1. Product-Specific Information
1.1 Specification Parameters
The 10, 20, and 35 kV
XLPE Insulated Cables with specifications 1x185mm² and 1x300mm², available in models N2XS2Y and NA2XS2Y, are engineered to meet the demanding requirements of medium to high-voltage power transmission systems. These single-
Core Cables are designed with precise parameters to ensure reliable performance across various applications.
For the 1x185mm² conductor size, the current-carrying capacity varies with the voltage rating. At 10kV, it can handle approximately 310A to 360A under standard underground installation conditions (ambient soil temperature of 25°C, thermal resistivity of 1.5 K·m/W). For 20kV applications, the capacity ranges from 300A to 350A, and at 35kV, it is slightly lower at 290A to 340A due to increased insulation thickness and associated thermal considerations. This size is well-suited for medium-load scenarios such as urban distribution branch lines and mid-sized industrial power circuits.
The 1x300mm² conductor, with its larger cross-sectional area, offers higher current-carrying capacities. At 10kV, it can carry 440A to 500A; at 20kV, 430A to 490A; and at 35kV, 420A to 480A under the same installation conditions. This makes it ideal for heavy-load applications including large industrial transmission lines and renewable energy power collection systems.
The voltage ratings of 10kV, 20kV, and 35kV correspond to phase-to-phase voltages, with phase-to-ground voltages of 5.77kV, 11.54kV, and 20.2kV respectively. These ratings ensure compatibility with standard medium-voltage power systems globally, adhering to international standards such as IEC 60502 and ASTM D1248.
Insulation thickness varies with voltage to provide adequate electrical isolation. For
10kv Cables, the XLPE insulation thickness is typically 4.0mm to 4.5mm; for 20kV, 5.0mm to 5.5mm; and for 35kV, 6.0mm to 6.5mm. This progressive increase in thickness ensures that each cable can withstand its respective voltage level, with a dielectric strength of 20kV/mm to 30kV/mm, preventing electrical breakdown.
The
Copper Conductors are made from high-purity electrolytic copper (99.9% pure) with a conductivity of at least 58 MS/m at 20°C, minimizing resistive losses. The conductors are stranded in a class 2 configuration, enhancing
Flexibility for easier installation in confined spaces.
Overall cable dimensions differ based on conductor size and voltage. The 1x185mm² cable has an outer diameter ranging from 38mm to 45mm (10kV to 35kV), while the 1x300mm² cable measures 45mm to 52mm in outer diameter across the voltage range. Weight per meter ranges from 4.8kg to 5.5kg for 1x185mm² and 6.5kg to 7.2kg for 1x300mm², influencing handling requirements but remaining manageable with standard equipment.
The minimum bending radius for fixed installations is 12 times the outer diameter, ensuring flexibility during installation without damaging the cable structure. For example, a 35kV 1x300mm² cable with a 52mm outer diameter has a minimum bending radius of 624mm.
1.2 Special Features and Applications
These cables offer a range of special features that make them versatile across numerous applications in medium to high-voltage power transmission.
A key feature is the XLPE insulation, which provides superior thermal stability compared to traditional materials like polyethylene or paper. XLPE can operate continuously at 90°C and withstand short-term overloads up to 130°C, making it suitable for high-demand scenarios. Its cross-linked molecular structure resists melting and flow, ensuring long-term performance even under thermal stress. This thermal resilience is particularly valuable in industrial environments where equipment may draw high currents intermittently.
The N2XS2Y and NA2XS2Y models incorporate a copper
Tape Shield, which serves dual purposes: equalizing electric field distribution around the conductor to prevent insulation degradation from field concentration, and providing electromagnetic interference (EMI) shielding. This EMI protection is crucial in areas where cables are routed near communication lines or sensitive electronic equipment, such as in smart grid installations or industrial control systems.
The PVC outer sheath offers excellent mechanical protection, with high resistance to abrasion, impact, and corrosion. This makes the cables well-suited for underground installations, where they may encounter rocky soil, chemical exposure, or physical damage during installation. The sheath also provides flame-retardant properties, meeting IEC 60332-3 standards to limit fire spread in case of faults.
