A 10mm² conductor can carry up to 56A (in air) or 45A (in soil), suitable for small-scale residential or commercial branch circuits.
A 120mm² conductor supports up to 210A (in air) or 175A (in soil), ideal for main Power Lines in large residential complexes or medium-sized industrial facilities.
A 240mm² conductor handles up to 325A (in air) or 270A (in soil), designed for heavy-duty applications like power distribution in factories or infrastructure projects.
Conductor Diameter: For a 50mm² aluminum conductor, the diameter of a single strand (Stranded Conductor design) is approximately 2.5mm, with 10 strands twisted together to form the core—providing Flexibility for easy bending during installation. The total diameter of one conductor (including strands) is about 8mm.
Insulation Thickness: The PVC insulation layer has a thickness of 1.0mm–2.2mm, depending on the conductor size. For example, a 16mm² conductor uses 1.0mm insulation, while a 240mm² conductor requires 2.2mm insulation to ensure adequate electrical isolation.
Filler and Binder: The 4-core design requires a non-hygroscopic filler (typically polypropylene rope) to fill the gaps between the Insulated Conductors, ensuring a round cross-section and uniform stress distribution. A polyester binder tape wraps around the filled cores to hold them in place.
Steel Tape Armour: The armour layer uses two layers of galvanized steel tape (thickness: 0.3mm–0.5mm) wrapped in opposite directions for enhanced mechanical strength. This adds 1.5mm–3.0mm to the cable’s diameter.
Outer Sheath: The outer PVC Sheath has a thickness of 1.2mm–2.5mm, providing additional protection against environmental factors.
Operating Temperature: The PVC insulation and outer sheath are rated for a continuous operating temperature of -15°C to 70°C. This allows the cable to perform reliably in cold climates (e.g., northern China, Canada) and warm environments (e.g., Southeast Asia, the Middle East) without losing flexibility or insulation properties. For short-term overloads (up to 2 hours), the cable can tolerate temperatures up to 105°C, providing a safety buffer for peak power demand periods (e.g., summer air conditioning use).
Temperature Cycling Resistance: The cable undergoes rigorous temperature cycling tests (e.g., -40°C to 80°C, 50 cycles) to ensure it does not crack or degrade when exposed to rapid temperature changes—critical for outdoor applications where day-night temperature fluctuations are common.
Moisture and Chemical Resistance: The PVC sheath and insulation are inherently water-resistant, preventing moisture ingress that could cause short circuits. The cable also resists corrosion from common chemicals, such as dilute acids, alkalis, and oils, making it suitable for industrial environments (e.g., factories producing chemicals, food processing plants) and underground installations where soil moisture or minor chemical contamination may occur.
UV Resistance: For outdoor exposed applications (e.g., Overhead Lines in residential areas), the outer sheath is formulated with UV stabilizers to resist degradation from sunlight. This extends the cable’s service life in outdoor environments to 15–20 years, compared to 5–10 years for non-UV-stabilized cables.
Insulation Resistance: Measured using a 1000V megohmmeter, the insulation resistance between conductors (or between conductor and armour) is ≥100MΩ at 20°C. This high resistance prevents current leakage, reducing the risk of electric shock and energy loss.
Withstand Voltage Test: The cable is subjected to a 3kV AC voltage test for 5 minutes (or 4.2kV DC for 15 minutes) without breakdown. This test verifies the insulation’s ability to withstand transient voltage spikes (e.g., from lightning or power surges), a common cause of cable failure.
Short-Circuit Current Rating: The aluminum conductors and steel tape armour are designed to withstand short-circuit currents for up to 5 seconds. For a 120mm² conductor, the short-circuit current rating is approximately 25kA, ensuring the cable does not melt or rupture during short-circuit events—providing time for protective devices (e.g., circuit breakers) to trip and isolate the fault.
Power Loss: The use of high-purity aluminum (99.7% purity) minimizes electrical resistance, reducing power loss during transmission. Compared to low-quality aluminum conductors (with impurities), the YJLV cable’s conductors reduce power loss by 5%–8%, translating to significant energy savings for end-users over the cable’s service life.
Balanced Current Distribution: The neutral conductor carries the unbalanced current between the three phases, preventing voltage fluctuations that could damage sensitive equipment. For example, in a residential complex, if one phase is heavily loaded (e.g., multiple households using air conditioners), the neutral conductor ensures the other phases remain stable, avoiding power outages or equipment failure.
Space and Cost Savings: Using a single 4-Core Cable eliminates the need to install separate Single-Core Cables for each phase and neutral, reducing the number of cables required for routing. This saves space in ducts or cable trays, simplifies installation, and lowers material costs by 20%–30% compared to using multiple single-core cables.
