1-core 1×240mm² YJV: Used for hospital backup generator connections, where high current (380A at 30°C) is needed to power the entire facility during outages.

2-core 2×185mm² YJLV: Powers elevator motors (15–20kW) in high-rises, with the two cores handling single-phase power and reducing cable count in elevator shafts.

3-core 3×95mm² YJV: Supplies three-phase power to shopping mall HVAC chillers (50–75kW), eliminating the need for separate neutral conductors.

4-core 4×50mm² YJLV: Distributes power to residential apartments, with three phase cores and one neutral core supporting mixed single/three-phase loads.

5-core 5×120mm² YJV: Used in data centers, with a dedicated earth core minimizing electrical interference for sensitive IT equipment.

Fillers: Polypropylene ropes (0.5–2mm diameter) are used to fill gaps between cores in Multi-Core cables. These ropes are UV-stabilized and moisture-resistant, preventing core shifting during installation and reducing sheath stress. In 4-core 4×50mm² cables, for example, fillers create a round core that fits standard 50mm conduits, eliminating the need for custom-sized conduits.

Binder Tape: A 0.1mm polyester tape is wrapped around the twisted cores to hold them in place. The tape is heat-resistant (up to 120°C) and tear-resistant, preventing core separation during cable pulling— a common issue in long conduit runs (100+ meters).

Jacket Adhesion: The PVC sheath is extruded with a 0.05mm adhesive layer that bonds to the underlying insulation, preventing delamination. This is critical in dynamic installations (e.g., elevator cables that move up/down 100m) where delamination could expose cores to moisture.

Aluminum/Copper Rods: Aluminum rods for YJLV are sourced from Canadian/Australian refineries (99.7% purity); copper rods for YJV from Chilean mines (99.95% purity). Each batch is tested for conductivity with a micro-ohmmeter: aluminum must meet 37 MS/m, copper 58 MS/m. Rods with impurities (e.g., iron >0.01%) are rejected, as they can increase resistance and cause overheating in enclosed building spaces.

XLPE Compound: A custom blend with 2% dicumyl peroxide (cross-linking agent) and 1% antioxidant (to prevent thermal degradation). QC tests melt flow rate (MFR) at 190°C: 0.5–1.0 g/10min ensures uniform extrusion around conductors—critical for avoiding insulation thin spots that could fail in high-voltage tests.

PVC Sheath Compound: Mixed with 32% magnesium hydroxide, 5% zinc oxide, and 2% plasticizer (for flexibility). Samples are tested for flame retardancy (per IEC 60332-1-2) and smoke density (per IEC 61034) before production—only batches meeting V-0 and 40% light transmittance are approved.

Drawing: Rods are pulled through diamond dies (12mm → 0.8mm diameter) at 20–40 m/min (slower for aluminum to prevent cracking). After drawing, wires are annealed (300–400°C for 1 hour) to restore flexibility—QC checks wire diameter with a laser gauge (tolerance ±0.01mm) to ensure consistent stranding.

Stranding: Wires are twisted in a Class 2 pattern (7 wires for 16mm², 61 wires for 240mm²) with a stranding pitch of 12–16× conductor diameter. QC measures strand resistance: a 4×120mm² YJLV conductor must have ≤0.153 Ω/km at 20°C—any deviation indicates poor stranding and potential power loss.

Extrusion: Conductors are fed into a single-screw extruder (180–200°C) with a die head tailored to insulation thickness (0.7mm for 16mm², 1.5mm for 240mm²). A laser thickness gauge checks insulation at 10 points per meter—thin spots<0.6mm are rejected, as they risk dielectric breakdown.

Cross-Linking: Insulated Conductors pass through a continuous vulcanization (CV) tube (180–200°C, 1.5 MPa steam) to cross-link XLPE molecules. QC tests gel content (≥75%) via solvent extraction—low gel content (<70%) means poor thermal stability, which is unacceptable for building cables.

Color Coding: Insulated conductors are coated with UV-resistant pigments (0.05–0.1mm thick) in a secondary extruder. QC checks color fastness via a 100-hour UV test—fading >5% means the pigment will degrade in sunlight (e.g., rooftop installations), making core identification difficult during maintenance.

