Cu/XLPE/PVC 3*70+1*35 Copper Power Cable

Material: High-purity electrolytic copper with a minimum purity of 99.95%, ensuring exceptional electrical conductivity (≥58 MS/m at 20°C). This high purity minimizes energy loss during transmission, a critical factor for efficient power distribution.

Stranding Configuration: Both the 70mm² phase conductors and 35mm² neutral conductor 采用 class B stranding (per IEC 60228). The 70mm² conductors consist of 37 strands of 1.5mm diameter Copper Wire, while the 35mm² conductor comprises 19 strands of 1.5mm diameter wire. This stranding design enhances Flexibility, allowing the cable to be bent and routed easily in complex installation environments.

Cross-Sectional Area: Precisely controlled at 70mm² for the Three Phase Conductors and 35mm² for the neutral conductor. This ratio (2:1) is optimized for three-phase systems where the neutral conductor typically carries less current than the phase conductors under balanced loads.

DC Resistance: At 20°C, the resistance is ≤0.268Ω/km for the 70mm² conductors and ≤0.524Ω/km for the 35mm² conductor, ensuring minimal voltage drop even over long cable runs.

Material Properties: Cross-linked polyethylene (XLPE) formed through either chemical cross-linking (using organic peroxides) or radiation cross-linking (via electron beam irradiation). This cross-linking process transforms the linear polyethylene molecules into a three-dimensional network, significantly enhancing thermal stability and mechanical strength compared to non-cross-linked polyethylene.

Thickness: Uniformly extruded at 1.4mm for all conductors (both 70mm² and 35mm²), providing a dielectric strength of ≥20kV/mm. This thickness ensures effective insulation between conductors and against ground, preventing electrical breakdown under normal operating conditions.

Temperature Ratings: Designed for continuous operation at 90°C, with short-circuit (5-second duration) temperature tolerance up to 250°C. This high-temperature capability allows the cable to handle temporary overloads and fault conditions without permanent insulation damage.

Insulation Resistance: Exceeds 1000MΩ·km at 20°C, ensuring low leakage current and reliable insulation performance over the cable’s service life.

Water Tree Resistance: The XLPE insulation is formulated to resist water treeing, a phenomenon where moisture-induced conductive paths form in the insulation, which can lead to premature failure. This makes the cable suitable for damp and wet environments.

Filling Material: Polypropylene rope is used to fill the interstices between the Insulated Conductors, ensuring a round and stable cable core. This prevents conductor movement within the sheath and provides additional mechanical support.

Binder Layer: A non-woven polyester tape is helically wrapped around the filled conductors with a 20% overlap. This layer holds the conductors and filler in place, preventing shifting during handling and installation, and provides a smooth surface for the outer sheath extrusion.

Material Composition: Polyvinyl chloride (PVC) compound blended with flame-retardant additives (antimony trioxide), UV stabilizers (carbon black), and phthalate-free plasticizers. This formulation ensures the sheath is flexible, durable, and resistant to environmental degradation.

Thickness: 1.8mm, providing robust mechanical protection against abrasion, impact, and crushing. The thickness is consistent around the entire cable circumference, ensuring uniform protection.

Mechanical Properties: Tensile strength ≥12MPa, elongation at break ≥150%, and impact resistance ≥10kJ/m² at -10°C. These properties ensure the sheath can withstand the rigors of installation and operation, including bending, pulling, and contact with sharp objects.

Flame Retardancy: Meets IEC 60332-1 (vertical flame test) and achieves a UL 94 V-0 rating, ensuring the sheath self-extinguishes within 10 seconds after the flame source is removed, reducing fire spread risk.

Chemical Resistance: Resistant to dilute acids, alkalis, mineral oils, and most industrial solvents, making it suitable for use in harsh chemical environments.

Rated Voltage: 0.6/1kV (phase-to-earth/phase-to-phase), compliant with IEC 60502-1 and BS 6346 standards, suitable for low-voltage distribution systems.

Current-Carrying Capacity (Ampacity):

Outer Diameter: Approximately 28mm, ensuring the cable can fit into standard conduits and cable trays.

Minimum Bending Radius: 12 times the outer diameter (336mm) for fixed installations; 20 times the outer diameter (560mm) for flexible installations, allowing for routing in tight spaces.

Weight: Approximately 2.2kg/m, influencing handling requirements and transportation costs.

Manufacturing Facilities: Serves as a primary Distribution Cable in factories, connecting main distribution panels to secondary panels that power machinery such as compressors, pumps, conveyors, and medium-sized motors (50-100kW). The cable’s high ampacity and thermal stability ensure continuous operation under the heavy, intermittent loads typical in manufacturing.

