C ampacities based on one non-current carrying conductor in the cable.
Passes General Motors EHS-221 Robotic Application Durability Test (4 AWG, 3 conductor).
Tiger ® Brand is a registered trademark of AmerCable Incorporated
v4.06.1
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15
37-829/849
Robotic and Manual Welding Power Cable 90°C • Flexible • 600 Volts
Application
Conductors
Flexible tinned copper
Separator
A suitable separator provides easy stripping of insulation
Insulation
90° ethylene-propylene rubber (EPR). Phase identified by color code
AmerCable robotic and manual welding cables are suitable for a wide range of applications in robotic and manual welding operations in harsh industrial environments. Applications include temporary feeders from bus plugs, primary power drops from weld controllers, interconnects from weld controllers to transformers and bus drop feeders.
Separator
A suitable separator providing easy stripping of jacket
Features
Flexible and easy to install Heat and chemical resistant thermoset jacket Suitable for continuous operating conductor temperature of 90°C
Reinforcement
Synthetic yarn over assembly
Jacket
Mold-cured thermoset with cable identification via permanent marking
Ratings & Approvals
UL listed c(UL) listed MSHA approved Flame Resistance: FT1 (Single Conductor) Flame Resistance: FT4 (Multi-Conductor) CSA: -40°C UL 44: Thermoset-Insulated Wires and Cables CSA C22.2 No. 38: Thermoset Insulated Wires and Cables
16
Manufactured by AmerCable Incorporated • (870) 862-4919 • (800) 643-1516 • Fax (870) 862-9613
Automotive Cables
37-829/849 • Robotic and Manual Welding Power Cable •600 Volts
Nominal Nominal Nominal Min. Min. Wires Outside Wires Insulation Ground per Ground Ground Conductor Number Dimensions of Power Thickness Size per Size Part No. Conductor Insulation in. Thk. in. Conductors Conductor in. AWG AWG 37829000SDL 849-001 849-002 849-003 849-004 849-008 849-006 849-058 849-059 4/0 4/0 2/0 2 4/0 2/0 2/0 4 2/0 2/0 250 250 400 262 262 1/0 6 2 2 2 3 3 3 3 3 2 3 2 3 3 2 3 3 3 532 532 323 259 532 323 323 133 323 323 627 627 999 646 646 266 133 0.080 0.080 0.080 0.080 0.080 0.080 0.080 0.060 0.080 0.080 0.095 0.095 0.095 0.095 0.095 0.080 0.060 1/0 1/0 4 7 (X2) 1/0 3 4 (X2) 8 1/0 6 1/0 1/0 3 1/0 1/0 6 8 1050 266 133 133 266 133 133 133 266 133 266 266 259 266 266 133 133 0.045 0.080 0.060 0.060 0.80 0.060 0.060 0.060 0.080 0.060 0.080 0.080 0.060 0.080 0.080 0.060 0.060
Typical Applications
BOC #
1.10 x 2.10 Power Drop to 19 Flat Controller, XFMR, J Box 1.95 Power Drop to 31 Diameter Controller, XFMR, J Box 1.66 Diameter 1.50 Diameter 2.34 Diameter 1.940 Diameter 1.940 Diameter 1.190 Diameter 1.685 Diameter 1.744 Diameter 2.034 Diameter 2.370 Diameter 2.745 Diameter 2.120 Diameter 2.425 Diameter 1.665 Diameter 1.130 Diameter Power Drop & Feeder Power Connections Feeder to Controllers Power Drop Power Connections Power Drop Power Drop Power Drop Power Drop Power Drop Power Drop Power Drop Power Drop Power Drop Power Drop 33 34 36 38 35 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
UL Type TC-ER APPROVED
849-060 849-061 849-062 849-063 849-064 849-065 849-066 849-067
UL Type TC-ER APPROVED!
• Cable dimensions and weights are subject to manufacturing tolerances. Consult factory for exact tolerances.
Formerly “Open Wiring”
v4.06.1
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17
37-809/849
Robotic and Manual Welding Power Cable 90°C • Flexible • 2000 Volts
Application
Conductors
Flexible tinned copper
Separator
A suitable separator provides easy stripping of insulation
Insulation
90° ethylene-propylene rubber (EPR). Phase identified by color code
AmerCable robotic and manual welding cables are suitable for a wide range of applications in robotic and manual welding operations in harsh industrial environments. Applications include temporary feeders from bus plugs, primary power drops from weld controllers, interconnects from weld controllers to transformers and bus drop feeders.