Impact Resistance: The galvanized steel tape can withstand impacts from construction equipment (e.g., excavators, forklifts) or falling debris, preventing damage to the inner insulation and conductors. This makes the cable ideal for direct burial in construction sites or industrial areas where accidental impacts are common.
Rodent and Pest Protection: Rodents (e.g., rats, mice) often chew through unArmoured Cables, causing short circuits and power outages. The steel tape armour acts as a physical barrier, resisting rodent bites and reducing maintenance costs associated with cable repairs.
Structural Stability: The armour layer adds rigidity to the cable, preventing sagging when installed overhead or in vertical runs (e.g., along building walls). This ensures the cable remains securely positioned, even in high-wind environments.
Cost Efficiency: Aluminum is approximately 70% cheaper than copper per kilogram, reducing the cable’s raw material cost by 30%–40%. This cost savings is passed directly to buyers through factory direct pricing, making the YJLV cable an affordable option for large-scale projects (e.g., infrastructure development, residential complexes) with tight budgets.
Lightweight Design: Aluminum has a density of 2.7g/cm³, compared to copper’s 8.9g/cm³. This makes the YJLV cable 60% lighter than Copper Cables of the same current-carrying capacity, simplifying transportation (lower shipping costs) and installation (reduced labor requirements). For example, a 1000m length of 50mm² YJLV cable weighs 350kg, while a copper equivalent weighs 950kg—cutting transportation costs by half.
Corrosion Resistance: The aluminum conductors are treated with an anti-corrosion coating (e.g., zinc or aluminum alloy) to prevent oxidation, ensuring long-term conductivity. This coating also enhances the conductor’s adhesion to the PVC insulation, reducing the risk of insulation separation during installation.
Residential Areas: In residential complexes, the cable is used as the main power line from the community substation to apartment buildings. Its 4-core design supports balanced power supply to households, while the steel tape armour protects against rodent damage in underground or wall-mounted installations. Common sizes used in residential projects are 16mm²–70mm², depending on the number of households and total power demand.
Commercial Buildings: Shopping malls, office towers, and hotels rely on the cable for internal power distribution. The PVC insulation and outer sheath make it suitable for hidden installation in walls, ceilings, or underground ducts, where moisture and minor mechanical impacts are common. For example, a 120mm² cable may be used to power the main electrical panel of a shopping mall, while 25mm² cables supply power to individual stores.
Industrial Facilities: Light industrial facilities (e.g., electronics factories, food processing plants) use the cable to power machinery, conveyors, and auxiliary equipment. The steel tape armour resists damage from workshop debris, while the aluminum conductors’ cost-effectiveness reduces overhead for large-scale installations. Sizes ranging from 50mm²–240mm² are common in industrial settings.
Infrastructure Projects: Street lighting systems, temporary construction site power networks, and rural electrification projects benefit from the cable’s durability and easy installation. The UV-stabilized outer sheath ensures longevity in outdoor environments, while the lightweight design simplifies overhead installation on utility poles. Sizes of 10mm²–50mm² are typically used for infrastructure applications.
Flexibility: Stranded conductors can be bent more easily during installation, reducing the risk of conductor breakage. This is particularly important for applications requiring tight bends (e.g., installation in narrow ducts).
Increased Conductivity: The twisted design reduces skin effect (the tendency of current to flow near the surface of a conductor), improving conductivity compared to solid conductors of the same cross-sectional area.
PVC Resin: The base material, providing insulation properties and mechanical strength.
Plasticizers: Added to improve flexibility (e.g., dioctyl phthalate, DOP), ensuring the insulation remains flexible at low temperatures.
Stabilizers: Prevent PVC degradation from heat and UV radiation (e.g., calcium-zinc stabilizers, which are environmentally friendly and comply with RoHS standards).
Flame Retardants: Reduce the cable’s flammability (e.g., aluminum hydroxide), ensuring it meets flame-retardant standards (e.g., IEC 60332-1 for single-cable flame tests).
High-Density PVC Resin: Provides greater mechanical strength than standard PVC, enabling the sheath to withstand abrasion from rocks, soil, or installation tools.
UV Absorbers and Stabilizers: As mentioned earlier, these additives prevent degradation from sunlight, a critical feature for outdoor applications. The stabilizers also resist thermal aging, ensuring the sheath retains its flexibility and protective properties over decades.
Impact Modifiers: Added to improve toughness, allowing the sheath to withstand low-temperature impacts (e.g., in cold climates where the ground freezes and hardens) without cracking.
