Technical specifications for water-cooled cables, induction furnace copper coils and related furnace copper components — with dimensions, selection guidance and test data. Every figure is given in metric and US units, so a plant working in inches, in², AWG or MCM reads the same table as a plant working in millimetres and mm².
ZZLZ series. Non-standard sizes between 50 and 9,000 mm² (1/0 AWG to 18,000 MCM) are made to order.
| Model | Cross section (mm²) | Cross section (in²) | US size | Rated current (A) | Cable OD (mm / in) | Water connection |
|---|---|---|---|---|---|---|
| ZZLZ100 | 100 | 0.15 | 4/0 AWG | 600 | 28 / 1.10 | G3/8" |
| ZZLZ150 | 150 | 0.23 | 300 MCM | 900 | 32 / 1.26 | G1/2" |
| ZZLZ200 | 200 | 0.31 | 400 MCM | 1,200 | 36 / 1.42 | G1/2" |
| ZZLZ300 | 300 | 0.46 | 600 MCM | 1,800 | 42 / 1.65 | G3/4" |
| ZZLZ400 | 400 | 0.62 | 800 MCM | 2,400 | 48 / 1.89 | G3/4" |
| ZZLZ500 | 500 | 0.78 | 1000 MCM | 3,000 | 54 / 2.13 | G1" |
| ZZLZ630 | 630 | 0.98 | 1250 MCM | 3,800 | 60 / 2.36 | G1" |
| ZZLZ800 | 800 | 1.24 | 1600 MCM | 4,800 | 68 / 2.68 | G1-1/4" |
| ZZLZ1000 | 1,000 | 1.55 | 2000 MCM | 6,000 | 76 / 2.99 | G1-1/4" |
| ZZLZ1200 | 1,200 | 1.86 | 2400 MCM | 7,200 | 83 / 3.27 | G1-1/2" |
| ZZLZ1500 | 1,500 | 2.32 | 3000 MCM | 9,000 | 92 / 3.62 | G1-1/2" |
| ZZLZ2000 | 2,000 | 3.10 | 4000 MCM | 12,000 | 104 / 4.09 | G2" |
| ZZLZ2500 | 2,500 | 3.88 | 5000 MCM | 15,000 | 115 / 4.53 | G2" |
| ZZLZ3000 | 3,000 | 4.65 | 6000 MCM | 18,000 | 126 / 4.96 | G2-1/2" |
Rated current applies with cooling water flowing at an inlet temperature up to 35 °C (95 °F). Values are indicative for selection; the figures for your cable are confirmed on the quotation drawing. Water connections are shown as BSP (G) threads; NPT and metric threads are available on request.
Determined by the conductor cross section and the actual operating conditions at your plant — current, frequency, duty cycle and water temperature.
0.6 MPa (87 psi / 6 bar) on the outer hose. Every assembly is pressure tested before shipment.
10,000 V withstand on the outer hose.
Continuous internal water cooling along the whole length of the conductor.
Suitable for equipment that tilts, swings or vibrates — furnace bodies, electrode arms and moving power connections.
A cold-pressed electrode joint withstands more than 8 t of pull (78 kN / 17,600 lbf), so the cable does not break at the terminal during repeated tilting.
North American plants usually call these cable lugs, terminals or contact pads; European plants call them electrodes or cable end fittings. The four designs below cover almost every installation.
Machined from one solid copper bar on CNC lathes and mills — no contact joints, no welds, no weld seams. Tin-plated surface, low resistance.
Mates with the flange on your heating equipment; quick to fit and remove, with reliable contact over the full face.
Two water-cooled cables share one electrode, connected on a precision-machined taper — reliable contact, easy removal.
Bent copper bar with welded copper tube, passivated surface, tapered conductor connection — easy to dismantle when the hose is replaced.
Screw with lock nut and sealing ring, connected straight into the electrode.
Same sealing arrangement, and the nozzle can be turned to any direction through a full 360° — useful where pipework runs close to the furnace.
Thread sizes G3/8" to G2-1/2" as standard (BSP). NPT threads for North American piping and metric threads are available to drawing.
The standard cable for induction melting. Stranded copper conductor, rubber hose, electrodes in any design.
Technical data →Hollow conductor construction for medium and high frequency equipment.
Technical data →Large hollow flexible cables for vacuum melting and heat treatment plants.
Technical data →Water inside, current outside — the modern replacement for solid stranded cable.
Technical data →Two conductors running coaxially with separate water circuits, for EAF and submerged arc furnaces.
Technical data →Large cross section cables connecting the short network to the electrode arms.
Technical data →The coaxial electrodes are machined from copper and tin plated against corrosion, with the insulating component between them made of PTFE. The two cooling circuits stay separate and the two conductors run coaxially, insulated from each other.
Because the go and return currents run concentrically, the magnetic fields largely cancel: less heat is generated, leakage inductance is lower, electrical losses are lower and transmission efficiency is higher — which is why coaxial construction is chosen for high-current EAF and submerged arc installations.
A hollow cable carries water on the inside and current on the outside. On medium and high frequency equipment this construction reduces the skin effect, cuts the voltage drop, raises current capacity and lowers losses — the ideal replacement for traditional solid stranded cable.
A coil is not selected from a tonnage table; it is designed from the furnace. These are the parameters we work from, and the ones to send us when you ask for a quotation.
| Parameter | Metric | US |
|---|---|---|
| Furnace capacity | t | short tons |
| Power | kW | kW |
| Frequency | Hz | Hz |
| Coil inside diameter (ID) | mm | in |
| Coil outside diameter (OD) | mm | in |
| Coil height | mm | in |
| Number of turns | pcs | pcs |
| Coil pitch | mm | in |
| Copper tube size & wall | mm × mm | in × in |
| Water connection | G thread / mm | NPT / in |
Custom coil dimensions are available according to customer drawings and furnace specifications. Testing includes insulation inspection, helium leak testing, pressure testing and water flow testing.
Data sheets are issued per project, so the document you receive matches the cable, coil or component actually quoted. Tell us which you need and we email it with the quotation.
| Document | Contents | Format | How to get it |
|---|---|---|---|
| Water-cooled cable data sheet | Construction, cross section, current, dimensions, terminals | Request → | |
| Cable terminal dimensions | Pad size, hole pattern, thread and water port | PDF / DWG | Request → |
| Copper coil data sheet | Coil geometry, turns, tube size, insulation | Request → | |
| Installation & maintenance guide | Fitting, water connection, hose replacement | Request → | |
| Pressure test report | Test pressure, holding time, result per item | Supplied with shipment |
Open a product page for photos, applications, FAQs and a direct inquiry form.
Water-cooled power leads, 50–9,000 mm² (1/0 AWG–18,000 MCM).
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Cable lugs and copper heads, cold pressed to the conductor.
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Ceramic insulated copper coils built to furnace drawings.
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Cold-pressed joint over 8 t (17,600 lbf), tapered seal.
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Oxygen-free copper, 99.99% tin coating, cage stranded.
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Laminated shunts and braided jumpers, foil 0.05–0.30 mm.
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KL, GW, GB, GL and CL series for the short network.
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Water-cooled bus tubes, contact pads, transition blocks.
View product →Send us your furnace capacity, current, cable length, terminal dimensions and a photo of the existing cable. Our engineers recommend a suitable configuration and issue the data sheet with the quotation.
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Email: sales@furnacecopperparts.com
