High Amp Rated Power Cords

The High Amp Rated Power Cords utilizes conductors with optimized cross-sectional areas to minimize electrical resistance and heat generation under high current flow. Copper or copper-alloy conductors are selected for superior conductivity and mechanical strength. The conductor strands are precisely engineered to balance flexibility and current-carrying capacity, reducing skin effect losses at AC frequencies. This design ensures the power cord safely carries elevated amperage without compromising performance or causing thermal degradation. 

Conductor Material

Electrolytic Grade Annealed Copper (99.97% purity)

Conductor Cross-Sectional Area

Up to 240 mm² (customizable per current rating)

Maximum Current Carrying Capacity

Up to 400 Amps (at 40°C ambient, free air)

Conductor Class

Class 5 or 6 (flexible fine stranded per IEC 60228)

Rated Voltage

600/1000V AC (Tested to 3.5 kV for 5 minutes)

Product Description

The insulation system in the High Amp Rated Power Cord employs advanced polymer compounds with high dielectric strength and thermal stability. Materials such as cross-linked polyethylene (XLPE) or thermoplastic elastomers (TPE) maintain insulation integrity at elevated temperatures commonly encountered in high-current applications. The insulation thickness is calibrated to withstand specified voltage levels, prevent partial discharge, and resist electrical tracking, ensuring safe and continuous operation even under transient voltage spikes. 

Insulation Material

XLPE / EPR / Silicone Rubber (based on application)

Insulation Thickness

1.5 mm – 3.5 mm (as per IEC/UL insulation grade)

Temperature Rating

-40°C to +125°C continuous (Short-term up to 150°C)

Flame Retardance Standard

UL 1685 / IEC 60332-1 & 3 compliant

Outer Sheath Material

Halogen-Free Flame Retardant Polyolefin / PU / TPE

Shielding Type

Tinned Copper Braid (70–85% optical coverage) with optional foil layer

EMI/RFI Attenuation

>60 dB at 30 MHz (with full shielding configuration)

Bending Radius

6×OD static / 10×OD dynamic (per VDE 0298-3)

Dielectric Strength

>20 kV/mm (insulation material dependent)

UL 62, UL 1581, IEC 60228, CSA C22.2, RoHS, REACH

UL 62, UL 1581, IEC 60228, CSA C22.2, RoHS, REACH

Technical Advantages

Thermal management is critical in High Amp Rated Power Cords to prevent conductor overheating and insulation failure. The cable design incorporates materials with high thermal conductivity and flame-retardant properties. Optimized conductor geometry and insulation thickness promote effective heat dissipation along the cable length. This prevents localized hot spots and extends the operational lifespan of the cord under sustained heavy loads. 

High Amp Rated Power Cords are engineered with robust outer jackets that resist mechanical stresses such as abrasion, crushing, and repeated flexing. The jackets use compounds resistant to oils, chemicals, UV radiation, and moisture ingress. This ensures the cable maintains electrical and mechanical integrity in harsh industrial and outdoor environments, minimizing failure risks due to environmental exposure or physical damage. 

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Industry Applications

Industrial Automation Equipment

Supplies high current to servo drives, motor controllers, and actuators operating under continuous duty cycles and variable load conditions. 

Data Center Power Distribution

Delivers stable high amperage to PDUs, UPS systems, and redundant power supplies within dense rack-mounted server environments. 

Welding and Fabrication Systems

Connects to arc welders and plasma cutters requiring sustained high current under fluctuating thermal and electrical stress conditions. 

Railway and Transit Systems

Supports traction control systems, auxiliary converters, and HVAC units requiring high ampacity and mechanical robustness in mobile platforms. 

EV Charging Infrastructure

Transfers high current from chargers to vehicle onboard systems with minimal voltage drop and heat rise during rapid charging cycles. 

Marine and Offshore Installations

Powers propulsion systems, switchboards, and high-capacity pumps, ensuring reliable current delivery in corrosive and high-vibration environments. 

Electromagnetic Compatibility (EMC) and Shielding

To mitigate electromagnetic interference (EMI) and maintain signal integrity in power systems, High Amp Rated Power Cords incorporate multi-layer shielding. Materials such as braided copper or aluminum foil shields are applied to reduce radiated and conducted noise. Proper grounding and shield termination methods ensure compliance with EMC standards and protect sensitive equipment connected downstream. 

High Amp Rated Power Cords meet stringent international safety and performance standards, including UL 1277, IEC 60228, and CSA C22.2. Certification involves rigorous testing for current carrying capacity, voltage withstand, thermal endurance, and mechanical resilience. Adherence to these standards guarantees that the power cords function reliably under specified electrical and environmental conditions. 

High Amp Rated Power Cords

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does Frigate ensure thermal stability in High Amp Rated Power Cord during sustained overload conditions?

Frigate uses high-temperature-rated insulation like XLPE or silicone rubber with thermal indexes exceeding 150°C. Conductors are sized above NEC ampacity tables to reduce I²R losses. Each cord undergoes thermal cycling tests to ensure material stability under overload conditions. This prevents insulation softening, jacket deformation, and long-term conductor fatigue. 

What mechanical protection methods are used by Frigate for High Amp Rated Power Cord in mobile or robotic systems?

Frigate applies abrasion-resistant polyurethane or thermoplastic elastomer outer sheaths with high flexural endurance. These jackets withstand continuous motion, mechanical vibration, and tensile strain. Cords are tested to DIN bending radius and dynamic motion standards. This ensures reliable power transmission in CNC, gantry, or drag-chain applications. 

How does Frigate address high inrush current protection in High Amp Rated Power Cord for inductive loads?

Frigate selects conductors with low reactance and minimizes loop area to limit inductive voltage rise. Stranding and core configuration reduce surge impedance. High dielectric strength insulation prevents flashover during high inrush transients. Cords are validated under simulated inductive load tests with rapid current rise times. 

 

What standards does Frigate follow for High Amp Rated Power Cord certification in hazardous environments?

Frigate designs are compliant with IEC 60502, UL 1685, and ATEX zone requirements where applicable. Materials used meet flame retardancy, low smoke, and halogen-free criteria. High Amp Rated Power Cords undergo oil, acid, and chemical exposure tests per ISO 6722-1 standards. These validations support usage in petrochemical and mining zones. 

How does Frigate control EMI in High Amp Rated Power Cord for sensitive electrical systems?

Frigate uses layered shielding—aluminum foil plus tinned copper braid—for full EMI suppression. Ground paths are engineered with low impedance terminations to reduce noise coupling. Jacket material dielectric constants are selected to avoid high-frequency resonance. Each cable is tested per CISPR 25 and MIL-STD-461 EMI benchmarks. 

 

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LOCATIONS

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

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High Amp Rated Power Cords

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