Rated Voltage: All three types of cables have a rated voltage of 450/750V, which is an important common feature. In AC electrical systems, this parameter specifies that the rated voltage between conductors is 450V, and the rated voltage between a conductor and the ground is 750V. This design enables them to be safely used in low-voltage distribution networks, meeting the basic voltage requirements of low-voltage power supply systems in family residences, commercial places, and small industrial facilities.
Cross-sectional Area and Current-carrying Capacity: The cross-sectional area is the most core distinguishing parameter among the three types of cables and directly affects the current-carrying capacity. The 1.5mm² cable has a cross-sectional area of 1.5 square millimeters, and under conventional environmental conditions (temperature around 30°C, well-ventilated), its current-carrying capacity is usually 10-16 amperes; the 2.5mm² cable has a cross-sectional area of 2.5 square millimeters, with a current-carrying capacity of approximately 16-25 amperes; the 4mm² cable has a cross-sectional area of 4 square millimeters, and its current-carrying capacity can reach 25-32 amperes. The difference in current-carrying capacity allows them to be adapted to electrical equipment of different powers: the 1.5mm² is suitable for low-power equipment, the 2.5mm² for low-to-medium power equipment, and the 4mm² for medium-to-high power equipment.
Conductor Structure: The conductors of all three types of cables are made of high-purity electrolytic copper, with a purity generally above 99.9%, ensuring excellent conductivity. The conductors all have a multi-strand stranded structure, but the number of Copper Strands and the diameter of a single strand vary with specifications. The 1.5mm² cable is usually formed by stranding 7 fine Copper Wires with a diameter of about 0.52mm; the 2.5mm² cable is generally formed by stranding 7 fine copper wires with a diameter of about 0.68mm; the 4mm² cable is mostly formed by stranding 19 fine copper wires with a diameter of about 0.52mm. This multi-strand stranded structure significantly improves the Flexibility of the cable, making it easy to bend and lay in narrow spaces, while enhancing its fatigue resistance, which can effectively cope with mechanical stress during installation and use and reduce the risk of conductor breakage.
Insulation Layer Parameters: The outer insulation layer is made of polyvinyl chloride (PVC) material, and its thickness increases slightly with the increase of the cross-sectional area. The insulation thickness of the 1.5mm² cable is about 0.6-0.8mm; that of the 2.5mm² cable is about 0.8-1.0mm; and that of the 4mm² cable is about 1.0-1.2mm. This thickness design not only ensures good electrical insulation performance, which can effectively isolate current and prevent short circuits and leakage accidents, but also reduces the weight of the cable to a certain extent, facilitating installation. At the same time, the insulation layer has a certain mechanical strength and can resist slight collisions and friction.
Conductor Resistance: At an ambient temperature of 20°C, the maximum resistance of the 1.5mm² Cable Conductor does not exceed 12.1Ω/km; that of the 2.5mm² cable conductor does not exceed 7.41Ω/km; and that of the 4mm² cable conductor does not exceed 4.61Ω/km. The low resistance value ensures less energy loss during current transmission, improves the efficiency of power transmission, and reduces heat generation due to excessive resistance, lowering safety hazards.
Insulation Resistance: The insulation resistance of all three types of cables at room temperature is greater than 100MΩ·km, indicating that their insulation layers can effectively prevent current leakage and ensure the safe operation of the cables during long-term use.
Outer Diameter Size: The outer diameter of the 1.5mm² cable is about 2.5-3.0mm; that of the 2.5mm² cable is about 3.0-3.5mm; and that of the 4mm² cable is about 3.5-4.0mm. The appropriate outer diameter size allows them to pass through conventional conduits smoothly and adapt to different laying environments.
1.5mm² Cable:
Home Lighting Systems: Lighting fixtures in homes, such as chandeliers, ceiling lamps, and downlights, have low power, generally ranging from a few watts to tens of watts. The 1.5mm² cable can fully meet their power supply needs. Its flexibility allows it to be easily laid along conduits in walls and ceilings without affecting the indoor appearance.
Ordinary Socket Circuits: Ordinary sockets in living rooms, bedrooms, studies, and other areas mainly supply power to low-power electrical appliances such as mobile phone chargers, desk lamps, and small electric fans. The 1.5mm² cable can carry the current when these appliances work simultaneously, which is safe and economical.
