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Product

EN 50525-2-81 & Low-Reactance Resistance Welding Cables600–1000 V ISO 5828 / RWMA3+3 Interleaved Low-Reactance200 MCM to 600 MCM Water-Cooled

Water-Cooled Kickless Welding Cable600 V low-reactance interleaved 3+3 sector water-cooled resistance spot-welding gun jumper

Water-Cooled Kickless Welding Cable is a low-inductance secondary power jumper engineered to ISO 5828, RWMA and AWS J1.1 for high-current (8,000 A to 25,000 A) automotive body-in-white portable and robotic resistance spot-welding guns. Six (3+3) pie-shaped rop

Zero Magnetic Kick (3+3 Sector)
Internal Closed-Loop Water Cooled
Spatter & Coolant Resistant EPDM
ISO 5828 / RWMA / AWS J1.1
Order designation
Kickless 350 MCM
Nom. OD
35.00 mm
Copper mass
3,550.0 kg/km
Total mass ≈
4,550.0 kg/km
Min. bend R
175.0 mm
All sizes (8)
Request a quoteDatasheetWhatsApp
Engineering reply in 2 business hoursCut-to-length export drumsEN 10204 3.1 certificate per drum
Rated voltage
600 V / 1000 V
Resistance weld transformer secondary
Core geometry
3 + 3 sector lay
Alternating + / − polarity cancellation
Size range
200 to 600 MCM
100 to 300 mm² per polarity
Welding current
8 kA to 25 kA pu
Water-cooled 3.8–7.5 L/min flow
Coolant pressure
4 to 10 bar work
Non-conductive EPDM outer hose
Min. bend radius
5 × hose OD
Robotic & overhead spot-weld guns

Typical values for this cable type, based on ISO 5828 / RWMA / AWS J1.1 — confirmed in the datasheet and quotation for your order.

Application fit

Is Water-Cooled Kickless Welding Cable right for your machine?

Specified to connect overhead welding transformers and MFDC (1000 Hz) or AC (50/60 Hz) spot-welding controllers to portable manual transguns, C-guns, X-guns and 6-axis robotic spot-welding arms.

Free-hanging vertical run

Suitable

Eliminates violent electromagnetic cable whip ('kick') during 15,000+ A spot-welding pulses.

Energy chain / drag chain

Suitable

Rope-lay 30–34 AWG copper strands and swivel terminal heads endure multi-axis robotic dress packs.

Trailing & towing

Suitable

Thick textile-reinforced EPDM outer coolant hose resists weld spatter, slag and hydraulic oils.

Fixed installation

Not suitable

Requires active closed-loop water flow (≥3.8 L/min); for air-cooled arc welding use H01N2-E.

H01N2-E air-cooled arc cable
Typical machinesAutomotive body-in-white spot weldingRobotic C-gun & X-gun dress packsOverhead manual portable spot gunsAppliance & sheet-metal resistance weldMFDC & AC weld transformer jumpers

Construction

Layer by layer

Central fluted elastomeric water-distribution core + 6 (3 positive + 3 negative) interleaved pie-sector rope-stranded bare/tinned copper conductors separated by heavy EPDM dielectric web + textile-braid-reinforced non-conductive EPDM outer cooling hose.

1234
Schematic, not to scale — generated from the layer data
#LayerMaterial & reference
13 + 3 interleaved sector copper ropesSix pie-shaped rope-stranded fine copper conductors (alternating + and − around 360°) cancelling opposing magnetic fields and skin-effect reactanceISO 5828
26-web Star EPDM polarity separatorExtruded six-fin cross-linked EPDM rubber star core isolating adjacent positive and negative copper sectors at 1000 V while channeling cooling water over the strandsISO 5828
3High-tenacity aramid/polyester reinforcementBraided textile reinforcement embedded in the outer hose wall to withstand 6–10 bar coolant water pressureISO 5828
4Non-conductive EPDM outer coolant hoseAbrasion-, weld-spatter- and heat-resistant EPDM outer jacket sealing the closed-loop water circuitISO 5828

Standard 3+3 Kickless Jumper (250 MCM to 500 MCM — Fixed or Swivel Lugs)

Complete factory-terminated assembly with silver-plated forged copper water-cooled 2-bolt or 4-bolt ISO 5828 terminal heads.