Processing Plants: Used in food processing, chemical, and pharmaceutical plants to supply power to processing equipment. The XLPE insulation’s resistance to moisture and chemicals, combined with the PVC sheath’s durability, makes it suitable for these harsh environments.

Warehouses and Logistics Centers: Powers material handling equipment (forklifts, pallet jacks), lighting systems, and climate control units. The cable’s flexibility allows for installation in tight spaces between racks and machinery.

Shopping Malls and Retail Complexes: Distributes power to central air conditioning systems, escalators, elevators, and tenant spaces. The flame-retardant PVC sheath enhances safety in crowded public areas, while the cable’s ampacity supports the high power demands of commercial facilities.

Hotels and Hospitality Buildings: Supplies power to guest rooms, kitchens, laundry facilities, and HVAC systems. The cable’s reliability ensures uninterrupted service, critical for maintaining guest comfort.

Office Buildings: Used in the main distribution system to connect building service panels to floor panels, powering lighting, computers, printers, and HVAC units. The cable’s compact design allows for installation in ceiling voids and wall cavities.

High-Rise Apartments: Serves as the main Feeder Cable from the building’s main switchboard to floor distribution boards, providing power to multiple residential units. The 370+135 configuration efficiently handles the combined load of lighting, appliances, and HVAC systems in multi-dwelling units.

Luxury Villas and Large Homes: Used for underground service entrances and main distribution within the property, supporting high-power appliances such as electric vehicles, home theaters, and central heating systems.

Hospitals and Healthcare Facilities: Powers critical equipment such as MRI machines, ventilators, and emergency lighting systems. The cable’s reliability and flame retardancy are essential in healthcare environments where power interruptions can have life-threatening consequences.

Educational Institutions: Distributes power to classrooms, laboratories, and sports facilities. The cable’s durability ensures long-term performance in high-traffic areas with frequent equipment movement.

Transportation Hubs: Used in airports, train stations, and bus terminals to power lighting, security systems, and passenger amenities. The cable’s resistance to environmental factors makes it suitable for both indoor and outdoor installations in these busy facilities.

Damp and Wet Locations: Suitable for installation in basements, underground parking lots, and near water features (swimming pools, fountains) due to the XLPE insulation’s moisture resistance and PVC sheath’s water resistance.

Outdoor Installations: When properly protected (e.g., in conduit or cable trays), the cable can be used for outdoor lighting, signage, and power supply to external equipment. The UV-stabilized PVC sheath prevents degradation from sunlight exposure.

Flame-Retardant Zones: Meets the fire safety requirements of buildings with strict flame-retardant standards, such as high-rise structures, hospitals, and schools, where fire spread must be minimized.

High-purity electrolytic copper is chosen for its exceptional electrical conductivity, which minimizes energy loss during transmission. The copper is annealed at 400-500°C in a nitrogen atmosphere to reduce brittleness and improve ductility, making it easier to strand and bend without cracking.

The stranded configuration (class B) enhances flexibility compared to solid conductors, allowing the cable to be routed around obstacles and bent to tight radii during installation. This flexibility is particularly important in commercial and industrial buildings where space is limited.

XLPE is preferred over traditional polyethylene due to its superior thermal and mechanical properties. Chemical cross-linking involves adding organic peroxides to the polyethylene, which decompose during extrusion to form cross-links between polymer chains. Radiation cross-linking uses electron beams to induce cross-linking without chemical additives, resulting in a purer Insulation Material with consistent properties.

The insulation is color-coded for phase identification: brown (L1), black (L2), gray (L3), and blue (neutral), ensuring correct installation in three-phase systems. This color coding helps electricians identify and connect the conductors properly, reducing the risk of phase reversal or short circuits.

Polypropylene rope is used as filler because it is lightweight, non-hygroscopic, and resistant to chemical degradation. It ensures the cable core remains round, which is essential for uniform sheath extrusion and prevents conductor movement that could lead to insulation damage.

The non-woven polyester binder tape is strong, tear-resistant, and heat-resistant, providing a stable base for the outer sheath. It also acts as a barrier between the insulated conductors and the sheath, reducing friction and preventing abrasion during installation.

The PVC sheath is formulated to provide a balance of flexibility, durability, and flame retardancy. Phthalate-free plasticizers are used to ensure flexibility at low temperatures (down to -15°C), while UV stabilizers protect against degradation from sunlight, extending the cable’s service life in outdoor applications.

The sheath is typically black, which provides UV resistance and a uniform appearance, making it suitable for both indoor and outdoor installations. Black is also a neutral color that blends with most environments, reducing visual impact.