Power Supply for Small Household Appliances: Small household appliances such as televisions, computers, routers, and low-power microwave ovens have relatively low power. Using a 1.5mm² cable for power supply can ensure stable power transmission and the normal operation of the appliances.
Connection of Weak Current Equipment: The line connection of weak current equipment such as telephones, networks, and cable TVs has low requirements on current-carrying capacity but requires a certain degree of flexibility. The 1.5mm² cable can well meet these needs and is convenient for laying in narrow spaces such as inside walls and under floors.
2.5mm² Cable:
Power Supply for Medium-power Household Appliances: Household appliances such as air conditioners of 1.5 horsepower and below, electric water heaters below 1500W, and high-power washing machines have moderate power. The current-carrying capacity of the 2.5mm² cable is sufficient to meet their power supply needs, ensuring the stable operation of these appliances.
Lighting Main Lines in Commercial Places: The lighting systems in commercial places such as shopping malls, office buildings, and hotels are complex with a large number of lamps. The lighting main lines need to carry a large current. The 2.5mm² cable can be used as the lighting main line to distribute power to each branch circuit.
Commercial Socket Circuits: Sockets in commercial places need to be connected to printers, copiers, small display equipment, etc. The total power of these equipment is relatively large. The 2.5mm² cable, as a socket circuit, can meet the electricity demand of multiple equipment working at the same time.
Small Industrial Control Circuits: In small factories or workshops, the control circuits of some control components such as relays and sensors have small working currents. The 2.5mm² cable can be used as a connecting line to ensure the accurate transmission of control signals.
4mm² Cable:
Power Supply for High-power Household Appliances: High-power household appliances such as air conditioners of 2 horsepower and above, electric ovens, bathroom heaters, and instant electric water heaters have large currents during startup and operation. The current-carrying capacity of the 4mm² cable can meet their power supply needs, ensuring the safe operation of the appliances.
Residential Main Incoming Lines: The main incoming lines of some residences use 4mm² cables, which can introduce external power into the residential distribution box to provide power support for the entire residential electrical system.
Special Lines for Kitchens and Bathrooms: Kitchens usually have multiple high-power electrical appliances such as refrigerators, microwave ovens, and electric kettles, and bathrooms may have water heaters, bathroom heaters, etc. To avoid overload, the special lines in these areas often use 4mm² cables, which can meet the needs of multiple high-power electrical appliances working at the same time.
Connection of Small Power Equipment: Small power equipment such as water pumps and fans have relatively large power. The 4mm² cable can be used as their power supply line to ensure the normal startup and operation of the equipment.
Conductor Material: The conductors of all three types of cables are made of high-purity electrolytic copper, which has undergone a special refining process to remove impurities, with a purity of up to 99.9% or more. High-purity electrolytic copper has excellent conductivity, with high conductivity, which can efficiently transmit current and reduce energy loss. At the same time, electrolytic copper has good ductility and plasticity, which is convenient for processing into fine copper wires and is not easy to break during stranding, ensuring the stability of the conductor structure. In addition, copper has relatively stable chemical properties, is not easy to be oxidized and corroded in normal use environments, can maintain good conductivity for a long time, and prolongs the service life of the cable.
Insulation Material: The insulation layers of all three types of cables are made of polyvinyl chloride (PVC) material, which is an excellent synthetic polymer material. PVC material has excellent electrical insulation performance, which can effectively isolate current, prevent current leakage and short-circuit accidents, and ensure the safe operation of the electrical system. It also has good chemical corrosion resistance, can resist the erosion of various chemical substances such as acids, alkalis, salts, and oils, and is suitable for use in environments with slight chemical pollution. At the same time, PVC material has certain wear resistance and mechanical strength, can withstand certain external friction and collision, and protect the internal Copper Conductor from damage. In addition, PVC material has certain flame retardant properties. When encountering an open flame, it burns slowly and can self-extinguish, reducing the risk of fire spread and buying time for personnel evacuation and fire fighting.
