ZZLZ series flexible water-cooled cables carry the furnace current between the power supply, the short network and the furnace body while cooling water runs through the conductor. Cross sections from 50 to 9,000 mm² (1/0 AWG to 18,000 MCM), any length, any electrode design — made to your drawing or copied from the cable you are replacing.
A water-cooled cable is a flexible high-current conductor with a cooling water circuit inside it. Stranded copper carries the current, water flowing through the cable removes the heat, and a carbon-free rubber hose seals and insulates the assembly. Because the copper runs cool, a water-cooled cable carries several times the current of a dry cable of the same size and stays flexible enough to follow a tilting furnace or a swinging electrode arm.
Large cross section cables connect the short network to the electrode arms, carrying very high current while allowing the arms to lift and swing. They are used mainly on steelmaking electric arc furnaces, ladle furnaces and induction furnaces, and with a high-temperature outer sleeve they also suit submerged arc furnaces.
Every cable is built to order. Send a drawing, the specification, or simply photos and the main dimensions of your existing cable, and we manufacture an identical replacement.
Our cables are in service on melting, heating and remelting plants worldwide.
Large cross section water-cooled cables connect the short network to the electrode arms and carry very high current while the arms lift, swing and rotate. They are used mainly on steelmaking electric arc furnaces, ladle furnaces and induction furnaces, and with a high-temperature outer sleeve they also serve submerged arc furnaces. Click any photo to enlarge.
ZZLZ series, metric and US units side by side. Non-standard sizes between 50 and 9,000 mm² are made to order.
| Model | Cross section (mm²) | US equivalent | Rated current (A) | Cable OD (mm / in) | Water connection |
|---|---|---|---|---|---|
| ZZLZ100 | 100 | 4/0 AWG | 600 | 28 / 1.10 | G3/8" |
| ZZLZ150 | 150 | 300 MCM | 900 | 32 / 1.26 | G1/2" |
| ZZLZ200 | 200 | 400 MCM | 1,200 | 36 / 1.42 | G1/2" |
| ZZLZ300 | 300 | 600 MCM | 1,800 | 42 / 1.65 | G3/4" |
| ZZLZ400 | 400 | 800 MCM | 2,400 | 48 / 1.89 | G3/4" |
| ZZLZ500 | 500 | 1000 MCM | 3,000 | 54 / 2.13 | G1" |
| ZZLZ630 | 630 | 1250 MCM | 3,800 | 60 / 2.36 | G1" |
| ZZLZ800 | 800 | 1600 MCM | 4,800 | 68 / 2.68 | G1-1/4" |
| ZZLZ1000 | 1000 | 2000 MCM | 6,000 | 76 / 2.99 | G1-1/4" |
| ZZLZ1200 | 1200 | 2400 MCM | 7,200 | 83 / 3.27 | G1-1/2" |
| ZZLZ1500 | 1500 | 3000 MCM | 9,000 | 92 / 3.62 | G1-1/2" |
| ZZLZ2000 | 2000 | 4000 MCM | 12,000 | 104 / 4.09 | G2" |
| ZZLZ2500 | 2500 | 5000 MCM | 15,000 | 115 / 4.53 | G2" |
| ZZLZ3000 | 3000 | 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.
Conductor: bare or tin-plated stranded T2 copper. Electrodes: copper bar, CNC machined, tin plated. Insulation between coaxial conductors: PTFE. Outer hose: carbon-free rubber.
Working pressure 0.6 MPa (87 psi). Inlet and outlet nozzles in vertical or 90° form; the 90° nozzle can be turned to any position through 360°. Thread sizes G3/8" to G2-1/2" or to your pattern.
Dielectric strength of the outer hose 10,000 V. Operating frequency from mains 50/60 Hz up to high-frequency equipment. Hollow conductors reduce skin effect and voltage drop at medium and high frequency.
Cross section follows the furnace current; length follows the distance between the power supply and the furnace plus the movement of the arm or the tilting angle; the electrode follows the existing connection on your equipment. Send us the four values below and we will propose the size.
| Furnace / application | Typical current | Usual cross section | Typical electrode |
|---|---|---|---|
| Induction melting, 0.5–3 t | 1,000–3,000 A | 150–500 mm² | Integral or standard |
| Induction melting, 5–15 t | 3,000–8,000 A | 500–1,500 mm² | Integral or flange |
| Induction melting, 20–60 t | 8,000–20,000 A | 1,500–3,000 mm² | Flange or parallel |
| EAF / ladle furnace short network | 20,000–60,000 A | 2,000–9,000 mm² per phase | Flange, coaxial |
| Vacuum & high-frequency equipment | 500–5,000 A | 50–800 mm² hollow | Integral, hollow flexible |
| Your requirement | — | — | — |
Ranges are for orientation only. We recommend the suitable cable size based on your current, frequency, length and furnace configuration.
The electrodes at both ends of a medium frequency furnace cable come in several designs, so the cable matches the connection you already have.
Machined from one solid copper bar on CNC lathes and mills — no contact joints, no welds, no weld seams. Tin-plated surface: neat, durable and low in resistance.
The flange 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. Cable and electrode meet on a precision-machined taper, giving reliable contact and easy removal. The tin-plated surface stays smooth and resists oxidation.
Formed from bent copper bar with a welded copper tube and a passivated surface. The conductor connects on a taper, so the cable is easy to dismantle when the outer hose is replaced — commonly called the union type.
Inlet and outlet nozzles in vertical or 90° form. Both use a screw with lock nut and sealing ring; the 90° nozzle can be turned to any direction through 360°.
Coaxial heads, busbar lugs, drilled copper pads and any pattern you send. If you have no drawing, photos of the old electrode with a few dimensions are enough.
Click any photo to enlarge.
Five families cover almost every furnace. Each is built to your length, cross section and electrode design. Click any photo to enlarge.
Water runs inside, current flows outside. On medium and high frequency equipment this construction reduces skin effect and voltage drop, raises current capacity and lowers losses.
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: less heat generated, lower leakage inductance, lower electrical loss, higher transmission efficiency and lower energy consumption.
The outer hose is carbon-free rubber rated for 0.6 MPa (87 psi) working water pressure and 10,000 V dielectric strength. Hose and electrode are sealed with a dedicated clamp, crimped on purpose-built equipment. Coaxial cable heads are available in several designs for the customer to choose from.
Large hollow flexible cables for vacuum melting and heat treatment plants, built for high current in a tight bending radius inside the equipment.
A hollow cable carries water on the inside and current on the outside. On medium and high frequency equipment it reduces skin effect, cuts voltage drop, raises current capacity and lowers losses — the ideal replacement for traditional solid stranded cable.
Standard water-cooled cables for vacuum furnace power feeds, with electrodes matched to the feed-through on your equipment.
The standard cable for induction melting, and any single conductor cross section between 50 and 9,000 mm² made to your drawing or to your requirement when no drawing exists.
Water-cooled cables are manufactured according to customer drawings, existing cable samples, furnace specifications and terminal dimensions. Most of our export orders are replacements for cables originally supplied with the furnace, and in almost every case photos plus a few measurements are enough for us to reproduce the part.
Our own drawing, tinning, stranding and assembly lines sit in one plant, so urgent replacements move quickly and your furnace goes back into production sooner.
Test records are issued with each shipment. Packing is in fumigation-free wooden cases or on pallets, marked to your instructions.
Click any photo to enlarge.
Tell us about the cable you need, or attach the drawing by email. We reply with price, weight, lead time and packing, normally within 24 hours.
WhatsApp: +86 188 3715 8450
Email: sales@furnacecopperparts.com