The cable has a round, compact design with the three phase conductors and one neutral conductor twisted together to form a stable core. The filling and binder layer ensure the core remains round and compact, while the outer PVC sheath provides a smooth, uniform surface.

The overall design is robust yet flexible, allowing for easy handling and installation. The cable’s diameter (28mm) is compatible with standard conduits, cable trays, and gland sizes, making it easy to integrate into existing electrical systems.

Wire Drawing: Copper rods (8mm diameter) are drawn through a series of diamond dies to reduce their diameter to 1.5mm. This process increases the copper’s tensile strength while maintaining its conductivity. The drawn wires are inspected for diameter uniformity and surface quality.

Annealing: The 1.5mm wires are annealed in a continuous furnace at 400-500°C under a nitrogen atmosphere to relieve internal stresses. Annealing softens the copper, improving its ductility and making it easier to strand.

Stranding: For the 70mm² conductors, 37 strands of 1.5mm wire are twisted together in a planetary stranding machine at a lay length of 16-20 times the conductor diameter. For the 35mm² conductor, 19 strands of 1.5mm wire are stranded using the same process. The stranding machine ensures uniform tension and lay length to maintain conductor roundness and flexibility.

Each Stranded Conductor is fed into an insulation extrusion line. The XLPE compound (mixed with cross-linking agents for chemical cross-linking) is melted in an extruder at 120-150°C and forced through a cross-head die, which applies a 1.4mm thick layer of insulation around the conductor.

Color Coding: Pigments are added to the XLPE compound during extrusion to achieve the required phase colors (brown, black, gray, blue).

Cross-Linking: The insulated conductors pass through a curing tube where cross-linking is completed. For chemical cross-linking, the tube is filled with high-pressure steam (180-200°C) to activate the peroxides. For radiation cross-linking, the conductors are exposed to an electron beam (10-30 MeV) to induce cross-linking.

Cooling and Sizing: The insulated conductors are cooled in a water bath to solidify the insulation, and a sizing die ensures the insulation thickness is uniform. The conductors are then spooled for the next process.

The three 70mm² insulated phase conductors and one 35mm² insulated neutral conductor are fed into a cabling machine, where they are twisted together with a lay length of 12-16 times the cable diameter. Polypropylene rope filler is added to fill the gaps between the conductors, ensuring a round core.

A non-woven polyester tape is helically wrapped around the cabled core with a 20% overlap to bind the conductors and filler together. This tape is applied under controlled tension to ensure a tight, stable core.

The cabled core is fed into a sheath extrusion line. The PVC compound (mixed with plasticizers, stabilizers, and flame retardants) is melted in an extruder at 170-190°C and extruded over the cabled core through a cross-head die, forming a 1.8mm thick outer sheath.

Cooling and Sizing: The Sheathed Cable is cooled in a water bath to solidify the PVC, and a sizing die ensures the outer diameter is consistent (28mm). The cable surface is inspected for imperfections, and any defects are corrected.

Conductor Testing: Each conductor is tested for resistance using a micro-ohmmeter to ensure it meets the specified DC resistance requirements.

Insulation Testing: Insulated conductors are tested for dielectric strength (applying 2.5kV for 5 minutes) and insulation resistance (using a megohmmeter) to verify insulation integrity.

Cable Testing: The finished cable undergoes several tests, including:

Dimensional Checks: The cable’s outer diameter, insulation thickness, and sheath thickness are measured at multiple points to ensure compliance with specifications.

The finished cable is wound onto steel or wooden spools with a diameter of 800mm-1200mm, depending on the order length. Standard lengths are 100m, 250m, 500m, and 1000m. Each spool is labeled with product details, batch number, and compliance marks for traceability.

Steel Spools: Used for lengths of 500m and 1000m. These spools have a steel frame with reinforced flanges (300mm width) to support the cable’s weight (approximately 1100kg for 500m and 2200kg for 1000m). The flanges are coated with a rust-resistant paint to prevent corrosion during storage and transportation.

Wooden Spools: Used for shorter lengths (100m and 250m). These spools are made from high-density plywood with steel reinforcing rings around the flanges to prevent splitting. The wood is treated with a water-resistant sealant to protect against moisture damage.

The cable on each spool is wrapped with a UV-resistant polyethylene film (0.1mm thick) to protect against dust, dirt, and moisture. This film is transparent, allowing for visual inspection of the cable without unwrapping.

For long-term storage (over 6 months), an additional layer of kraft paper is applied between the cable and the polyethylene film. This paper absorbs any condensation that may form, preventing moisture from reaching the PVC sheath and causing degradation.