Style Design:
Color Options: The insulation layers of all three types of cables have a variety of colors to choose from, commonly including black, white, red, blue, yellow, etc. Different colors are used to distinguish different uses of the cables. For example, red and yellow are usually used as live wires, blue and black as neutral wires, and yellow-green bicolor as Ground Wires. Clear color identification can help quickly and accurately identify the function of the cable during installation and maintenance, reduce the risk of incorrect connection, and improve construction efficiency and the safety of the electrical system.
Appearance: All three types of cables are cylindrical overall with smooth and flat surfaces, without obvious protrusions or depressions. This regular appearance allows them to pass through conduits smoothly during laying, reducing frictional resistance. At the same time, the smooth surface is convenient for cleaning and maintenance, and is not easy to accumulate dust and dirt.
Identification Information: On the surface of the insulation layer of all three types of cables, clear identification information is printed in accordance with relevant standards, including model, specification (1.5mm², 2.5mm², 4mm²), rated voltage (450/750V), execution standard, manufacturer's name or trademark, production date, etc. These marks not only facilitate users to identify and purchase but also provide a basis for quality traceability and after-sales service, ensuring product traceability.
Copper Rod Melting and Casting: First, high-purity electrolytic copper raw materials are put into a melting furnace for melting, and the copper is melted into copper liquid at high temperature. During the melting process, the temperature and time are strictly controlled to ensure the purity and uniformity of the copper liquid. Then, the copper liquid is cast into copper rod blanks, and the diameter of the copper rod blanks is determined according to the specifications of the cable to be processed later. During casting, impurities are prevented from mixing in to ensure the quality of the copper rod blanks.
Copper Rod Drawing: The copper rod blanks are drawn through a wire drawing machine to draw the thick copper rods into fine copper wires of the required diameter. Drawing is to gradually thin the copper rod through a series of dies with different apertures, and each drawing reduces the diameter of the copper wire by a certain extent. During the process, the drawing speed, tension, and die temperature are controlled to ensure that the diameter of the copper wire is uniform, the surface is smooth, and there are no burrs or scratches. At the same time, the heat generated during drawing needs to cool the copper wire to prevent excessive temperature from affecting its mechanical properties and conductivity. The drawn fine copper wire is annealed. By heating and heat preservation, the internal stress is eliminated, and the flexibility and ductility are improved, facilitating subsequent stranding. The copper wires of different specifications have different diameters, and the die apertures used during drawing are also different.
Copper Wire Stranding: According to the requirements of cables of different specifications, multiple strands of annealed fine copper wires are stranded by a stranding machine to form conductors with corresponding cross-sectional areas. During stranding, it is carried out according to a certain stranding pitch and direction, usually using regular stranding or bunch stranding. The size of the stranding pitch affects the flexibility and filling factor of the conductor, and needs to be precisely controlled according to design requirements. During the process, it is ensured that each strand of copper wire is evenly stressed and neatly arranged, avoiding loose strands and broken strands, so as to ensure the stable structure and good conductivity of the conductor. The number of copper strands of 1.5mm², 2.5mm² and 4mm² cables is different, and the parameter settings during stranding are also different. The Stranded Conductor needs to undergo appearance inspection and size measurement to ensure that it meets the specification requirements.
Insulation Extrusion: The Stranded Copper Conductor is fed into the extruder head, and at the same time, PVC Insulation Material (granular) is added to the extruder hopper. After being heated, melted, and plasticized in the extruder, the PVC particles are uniformly extruded through the die of the head and wrapped around the outer layer of the copper conductor to form an insulation layer. During the extrusion process, parameters such as extrusion temperature, screw speed, and traction speed are precisely controlled to ensure that the insulation layer has uniform thickness, high concentricity with the conductor, a smooth surface, and no defects such as bubbles, pinholes, or cracks. The insulation layers of cables of different specifications have different thicknesses, so the dies and parameter settings during extrusion need to be adjusted accordingly. The insulation layer of the 1.5mm² cable is thinner, and that of the 4mm² cable is thicker.
Cooling and Solidification: The extruded cable immediately enters a cooling water tank for cooling. The PVC Insulation layer is quickly cooled and solidified into the required shape by cold water. The water temperature of the cooling water tank is strictly controlled, and segmented cooling is usually adopted. First, water at a lower temperature is used for preliminary cooling, and then the water temperature is gradually increased to avoid internal stress or cracks in the insulation layer due to too fast cooling. The cooled cable insulation layer should have a certain hardness and elasticity, with a smooth and tough feel.