Core Twisting: Colored cores are twisted with polypropylene fillers and wrapped in polyester tape. The twisting direction alternates (left/right) to reduce cable torsion—QC measures core roundness (tolerance ±0.5mm) to ensure compatibility with standard conduits.

Extrusion: Cores are fed into a twin-screw extruder (160–180°C) with a sheath thickness of 1.2mm (16mm²) to 2.5mm (240mm²). A vacuum sizing sleeve ensures uniform diameter—QC checks sheath thickness with a caliper (tolerance ±0.1mm) to prevent thin spots that could tear during installation.

Cooling: Sheathed Cables pass through a water tank (20–25°C) to solidify PVC. QC checks adhesion by peeling the sheath—bond strength >5N/cm means no delamination in dynamic applications.

Conductor Resistance: Micro-ohmmeter test at 20°C—4×120mm² YJLV must be ≤0.153 Ω/km to ensure minimal power loss in apartment distribution.

Insulation Resistance: 2.5kV megohmmeter test—≥100 MΩ/km ensures no short circuits in wet building spaces (e.g., basements).

High-Voltage Test: 3.5kV AC for 5 minutes—no breakdown means insulation can withstand voltage surges from building generators.

Flame Retardancy Spot Test: Random samples undergo IEC 60332-1-2—failure results in batch quarantine, as fire safety is non-negotiable for buildings.

Precision Cutting: Computer-controlled machines trim cables to customer lengths (10m–1000m) with ±0.5% accuracy. For residential projects, 500m spools of 4×50mm² YJLV reduce on-site waste by 20% vs. 1000m spools.

Spooling: Cables are wound onto wooden or steel spools, depending on cable size and customer needs. For cables ≤120mm² (e.g., 4×50mm² YJLV), 600–800mm diameter wooden spools are used—these are lightweight (15–20kg per spool) and easy to handle on construction sites with limited lifting equipment. For larger cables ≥150mm² (e.g., 3×240mm² YJV), 1000–1250mm diameter steel spools are preferred, as they can support the heavier cable weight (up to 200kg per spool) without warping. Each spool is wrapped with a layer of non-woven fabric between cable layers to prevent abrasion during storage and transportation, and labeled with clear product information: cable type (YJV/YJLV), core configuration (e.g., 4×120mm²), length (e.g., 500m), batch number, production date, and compliance marks (CE, CCC, UL). This labeling ensures full traceability—if a quality issue arises during installation, the batch can be quickly identified and investigated.

Main Power Distribution: 4×50mm² YJLV cables serve as the backbone of residential power systems, distributing power from the building’s main substation to each apartment’s electrical panel. A single 4×50mm² YJLV cable can support 8–10 apartments (each with a typical 15–20A load), thanks to its 150A current rating at 30°C ambient temperature. The aluminum conductor reduces material costs by 30–40% compared to copper, which translates to \(5,000–\)10,000 in savings for a 500-unit complex.

Appliance Wiring: 2×4mm² YJLV cables power high-wattage household appliances like electric water heaters (2–3kW) and split-system air conditioners (1.5–2.5kW). The Class 2 stranding allows the cable to be routed through narrow wall cavities (often just 20–30mm wide) behind appliances, eliminating the need to widen walls—a major time-saver in retrofits. The flame-retardant PVC sheath also adds a layer of safety: if an appliance overheats and ignites, the sheath self-extinguishes, preventing the fire from spreading to surrounding walls.

Lighting and Small Loads: 1×2.5mm² YJLV cables are used for general lighting circuits and small devices (e.g., refrigerators, televisions). These cables are lightweight (0.15kg/m) and flexible, making them easy to install in ceiling voids and under floorboards. For emergency lighting circuits (required by residential building codes worldwide), 1×10mm² YJV cables (copper conductor) are preferred—their higher conductivity ensures reliable power during outages, and the fire-resistant design maintains operation for 90 minutes (per IEC 60331) to guide occupants during evacuations.

