ISO 8205:2021

Overview

ISO 8205:2021 specifies requirements for water-cooled secondary connection cables used in resistance welding equipment. It covers both double-conductor and single-conductor secondary cables and defines electrical, mechanical and cooling characteristics plus the required test procedures, dimensions, marking and designation rules. This international standard replaces earlier part-based publications (ISO 8205-1:2002, ISO 8205-2:2002 and ISO 8205-3:2012).

Key topics and requirements

• Scope & classification

  • Applies to single- and double-conductor water-cooled secondary connection cables for resistance welding and allied processes.
  • Double-conductor types: A‑1, A‑2; Single-conductor types: C‑1, C‑2, D.
  • For double-conductor cables a power factor requirement cosφ ≥ 0.95 is noted for classification.

• Dimensions & construction

  • Lists permitted cross-sectional areas (examples):
    • Double-conductor: 100, 150, 160, 200, 250, 315 mm² per conductor.
    • Single-conductor: 150, 160, 180, 200, 250, 315 mm².
  • Standardized length options, tolerance rules and detailed end-lug geometry for each type (figures and tables provided).

• Electrical characteristics & tests

  • Requirements and test methods for permanent current, resistance, impedance (double-conductor), insulation resistance and power factor calculation.
  • Distinguishes type tests and routine tests depending on cable type.

• Mechanical, cooling and durability tests

  • Tests for leak tightness and pressure resistance of the water circuit, water flow verification, flexibility at cable ends, torsion, and endurance cycles (including test rig descriptions and test-cycle parameters).

• Marking & designation

  • Rules for indelible marking on end lugs, manufacturer identification and standardized designation format (example: A – 2 × 200 – 2 500).

Applications and users

• Typical users:

  • Manufacturers of resistance welding machines, cooling-equipped welding guns and robotic welding systems.
  • Welding engineers, procurement/specification writers and testing laboratories.
  • Quality and maintenance teams responsible for high-current cable selection, life-cycle testing and safety compliance.

• Practical benefits:

  • Ensures interchangeability, predictable electrical performance and reliable cooling under high current loads.
  • Supports consistent procurement specifications, helps reduce downtime and improves operator safety in industrial welding operations.

Related standards

• Replaces ISO 8205-1:2002, ISO 8205-2:2002 and ISO 8205-3:2012.
• Users should coordinate with other ISO/CEN welding and electrical standards when specifying complete welding systems.