Spark Test: To test the electrical insulation performance of the insulation layer, the cooled cable is subjected to a spark test. When the cable passes through the high-voltage electrode, if the insulation layer has defects such as pinholes and cracks, the high-voltage electricity will break down the defective part to generate sparks, and the equipment will automatically alarm. The operator will mark the defective cable for repair or rejection. The spark test can effectively detect tiny defects in the insulation layer, ensuring that the insulation performance of the cable meets the standard requirements.
Take-up and Packaging: The cables that pass the spark test are pulled to the take-up machine and wound according to the specified length (such as 100 meters, 200 meters, 500 meters, etc.). During take-up, the tension is controlled to make the cable wound neatly and tightly, avoiding looseness, distortion, or knotting. After winding, the cable is packaged, usually wrapped with plastic film. Long-length cables are wound on plastic reels or wooden shafts and then packaged as a whole. The package is printed with clear product information and logos, facilitating storage, transportation, and sales. The take-up tension and packaging methods of cables of different specifications may vary slightly due to weight and size.
Packaging Materials:
Plastic Reels: For long-length cables (such as 500 meters and 1000 meters) of all three types, plastic reels are often used for packaging. Plastic reels are made of high-strength polyethylene (PE) or polypropylene (PP) materials, which have the characteristics of light weight, high strength, corrosion resistance, and impact resistance. There is a circular shaft hole in the middle of the reel, which is convenient for operation with mechanical devices during take-up and pay-off. There are baffles on both sides to prevent the cable from slipping off the reel during transportation and storage and to protect the end of the cable from damage. Since the 4mm² cable is thicker and heavier, the plastic reels used for it have relatively higher strength.
Wooden Shafts: Some long-length cables of all three types also use wooden shafts for packaging. Wooden shafts are made of high-quality wood, with high strength and stability, and can bear large weights. Wooden shafts have low cost and are environmentally friendly and recyclable. For long-length 4mm² cables with larger weight, the load-bearing advantage of wooden shafts is more obvious.
Cartons: Short-length cables (such as 10 meters, 20 meters, 50 meters, 100 meters) of all three types are generally packaged in cartons. Cartons are made of high-strength corrugated paper, which has certain pressure resistance and moisture resistance, and can protect the cables from external pressure and moisture. The inside is usually padded with moisture-proof paper or bubble film to enhance the protection effect. Since the 4mm² cable is thicker, the cartons used for it are relatively larger in size when the length is the same.
Plastic Film: Regardless of reel or carton packaging, the outer layer of all three types of cables is wrapped with a layer of plastic film. The plastic film has good moisture-proof and dust-proof performance, which can prevent the cable from being polluted and damp during transportation and storage, and keep it clean and dry.
Packaging Methods:
Reel Packaging: The three types of cables are respectively and neatly wound on corresponding plastic reels or wooden shafts. During winding, the tension is controlled to make the cables arranged tightly and evenly without overlapping, twisting, or loosening. After winding, the entire reel and cable are tightly wrapped with plastic film and fixed with tape. Product labels are pasted on the baffles on both sides of the reel, indicating the cable's model, specification, length, rated voltage, execution standard, manufacturer, production date, etc.
Carton Packaging: A certain length of the three types of cables is respectively coiled into a circle or ellipse and placed in the corresponding carton. To prevent the cable from shaking in the carton, buffer materials such as foam blocks and bubble film are filled around the cable. Then the carton lid is closed and sealed tightly with tape. Product labels with the same information as reel packaging are printed or pasted on the surface of the carton.
Packaging Labels: The label information on the packaging is clear and standardized, meeting the requirements of relevant standards. In addition to the basic product information, some warning signs may also be printed, such as "Keep away from sunlight", "Protect from rain", "Handle with care", "Do not stack heavily", etc., to remind transportation and storage personnel to operate correctly and avoid damaging the cable due to improper operation. At the same time, the contact information of the manufacturer is indicated on the label, which is convenient for users to consult and communicate.