HVAC Systems: Large HVAC chillers (50–75kW) in shopping malls rely on 3×95mm² YJV cables. The copper conductor’s 230A current rating at 30°C easily handles the chiller’s peak load, while the XLPE insulation’s thermal stability (up to 90°C) withstands the high temperatures in mechanical rooms. For smaller rooftop HVAC units (10–15kW) in office buildings, 3×25mm² YJLV cables are used—their aluminum conductor reduces weight by 40%, making rooftop installation safer and faster.

Elevator Power: Elevator motors (15–20kW) in high-rise hotels require cables that can withstand vertical movement (up to 100m) and frequent bending. 2×185mm² YJLV cables are ideal here: the Class 2 stranding allows a dynamic bending radius of 15× the cable diameter (vs. 20× for solid conductors), preventing sheath cracking during elevator operation. The aluminum conductor also reduces the cable’s weight by 50% compared to copper, lowering the stress on elevator shafts and extending the lifespan of elevator components.

Data Centers and Server Rooms: Modern office buildings often include on-site data centers for IT operations, which require cables with low electrical interference and high fire safety. 5×120mm² YJV cables are used here: the 5-core design (3 phases + neutral + dedicated earth) minimizes electromagnetic interference (EMI) for sensitive server equipment, while the low-smoke PVC sheath ensures smoke density remains ≤40% (per IEC 61034) during fires—critical for protecting IT staff and preventing data loss. The copper conductor’s low resistance (0.158 Ω/km for 120mm²) also minimizes power loss, keeping server temperatures 2–3°C lower and reducing cooling costs.

Machinery Power: Conveyor belts (5–10kW) and packaging machines (3–5kW) in warehouses use 3×50mm² YJLV cables. The aluminum conductor’s natural oxide layer provides corrosion resistance, which is essential in humid warehouse environments (where relative humidity can reach 80%). The PVC sheath’s abrasion resistance (tested per IEC 60811-1-3: 100 cycles of 5N force with 120-grit sandpaper) prevents damage from accidental contact with moving machinery parts.

Forklift Charging Stations: Warehouses with electric forklifts require cables that can handle high current during charging. 2×70mm² YJLV cables are used for this purpose—their 180A current rating at 30°C supports fast charging (2–3 hours per forklift), while the flexible stranding allows the cable to be coiled and stored when not in use. The flame-retardant sheath also complies with OSHA 1910.305 (U.S. industrial safety standards), which mandates fire-safe cabling in areas with flammable materials (e.g., cardboard storage).

Lighting and Utility Areas: 1×6mm² YJLV cables power warehouse lighting and utility outlets. These cables are resistant to common industrial chemicals (e.g., cleaning detergents, oil-based lubricants) —a test per IEC 60811-2-1 shows no sheath degradation after 7 days of immersion in mineral oil—ensuring long-term performance in harsh conditions.

Hospital ICUs: Life-saving equipment like ventilators (1–2kW), heart monitors (0.5kW), and infusion pumps (0.1kW) rely on 5×70mm² YJV cables. The 5-core design includes a dedicated earth conductor that limits ground fault current to<500mA, preventing electrical shocks to patients. The cable’s fire resistance (90 minutes at 750°C per IEC 60331) ensures power remains available during fires, allowing medical staff to stabilize patients before evacuation. Additionally, the low-smoke PVC sheath complies with hospital hygiene standards (ISO 14644-1), as it is easy to clean with disinfectants and does not release toxic particles.

Data Center Server Racks: Each server rack (10–15kW) in a commercial data center uses 3×120mm² YJV cables. The copper conductor’s high conductivity (58 MS/m) minimizes power loss, which reduces heat generation in the rack—lowering cooling costs by 15–20%. The XLPE insulation’s resistance to electrical treeing prevents short circuits, which is critical for 24/7 data operations: a single short circuit can cause $50,000+ in downtime.

Elderly Care Facilities: Emergency call systems and mobility aid chargers (e.g., wheelchair chargers, 1–2kW) use 2×10mm² YJV cables. The copper conductor’s reliability ensures emergency calls are never interrupted, while the flame-retardant sheath reduces fire risks for residents with limited mobility.

A 4×120mm² YJLV cable sold through a distributor costs \(3.50–\)4.00 per meter.

The same cable sold factory-direct costs \(2.80–\)3.20 per meter—a 20% savings.

Orders of 10,000–20,000 meters: 5% extra discount.

