Voltage Class: U1000, indicating a maximum rated voltage of 1kV (DC or AC), suitable for low-voltage power distribution and signal transmission in industrial, mining, and commercial settings.
Current Rating: 16A (at 25°C ambient temperature, free air), with derating factors for high-temperature environments:
50°C: 12.8A (80% of rated current)
70°C: 9.6A (60% of rated current)
Conductor Design:
Structure: 37 strands of 1.5mm² high-purity electrolytic copper, twisted in a concentric pattern (1 central strand + 6 strands in layer 1 + 12 strands in layer 2 + 18 strands in layer 3). The stranding pitch is 100–120mm, optimized to balance Flexibility and current distribution.
Electrical Properties: Conductivity of 58 MS/m (20°C) and resistivity of 1.72×10⁻⁸ Ω·m, ensuring minimal energy loss (≤2% per 100 meters) even when powering medium-load equipment (e.g., 3kW industrial pumps, 2.5kW construction tools).
Mechanical Flexibility: Minimum bending radius of 10× cable diameter (static) and 15× (dynamic). For a cable diameter of 12mm, this translates to a 120mm static bending radius—allowing it to wrap around mining equipment joints or construction site obstacles without conductor damage.
Overall Diameter: 12–14mm, including:
Conductor: 5–6mm (37×1.5mm² strands)
XLPE insulation: 1.5–2.0mm
SWA layer: 2.0–2.5mm
Outer sheath (optional, for extra protection): 1.0–1.5mm (typically PVC or PE, depending on sector needs)
Weight: 0.18–0.22kg/m (100m reel: 18–22kg), lightweight enough for manual handling in construction sites or mining tunnels while remaining durable.
Temperature Range:
Continuous Operation: -40°C to +90°C, covering extreme climates from Arctic construction sites to desert mining operations.
Short-Term Peak: Up to +120°C (for 1 hour), to withstand transient heat spikes from equipment malfunctions or direct sunlight on construction sites.
Environmental Resistance:
Moisture: IP65 rated (water jet resistance) when terminated, with XLPE insulation absorbing <0.1% water by weight after 24 hours immersion—critical for damp mining shafts or rainy construction sites.
Chemicals: Resists degradation from mining acids (pH 4–6), industrial oils (e.g., hydraulic fluid), and construction contaminants (cement dust, diesel fuel) per IEC 60811-404.
UV Radiation: UV-stabilized outer sheath (when specified) maintains integrity after 1000 hours of UV exposure (IEC 60068-2-5), suitable for outdoor construction sites.
Purity and Processing: 99.95% pure electrolytic copper is drawn into 1.5mm² strands via cold drawing, a process that maintains material strength and conductivity. Cold drawing also ensures uniform strand diameter (±0.02mm), critical for consistent current distribution.
Stranding Advantages:
Flexibility: Stranded construction allows the cable to bend repeatedly without work hardening (a common issue with solid conductors), making it ideal for mining equipment with moving parts (e.g., excavator arms) or construction tools that require frequent repositioning.
Vibration Resistance: Strands absorb vibration from industrial machinery (e.g., assembly line robots), preventing conductor fatigue and breakage over time.
Current Capacity: The 37-strand design reduces skin effect (AC resistance), enabling the cable to carry the full 16A rating without overheating—even in industrial AC systems.
Cross-Linking Process: XLPE insulation is formed by extruding polyethylene resin onto the conductor, then cross-linking it via electron beam (EB) irradiation (10–15 MeV energy, 80–120 kGy dose). This creates covalent bonds between polymer chains, transforming the linear polyethylene structure into a three-dimensional network.
Key Properties of XLPE:
Thermal Stability: Cross-linking eliminates the risk of insulation melting at high temperatures, a critical advantage over PVC (which softens at 70–90°C) in mining shafts or industrial facilities with high-heat equipment.
Chemical Resistance: The cross-linked structure repels oils, solvents, and acids, ensuring insulation integrity even if the cable comes into contact with mining chemicals (e.g., sulfuric acid) or industrial lubricants.
Aging Resistance: XLPE minimizes oxidation and hydrolysis, extending the cable’s service life to 20+ years—double the lifespan of PVC Insulation in harsh environments.