Transportation Methods:
Road Transportation: It is a commonly used transportation method for the three types of cables, suitable for medium and short-distance transportation. Road transportation has high flexibility, fast speed, and can realize door-to-door service. The transport vehicles are usually trucks, and the carriage should be kept clean, dry, and flat, without sharp objects and corrosive substances. For reel-packaged cables, they are fixed in the carriage to prevent rolling; for carton-packaged cables, they are stacked neatly to avoid excessive squeezing. Since the 4mm² cable is heavier, more attention should be paid to the fixation during road transportation to prevent displacement and collision.
Railway Transportation: Suitable for long-distance and large-volume transportation of the three types of cables. Railway transportation has the characteristics of large transportation volume, low cost, and good stability, which can reduce the impact of bumps and vibrations during transportation on the cables. Cables are usually transported in containers or boxcars. Container transportation can provide better protection, preventing the cables from being affected by the external environment such as rain and dust. For 4mm² cables with larger weight, railway transportation is more stable and can reduce the risk of damage.
Waterway Transportation: Mainly used for long-distance transportation across countries or regions, especially for large quantities of exported cables of the three types. Waterway transportation has low cost but takes a long time. During waterway transportation, the cables need to be stored in the cabin to avoid exposure to the open air to prevent erosion by rain, seawater, etc. It is also necessary to fix the cables to prevent them from colliding and being damaged due to ship shaking. Due to the heavy weight of 4mm² cables, more firm fixing measures are needed during waterway transportation.
Transportation Precautions:
Loading and Unloading: During loading and unloading, mechanical equipment or manual handling should be used gently to avoid rough operations such as throwing, dropping, or dragging the cables, which may cause damage to the insulation layer or conductors of the cables. For reel-packaged cables, special tools should be used to lift and move them to prevent the reels from being deformed or damaged. For 4mm² cables, due to their heavy weight, mechanical loading and unloading are preferred to ensure safety.
Stacking Requirements: When stacking cables, they should be stacked neatly and stably, and the stacking height should be appropriate to avoid collapse. Cables of different specifications and packaging forms should be stacked separately, and signs should be set for easy identification and counting. The bottom layer of the stacked cables should be padded with pallets or wooden boards to prevent moisture and corrosion. For 4mm² cables, the stacking height should be lower than that of 1.5mm² and 2.5mm² cables to avoid excessive pressure on the lower layer.
Environmental Protection: During transportation, avoid exposing the cables to harsh environments such as high temperature, low temperature, strong sunlight, and heavy rain for a long time. In hot summer, measures such as covering with sunshade nets can be taken to prevent the PVC insulation layer from aging and cracking due to high temperature; in rainy days, rainproof cloth should be used to cover the cables to prevent moisture. These environmental protection measures are applicable to all three types of cables.
Prohibition of Mixed Loading: Cables must not be mixed with flammable, explosive, corrosive, or toxic substances for transportation to avoid accidents such as fire, explosion, or cable pollution. If it is necessary to transport together with other goods, effective isolation measures must be taken. This regulation applies to all three types of cables.
Transportation Documentation: Complete transportation documents should be prepared during transportation, including waybills, packing lists, product certificates, etc. The documents should clearly indicate the product name, specification, quantity, destination, consignee, etc., to ensure smooth transportation and delivery.
Order Confirmation: After receiving the user's order, the manufacturer's sales staff will confirm the order details with the user in a timely manner, including the product specifications (1.5mm², 2.5mm², 4mm²), quantity, delivery address, delivery time, packaging requirements, etc. For special requirements put forward by users, such as customized lengths or special packaging, in-depth communication is required to ensure that both parties have a consistent understanding.
Inventory Check: According to the confirmed order information, the warehouse staff will check the inventory. If the inventory is sufficient, they will arrange for goods preparation in time; if the inventory is insufficient, they will notify the production department to arrange production as soon as possible to ensure that the goods can be delivered within the agreed delivery time. During the inventory check, it is necessary to carefully check the product's model, specification, production date, and quality status to ensure that the delivered products are qualified. For the three types of cables, separate inventory checks are required to avoid confusion.
Goods Preparation and Inspection: The warehouse staff will pick the corresponding cables according to the order requirements and conduct a comprehensive inspection of the products, including checking whether the packaging is intact, whether the labels are clear, whether the cable's appearance is damaged, etc. If any unqualified products are found, they will be replaced in time to ensure that the delivered products meet the quality standards. For 4mm² cables, special attention should be paid to checking whether the insulation layer is damaged due to its heavy weight.