Flame Retardants: Consistent with the insulation layer, flame retardants (e.g., magnesium hydroxide) ensure the sheath meets fire safety standards, reducing the spread of flames in the event of a fire.
Aluminum Ingots/Wire Rods: Inspected for purity (via chemical analysis) and mechanical properties (e.g., tensile strength). Only ingots with 99.7% purity are approved for use.
PVC Compounds: Tested for electrical insulation resistance, flexibility, and flame retardancy. Samples of the insulation and sheath compounds are extruded into small strips and subjected to temperature cycling and impact tests.
Steel Tape: Checked for galvanization thickness (via magnetic induction testing) and tensile strength. The tape must have a zinc coating of at least 80g/m² to ensure corrosion resistance.
Aluminum Wire rods are drawn into thin strands (diameter 1.0mm–3.0mm) using a wire drawing machine, which reduces the rod diameter while increasing tensile strength.
PVC compounds are melted and mixed in a banbury mixer to ensure uniform distribution of additives (e.g., plasticizers, stabilizers), creating a homogeneous melt ready for extrusion.
Uniform current distribution across the conductor.
Flexibility for installation.
Mechanical stability (preventing strand separation during handling).
Feeding the stranded conductor into an extruder, where the melted PVC compound is forced through a die (custom-sized for the conductor diameter) to form a uniform insulation layer.
Controlling the extruder temperature (160°C–180°C) to ensure the PVC melts fully without degradation. A temperature sensor monitors the melt, with automatic adjustments if deviations occur.
Cooling the insulated conductor in a water bath (temperature 20°C–30°C) to solidify the PVC, followed by a puller that maintains a constant speed (10m/min–20m/min) to ensure consistent insulation thickness.
Thickness (via laser measurement tools, which check thickness at 12 points around the conductor to ensure uniformity).
Surface quality (no scratches, bubbles, or discoloration).
Insulation resistance (using a megohmmeter to test between the conductor and a metal electrode wrapped around the insulation).
Non-hygroscopic filler (polypropylene rope) is added to the gaps between the conductors to maintain a round cross-section, which is essential for uniform armour and sheath application.
A polyester binder tape is wrapped around the Stranded Core to hold the conductors and filler in place, preventing movement during subsequent steps.
The first layer is wrapped around the core in a left-hand spiral, with an overlap of 20%–30%.
The second layer is wrapped in a right-hand spiral, overlapping the first layer to ensure full coverage.
The cable passes through an extruder with a large die (matching the cable’s final diameter), and the melted PVC sheath compound is extruded over the armour.
The extruded cable is cooled in a water bath (with temperature gradually decreasing from 60°C to 20°C to prevent sheath cracking) and then dried with compressed air.
Thickness (via ultrasonic testing, which can detect internal defects like voids).
Surface quality (no pinholes, which could allow moisture ingress).
Adhesion to the armour (a pull test is performed to ensure the sheath does not separate from the armour).
Electrical Tests: Includes insulation resistance, withstand voltage, and short-circuit current tests (as detailed in Section 1.1.4).
Mechanical Tests: The cable is bent around a mandrel (diameter 10–20 times the cable diameter) to test flexibility, followed by an impact test (a weight is dropped onto the cable to check for sheath/armour damage).
Environmental Tests: Samples of the cable are subjected to temperature cycling (-40°C to 80°C) and humidity testing (95% relative humidity at 40°C) to verify environmental resistance.
Material: Wooden drums are made from high-density plywood (thickness 18mm–25mm) treated with anti-mold chemicals to prevent rot during storage in humid environments. Steel drums (used for larger conductor sizes, e.g., 120mm²–240mm²) are made from galvanized steel, offering greater durability for heavy cables (a 1000m length of 240mm² cable weighs 850kg).
Dimensions: Drum diameter ranges from 600mm (for 10mm²–50mm² cables) to 1200mm (for 120mm²–240mm² cables), with a width of 300mm–600mm. The drum’s flanges (the circular ends) are reinforced with steel rings to prevent bending during lifting.
Protection: The cable is wrapped in a layer of moisture-proof plastic film (polyethylene) before being wound onto the drum, preventing moisture ingress. A layer of heavy-duty kraft paper is then wrapped around the plastic film to protect against abrasion. The drum is labeled with:
Product details (model: YJLV 0.6/1kV, conductor size, length).
Batch number and production date.
Handling instructions (e.g., “Lift only at drum ends,” “Store in dry area”).
Safety warnings (e.g., “Keep away from open flames,” “Do not stack more than 2 drums high”).
Box Material: Double-walled corrugated cardboard (thickness 5mm–8mm) with a bursting strength of ≥1500kPa, ensuring it can withstand stacking and minor impacts.