Heavy-Duty 600 MCM / 300 mm² Robotic MFDC Jumper

High-capacity water-cooled kickless cable with replaceable outer spatter sleeve for high-duty-cycle robotic spot welding.

Technical data

Ratings & operating limits

Typical values: Typical values for this cable type, based on ISO 5828 / RWMA / AWS J1.1. Values for your order are confirmed in the datasheet and quotation.

Electrical

Rated insulation voltage
600 V / 1,000 V rms between positive and negative sectors
Dielectric withstand test
2.5 kV AC rms dry / 1.5 kV AC wet between polarities
Inductive reactance @ 60 Hz
≈30–40 μΩ/m (up to 80 % lower voltage drop than twin single-core cables)

Thermal

Required cooling water flow rate
3.8 to 7.5 L/min (1.0 to 2.0 GPM) at ≤+30 °C inlet water temperature
Max. coolant outlet temperature
+60 °C (+85 °C hose compound rating)

Mechanical

Coolant working / burst pressure
6.0 bar (90 psi) working · ≥17 bar (250 psi) burst pressure
Minimum bending radius
5 × outer hose diameter

Resistance

Electromagnetic force cancellation
Alternating 3+3 sector geometry neutralizes repulsive Lorentz kick during 10–25 kA weld pulses
Outer hose resistance
Non-conductive EPDM resists molten weld spatter, ozone, glycol coolant & shop oils

Reference standards

Reference standards
ISO 5828, RWMA Bulletin 16 & AWS J1.1
Terminal lug interface
ISO 5828 / RWMA 2-hole & 4-hole silver-plated copper water-cooled terminals

Identification

Size designation
Specified by MCM (or mm²) per polarity (e.g. 400 MCM = 400 MCM + and 400 MCM −)
Hose colour
Black, Red or Blue non-conductive EPDM

Sizes

8 standard configurations (Water-Cooled Kickless Welding Cable)

Nominal dimensions, copper weight, total mass and electrical parameters for Water-Cooled Kickless Welding Cable per ISO 5828 / RWMA / AWS J1.1.

Dimensions & masses
DesignationSize per PolarityTotal Cu / Water FlowNom. OD
mm		Copper
kg/km		Total mass ≈
kg/km		Min. bend R
mm		Enquiry
Water-Cooled Kickless Welding Cable size schedule
Kickless 200 MCM200 MCM (100 mm²)2×100 mm² · 3.8 L/m28.501,920.02,650.0142.5
Kickless 250 MCM250 MCM (125 mm²)2×125 mm² · 4.2 L/m30.502,400.03,200.0152.5
Kickless 300 MCM300 MCM (150 mm²)2×150 mm² · 4.5 L/m33.002,880.03,780.0165.0
Kickless 350 MCM350 MCM (185 mm²)2×185 mm² · 5.0 L/m35.003,550.04,550.0175.0
Kickless 400 MCM400 MCM (200 mm²)2×200 mm² · 5.7 L/m38.003,840.04,950.0190.0
Kickless 450 MCM450 MCM (225 mm²)2×225 mm² · 6.0 L/m39.504,320.05,500.0197.5
Kickless 500 MCM500 MCM (250 mm²)2×250 mm² · 6.5 L/m41.504,800.06,100.0207.5
Kickless 600 MCM600 MCM (300 mm²)2×300 mm² · 7.5 L/m44.505,760.07,250.0222.5
  • Typical values for this cable type; dimensions and weights for your order are confirmed in the quotation.
  • Dimensions and tolerances conform to ISO 5828 / RWMA / AWS J1.1.