Separator
A suitable separator providing easy stripping of jacket
Features
Flexible and easy to install Heat and chemical resistant thermoset jacket Suitable for continuous operating conductor temperature of 90°C
Reinforcement
Synthetic yarn over assembly
Jacket
Mold-cured thermoset with cable identification via permanent marking
Ratings & Approvals
UL listed c(UL) listed MSHA approved Flame Resistance: FT1 (Single Conductor) Flame Resistance: FT4 (Multi-Conductor) CSA: -40°C UL 44: Thermoset-Insulated Wires and Cables CSA C22.2 No. 38: Thermoset Insulated Wires and Cables
18
Manufactured by AmerCable Incorporated • (870) 862-4919 • (800) 643-1516 • Fax (870) 862-9613
Automotive Cables
37-809/849 • Robotic and Manual Welding Power Cable • 2000 Volts
Nominal Nominal Min. Min. Wires Wires Insulation Ground per Ground Ground Conductor Number Insulation of Power Thickness Size per Size Part No. Conductor Thk. in. Conductors Conductor in. AWG AWG 37809-040 4/0 1 532 0.090 NA NA NA 849-007 849-000 2 2 2 2 259 259 0.080 0.080 2 6 259 133 0.080 0.070 Nominal Outside Diameter in. 0.930 1.355 1.310
Typical Applications Temporary Feeder Power Connections Diameter Power Connections Diameter
BOC # 18 37 32
v4.06.1
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19
37-431/432/445
Automotive Cables for Toyota Flexible • 2000 Volts • 90°C
Conductors
Flexible tinned copper
Application
Separator
A suitable separator providing easy stripping of insulation
Insulation
90°C ethylene-propylene rubber (EPR)
These 600 Volt and 2kV flexible cables are specially designed and manufactured to meet requirements of Toyota Motor Company. These cables are suitable for use in the harsh environment of automotive assembly operation and meet applicable UL and Canadian listings.
Features
Flexible and easy to install Gray jackets to meet Toyota requirements UL and c(UL) listed as appropriate
Reinforcement
Synthetic yarn over assembly
Jacket
Mold-cured thermoset with cable identification via permanent marking
Ratings & Approvals
UL 1277: Electrical Power and Control Tray Cables with Optional Optical Fiber Members CSA C222 No. 96: Portable Power Cables ASTM B33: Tinned Soft or Annealed Copper Wire for Electrical Purposes Flame Resistance: FT4 CSA: -40°C
Formerly “Open Wiring”
UL Type TC-ER APPROVED!
Part No. 37445-002TOY 445-010TOY 431-002GRY 432-002GRY 431-010GRY 432-010GRY 432-040GRY
Conductor Number of Power Size Conductors AWG 2 1/0 2 2 1/0 1/0 4/0 3* 3* 3 4 3 4 4
Voltage 600 UL/1000 c(UL) 600 UL/1000 c(UL) 2000 2000 2000 2000 2000
Nominal Outside Diameter in. 1.205 1.465 1.346 1.500 1.665 1.810 2.260
Approx. Weight lbs. per 1,000 ft. 1416 1682 1246 1622 1967 1396 4376
UL Listing TC-ER TC-ER W W W W W
c(UL) Listing R-90 R-90 W, TC W, TC W, TC W, TC W, TC
*This cable also contains a #6 AWG insulated ground.
20
Manufactured by AmerCable Incorporated • (870) 862-4919 • (800) 643-1516 • Fax (870) 862-9613
37-431/430/119/809
Automotive Cables for DaimlerChrysler Flexible • 2000 Volts • 90°C
Conductors
Flexible tinned copper
Application
Separator
A suitable separator providing easy stripping of insulation
Insulation
90°C ethylene-propylene rubber (EPR)
These 2000 Volt portable power cables are manufactured to meet a variety of DaimlerChrysler cable specifications. These cables are suitable for use in a wide range of applications in the harsh environment of automotive assembly plants.