Interior Protection: The cable is coiled into a compact circle and wrapped in bubble wrap to prevent kinking or abrasion. A moisture-proof sachet (silica gel) is added to the box to absorb any residual moisture.
Labeling: Similar to drum packaging, the box is labeled with product details, batch number, and handling instructions. Sample boxes also include a certificate of analysis (COA) summarizing the cable’s test results.
Indoor Storage: Cables should be stored in a dry, well-ventilated warehouse with a temperature range of -5°C to 40°C and relative humidity ≤75%. Avoid storing near heat sources (e.g., heaters, boilers) or chemicals that could damage the PVC sheath.
Drum Storage: Drums should be placed on level ground, with wooden blocks under the drum ends to prevent rolling. Do not stack drums higher than 2 layers (for wooden drums) or 3 layers (for steel drums) to avoid crushing the lower drums.
Unpacked Cable: If a cable is partially used, the remaining length should be rewound onto the drum and wrapped with the original plastic film to prevent moisture and dust contamination. Unused cables should be inspected for damage (e.g., sheath cracks) before installation.
Trucks: Heavy-duty trucks with flatbed or enclosed trailers. Enclosed trailers are used for long-distance transportation to protect the cable from weather (e.g., rain, snow) and road debris. Flatbed trailers are used for large drum shipments, with the drums secured using steel straps and wooden blocks to prevent movement during transit.
Railway: For very large orders (e.g., ≥100 drums), railway transportation is used, as it is more cost-effective and reduces carbon emissions compared to trucks. Railway containers are equipped with moisture-proof liners to protect the cables.
Container Shipping: Cables are shipped in 20ft or 40ft standard containers. Wooden drums are secured to the container floor using steel bolts to prevent rolling during rough seas. The container is lined with moisture-proof film to protect against saltwater spray.
Bill of Lading (B/L): The factory provides a detailed B/L, including product quantity, weight, dimensions, and destination port. The B/L is used for customs clearance and serves as proof of shipment.
Customs Documentation: The factory assists with preparing all necessary customs documents, including:
Commercial invoice (detailing product value and quantity).
Packing list (itemizing each package’s contents and weight).
Certificate of Conformity (CoC) verifying compliance with the destination country’s standards (e.g., CE for Europe, UL for North America, SABS for South Africa).
Import 许可证 (if required by the destination country).
Cargo Planes: Cables are shipped in air cargo containers, with small-length cables packaged in cardboard boxes and larger lengths in lightweight steel drums.
Speed: Air transportation takes 2–7 days worldwide, making it ideal for time-sensitive projects.
Damage from accidents (e.g., truck collisions, ship grounding).
Loss from theft or natural disasters (e.g., floods, hurricanes).
Damage from improper handling (e.g., dropping a drum during loading).
Standard Orders: For cables with standard specifications (conductor size 10mm²–240mm², length 100m–1000m), production takes 5–10 working days.
Customized Orders: For cables with non-standard specifications (e.g., modified sheath thickness, special color coding), production takes 10–15 working days, as additional time is required to adjust the extrusion dies and test the customized product.
Land Transportation: Tracking via the logistics company’s website (e.g., for China Post or SF Express) or mobile app, with updates on the truck’s location and estimated arrival time (ETA).
Sea Transportation: Tracking via the shipping line’s website (e.g., Maersk Line, Cosco Shipping), with updates on the container’s location (e.g., “At port of origin,” “In transit,” “At port of destination”) and ETA at the destination port.
Air Transportation: Tracking via the airline’s website (e.g., DHL Express, FedEx) or the International Air Transport Association (IATA) tracking system, with updates on flight status and ETA at the destination airport.
Package Integrity: Check for signs of damage to drums or boxes (e.g., broken flanges, torn cardboard, water stains). If the package is damaged, take photos as evidence for insurance claims.
Quantity Verification: Confirm that the number of drums/boxes matches the packing list provided by the factory.
Label Check: Ensure the product details (model, conductor size, length) on the labels match the order specifications.
Laboratory Testing: 1m–5m lengths, suitable for electrical performance tests (e.g., insulation resistance, withstand voltage) or material analysis (e.g., conductor purity, PVC composition).
On-Site Installation Trials: 10m–20m lengths, ideal for testing the cable’s flexibility, ease of installation, and compatibility with existing electrical systems (e.g., connectors, cable trays).
Submit a Sample Request Form: The form requires details such as the desired conductor size, length, quantity of samples, and intended use (e.g., laboratory testing, installation trial).
Confirmation and Quotation: The sales team reviews the request and confirms availability within 2 working days. For customized samples, a quotation for any additional costs (e.g., die adjustments for special insulation thickness) is provided.