In terms of applications, the 10kV 1x185mm² cable is widely used in urban distribution networks, connecting substations to residential and commercial areas. Its medium current capacity efficiently serves these moderate-load environments. The 10kV 1x300mm² variant is employed in larger urban zones or industrial estates with higher power demands.
The 20kV cables are commonly deployed in industrial parks and manufacturing facilities. The 1x185mm² size powers medium-sized industrial equipment, while the 1x300mm² variant handles larger machinery and multiple production lines. Their ability to transmit higher voltage reduces current levels, minimizing energy losses over longer distances within the facility.
35kv Cables find extensive use in renewable energy projects. The 1x185mm² cable connects groups of wind turbines or solar panels to collection points, while the 1x300mm² cable transmits power from these collection points to grid connection substations. Their robust construction withstands the harsh environmental conditions typical in renewable energy installations, including temperature extremes and exposure to elements.
Other applications include infrastructure projects such as airports, seaports, and large commercial complexes. The 35kV 1x300mm² cable is often used as the main power feeder in these facilities, ensuring reliable supply to critical systems. The 20kV 1x185mm² cable may serve secondary distribution within these complexes, powering lighting, HVAC, and other auxiliary systems.
The cables are also suitable for rural electrification projects, where 10kV and 20kV variants can extend power grids to remote areas. Their durability reduces maintenance needs in locations with limited access, ensuring consistent power supply to communities and agricultural operations.
1.3 Material Selection and Styles
Material selection for these cables is critical to their performance, with each component chosen for specific functional requirements.
The conductors use high-purity electrolytic copper due to its exceptional conductivity and ductility. Copper's conductivity minimizes energy loss during transmission, while its ductility allows stranding into
Flexible Conductors that resist fatigue during installation and operation. The stranding process combines multiple fine wires to create a conductor that balances flexibility with current-carrying capacity, ensuring efficient heat dissipation through increased surface area.
XLPE insulation is selected for its superior electrical and mechanical properties. Produced through either chemical (peroxide) or radiation cross-linking, XLPE forms a three-dimensional molecular structure that enhances thermal stability and
Chemical Resistance. This structure prevents the insulation from softening at high temperatures, a common issue with non-cross-linked polyethylene. XLPE also exhibits low water absorption, critical for underground applications where moisture exposure is constant, maintaining insulation integrity over decades.
The
Copper Tape Shield is made from high-conductivity copper (minimum 99.5% pure) with a thickness of 0.1mm to 0.3mm. The tape is helically wrapped with 15-25% overlap to ensure continuous electrical contact, providing a low-impedance path for fault currents. This ensures rapid operation of protective devices during faults, minimizing downtime and potential damage.
The inner lining, between the shield and outer sheath, is typically a semi-conductive or non-conductive polyethylene layer. It protects the shield from mechanical damage during sheath extrusion and ensures a smooth interface, preventing sheath material from penetrating the shield overlap.
The PVC outer sheath is formulated for underground use, with additives to enhance UV resistance, chemical resistance, and mechanical strength. The PVC compound meets RoHS standards, ensuring environmental safety during its lifecycle.
The two models offer distinct styles: N2XS2Y is non-armored, relying on the
PVC Sheath for mechanical protection, making it lighter and more flexible for installation in ducts or protected trenches. NA2XS2Y includes a galvanized
Steel Tape armor layer between the shield and sheath, providing enhanced protection against crushing and impact, suitable for direct burial in rocky or high-risk environments.
Both models are available with optional features such as water-blocking tape or jelly to prevent water ingress in case of sheath damage, critical for maintaining insulation performance in wet environments.
1.4 Manufacturing Process
The manufacturing process of these cables involves precision engineering and rigorous quality control to ensure consistent performance.
