Water cooled cable terminals are the connection components at the end of a high-current water-cooled cable, used on induction furnaces, vacuum furnaces, electric arc furnaces, ladle furnaces and other high-current industrial equipment. They carry the current, hold the cable mechanically and seal the cooling water circuit.
Our water cooled cable terminals are manufactured from high-conductivity copper and designed for a reliable connection between flexible copper conductors and furnace power equipment. They are supplied for induction furnaces, vacuum furnaces, electric arc furnaces, submerged arc furnaces and other high-current applications.
Depending on the application, a terminal can be supplied with different connection structures, water ports, mounting holes, threaded connections and copper cable configurations. For demanding furnace applications, terminal dimensions and connection geometry are manufactured according to the customer's drawing and cable requirements.
The terminal is joined to the flexible copper conductor by cold pressing, a hydraulic crimping process carried out on dedicated equipment. No soldering and no pre-heating of the copper is involved, so the individual strands are not damaged and the joint stays flexible where the cable moves.
The crimped joint holds the conductor through repeated furnace tilting and pouring, so the cable does not break at the terminal. Tensile strength is designed and tested according to the cable size and your requirements.
Low contact resistance and full-section current transfer between the stranded copper and the copper body, which keeps the joint cool in service.
The connection can be opened again, so a worn outer hose is replaced without scrapping the copper terminal.
The internal terminal structure is machined with a tapered sealing surface. When the copper nut is tightened, the taper provides the electrical connection and the water seal at the same time, giving reliable contact while reducing the risk of coolant leakage at the cable end. The taper bore is precision machined, and the surface can be tin plated so it stays smooth and resists oxidation.
When the water-cooled cable hose has to be replaced, the connection is opened by loosening the copper nut on the terminal. Where the construction and the application allow it, the cable is serviced without replacing the complete copper terminal.
| Product | Water-cooled cable terminal / copper cable head |
|---|---|
| Main material | High-conductivity copper |
| Copper grade | T2 / C11000 / as specified |
| Connection method | Cold-pressed, hydraulic crimping |
| Conductor | Flexible stranded copper cable |
| Cooling medium | Water, internal cooling passage |
| Terminal type | Flat, flanged, threaded or to drawing |
| Surface | Bare copper or tin plated |
| Sealing structure | Tapered sealing face with copper nut |
| Hose connection | Stainless steel clamp, crimped on dedicated equipment |
| Outer hose | Carbon-free, non-conductive rubber hose |
| Water connection | To drawing |
| Mounting holes | Diameter and spacing to drawing |
| Rated current | Designed according to conductor cross section, operating frequency, cooling conditions and furnace requirements |
| Testing | Dimensional, electrical resistance, water pressure and leakage |
| OEM / drawing service | Available |
Rated current is not a fixed figure: it follows the conductor cross section, the operating frequency, the cooling water conditions and the furnace requirements. Send us those values and we confirm the terminal on the quotation drawing.
| Cable cross section | US equivalent | Typical application |
|---|---|---|
| 400–800 mm² | 800–1,600 MCM | Small induction furnace |
| 800–1,200 mm² | 1,600–2,400 MCM | Induction heating / melting |
| 1,200–2,000 mm² | 2,400–4,000 MCM | Medium induction furnace |
| 2,000–3,000 mm² | 4,000–6,000 MCM | Large induction furnace |
| 3,000–4,000 mm² | 6,000–8,000 MCM | High-current furnace |
| 4,000–5,000 mm² | 8,000–10,000 MCM | High-power furnace |
| 5,000 mm² and above | 10,000 MCM and above | Heavy-duty furnace, customised |
Reference values only. There is no fixed relationship between cross section and furnace tonnage — actual selection depends on current, frequency, cooling water conditions and the bending required in service.
Copper water cooled cable terminals for induction furnaces and vacuum furnace power connections. Available with customised copper plates, threaded connections, water fittings and mounting holes. Click any photo to enlarge.
Tin-plated copper terminals for applications that need extra surface protection and a reliable electrical connection. Terminal dimensions, connection holes and water fittings are customised to the cable and equipment design.
High-conductivity copper terminals for induction furnaces, high-frequency heating equipment and vacuum furnace applications. Custom terminal dimensions and connection configurations are available.
Heavy-duty copper water cooled cable terminals for electric arc furnaces, submerged arc furnaces and other high-current furnace systems. The design is customised for large cross section cables and high-current connections.
Connect flexible high-current cables between the power supply, capacitor bank, busbar and the induction furnace.
Water-cooled cable assemblies for vacuum and high-temperature systems where conductivity and reliable cooling are both required.
Heavy-duty terminals for high-current connections in EAF systems and other demanding steelmaking applications.
Water-cooled power cables with customised copper terminals for high-current connections on submerged arc plants.
LF and secondary metallurgy equipment, where high current and mechanical flexibility are both needed.
Connections inside power cabinets, transformers and short networks where a water-cooled joint is required.
Each terminal is inspected according to the customer's technical requirements.
We manufacture customised water cooled cable terminals according to customer drawings, samples and technical requirements. Send us your cable drawing, terminal drawing or the existing sample, and our engineers develop a suitable terminal for your furnace.
Where no drawing exists, photos of the old terminal with a few measured dimensions are enough for us to prepare a manufacturing drawing for your approval.
Looking for a replacement water cooled cable terminal, or a complete water-cooled cable assembly? Send us your drawing, cable size, current rating, furnace type, terminal dimensions or the existing sample.
WhatsApp: +86 188 3715 8450
Email: sales@furnacecopperparts.com