Watteredge, Inc.

Air Cooled Cables

Watteredge Air Cooled Cable Assemblies are made from non-insulated copper wire of various MCM sizes. Cable ends are terminated using crimped lugs, compression terminals or Watteredge exclusive Press Welded compression terminals. The cable is provided with or without a cover sleeve over the wire. The air cooled cables are used in many different industries and applications; primarily they are used in resistance welding applications. Standard sizes from 400 to 2000MCM are available in our Dry Jumper (DJ) product range.

DRY JUMPER (DJ) product range

Every Watteredge Dry Jumper (DJ) has completely silver plated and swaged terminals. Terminals can be manufactured up to 3 7/8” long for special applications.

Type DJ-IC & DJ-SC with Stabilizer Collar

DJ-IC

The Watteredge Isolated Conductor Type Dry Jumper (IC) increases cable life by correcting these common causes of failure:

Eliminates frictional wear between adjacent ropes by the use of rubber tubing.
Reduces frictional wear between strands of adjacent bunches within a rope by reducing wear points from 36 to 9 within the rope cross section.
Reduces strand failure at rear of terminal, resulting from the added stabilizer flare.
Increases flexibility and versatility due to an improved insulation method.

DJ-SC

The Watteredge Stabilizer Collar (SC) increases dry jumper life by reducing strand failure at the cable terminal. This is accomplished by a slight increase in the minimum flex radius which in turn reduces overstressing.

Type DJ-XF (extra flexible)

The Watteredge Extra Flexible Type Dry Jumper (XF) increases cable life by the use of 36 AWG copper rope stranding and an extremely flexible protective cover.

Installation Methods

Air cooled jumpers should be installed in such a manner that the mechanical stresses at the terminals will be reduced to a minimum. This may be accomplished by installing the jumper with a little slack, which will allow the jumper to flex freely.

Bend radii should not be sharp. (See “Jumper Bend Specifications” chart below for minimum bend radii)

Jumper Bend Specifications
Recommended Minimum Bend Radii:

500 MCM and below ... 2”
600 MCM - 1500 MCM ... 3”

Minimum Distance from the Bolt Hole Center to the point where the Bend Radius begins is as follows:

350 MCM - 600 MCM ... 2”
750 MCM ....... 2 1/2”
1000 MCM ....... 3”
1200 MCM ...... 3 1/2”
1500 MCM ........ 4”

Maintain the bend radii as large as possible in an effort to distribute the frictional wear over the entire jumper length rather than to concentrate it in one area.