Steel Wire Specifications: Galvanized low-carbon steel wires (1.2–1.5mm diameter) are used for the SWA layer, chosen for their high tensile strength (≥400 MPa) and corrosion resistance. The galvanization layer (zinc thickness ≥8μm) prevents rust in damp mining shafts or outdoor construction sites.
Armoring Process: Wires are twisted helically around the XLPE-Insulated Conductor at a pitch of 10–15× cable diameter, ensuring uniform coverage without overlapping. The twist direction alternates (left/right) for adjacent layers (if multiple layers are used), enhancing armor rigidity while maintaining flexibility.
Protection Benefits:
Impact Resistance: SWA absorbs the force of falling rocks in mining tunnels or dropped tools on construction sites, preventing damage to the insulated conductor.
Compression Resistance: Withstands pressure up to 100 kPa, allowing direct burial in construction site soil or under mining conveyor belts without insulation deformation.
Pest Resistance: Steel is impervious to gnawing by rodents (e.g., rats in mining shafts) or termites in outdoor construction areas, a common cause of cable failure in unarmored alternatives.
Flame Retardancy: The cable self-extinguishes within 60 seconds of removing the flame (per IEC 60332-1), preventing fire spread in enclosed spaces like mining tunnels or data centers.
Low Smoke: In the event of combustion, smoke density is ≤0.15 optical density (per IEC 61034), improving visibility for emergency responders and reducing respiratory hazards. This is critical for data centers with dense server racks or mining tunnels with limited ventilation.
Primary Applications:
Powering underground equipment: Ventilation fans, drill rigs, and conveyor belt motors, where flexibility is needed to accommodate equipment movement and SWA protects against rock impacts.
Signal transmission: Connecting control systems to sensors (e.g., temperature, gas detectors) in mining shafts, where XLPE’s moisture resistance ensures reliable signal integrity.
Sector-Specific Benefits:
Resistance to mining chemicals (e.g., acids from ore processing) prevents insulation degradation.
Low smoke emission (RO2V) reduces risks in enclosed tunnels, where smoke can quickly become lethal.
Example: A 100m reel of U1000 RO2V cable powers a 3kW underground ventilation fan, with its 16A rating and SWA armor ensuring safe operation despite frequent rock debris and damp conditions.
Primary Applications:
Machinery power: Connecting industrial control panels to assembly line robots, pumps, and compressors, where SWA withstands vibration and XLPE resists oil spills.
Auxiliary systems: Powering lighting, heating, and cooling units in manufacturing plants, where the cable’s 1kV rating and flame retardancy meet safety codes.
Sector-Specific Benefits:
Thermal stability (-40°C to +90°C) ensures operation in factories with extreme temperature fluctuations (e.g., foundries, cold storage facilities).
Flexible Stranded Conductor simplifies installation around machinery obstacles.
Example: A 50m length of the cable connects a control panel to a 2.5kW industrial pump, with XLPE insulation protecting against hydraulic fluid spills and SWA absorbing vibration from the pump motor.
Primary Applications:
Auxiliary power: Supplying cooling units, backup generators, and UPS systems in data centers, where low energy loss (≤2%) ensures stable power for sensitive computer equipment.
Signal transmission: Low-voltage signal lines between server racks and network switches, where the cable’s flexibility fits in dense cable trays.
Sector-Specific Benefits:
Flame retardancy (RO2V) reduces fire risks in server rooms with high-density equipment.
Compact diameter (12–14mm) saves space in crowded cable management systems.
Example: A 20m pre-terminated length of the cable powers a data center cooling unit, with its 16A rating and low smoke emission ensuring compliance with data center safety standards (e.g., TIA-942).
Primary Applications:
Temporary wiring: Powering construction tools (e.g., small welders, concrete mixers), site lighting, and temporary offices, where SWA protects against accidental damage from tools or vehicles.
Permanent installation: Wiring for new buildings (e.g., residential complexes, commercial offices) during construction, where XLPE’s durability ensures long-term performance.
Sector-Specific Benefits:
UV resistance (with optional UV-stabilized sheath) withstands outdoor exposure on construction sites.
Lightweight design (0.18–0.22kg/m) simplifies manual handling by construction crews.
