Water Cooled Jumper Cables
Water Cooled Sub / Jumper Cable
Resistance checking of Aid/Sub Cable
Water - Cooled Aid/Sub Cable Final Packing Process
Specification of Water Cooled Jumper / Sub Cable :
1. Design of Cable as per Customers Specification with very less tolerance.
2. Special type of rubber hose with the High flexibility, more than 10 Kg/cm2. Capacity and to protect to high temperature water for safe operation. Excellent cooling effect even in continued welding operation.
3. Copper wire size is 33 Gauge for 300 MCM & 400 MCM as per standard of RWMA.
4. Accurate copper straight lugs or copper bend lug with 99% conductivity of Electrolytic Copper. Little Impedance & little Reactance drop.
5. Fantastic water testing units with Pressure 10 to 12 Kg/cm2, each and every Cable are tested.
6. Good Quality product with Long Life and very competitive rate. Long cable life reduces cable cost per weld - the true measure of cost cable.
7. We have good team of engineers with more than 10 Years experience in same field.
8. Strict Quality Control during production, delivery as per schedule.
9. Easy for check & replacement & maintenance.
10. We have own Quality Assurance Plan of our products.
Water Cooled Jumpers (WJ) come equipped with full length filter tubes, to insure the free flow of water through the entire cable. Bending or kinking will not reduce water flow.
To order cables you need to determine: 1] Type of end 2] Cable Gauge 3] Length
A chart for sizing the correct gauge cable is on the right of the page, as well as guidelines for installation.
Water Cooled Jumper End Styles
Water Cooled Jumper Sizing
Use the following method to determine what size cable should be used for your application. First you use the Conversion Factor chart to determine your “Continuous Duty Current”; then you read the correct size cable off the second chart. An example is worked out below.
Step 1: Lay one side of a straight edge across the graph at the six cycles of current “one time” point (the left hand vertical scale of the conversion factor chart).
Step 2: Pivot the other end of the straight edge across to line up with the “60 welds per minute” on the far right vertical scale.
Step 3: At the intersection of your straight edge with the diagonal conversion factor scale line, you should be able to read a conversion factor of .32 off the lower 1/2 of the line.
Step 4: Multiply the required current (60,000 amps) by the conversion factor (.32) to get the “continuous duty current” of 19,200 amps. Now proceed to the Water Cooled Jumper Selection Chart to read complete the selection.
Step 5: Line up your straight edge on the 19,200 continuous duty amp mark, and find the intersection with your desired length line (from below, we want 60 inches).
Step 6: Any cable whose line is above this point may be safely used, since the load it would carry will be within its thermal capacity. In our case the 1000 MCM cable would be the best match, and will not exceed the design specifications of the jumper cable.
Example Data:
6 cycles of current “on time” per weld
60 welds per minute
60,000 amps per weld
5 ft cable Length
Good Working shapes for Water Cooled Cables
Installation Guidelines
How to install water cooled cables
Water cooled jumpers should always be installed with a bend radii ranging from 90° to 180°. See the chart below for the minimum recommended radii.
It should be noted that jumper life is inversely related to the operating temperature of the cable; the higher the temperature the shorter the life. The recommended operating temperature is 131°F (55°C) or less, and the maximum operating temperatures should not exceed 158°F (70°C). Making sure there is enough water flow is critical for insuring a low operating temperature.
Recommended Minimum Bend Radii:
350 MCM – 400 MCM: 2″
500 MCM – 600 MCM: 3″
750 MCM – 1000 MCM: 4″
Minimum Distance from the end of the hose to the point where the bend radii should start is:
350 MCM – 400 MCM: 2-1/2″
500 MCM – 600 MCM: 3″
750 MCM – 1000 MCM: 3-1/2″
More Specifications
D.C. Resistance of Single Conductor Water Cooled
(and Air Cooled) Cables
Recommended Minimum Gallons/min
WJ (single conductor). . . .2 GPM
UT (dual conductor) . . . .2-1/2 GPM