Conductor production begins with high-purity copper rods, which are drawn through dies to form wires of specific diameters. These wires are then stranded using a basket or planetary strander, twisting them in a controlled pattern to form the 1x185mm² or 1x300mm² conductor. The stranding lay length is optimized—typically 12-20 times the conductor diameter—to balance flexibility and structural stability.
Next, a semi-conductive layer is extruded over the conductor. This layer, composed of carbon-black filled polyethylene, is applied using a cross-head die to ensure uniform thickness (typically 0.5mm to 1.0mm). It eliminates air gaps between the conductor and insulation, reducing electric field stress that could cause partial discharges.
XLPE insulation extrusion follows, with the
Insulation Material (either peroxide-containing for chemical cross-linking or pure for radiation cross-linking) fed into an extruder. The molten XLPE is applied over the semi-conductive layer via a precision cross-head die, ensuring concentricity and consistent thickness. For 10kV cables, the insulation is extruded to 4.0-4.5mm; 20kV to 5.0-5.5mm; and 35kV to 6.0-6.5mm.
Cross-linking then occurs: chemical cross-linking involves passing the cable through a vulcanization tube at 200-250°C, activating peroxides to form cross-links. Radiation cross-linking uses an electron beam accelerator to induce cross-linking without heat. Both processes transform the thermoplastic XLPE into a thermoset material with enhanced properties.
After cross-linking, the copper tape shield is applied using a wrapping machine that helically wraps the tape with precise tension and overlap (15-25%). The tape edges may be bonded with heat or adhesive to ensure electrical continuity.
For NA2XS2Y models, a galvanized steel tape armor is applied over the shield. The steel tape is wrapped with 10-15% overlap and may be bonded to prevent unraveling.
The inner lining (if present) is extruded next, followed by the PVC outer sheath. The PVC compound is melted in an extruder and applied over the previous layer, then cooled in a water bath to solidify. The sheath is sized to ensure consistent outer diameter and wall thickness.
Throughout production, quality control checks include measuring conductor resistance, insulation thickness, and dielectric strength. Samples undergo impulse voltage testing (10kV: 75kV, 20kV: 125kV, 35kV: 200kV) and thermal aging tests to validate performance over the 30+ year design life.
1.5 Production Standards Compliance
These cables comply with multiple international standards to ensure global acceptability and performance. They meet IEC 60502-2 for
Power Cables with rated voltages from 6kV to 30kV, covering construction, testing, and performance requirements. For North American markets, they adhere to ASTM D1248 for polyethylene materials and ICEA S-94-649 for medium-
Voltage Cables.
Flame retardancy meets IEC 60332-3-22 for vertical flame propagation, ensuring safety in fire scenarios. The cables are also RoHS compliant, restricting hazardous substances to protect environmental and human health.
2. General Product Information
2.1 Packaging
Packaging is designed to protect the cables during storage, transportation, and handling, ensuring they reach customers in pristine condition.
Cables are wound onto sturdy reels, available in wooden or steel construction. Wooden reels, made from high-density plywood, are used for shorter lengths (up to 500m) and offer a cost-effective solution with good strength-to-weight ratio. Steel reels, constructed from galvanized steel, handle longer lengths (500m to 1000m) and provide superior durability for heavy cables, especially 1x300mm² variants.
Reel dimensions vary by cable size and length: 1x185mm² cables use reels with 800mm to 1200mm flange diameters, while 1x300mm² cables require 1200mm to 1600mm flanges. The reel core diameter is sized to maintain the cable's minimum bending radius during winding, preventing insulation damage.
Cables are secured to reels with galvanized steel strapping at 300mm intervals, ensuring tight winding to prevent movement during transit. A moisture-resistant barrier, consisting of polypropylene film and kraft paper, wraps the cable to protect against dust, moisture, and UV radiation—critical for outdoor storage.
Each reel features a label with comprehensive information: cable type, voltage rating, conductor size, model (N2XS2Y/NA2XS2Y), length, batch number, manufacturing date, and compliance standards. Handling instructions include maximum reel weight, lifting points, and warnings against dropping or improper storage.