Example: A 150m reel of the cable is used for temporary wiring on a residential construction site, powering a 2kW concrete mixer and site lighting—with SWA protecting against dropped tools and XLPE resisting rain and dust.
Wire Drawing: Copper rods (12mm diameter) are drawn through diamond dies to reduce strand diameter to 1.5mm². Cold drawing is used to maintain conductor strength, with mineral oil lubrication preventing strand damage and ensuring uniform diameter.
Stranding: 37 strands are twisted into a concentric conductor using a high-speed stranding machine (1000–1500 RPM). The stranding pitch is monitored via laser sensors to ensure consistency (100–120mm), and tension control (5–10N per strand) prevents strand breakage.
Annealing: The stranded conductor is heated to 350–400°C in a nitrogen atmosphere to reduce residual stress from drawing and stranding. Annealing improves flexibility and conductivity, critical for the cable’s performance in high-flex applications.
Material Preparation: XLPE resin is mixed with antioxidants, UV stabilizers (if specified), and flame retardants (for RO2V compliance) in a twin-screw extruder (180–200°C). The mixture is granulated into uniform pellets to ensure consistent extrusion.
Extrusion: Molten XLPE is extruded onto the stranded conductor via a crosshead die, with insulation thickness controlled to 1.5–2.0mm using an online laser gauge. The extrusion speed (10–15m/min) is synchronized with the conductor feed rate to avoid uneven thickness (thickness variations).
Cross-Linking: The insulated conductor is passed through an electron beam (EB) accelerator, where high-energy electrons initiate cross-linking. The radiation dose (80–120 kGy) is calibrated to achieve a gel content of ≥65%—a measure of cross-linking efficiency. Post-irradiation, the cable is cooled in a water bath (20–25°C) to set the insulation.
Wire Preparation: Galvanized steel wires (1.2–1.5mm diameter) are spooled onto armoring machines, with each wire tensioned to 50–100N to ensure uniform wrapping. Wires are inspected for defects (e.g., cracks, rust) before use.
Armoring Application: Wires are twisted helically around the XLPE-insulated conductor at a pitch of 10–15× cable diameter. The number of wires varies by cable size (typically 12–16 wires for 12mm diameter), ensuring complete coverage without overlapping. A binder tape (polyester or fiberglass) is wrapped over the armor to hold wires in place and prevent fraying.
Material Selection: PVC (for cost-effectiveness) or PE (for chemical resistance) is used, with flame retardants added to maintain RO2V compliance.
Extrusion Process: The sheath is extruded at 160–180°C (PVC) or 180–200°C (PE), with thickness controlled to 1.0–1.5mm. The sheath is printed with product information (e.g., "U1000 RO2V 37×1.5mm²") using a laser printer for durability.
Electrical Tests:
Insulation Resistance: A 2.5kV DC megohmmeter measures resistance between conductor and sheath—minimum 1000 MΩ (20°C).
Dielectric Strength: The cable is submerged in water and subjected to 3kV AC for 1 minute—no breakdown allowed.
Current Capacity: The cable is loaded to 16A at 25°C, with temperature rise monitored (maximum 30°C above ambient) to confirm it meets rating requirements.
Mechanical Tests:
Bending Test: Bent around a mandrel (10× diameter) 10 times—no conductor exposure or insulation cracking.
Impact Test: A 1kg weight is dropped from 1m onto the cable—SWA and insulation remain intact.
Tensile Test: A 1-meter sample is pulled until break—minimum breaking force ≥2.5kN.
Environmental Tests:
Moisture Resistance: Submerged in water for 24 hours—insulation resistance remains ≥100 MΩ.
Chemical Resistance: Exposed to mineral oil (70°C, 7 days)—no insulation swelling or degradation.
Flame Retardancy: Tested per IEC 60332-1—self-extinguishes within 60 seconds.
Certification: After passing all tests, the cable is certified to IEC 60502-1, EN 50525, and regional standards (UL 1569 for North America, BS 6346 for the UK). Certification documents are provided to customers to facilitate regulatory approval.