Features
Flexible and easy to install Heat and chemical resistant thermoset jacket Suitable for continuous operating conductor temperatures of 90°C
Reinforcement
Synthetic yarn over assembly
Jacket
Mold-cured thermoset with cable identification via permanent marking
Ratings & Approvals
Ratings and Approvals for these cables can be found on the appropriate AmerCable catalog page: Type W – Pages 14-15 DLO – Pages 22-23 BOC-18 – Pages 18-19
Conductor Size Part No. AWG 37431-002TF 430-002 431-002 430-010 119-205 119-207 119-209 119-210 119-211 119-212 809-040 2 2 2 1/0 6 4 2 1 1/0 2/0 4/0
Number of Power Conductors
Nominal Outside Diameter in. 1.350 1.280 1.340 1.560 0.365 0.460 0.534 0.623 0.664 0.704 0.930
Approx. Weight lbs. per 1,000 ft. 1287 1045 1295 1464 124 198 261 400 468 561 968
*DaimlerChrysler Specification NPM Code M/C Type W / 27-795-1023 M/C Type W / 27-795-2150 M/C Type W / 27-795-2155 M/C Type W / 27-795-2800 NPEY-121 / 27-795-5004 NPEY-121 / 27-795-5006 NPEY-121 / 27-795-5008 NPEY-121 / 27-795-5012 NPEY-121 / 27-795-5014 NPEY-121 / 27-795-5016 NPEY-121 / 27-795-5020
DaimlerChrysler Part No. 37-431-002TF 37-430-002 37-431-002 37-430-010 10060-C 10070-C 10090-C 10100-C 10110-C 10120-C 10140-C
Cable Type Type W Type W Type W Type W DLO DLO DLO DLO DLO DLO BOC-18
3 2 3 2 1 1 1 1 1 1 1
*CPE Jacket is standard on all NPEY-121 cables • Customized legends are available upon request.
v4.06.1
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21
37-119
Flexible Power Cable • DLO 2000 Volts • 90°C
Diesel Locomotive Cable • EP/CPE • RHH, RHW-2 Conductors
Flexible-stranded, tinned, annealed coated copper
Application
AmerCable’s 2000V Diesel Locomotive Cable (DLO) is a single conductor Portable Power Cable suitable for use in industrial applications needing great flexibility, excellent wearability and a good flex life. Applications include locomotive and car equipment, motor and generator leads, battery leads, shipyards, telecommunications power, heavy earth moving equipment and other heavy duty flexing applications.
Separator Jacket
Flame retardant, oil and sunlight resistant Chlorinated Polyethylene (CPE) Jackets are available in: • black (standard) • red • blue • green Suitable separator tape provides easy stripping of insulation
Insulation
Ethylene-Propylene rubber (EPR)
Features
A two layer composite of flame retardant, oil and sunlight resistant Chlorinated Polyethylene (CPE) outer layer and Ethylene-Propylene rubber (EPR) inner layer. The composite design provides significant diameter reductions compared to designs using full thickness jackets. Suitable for continuous operating temperatures of 90°C, wet or dry Rated RHH, RHW-2; 2/0 – 1000 kcmil listed and marked “for CT use” UL listed as Sunlight Resistant UL listed as Marine Shipboard Cable (4/0 and larger) – Special order only Insulation and jacket meet hazardous waste regulations, per Code of Federal Regulations 40 Section 261 (40CFR261) for characteristic lead content Flame Resistance: FT-4/IEEE1202 for 2/0 and larger, and UL VW-1 Meets smoke release and other requirements of Vertical Cable Tray Test UL 1685 and is marked “LS” for 2/0 and larger Extremely flexible stranding used for increased flexibility and ease of installation Jackets also available in red, blue and green
DaimlerChrysler Approved Supplier for 6AWG-2/0
Ratings & Approvals
ICEA S- 95-658/ NEMA WC-70: Nonshielded Power Cables Rated 2000 Volts or Less for the Distribution of Electrical Energy UL Standard 44: Thermoset Insulated Wires & Cables, Types RHH, RHW-2. UL VW-1 UL Standard 1685: Vertical Tray Fire propagation and Smoke Release Test for Electrical and optical Fiber Cables. (UL, LS) ASTM B-33: Standard Specification for Tinned Soft or Annealed Copper Wire for Electrical Purposes ASTM B-172: Standard Specification for Rope-LayStranded Copper Conductors having Bunch-Stranded Members, for Electrical Conductors MSHA P-184
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Manufactured by AmerCable Incorporated • (870) 862-4919 • (800) 643-1516 • Fax (870) 862-9613
Automotive Cables
37-119 • Single Conductor Portable Power Cable • DLO