Quality & approvals

Testing & inspection

Routine tests on every production length, sample and type tests per batch — documented on an EN 10204 3.1 inspection certificate.

  1. ConductorClass 5 stranding
  2. Spark test100 % in-line
  3. Lay-upCores, earth, fillers
  4. SheathingInner, braid / screen, outer
  5. Electrical testsAC voltage, resistance
  6. DimensionsOD, wall thickness
  7. Inspection documents & dispatchDrum & dispatch
Testing & inspectionTest value / referenceFrequency
Routine tests
2.5 kV AC polarity-to-polarity dielectric & 10 bar hydrostatic testZero electrical breakdown and zero water leakage100 % of assemblies
Sample tests
DC resistance per polarity, water flow pressure drop & lug pull testVerifies low contact resistance and ≥4.0 L/min flowEvery batch
Torsional robotic flex life & 20 kA impulse reactance testCertified to ISO 5828 & RWMAType qualification

Inspection certificate

Issued with every drum, listing the routine test results for that length.

Product approvals

ISO 5828 Secondary Welding CablesRWMA (Resistance Welding Manufacturing Alliance)AWS J1.1 CompliantRoHS 3 & REACH Compliant

Company certificates

ISO 9001ISO 14001ISO 45001VDE marks approvalUL / cULCE · LVD / EMC

Marking & supply

Ordering & delivery

Sheath marking

TEBAOFLEX WATER-COOLED KICKLESS WELDING CABLE [MCM/mm2] ISO 5828 NON-CONDUCTIVE EPDM [lot]
Delivery form
Non-returnable wooden drums, export reels or shrink-wrapped coils
Standard drum lengths
100 m · 250 m · 500 m · 1000 m
MOQ
200 m (stock sizes) · 500 m (custom lengths)
Lead time
2–3 weeks ex-works
Incoterms
EXW, FOB, CIF, DAP

Technical documents

Downloads

PDFWater-Cooled Kickless Welding Cable – technical datasheet8 sizes · construction, technical data, approvalsXLSXWater-Cooled Kickless Welding Cable spec data (Excel)All 8 sizes with dimensions and data, for your BOM or quotation
Revision
2026-10-20
Updated
2026-10-20

FAQ

Questions engineers ask first

Not covered here? Send your drawing — an engineer replies within 2 business hours.

Why is this cable called 'kickless' and how does the 3+3 sector design work?
When 10,000 to 25,000 A of welding current surges through two separate parallel single-core cables, intense opposing magnetic fields cause the cables to violently repel each other ('kick'), fatiguing operators and snapping robot brackets. By dividing the positive and negative conductors into 6 pie-shaped sectors arranged alternately (+, −, +, −, +, −) around a single axis, the magnetic forces cancel internally and reduce inductive reactance by up to 80 %.
How does water cooling allow a 400 MCM (200 mm²) kickless cable to carry 10,000+ A spot-welding pulses?
De-ionized or treated cooling water flows directly through the internal channels over the bare copper strands at 4 to 7 L/min, removing Joule heat immediately so a compact, flexible cable can carry 5 to 8 times the current of an air-cooled cable.
How is the size of a kickless welding cable specified (e.g. 400 MCM)?
By industry convention (RWMA / ISO 5828), a '400 MCM' kickless cable contains 400 MCM (~200 mm²) of positive copper AND 400 MCM (~200 mm²) of negative copper inside the same hose (total copper area = 800 MCM / ~400 mm²).
Can Water-Cooled Kickless Welding Cables be ordered with swivel terminal heads?
Yes. We supply both fixed and 360° low-resistance silver-plated swivel terminal heads (2-bolt and 4-bolt ISO/RWMA patterns) in custom point-to-point assembly lengths.

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Water-Cooled Kickless Welding Cable

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