Reel Type: Heavy-duty steel or wooden reels, chosen for durability:
Steel Reels: Used for mining/industrial orders (heavyweight, 18–22kg per 100m). Reels have a diameter of 800–1000mm, flange thickness of 15–20mm, and load capacity of 50–100kg. Galvanized steel prevents rust in damp storage areas (e.g., mining warehouses).
Wooden Reels: Used for construction/computer infrastructure orders (lighter weight). FSC-certified pine reels (diameter 700–900mm) are treated with anti-rot chemicals to withstand outdoor storage on construction sites.
Protection Layers:
Inner Layer: 200-micron UV-stabilized PE film wraps the wound cable to repel dust and moisture. For mining orders, an additional layer of waterproof PVC shrink wrap is applied to protect against mine water.
Outer Layer: Woven polypropylene bags (for steel reels) or tarpaulins (for wooden reels) cover the reel, preventing damage during transit.
Labeling: Each reel has two weather-resistant metal tags with:
Product Info: Cable type (U1000 RO2V), conductor size (37×1.5mm²), current rating (16A), Insulation Material (XLPE), and armor type (SWA).
Logistics Info: Order number, customer name, destination address, reel weight, and dimensions.
Safety Info: Symbols for “Heavy Load—Use Crane,” “Keep Dry,” and “Flame-Retardant” (RO2V designation).
Reinforced Cardboard Boxes: Double-walled corrugated boxes (300-lb test strength) with foam inserts at both ends to prevent cable movement. The box interior is lined with a PE bag to block moisture.
Labeling: A clear plastic tag on the box indicates length (e.g., 50m), application (e.g., “Construction Tool Power”), and handling instructions (“Do Not Stack Over 3 Boxes”).
Steel reels are 100% recyclable, and the company offers a take-back program—customers receive a 5% discount on their next order when returning intact reels.
Wooden reels are sourced from FSC-certified forests, ensuring responsible logging. Unused wood scraps are repurposed into packaging 填充物 (e.g., wooden blocks for pallet stabilization).
PE film and cardboard boxes are recyclable, with clear sorting labels to guide waste management at construction sites or industrial facilities.
Truck Delivery:
Small Orders (1–5 Reels): Delivered via light commercial vehicles (5–10 ton capacity) with covered cargo areas. For construction sites, trucks with off-road capabilities are used to access remote locations. Delivery times: 1–3 business days for urban areas, 3–5 days for rural/mining regions.
Large Orders (10+ Reels): Shipped via flatbed trucks (20–30 ton capacity) with steel straps and wooden dunnage to secure reels. GPS tracking is provided, allowing customers to monitor shipment location in real time—essential for coordinating on-site installation.
Courier Services: For urgent orders (e.g., emergency mining equipment repairs), courier services (e.g., DHL, FedEx) are used. Small custom-cut lengths (<10m) are packed in padded envelopes and delivered within 24–48 hours, with insurance coverage for damage up to $5,000.
Sea Freight:
The majority of international orders are shipped via sea freight, cost-effective for heavy reels. Reels are loaded into 20ft or 40ft shipping containers (FCL for large orders, LCL for small batches):
Container Preparation: Reels are stacked in a single layer (to avoid crushing) with wooden blocks between them. Humidity packs (500g each) are placed in the container to absorb moisture—critical for tropical destinations (e.g., Southeast Asian mining sites).
Transit Times: 2–4 weeks for regional shipments (e.g., Europe to North Africa), 4–8 weeks for intercontinental shipments (e.g., China to Brazil), and 6–10 weeks for transoceanic shipments (e.g., U.S. to Australia).
Air Freight:
For time-sensitive projects (e.g., a data center opening in Singapore), air freight is used. Reels are packed in lightweight aluminum frames to reduce weight (air freight costs are calculated by weight and volume). A 100m reel (22kg) costs approximately $700 to ship via air from Germany to Singapore, with delivery times of 2–5 business days.
Customs Compliance:
All international shipments include documentation to avoid delays:
Commercial Invoice: Details product description, quantity, unit price, total value, and country of origin (e.g., “Made in Germany”).
Packing List: Specifies package dimensions, weight, and contents (e.g., “5 reels of U1000 RO2V cable, 100m each”).
Certification Copies: Includes IEC/EN/UL certificates to verify compliance with the importing country’s standards (e.g., SABS certification for South Africa, JIS certification for Japan).
