Durable Water-Cooled Conductive Component for Industrial Melting Furnace

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Durable Water-Cooled Conductive Component for Industrial Melting Furnace

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Product Description

Basic Information

Model NO.

250A~1500A 750V/1500V DC Water-Cooled Copper Elect

Conductor Material

Copper

Sheath Material

PVC

Insulation Material

Cross-Linked Polyethylene

Material Shape

Round Wire

Range of Application

Industrial or EV Charging

Certification

ISO9001, CE, RoHS

Quality Standard

Strict Pressure and Leakage Test

Cooling Method

Water-Cooled

Compatible Equipment

Single-Crystal Furnace, Ingot Furnace, Sapphire Furnace

Transport Package

Carton Box + Wooden Pallet

Origin

China

Product Overview

Water-Cooled Power Cables: Known as water-cooled leads or flexible connectors, these are engineered to transport large currents efficiently within electric melting and heating apparatus. Their integrated water-cooling system effectively reduces conductor temperature, decreases electrical losses, and minimizes unexpected downtime.

Core Capabilities

OEM / ODM manufacturing
Build-to-print or build-to-sample customization
Fast quotation support and application engineering assistance
After-sales spare parts and repair services
Quality management system: [ISO 9001 / others]

Typical Applications

Electric arc furnace (EAF) / UHP furnace
Ladle furnace
Induction melting / heating equipment
Vacuum furnaces
Semiconductor crystal growth equipment
Welding systems and high-current power supply

Key Advantages

Unparalleled electrical efficiency with low resistance and minimal transmission loss.
Optimized coolant flow path ensures even and consistent conductor cooling.
Durable heat-resistant and wear-resistant external protection for challenging environments.
Withstands bending and torsional stress, allowing for flexible installation.
High-quality copper materials with robust terminations ensure extended service life.
Consistent quality through precise and repeatable manufacturing processes.
Reduced maintenance costs and shorter downtimes throughout the lifecycle.

Construction & Design Features

Terminal / Cable Head

CNC machined from a single copper bar
No contact joints or welded seams in the terminal body
Tin-plated surface for oxidation resistance
Available in non-contact, water-cooled, and rotary types

Flexible Conductor & Hose

TU1 oxygen-free copper stranded conductor
Tin-plated strands for corrosion resistance
High natural-rubber content non-carbon insulation hose
Dedicated crimping for long-term sealing

Standard Water-Cooled Cable: Premium non-carbon rubber hose, suitable for pressures up to 0.8 MPa and voltages up to 6,000 V.

High-Voltage Water-Cooled Cable: Enhanced with an additional shielding layer for safety. Designed for up to 1.0 MPa and 10 kV.

Coaxial Water-Cooled Cable: Innovative design separates coaxial conductors and cooling circuits via PTFE. Minimizes heat and electrical losses.

General Technical Specifications

Item	Typical / Reference Value
Rated current range	0.6-10 kA
Conductor structure	Multi-strand copper conductor
Cable outer diameter range	28-100 mm
Rated voltage	3,000 V (Up to 10 kV for high-voltage versions)
Cooling water working pressure	0.6 MPa
Factory air-pressure test pressure	0.8 MPa
Recommended current density	10 A/mm2
Minimum bending radius	350 mm

Quality Assurance and Testing

Rigorous incoming material inspection.
Meticulous dimensional inspection against approved drawings.
Integrity check of crimped or welded joints.
Comprehensive leakage and pressure tests.
Precise DC resistance measurement.
Withstand-voltage test for insulation strength.
Inspection report and certificate of conformity (CoC) provided.

Installation & Maintenance

Installation Safety

Avoid twisting the hose; ensure no torsional preload.
Adhere to minimum bending radius; prevent sharp kinks.
Verify water flow and pressure before energizing.

Maintenance Tips

Inspect external hose for wear, scorching, or cracking regularly.
Replace cable assembly immediately if leakage is suspected.
Keep spare cables readily available to minimize production downtime.

Frequently Asked Questions

Q: What is the main benefit of using a water-cooled system in these cables?

A: The integrated water-cooling system effectively reduces the conductor temperature, which significantly decreases electrical losses and helps prevent unexpected equipment downtime.

Q: What materials are used for the conductors and insulation?

A: We use TU1 oxygen-free copper for the conductors (often tin-plated) and high-quality non-carbon rubber with high natural-rubber content for the outer insulation hose.

Q: Are the cable terminals customizable?

A: Yes, terminal designs, mounting holes, water connections, and overall cable lengths can be tailored to meet specific customer drawings or site-specific requirements.

Q: What is the typical voltage rating for these cables?

A: Standard cables are suitable for up to 6,000 V, while high-voltage versions are designed to withstand up to 10 kV.

Q: What kind of testing is performed before the cables are shipped?

A: Every cable undergoes rigorous leakage and pressure tests (typically at 0.8 MPa), DC resistance measurements, dimensional inspections, and withstand-voltage tests where applicable.

Q: How do I choose the correct cable model for my furnace?

A: Selection is based on your equipment type (EAF, Induction, etc.), rated current, duty cycle, installation layout, and specific cooling water conditions.

Disclaimer: Final product configurations and performance values are subject to mutually confirmed technical agreements.