Payment (If Applicable): For fee-based samples, the customer makes payment via bank transfer or online payment platforms (e.g., PayPal). For free samples, the customer provides shipping details (address, contact person, phone number).
Production and Shipping: Samples are produced within 3–5 working days and shipped via the customer’s preferred logistics method (e.g., DHL, FedEx). A tracking number is provided once the sample is shipped.
Certificate of Analysis (COA): Summarizes the results of tests conducted on the sample, such as insulation resistance, conductor resistance, flame retardancy, and temperature resistance.
Material Safety Data Sheet (MSDS): Provides information on the hazards, handling, and storage of the cable’s materials (e.g., PVC, aluminum), ensuring compliance with occupational health and safety regulations.
Installation Guide: Includes basic instructions for handling and installing the sample, such as recommended bending radii, termination methods, and compatibility with connectors.
Phone and Email Support: Available 24/7 for urgent issues (e.g., installation errors, performance failures). Engineers can provide real-time guidance, such as correcting termination methods or identifying the cause of a short circuit.
On-Site Support: For large-scale projects (e.g., infrastructure developments, industrial facilities), the factory can dispatch engineers to the customer’s site to provide hands-on assistance. On-site support includes:
Inspecting installation quality (e.g., checking for proper routing, adequate bending radii, secure terminations).
Conducting on-site tests (e.g., insulation resistance checks) to verify the cable’s performance after installation.
Training the customer’s installation team on best practices for handling and maintaining the cable.
Online Resources: The factory’s website features a knowledge base with technical documents, including installation manuals, troubleshooting guides, and frequently asked questions (FAQs). Customers can also access video tutorials on topics such as cable termination and drum handling.
A copy of the delivery acceptance form.
Photos or videos of the defective cable, showing the nature of the issue (e.g., insulation cracking, conductor breakage).
A detailed description of the problem, including when it was discovered and the operating conditions (e.g., temperature, voltage).
Replacement: Providing a new cable of the same specifications to replace the defective one, with the factory covering all shipping and handling costs.
Repair: For minor defects (e.g., small sheath damage), the factory may send a repair kit and provide guidance on fixing the issue on-site.
Refund: In cases where replacement or repair is not feasible, the factory offers a full or partial refund based on the extent of the defect.
Regular Inspections: Conduct visual inspections of the cable every 6–12 months, checking for signs of damage (e.g., sheath cracks, armour corrosion, loose terminations). For Underground Cables, use cable fault locators to detect hidden issues (e.g., insulation breakdown) that may not be visible.
Cleaning: Keep the cable’s surface clean of dust, dirt, and oil, as these substances can degrade the PVC sheath over time. Use a damp cloth to wipe down exposed cables; avoid using harsh chemicals that could damage the sheath.
Temperature Monitoring: For cables used in high-temperature environments (e.g., industrial workshops), install temperature sensors to monitor the cable’s operating temperature. If the temperature exceeds 70°C (the maximum continuous operating temperature), take steps to reduce the load or improve ventilation.
Protection from External Hazards: For Outdoor Cables, ensure they are protected from UV radiation (the factory’s UV-stabilized sheath provides protection, but additional shielding may be needed in areas with intense sunlight). For Underground Cables, avoid digging near the installation route to prevent accidental damage; mark the cable’s location with warning signs or underground markers.
IEC 60502-1: International Electrotechnical Commission standard for low-voltage Power Cables (0.6/1kV), specifying requirements for electrical performance, mechanical properties, and environmental resistance.
IEC 60332-1: IEC standard for flame retardancy, ensuring the cable does not support combustion in the event of a fire.
UL 44: Underwriters Laboratories standard for thermoset-Insulated Wires and cables, applicable for sales in North America.
CE Marking: Compliance with European Union (EU) directives, allowing the cable to be sold and used within the EU and European Economic Area (EEA).
Insulation Resistance Testers: To measure the resistance of the PVC insulation, ensuring no current leakage.
Withstand Voltage Testers: To verify the cable’s ability to withstand high voltage without breakdown.
Tensile Testing Machines: To evaluate the mechanical strength of the aluminum conductors and PVC sheath.
Temperature Cycling Chambers: To test the cable’s performance under extreme temperature changes.
Flame Test Apparatus: To assess the cable’s flame retardancy in accordance with IEC 60332-1.
Hongtai Cable Technology Co., Ltd
Электронная почта: export@qlcables.com
sales@qlcables.com
Тел/WhatsApp:+86-18032066271
Добавить ： Зона промышленного развития Сяоку, округ Нинджин, Сингтай -Сити ， провинция Хэбей, Китай
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