Online Portal: The company’s secure web portal allows 24/7 order placement, with real-time inventory updates (e.g., “U1000 RO2V 100m reels: 50 in stock”). Users can select cable length, quantity, and optional add-ons (e.g., pre-terminated connectors for data center use), generate instant quotes, and track order status. For repeat customers, the portal stores past orders for quick reordering.
Dedicated Sales Teams: For large-scale orders (e.g., 100+ reels for a mining project), dedicated industry specialists provide personalized support. They assist with technical 选型 (e.g., recommending PE outer sheaths for humid mining shafts), negotiate volume discounts (up to 15% for orders over 50 reels), and coordinate with production to prioritize urgent requests.
Phone/Email Orders: For small businesses or emergency repairs, orders can be placed via phone or email. The customer service team responds within 1 hour, confirms order details, and provides an estimated delivery date—critical for construction sites facing unexpected cable damage.
In-Stock Items: Standard 100m/200m reels of U1000 RO2V cable are shipped within 1–2 business days. This includes cables with PVC outer sheaths (most common for construction/industrial use) and basic SWA configurations.
Custom Orders: Specialized variants (e.g., PE outer sheaths for mining, pre-terminated connectors for data centers) have a lead time of 3–5 business days. The production team provides weekly progress updates (e.g., “50% complete—scheduled for insulation extrusion on Day 3”) to keep customers informed.
Emergency Rush Orders: For critical scenarios (e.g., a mining shaft power outage), the company offers 24-hour rush production. Additional fees apply (20–30% of the order value), but production is prioritized, and shipping is expedited via courier to ensure delivery within 48 hours.
Tracking Details: For domestic orders, a link to the courier’s tracking page (e.g., UPS, DPD) with real-time location updates. For international sea freight, a container number and link to the shipping line’s portal (e.g., Maersk, CMA CGM) to monitor port arrivals and customs clearance.
Delivery Instructions: Specific guidance for on-site receipt, such as “Use forklift for steel reel unloading” or “Store in shaded area to protect UV-sensitive sheath.” For mining orders, additional notes include “Inspect SWA for damage before lowering into shafts.”
Contact Information: A dedicated logistics manager’s phone/email for resolving delivery issues (e.g., missed appointments, damaged packaging) within 2 hours of contact.
External Packaging Check: Verify that reels/boxes are free of cracks, tears, or water damage. If damage is found, take photos and notify the logistics team immediately to initiate a damage claim.
Product Identification Check: Confirm that the cable type (U1000 RO2V), conductor size (37×1.5mm²), and current rating (16A) match the order invoice. Check for certification labels (IEC/EN/UL) to ensure compliance.
Physical Condition Check: Unwind a 1-meter section of cable to inspect for insulation cracks, SWA wire fraying, or conductor exposure. For pre-terminated cables, test connector continuity with a multimeter to confirm no crimping errors.
Standard Samples: 1-meter lengths of the U1000 RO2V cable are available for all standard configurations (e.g., PVC/PE sheath, with/without pre-terminated connectors). Samples include a product datasheet and test report summary (insulation resistance, flame retardancy).
Customized Samples: For unique applications (e.g., high-chemical industrial facilities), the company produces tailored samples—such as cables with extra-thick XLPE insulation (2.5mm) or corrosion-resistant SWA (zinc-nickel plated). Custom samples require a 1-week lead time and a nominal fee ($20–$50), refundable if a bulk order is placed within 30 days.
Online Portal: Navigate to the “Sample Request” page, select cable configuration, and provide shipping address/project details (e.g., “Mining shaft application—need to test moisture resistance”). Samples are shipped within 2 business days.
Sales Team: For industrial/mining customers, sales specialists can recommend sample types based on project requirements (e.g., “PE-sheathed sample for your coastal construction site”) and coordinate direct delivery to on-site labs.
Technical Support: For data center customers requiring performance testing (e.g., signal interference for server power), the technical team provides samples with attached test protocols (e.g., “How to measure XLPE dielectric strength in server room temperatures”).
Test Guidance: A step-by-step guide for common tests, such as “Bending fatigue test for mining equipment cables” or “Chemical immersion test for industrial applications.”