For smaller quantities, cables are supplied in coils of 50m, 100m, or 200m. Coils are wrapped in heavy-duty plastic film and placed in corrugated cardboard boxes with foam inserts to prevent damage. Boxes include the same labeling as reels for easy identification.
2.2 Transportation
Transportation procedures ensure safe delivery of cables to various destinations, considering their size, weight, and sensitivity to environmental conditions.
For road transport, reels are loaded onto flatbed trucks or trailers using forklifts or cranes, with lifting points marked on each reel. Reels are secured with chains and ratchet straps to the truck bed, with wooden blocks placed between reels to prevent shifting. Trucks equipped with air suspension minimize vibration, reducing the risk of internal cable damage or strapping loosening.
Rail transport is preferred for long-distance domestic shipments, with reels loaded into covered railcars. Similar securing methods as road transport are used, with additional bracing to withstand rail vibrations. Rail transport offers cost efficiency for large quantities and reduces carbon footprint compared to road transport.
International shipments use 20ft or 40ft shipping containers. Reels are loaded using container cranes, with smaller reels stacked (where possible) to maximize space. Each reel is secured to container floor points using twist locks or steel straps. Containers may include desiccant packs to control moisture, especially for shipments to humid climates.
Temperature control is critical during transport: in hot climates, trucks and containers are shaded or equipped with ventilation to prevent PVC sheath softening (PVC softens above 60°C). In cold climates, insulation ensures temperatures remain above -20°C to prevent PVC brittleness.
Transport documentation includes a detailed packing list, bill of lading, and certificate of compliance, facilitating customs clearance for international shipments. Tracking systems provide real-time location updates, allowing customers to monitor delivery progress.
Upon delivery, a receipt is signed acknowledging receipt condition, with any visible damage noted to facilitate claims processing if necessary.
2.3 Shipment and Delivery
The shipment and delivery process is structured to ensure timely and efficient distribution, with flexibility to meet customer project schedules.
Order processing begins with order confirmation, including verification of cable specifications, quantities, and delivery details. Production scheduling aligns with customer timelines, with standard lead times of 2-4 weeks for stock items and 6-8 weeks for custom configurations.
Once production is complete, cables undergo final inspection before packaging. Customers receive a pre-shipment notification with estimated dispatch date, tracking information, and delivery window. For large orders, partial shipments may be arranged to align with project milestones, with clear documentation of remaining quantities.
Delivery coordination includes confirming on-site receiving capabilities, such as crane availability for unloading reels. Delivery personnel are trained to assist with safe unloading, ensuring reels are placed in designated storage areas to prevent damage.
In case of delivery delays (due to weather, logistics issues, etc.), customers are notified promptly with revised timelines. The company maintains buffer stock for common configurations to mitigate delays for urgent orders.
After delivery, a confirmation is sent, including delivery receipt and any required documentation (installation guides, test certificates). This closes the shipment cycle while providing a reference for future support.
2.4 Samples
Sample provision allows customers to evaluate cable quality and performance before placing large orders, supporting informed purchasing decisions.
Samples are typically 1-5m lengths of cable, including all layers (conductor, semi-conductive layer, XLPE insulation, shield, sheath) to represent the full product. They are available for all combinations of voltage, conductor size, and model.
Sample requests can be submitted through the company’s website, email, or sales representatives, with a typical processing time of 3-5 business days. A nominal fee may apply for samples, which is refundable upon placement of a full order exceeding a specified quantity (usually 1000m or more).
Each sample is packaged in a labeled cardboard box with a test report detailing key parameters such as conductor resistance, insulation thickness, and dielectric strength. This allows customers to conduct their own tests, such as bending trials, flame resistance checks, or chemical exposure tests, to validate suitability for their specific applications.
For specialized testing requirements, the company can arrange third-party laboratory certifications (e.g., from UL or VDE) at an additional cost, providing customers with independent verification of performance.
2.5 After-Sales Service
Comprehensive after-sales service ensures customer satisfaction and long-term performance of the cables, with support spanning installation, operation, and maintenance.