Delivery Scheduling: According to the delivery address and quantity, the logistics department will choose a suitable transportation method and logistics company, and sign a transportation contract with the logistics company to clarify the rights and obligations of both parties. The delivery information, such as the logistics company's name, waybill number, and estimated arrival time, will be fed back to the user in a timely manner so that the user can track the logistics information. For large quantities of 4mm² cables, more appropriate transportation methods should be selected according to their weight and volume.
Delivery Follow-up: After the goods are delivered, the staff will track the logistics information in real-time. If there is a delay in delivery, damage to the goods, or other abnormal situations, they will communicate with the logistics company in a timely manner to solve the problem and inform the user of the processing progress. After the user receives the goods and confirms that they are correct, the delivery process is completed.
Sample Provision: Users can apply for samples of the three types of cables through the manufacturer's official website, phone, email, or other channels. When applying, they need to provide basic information such as the contact person, contact information, and delivery address, and specify the required cable specifications (1.5mm², 2.5mm², 4mm²). Generally, the manufacturer will provide samples free of charge, but the user needs to bear the sample transportation cost. The length of each sample is usually 1-5 meters, which is sufficient for users to conduct tests and evaluations.
Sample Production and Delivery: After receiving the user's sample application, the manufacturer will arrange for sample production or select qualified products from the stock as samples. The sample production strictly follows the same production process and quality standards as formal products to ensure that the sample's performance is consistent with the batch products. After the samples are ready, they will be delivered to the user through a suitable logistics method, and the logistics information will be notified to the user. For samples of different specifications, they should be packaged separately and marked clearly to avoid confusion.
Sample Feedback: After receiving the samples, the user can conduct various tests on the three types of cable samples, such as checking the appearance, measuring the size, testing the conductivity and insulation performance, etc. If the user has any questions or suggestions about the samples, they can feedback to the manufacturer in a timely manner. The manufacturer will provide professional answers and explanations based on the user's feedback, and if necessary, adjust the product according to the user's reasonable suggestions.
Quality Guarantee: The manufacturer provides a quality guarantee period for the three types of products, usually 1-3 years from the date of delivery. During the guarantee period, if the cable has quality problems (such as insulation layer cracking, conductor breakage, etc.) due to manufacturing defects, which affect the normal use, the user can apply for repair, replacement, or return with the purchase certificate and after-sales service application form. The manufacturer will verify the problem and handle it in a timely manner according to the actual situation. For 4mm² cables, which are often used in high-power scenarios, more attention is paid to the quality guarantee to ensure safe use.
Technical Support: Users can consult the manufacturer's technical staff for technical problems encountered in the process of installing, using, and maintaining the three types of cables. Technical staff will provide professional guidance and solutions through phone, email, video, or on-site service, such as providing installation specifications, answering questions about cable selection and use, and troubleshooting. For example, they can guide users to select the appropriate specification of cable (1.5mm², 2.5mm², 4mm²) according to the power of electrical equipment.
Complaint Handling: If users are dissatisfied with the product quality or service of any of the three types of cables, they can file a complaint with the manufacturer's after-sales department. The after-sales department will record the complaint content in detail, conduct an investigation and verification, and give a clear reply and handling plan within the specified time (usually 3-5 working days). For reasonable complaints, the manufacturer will take active measures to make up for the user's losses and improve the service quality.
Regular Return Visit: The manufacturer will conduct regular return visits to users who have purchased the three types of products, understand the use of the cables, collect user opinions and suggestions on the products and services, and take them as an important basis for product improvement and service optimization. Through return visits, the manufacturer can maintain good communication with users, enhance user trust and satisfaction, and establish a good corporate image. For users who use 4mm² cables in high-power scenarios, the return visit frequency may be appropriately increased to ensure the safe operation of the cables.
Hongtai Cable Technology Co., Ltd
E-mail: export@qlcables.com
sales@qlcables.com
Tel / WhatsApp: + 86-18032066271
Ajouter: Zone de développement industriel de Xiaokou, comté de Ningjin, City de Xingtai ， Province de Hebei, Chine
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