Water Cooled Power Cables

Water Cooled Cables are specially designed high-current flexible conductors that use a water circulation system to actively remove heat from the cable during operation. These cables are essential in high-temperature, high-load industrial environments—particularly in induction furnaces, arc furnaces, and electrolytic plants—where natural air cooling is insufficient to maintain safe operating temperatures.

Construction:

• Conductor: High-conductivity, stranded or braided electrolytic copper

• Inner Hose: Durable rubber or silicone tube allowing water flow through the center

• Outer Jacket: Reinforced heat-resistant rubber, silicone, or fiberglass braid, providing insulation and protection

• Terminals: Copper lugs or customized water-cooled connectors (often flanged) at both ends

• Water Ports: Inlet and outlet fittings for coolant connection

Key Features:

• 💧 Active Cooling via Internal Water Flow

• 🔥 Handles Extremely High Currents

• 🌡️ Controls Thermal Expansion & Heat Build-Up

• ⚙️ Flexible for Moving Connections

• 🧱 Protected Against Mechanical and Electrical Stress

Working Principle:

As electrical current flows through the cable, it generates heat. In water-cooled cables, coolant water is circulated through an internal channel, effectively absorbing and carrying away this heat, which helps:

• Maintain conductor performance

• Protect surrounding components

• Extend the life of the cable

Applications:

• Induction Melting & Heating Furnaces

• Electric Arc Furnaces (EAF)

• Resistance Welding Equipment

• Electrolysis and Electroplating Systems

• Heavy Industrial Machinery in Steel, Glass, and Mining Sectors

Advantages:

• ✅ Superior Heat Dissipation for High-Load Systems

• ✅ Extended Cable Life in Harsh Environments

• ✅ Minimizes Thermal Degradation of Conductors

• ✅ Supports Continuous Duty Applications

• ✅ Customizable Lengths, Hose Sizes, and Connectors

Comparison: Water Cooled vs. Air Cooled Cables

Safety and Maintenance Tips:

• Ensure clean, non-corrosive water supply to prevent scaling or blockages

• Regularly inspect for leakage or hose wear

• Monitor water flow and pressure for optimal cooling efficiency

Conclusion:

Water Cooled Cables are critical components for high-power electrical systems operating under extreme thermal loads. Their ability to maintain low conductor temperatures during intense operation makes them indispensable for industrial heat-processing equipment and electrometallurgical systems. With proper installation and maintenance, they deliver safe, efficient, and long-lasting performance.

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