Water-Cooled Jumper Cables

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Water-cooled jumper cables FOR SALE from Weld Systems Integrators (WSI) are available for a variety of high-current applications. Our water-cooled jumper cables range from standard resistance welding jumpers to advanced high-frequency coaxial designs. Our cables are equipped with full-length filter tubes to ensure water can flow through the entire cable for maximum efficiency. The rugged construction ensures that acute bending or kinking won’t impede or reduce water flow.

All WSI water-cooled jumper cables are provided in exact lengths as specified. To order cables, you need to determine:

• End Style
• Cable MCM
• Cable Length

A chart for sizing the correct gauge cable is towards the bottom of the page, as well as guidelines for installation. If needed, our in-house engineering team can assist with custom designs and unique customer specifications.

Weld Systems Integrators maintains an inventory of water-cooled jumper cables at our Warrensville Heights, OHIO location. Contact us TODAY for pricing and availability.

End StylesSizingInstallationBrands We Represent

Water-Cooled Jumper Cable – Type B

MCM	A	B	C
350/400	9/16″	1-15/16″	9/16″
500/600	9/16″	1-15/16″	5/8″
750	5/8″	1-3/8″	11/16″
1000	3/4″	1-1/2″	3/4″

Water-Cooled Jumper Cable – Type B-2

MCM	A	B	C	D
350/400	11/16″	1-1/16″	2-11/16″	17/32″
500/600	13/16″	1-3/8″	2-7/8″	17/32″
750	13/16″	1-5/8″	3-1/8″	21/32″
1000	15/16″	1-7/8″	3-1/4″	21/32″

Water-Cooled Jumper Cable – Type B-4

MCM	A	B
350/400	1-3/8″	1/2″
500/600	1-7/8″	5/8″
750	1-7/8″	5/8″
1000	2″	11/16″

Water-Cooled Jumper Cable – Type B-5

MCM	A	B	C	D
350/400	9/16″	1-1/8″	1-1/4″	1/2″
500/600	5/8″	1-1/4″	1-3/8″	5/8″
750	5/8″	1-3/8″	1-3/8″	5/8″
1000	5/8″	1-5/8″	1-3/8″	5/8″

Water-Cooled Jumper Cable – Type B-6

MCM	A	B
350/400	9/16″	1-1/8″
500/600	5/8″	1-1/4″
750	5/8″	1-3/8″
1000	5/8″	1-5/8″

Water-Cooled Jumper Cable – Type B-6 (2-hole)

MCM	A	B
350/400	9/16″	1-1/8″
500/600	5/8″	1-1/4″
750	5/8″	1-3/8″
1000	5/8″	1-5/8″

Water-Cooled Jumper Cable – Type B-7

MCM	A	B
350/400	9/16″	1-1/8″
500/600	5/8″	1-1/4″
750	5/8″	1-3/8″
1000	5/8″	1-5/8″

Water-Cooled Jumper Cable – Type B-9

MCM	A	B	C
350/400	9/16″	2-1/8″	17/32″
500/600	9/16″	2-1/8″	17/32″
750	9/16″	2-5/16″	21/32″
1000	5/8″	2-3/8″	21/32″

Water-Cooled Jumper Cable – Type B-11

MCM	A	B	C	D
350/400	3/8″	2″	1-1/8″	9/16″
500/600	3/8″	2″	1-1/8″	9/16″
750	5/8″	2-1/2″	1-1/2″	7/8″
1000	3/4″	2-1/2″	1-1/2″	7/8″

Use the following method to determine what size water-cooled jumper 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.

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. Conversion Factor & Duty Cycle Chart Water Conversion and Duty Cycle Chart – Production Engineering

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.

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 2.5″
• 500 MCM – 600 MCM 3″
• 750 MCM – 1000 MCM 3.5″

WATER-COOLED JUMPER CABLE BRANDS
Tuffaloy	RWP	Cal Cable	Southwire/Watteredge Products	QuickCable	Tipaloy	Centerline

HTRF Cover Hose

Developed by WATTEREDGE-UNIFLEX to combat the primary cause of water-cooled cable failure: wear through of the outer cover. Often a hose wears through due to abrasion on the welding equipment or production components. HTRF cover hose uses a super high abrasion compound which can outlast other materials 40 to 1 against failure due to abrasion. This compound is integrated into the HTRF cover hose, which is available for all kickless cables and also for water cooled jumpers up to 600 MCM in size.

Also available is a high abrasion thin wall sleeve, which can be mounted over the standard kickless cable hose.

DC Cable / 500 and 650 MCM

Opposed polarity cables for high amperage, direct current applications.

These heavily reinforced, two conductor water cooled cables are primarily used on heavy duty spot welding stations for joining aluminum panels. This cable is designed to operate at welding currents typically in the range of 45,000 to 55,000 amps D.C.

Several design features maximize cable life and are exclusive to these cables:

Stranding is press welded to the terminal to provide the lowest possible electrical resistance properties and a virtually indestructible bond. (Patent # 4,640,982) Opposed polarity for optimum efficiency.

High strength, high temperature teflon reinforced retaining rings throughout the entire cable length. High pressure, impact resistant cover hose.

Still can’t find your Water-Cooled Jumper? Have questions before ordering?

Call Weld Systems Integrators and our Application Engineers will assist you with all your needs!