Technical support is available via a dedicated hotline, email, or on-site visits. A team of qualified engineers provides guidance on cable installation, including proper handling, bending, and termination techniques. They can also assist with system design, helping customers select the appropriate cable model and size based on load calculations and environmental conditions.
The cables come with a standard 10-year warranty covering defects in materials and workmanship. Warranty claims are processed by a dedicated team, which reviews documentation (proof of purchase, installation records) and may conduct on-site inspections to determine the cause of issues. Repairs or replacements are arranged promptly, with minimal disruption to the customer’s operations.
For installations requiring periodic maintenance, the company offers inspection services, including insulation resistance testing, partial discharge measurement, and sheath integrity checks. These services help identify potential issues early, extending the cable’s service life and preventing unplanned downtime.
In the event of a cable failure, the company provides troubleshooting support to determine the root cause, whether due to installation errors, external damage, or material issues. This includes analysis of failed components and recommendations to prevent recurrence.
Customer feedback is actively solicited through post-delivery surveys and regular account reviews. This input is used to improve product design, manufacturing processes, and service quality, ensuring continuous enhancement of the product offering.
Training programs are available for customer personnel, covering cable handling, installation best practices, and maintenance procedures. These programs can be conducted on-site or at the company’s training facilities, equipping customers with the knowledge to maximize cable performance and safety.
3. Environmental and Safety Considerations
3.1 Environmental Impact
The cables are designed with environmental sustainability in mind, from material selection to end-of-life disposal.
XLPE insulation is free from toxic additives such as lead or cadmium, and the PVC sheath is formulated to meet RoHS standards, restricting the use of hazardous substances. This reduces environmental impact during production, use, and disposal.
The copper conductors are fully recyclable, with a high recycling rate (over 90%) at the end of the cable’s service life. Steel armor (in NA2XS2Y models) is also recyclable, contributing to a circular economy approach.
Manufacturing processes are optimized to minimize energy consumption and waste. Cross-linking by radiation (where used) reduces energy use compared to chemical cross-linking, while extrusion processes employ efficient heating systems to lower carbon emissions.
The cables’ long service life (30+ years) reduces the frequency of replacement, minimizing material consumption and waste generation over time.
3.2 Safety Standards
Safety is a paramount consideration, with the cables meeting rigorous international safety standards to protect personnel and property.
Electrical safety is ensured through compliance with IEC 60502-2, which specifies requirements for insulation strength, impulse withstand voltage, and short-circuit current handling. This prevents electrical hazards such as shock, fire, or equipment damage.
Mechanical safety features include the robust PVC sheath and (in NA2XS2Y models) steel armor, which protect against physical damage that could expose live conductors. The cables are tested for impact resistance, crush resistance, and abrasion resistance to ensure they can withstand installation and operational stresses.
Flame safety is addressed through compliance with IEC 60332-3-22, which measures vertical flame propagation. The cables’ flame-retardant properties limit fire spread, providing valuable time for evacuation and fire suppression in case of a fault.
Installation safety is supported by clear handling instructions, which include guidelines for lifting, bending, and termination to prevent accidents. The company also provides training on safe installation practices to minimize risks during deployment.
4. Conclusion
The 10, 20, and 35 kV
XLPE Insulated Cables (1x185mm², 1x300mm², N2XS2Y, NA2XS2Y) represent a versatile and reliable solution for medium to high-voltage power transmission. Their precise specification parameters, high-quality materials, and robust construction ensure performance across a wide range of applications, from urban distribution networks to industrial facilities and renewable energy projects.
The combination of XLPE insulation, copper conductors, and protective sheathing provides excellent electrical, thermal, and mechanical properties, while compliance with international standards ensures global acceptability. General product information, including packaging, transportation, and after-sales service, is designed to support customers from order placement to long-term operation, ensuring a seamless experience.
With a focus on sustainability and safety, these cables not only meet current industry demands but also anticipate future requirements for efficiency, reliability, and environmental responsibility. Whether for new installations or network upgrades, they offer a cost-effective solution that balances performance, durability, and ease of use.
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