Orders of 20,000–50,000 meters: 8% extra discount.

Orders of 50,000+ meters: 12% extra discount.

Custom Length Cutting: Cables can be cut to exact on-site requirements (e.g., 450m spools for a residential tower’s floor-by-floor distribution), reducing on-site waste by 15–20% (vs. standard 500m spools).

Color Customization: The outer PVC sheath can be colored to match building codes (e.g., red for emergency circuits, green for general power) —a service that distributors typically charge \(0.20–\)0.30 per meter for.

Weight Savings: Aluminum conductors are 40–50% lighter than copper, which reduces transportation costs. For a 50,000-meter order of 4×120mm² cable, YJLV weighs ~38,000kg vs. ~65,000kg for YJV—lowering shipping costs by \(3,000–\)4,000 (based on $0.10/kg for road transport).

Installation Efficiency: The lighter weight also reduces labor time—2 electricians can install YJLV cables 25% faster than YJV, as they require fewer lifting tools (e.g., cable pullers, cranes). For a 10,000-meter installation, this saves 80–100 labor hours, translating to \(4,000–\)5,000 in labor costs.

Current-Carrying Parity: In low-voltage (0.6/1KV) applications, YJLV’s current-carrying capacity is comparable to smaller-gauge YJV. For example, 4×120mm² YJLV carries ~220A at 30°C, similar to 4×100mm² YJV (~230A)—but at 30% lower cost per meter. This means projects can achieve the same power output with YJLV while reducing material expenses.

ISO 9001-Certified Production: The manufacturing process is audited annually to ensure consistency, with 100% of batches tested for conductor resistance, insulation thickness, and flame retardancy.

Third-Party Certification: All cables are certified by independent labs (e.g., SGS, Intertek) to meet IEC, GB, and UL standards. This certification provides building owners with peace of mind—if a cable fails to meet specifications, the lab’s warranty covers replacement costs.

IEC 60502-1: This international standard governs low-voltage power cables (0.6/1KV) for fixed installations. The YJV/YJLV series meets all IEC 60502-1 requirements, including conductor resistance (≤0.153 Ω/km for 4×120mm² YJLV), insulation thickness (≥0.7mm for 16mm² conductors), and dielectric strength (>3.5kV for 5 minutes).

GB/T 12706.1: The Chinese national standard for low-voltage power cables, which aligns closely with IEC 60502-1 but includes additional tests for moisture resistance (7 days of immersion in 20°C water, insulation resistance ≥100 MΩ/km). The YJV/YJLV series is CCC-certified (China Compulsory Certification), meaning it is mandatory for use in Chinese building projects.

ANSI/UL 44: The U.S. standard for thermoset-Insulated power cables. YJV cables meet UL 44 requirements for flame retardancy (UL 94 V-0) and thermal stability (operation at 90°C continuous). This certification allows the series to be used in U.S. commercial and industrial buildings, as well as projects in North American markets (e.g., Canada, Mexico).

IEC 60332-1-2: This standard tests vertical flame propagation for single cables. The YJV/YJLV series self-extinguishes within 30 seconds of removing the ignition source, with no flame spread beyond 50mm—meeting the highest “Class A” rating.

IEC 60331: Tests fire resistance under load—critical for emergency systems. The series maintains power transmission for 90 minutes at 750°C, meeting the “EI 90” rating required by EU (CE), U.S. (NFPA 70), and Chinese (GB 50016) building codes.

IEC 61034: Measures smoke density during combustion. The series achieves ≤40% light transmittance after 10 minutes, which is classified as “low smoke” and compliant with smoke control requirements in high-occupancy buildings (e.g., shopping malls, hospitals).

RoHS Directive: The EU’s Restriction of Hazardous Substances directive prohibits the use of lead, cadmium, and mercury in electrical products. The YJV/YJLV series’ PVC sheath contains<100ppm lead and <10ppm cadmium, fully complying with RoHS.

LEED and BREEAM Compatibility: For eco-friendly building certifications (LEED in the U.S., BREEAM in Europe), the series’ low-smoke, halogen-reduced design contributes to “Indoor Environmental Quality” credits. The aluminum conductor’s lower carbon footprint (aluminum production emits 50% less CO₂ than copper) also supports “Sustainable Sites” credits.

