1. Fatigue Fracture of Internal Copper Strands
Fatigue fracture of internal copper strands is one of the most common faults of water-cooled cables. The main manifestations are that the appearance may be intact or partially bulging and hard, however, the power supply is difficult to start, and overcurrent/overvoltage occurs when the power is increased. In serious cases, the core may be broken, sparks may occur, and the terminals may be burned.
How to resolve the fatigue fracture of internal copper strands ?
Extend the water cable to increase the bending radius.
Install flexible sheath/anti-bending cover.
Reduce unnecessary tilting angles.
2.Outer skin damage
The main manifestations of outer skin damage include cracks and trachoma in the hose, which are mainly caused by aging or mechanical damage of the hose, such as friction, extrusion, scratches by sharp objects, and burns by high-temperature welding slag. The outer skin damage will cause water and electricity leakage.
How to resolve the outer skin damage ?
The water-cooled cables must be suspended with insulating materials during operation. This prevents dragging and abrasion on the ground during lifting and lowering operations,keeps them away from wet or damp surfaces, and avoids contact with falling magnetic inductive materials, thereby reducing the likelihood of cable accidents.
3. Connecting Terminals Heating, Sparking and Oxidation
The main manifestations of connecting terminals heating, sparking and oxidation are discoloration, blackening, thick oxide layer and melting pits, which maybe caused by loose bolts, vibration, dirty contact surfaces, or loose terminal crimping.
How to resolve the connecting terminal heating, sparking and oxidation ?
Tighten the bolts evenly and diagonally according to the torque requirements and install anti-loosening washers.
Use sandpaper/wire brush to polish the contact surface until it is bright and free of oxidation.