Nominal Insulation Thickness in. 0.045 0.045 0.045 0.055 0.055 0.055 0.055 0.065 0.065 0.065 0.065 0.065 0.075 0.075 0.075 0.075 0.090 0.090 0.090 0.090 0.115 Nominal Jacket Thickness in. 0.015 0.015 0.015 0.030 0.030 0.030 0.030 0.045 0.045 0.045 0.045 0.045 0.065 0.065 0.065 0.065 0.065 0.065 0.065 0.065 0.095 Nominal Outside Diameter in. 0.214 0.233 0.257 0.349 0.365 0.460 0.534 0.623 0.664 0.704 0.789 0.839 0.973 1.029 1.110 1.181 1.284 1.368 1.488 1.640 1.800 Approx. Weight lbs. per 1,000 ft. 31 41 58 86 124 198 261 400 468 561 725 888 1048 1227 1436 1691 2034 2395 2837 3448 4304
Part No. 37-119201 202 203 204 205 207 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223
Size AWG/ kcmil 14 12 10 8 6 4 2 1 1/0 2/0 3/0 4/0 262 313 373 444 535 646 777 929 1111
Minimum Wires per Conductor 19 19 27 37 61 105 147 224 266 323 418 532 646 777 925 1110 1332 1591 1924 2318 2745
*Ampacity 90°C 35 40 55 80 105 140 190 220 260 300 350 405 467 522 591 652 728 815 904 1005 1119
* Ampacity is calculated with a 90°C conductor temperature and 30°C ambient air, per 2005 NEC, Table 310-17 • Cable diameters and weights are subject to +/- 5% manufacturing tolerance
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Trans-Gun Quick Disconnect Assemblies
Factory prepared cable assemblies are a reliable way to lower your overall cable connectivity costs through enhanced reliability, reduced handling and lower installation time.
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Contact factory for details
www. amercable.com • e-mail: [email protected]
Automotive Cables
Type W Cables 600-2000 Volts Motor Lead Cable • 90°C 1-6 Conductor
AmerCable’s Type W cables deliver great flexibility and durability. Applications include heavy duty or temporary power supply service, AC or DC, to motor or generators, portable and stationary heavy duty equipment, cranes, conveyors and other mobile equipment. Also recommended for payout and retractable reels, festoons, suspended loops and power tracks. Some of our Type W’s also carry a UL Type TC-ER listing.
VFD Power Cable Shielded • 2000 Volts 3 Conductors + 3 Grounds + Ground Check(s)
AmerCable’s flexible, braid and foil shielded, 2kV power cable specifically engineered for use in variable frequency AC motor drive (VFD) applications.
Ask your rep for more details about these, and other, AmerCable industrial cables
Specially engineered cable design produces a longer cable life in VFD applications. Overall braid and foil shield provides 100% coverage containing VFD EMI emissions. Symmetrical insulated ground conductors reduce induced voltage imbalances and carry common mode noise back to the drive. High strand count conductors and braid shield design is much more flexible, easier to install and more resistant to vibration than Type MC cable. 2kV insulation thickness resists the repetitive 2x voltage spikes from 600V VFDs and reduces drive over current trip problems due to cable charging current.
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Automotive Cables
AmerCable manufactures high quality jacketed electrical cables for the automotive industry and other specialized industrial applications. AmerCable is an ISO 9001 certified cable manufacturer that combines leading-edge technology, proven manufacturing techniques, and high quality service to deliver the finest automotive cable products available. AmerCable serves a worldwide customer base from our manufacturing facility in El Dorado, Arkansas. Our professional field engineering and sales force work in partnership with our network of independent distributors to identify and fulfill your specific cable requirements.
AmerCable’s manufacturing facility and corporate headquarters in El Dorado, Arkansas.
What can you expect from AmerCable?
High Quality Cable On Time Delivery (99%+ in the last 36 months)* Professional Sales, Support and Service Strategic Inventory Locations Operational Excellence Short Lead Times
* Check www.amercable.com for our most current on time delivery record
El Dorado, Arkansas
Made in America
AmerCable Industrial Cable Products
Industrial Automotive Reeling
For complete product information visit our website! www.amercable.com
For complete product information visit our web site!
Room & Pillar Surface
Longwall
© 2006, AmerCable Incorporated
350 Bailey Road • El Dorado, Arkansas USA (870) 862-4919 • (800) 643-1516 • Fax (870) 862-9613 e-mail: [email protected] • www.amercable.com
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