Bending Radius: The Class 2 stranding allows tight bending radii: 10× the cable diameter for static installation (e.g., ceiling ducts) and 15× for dynamic installation (e.g., elevator shafts). For example, a 4×50mm² YJLV cable (18mm diameter) has a static bending radius of 180mm—

Cable Pulling: The smooth PVC sheath and round core design (achieved via filler ropes in Multi-Core Cables) minimize friction during pulling through conduits. For a 100-meter conduit run, two electricians can pull a 4×120mm² YJLV cable in ~30 minutes—vs. 45 minutes for cables with irregular cores. This is especially valuable in high-rise buildings, where vertical conduit runs (50+ meters) are common.

Compatibility with Standard Hardware: The YJV/YJLV series works with all standard building electrical components, including copper/aluminum-compatible terminal blocks, circuit breakers (rated for 0.6/1KV), and cable glands (IP44/IP65-rated). No specialized hardware is required—unlike some high-Performance Cables that need custom lugs or connectors—simplifying inventory management for contractors.

Mechanical Resistance: The PVC sheath is tested to withstand common building installation stresses:

Environmental Resistance:

Service Life: With proper installation and maintenance, the YJV/YJLV series has a service life of 20+ years—matching the typical lifespan of modern buildings. This reduces the need for cable replacement during building renovations, saving owners \(10,000–\)20,000 per 10,000 meters of cable.

Pre-Installation Inspection: Check cables for sheath damage (e.g., cracks, tears) and verify spool labels match the project’s specifications (core configuration, length). Do not install damaged cables—they may fail during use.

Conduit Preparation: Ensure conduits are clean (no debris) and properly sized: use 25mm-diameter conduits for 1–2 Core Cables ≤10mm², 40mm conduits for 4-core cables ≤50mm², and 63mm conduits for 4-core cables ≥70mm². Oversized conduits reduce pulling friction, while undersized ones risk sheath damage.

Bending and Pulling Limits: Never exceed the minimum bending radius (10× static, 15× dynamic) or pull tension (1.5kN for cables ≤50mm², 3kN for cables ≥70mm²). Exceeding these limits can damage the conductor or insulation.

Termination: Use crimp lugs compatible with the conductor material (aluminum for YJLV, copper for YJV) and torque them to the manufacturer’s specifications (typically 15–25 N·m for 120mm² conductors). Poor terminations cause overheating, which is a leading cause of cable failures in buildings.

Earthing: For multi-core cables, connect the earth core (yellow-green) to the building’s earthing system using a copper earth bar. This ensures proper fault current dissipation, reducing the risk of electrical shocks.

Wooden Spools (for Cables ≤120mm²):

Steel Spools (for Cables ≥150mm²):

Carton Packaging (for Small Lengths):

Weather-Resistant Packaging: For projects in humid or rainy regions (e.g., coastal buildings), spools are wrapped with UV-resistant PVC film (0.2mm thick) and sealed with butyl tape to create a waterproof barrier. An additional layer of aluminum foil is added to reflect sunlight, preventing cable overheating during outdoor storage.

Compact Packaging for High-Rise Sites: For construction sites with limited storage space (e.g., high-rise apartment rooftops), cables can be packed in stackable steel spools (height ≤500mm) that fit in standard 1m×1m storage cages. This reduces storage footprint by 40% compared to traditional spools.

Road Transport:

Rail Transport:

Sea Freight (Primary Mode for Bulk Orders):

Air Freight (for Urgent Orders):

Temperature Limits: Cables must be transported at -20°C to +50°C. In extreme temperatures (e.g., desert regions in summer), trucks/ containers are equipped with cooling systems to keep cables below 50°C—preventing PVC sheath softening.

Weight Restrictions: Wooden spools are limited to 150kg per spool (including cable) to avoid forklift overload, while steel spools are limited to 300kg per spool.

Unloading Timing: Cables should be unloaded within 24 hours of delivery to avoid prolonged exposure to outdoor conditions. If unloading is delayed, spools must be stored in a covered, dry area with proper ventilation.