Lab Partnerships: For complex testing (e.g., long-term UV exposure, SWA impact resistance), the company partners with accredited labs (e.g., TUV Rheinland, UL) to provide discounted testing services—with results delivered within 1 week.
Performance Consultation: After testing, a technical engineer reviews results with the customer to confirm if the cable meets their needs (e.g., “Sample passed 500 hours of salt spray—suitable for your coastal mining project”) or recommend modifications (e.g., “Upgrade to zinc-nickel SWA for enhanced corrosion resistance”).
24/7 Hotline: A toll-free hotline is available for urgent technical issues (e.g., “Cable insulation damaged in mining shaft—how to repair?”). Certified engineers specializing in mining/industrial/construction/data center applications respond within 1 hour, providing actionable solutions:
For insulation damage: “Use heat-shrinkable sleeves with adhesive lining to seal small cracks; replace the cable if damage exceeds 50mm in length.”
For SWA fraying: “Trim frayed wires and apply epoxy resin to prevent corrosion; schedule a replacement for critical power circuits.”
Online Resource Center: The company’s website hosts a library of technical resources, including:
Installation Manuals: Sector-specific guides like “U1000 RO2V Cable Installation in Underground Mining Shafts” or “Data Center Server Rack Wiring Best Practices.”
Troubleshooting Videos: Step-by-step tutorials for common issues, such as “Resolving SWA Grounding Errors” or “Fixing Connector Continuity Problems.”
FAQs: Answers to sector-specific questions, e.g., “Can the cable be used in temperatures below -40°C?” (No—recommend heated cable trays for Arctic construction) or “Is the RO2V flame retardancy suitable for server rooms?” (Yes—meets NFPA 70 fire codes).
On-Site Training: For large customers (e.g., mining operators, industrial contractors), the company provides on-site training sessions led by experienced technicians. These half-day sessions cover:
Safe Handling: Proper reel unwinding techniques to avoid cable kinking (critical for maintaining SWA integrity) and lifting procedures to prevent back injuries.
Correct Installation: Step-by-step wiring for industrial control panels, mining equipment connection, or data center server racks—including torque specifications for connector crimping (15–20 N·m for 1.5mm² conductors).
Compliance Training: Guidance on meeting sector-specific codes, such as “IEC 60079 for explosive mining environments” or “TIA-942 for data center cable management.”
Virtual Training: For remote customers or small teams, live virtual training is offered via Zoom, with 3D models demonstrating installation scenarios (e.g., “Routing Cable Around Mining Conveyor Belts”) and interactive Q&A sessions.
Standard Warranty: 15 years for construction/computer infrastructure applications, covering manufacturing defects (e.g., insulation breakdown, SWA wire detachment). The warranty includes free cable replacement and reimbursement for labor costs if defects are reported within 5 years.
Mining/Industrial Warranty: 10 years (due to harsher conditions), with extended coverage for SWA corrosion (common in mining shafts) and XLPE chemical damage (industrial facilities). This warranty also includes annual on-site inspections (for orders over 100 reels) to proactively identify potential issues.
Maintenance Program: Customers receive a “Cable Maintenance Guide” tailored to their sector:
Mining: Monthly SWA corrosion checks using a magnetic flux tester; quarterly insulation resistance testing (≥500 MΩ at 20°C) to detect moisture ingress.
Industrial: Semi-annual chemical exposure inspections; annual cable routing checks to prevent abrasion against machinery.
Data Centers: Annual connector torque checks (15 N·m) to ensure low resistance; bi-annual thermal imaging scans to detect overheating.
Recycling Program: To support sustainability goals, the company offers a take-back program for end-of-life cables (after 10–15 years of service):
Collection: Free pickup for quantities ≥50kg (e.g., old mining cables). For smaller quantities, customers can drop off cables at designated recycling centers.
Processing: Cables are shredded to separate Copper Conductors (recycled into new wire), XLPE insulation (processed into plastic pellets for non-electrical applications), and SWA steel (melted and repurposed into construction materials).
Sustainability Reporting: A recycling certificate and carbon footprint report are provided, helping customers meet ESG (Environmental, Social, Governance) targets—critical for data centers and industrial facilities with green initiatives.
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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