Order Confirmation: After receiving an order, a sales representative sends a detailed order acknowledgment within 24 hours, including:

Lead Times:

EXW (Ex Works): Customer collects cables from the factory. The factory provides loading assistance, but the customer is responsible for all transportation, insurance, and customs costs. Ideal for customers with their own logistics teams.

FOB (Free On Board): Factory delivers cables to the port of shipment (e.g., Shanghai Port for Chinese exports, Los Angeles Port for U.S. exports) and loads them onto the vessel. Customer is responsible for sea freight, insurance, and destination customs.

CIF (Cost, Insurance, Freight): Factory covers costs of transportation to the destination port and marine insurance (coverage for 110% of the order value). Customer is responsible for destination port fees and customs clearance.

DDP (Delivered Duty Paid): Factory handles all costs, including transportation, insurance, customs duties, and delivery to the building site. Ideal for customers who want a “turnkey” shipping solution.

Commercial Invoice: Details the order value, currency, and payment terms (e.g., 30% advance, 70% against B/L copy).

Packing List: Itemizes each spool/carton, including length, weight, and batch number—used for inventory checks at the building site.

Certificate of Conformity (CoC): Issued by the factory’s quality department, confirming the cables meet IEC/GB/UL standards.

Test Reports: Includes results of routine tests (conductor resistance, insulation thickness, flame retardancy) for the specific batch.

Customs Declaration Form: Completed per the destination country’s requirements (e.g., EU EORI number, U.S. HTS code).

Available Samples: Samples are available for all core configurations and sizes, including:

Sample Variants: Customers can request samples of both YJV (copper) and YJLV (aluminum) variants, as well as special options (e.g., IP65-rated sheaths, color-coded sheaths).

Request Submission: Customers can request samples via email, phone, or the factory’s online portal. The request must include:

Approval and Processing: Sample requests are approved within 24 hours. For standard samples (1–5 meters), no fee is charged—only shipping costs apply. For custom samples (e.g., 10m of IP65-rated YJV), a nominal fee (\(50–\)100) is charged, which is refundable if a bulk order (≥1000 meters) is placed within 30 days.

Delivery: Samples are shipped via express courier (DHL, FedEx, or UPS) for fast delivery—domestic samples arrive in 2–3 working days, while international samples take 5–7 working days. A tracking number is provided once the sample ships, allowing customers to monitor delivery progress.

Sample Evaluation Checklist: A detailed form outlining key test points, including:

Technical Support: A dedicated engineer is assigned to each sample request, available via phone or email to answer questions (e.g., “How does YJLV’s current capacity compare to copper in high-temperature environments?”) or provide installation guidance.

Compliance Documentation: Sample packages include a mini Certificate of Conformity and abridged test reports, allowing customers to verify compliance with local building codes during pre-project approvals.

Standard Warranty: All cables come with a 24-month warranty against manufacturing defects, starting from the date of delivery. The warranty covers:

Extended Warranty: For bulk orders (≥50,000 meters) or critical projects (e.g., hospitals, data centers), customers can purchase an extended warranty of 36–60 months. The extended warranty includes annual on-site inspections by factory engineers, who check cable performance (insulation resistance, conductor temperature) and provide maintenance recommendations—reducing the risk of unexpected failures.

On-Site Installation Guidance: For complex projects (e.g., high-rise commercial towers, hospital ICUs), factory engineers can visit the site to:

Remote Troubleshooting: For urgent issues (e.g., a cable failure during installation), customers can contact the 24/7 technical support hotline. Engineers use video calls to assess the problem in real time, providing step-by-step solutions (e.g., “How to repair a minor sheath tear without compromising fire resistance”).

Technical Documentation: A library of resources is available on the factory’s website, including:

Annual Maintenance Checklist: A customizable checklist for building owners, including:

Lifespan Extension Services: For buildings undergoing renovations (e.g., 10–15 years after initial cable installation), the factory offers:

Post-Installation Survey: 3–6 months after cable installation, customers receive a survey asking about:

Feedback Implementation: Feedback is reviewed quarterly by the product development team. For example, if multiple customers request a more abrasion-resistant sheath for industrial buildings, the team may reformulate the PVC compound to include additional reinforcing agents—incorporating the improvement into future production runs.