Each spool features a durable, weather-resistant label printed with the following information:

Smaller spools (100m and 250m) are palletized on wooden pallets (1200mm x 800mm) with a maximum of 4 spools per pallet. The pallets are shrink-wrapped with a heavy-duty polyethylene film to secure the spools and protect against damage during transportation.

Larger spools (500m and 1000m) are shipped individually, with steel brackets attached to the spool flanges to facilitate handling with forklifts or cranes.

Road Transport: For domestic shipments, flatbed trucks or enclosed vans are used. Flatbed trucks are equipped with spool-holding racks and winches to secure the spools, while enclosed vans are used in inclement weather to protect against rain, snow, and extreme temperatures.

Rail Transport: For long-distance domestic or international shipments, railcars with specialized spool cradles are utilized. The cradles are padded with rubber to prevent damage to the spool flanges during transit.

Sea Transport: For international shipments, spools are loaded into 20-foot or 40-foot shipping containers. Steel spools are secured to the container floor using twist locks, while wooden spools are strapped down with steel bands. Desiccant bags are placed inside the containers to control humidity and prevent moisture buildup.

Spools must be lifted using forklifts with padded tines or cranes with soft slings (nylon webbing) to avoid damaging the flanges. Under no circumstances should a spool be lifted by the cable itself, as this can stretch or damage the conductors and insulation.

During loading and unloading, the cable end must be secured to the spool with a plastic tie to prevent unwinding. Spools should be stored upright at all times to maintain stability.

When transporting multiple spools, they must be separated by wooden blocks to prevent contact and friction, which could damage the PVC sheath.

The cable should be transported at temperatures between -20°C and 50°C. In cold climates, spools should be wrapped with insulation blankets to prevent the PVC sheath from becoming brittle. In hot climates, reflective tarps should be used to shield the spools from direct sunlight, preventing overheating of the insulation and sheath.

During sea transport, containers must be ventilated to prevent condensation. Humidity levels inside the container should be maintained below 70% to avoid moisture damage.

Upon receipt of an order, a confirmation is sent to the customer within 24 hours, including details such as order number, cable specifications, quantity, delivery address, and estimated delivery date.

For custom orders (e.g., non-standard lengths or special sheath colors), a production timeline is provided, typically 7-10 business days for manufacturing and 3-5 business days for delivery.

Customers are provided with a tracking number once the shipment leaves the warehouse. This allows them to monitor the shipment’s progress in real-time via the carrier’s website or mobile app.

Delivery notifications are sent 24 hours in advance, including the carrier’s name, estimated delivery time window, and contact information for the delivery driver.

Upon delivery, the customer is required to inspect the spools for visible damage (e.g., dented flanges, torn packaging, or cable sheath damage). Any damage must be noted on the delivery receipt and reported to the supplier within 48 hours.

The customer should also verify that the quantity and specifications of the delivered cable match the order confirmation.

Standard samples are 1m in length, with both ends stripped of the PVC sheath and insulation to expose the conductors. This allows customers to inspect the conductor stranding, insulation thickness, and overall construction.

Custom samples (e.g., longer lengths or with specific testing modifications) can be provided upon request, with a lead time of 3-5 business days.

Samples can be ordered through the supplier’s website, email, or phone. There is no charge for standard samples, but customers are responsible for shipping costs (typically \(10-\)20 via express courier).

A sample request form must be completed, including the customer’s name, company, contact information, and intended use of the sample (e.g., electrical testing, mechanical testing, or quality inspection).

The supplier provides a certificate of compliance with each sample, detailing the cable’s specifications and test results (e.g., conductor resistance, insulation thickness, and flame retardancy).

Technical support is available to assist customers with testing procedures, including recommendations for accredited laboratories and test standards (e.g., IEC 60502-1, UL 44).

The cable is covered by a 5-year warranty against manufacturing defects, including issues such as insulation breakdown, conductor corrosion, or sheath cracking under normal operating conditions.

The warranty does not cover damage caused by improper installation, mishandling, or exposure to extreme conditions beyond the cable’s rated specifications.

A team of technical engineers is available to provide assistance with installation, troubleshooting, and maintenance. This support can be accessed via phone, email, or video conference, with response times typically within 2 hours during business hours.

Installation guides and technical datasheets are available for download from the supplier’s website, including detailed instructions on cable handling, termination, and testing.

If a cable is found to be defective within the warranty period, the supplier will arrange for a replacement or refund, including shipping costs. The defective cable must be returned to the supplier for inspection, with a return authorization number provided by the customer service team.

For non-defective returns (e.g., overstock or incorrect order), a 20% restocking fee applies, and the cable must be in its original packaging, unused, and returned within 30 days of delivery.

The supplier actively seeks customer feedback on the cable’s performance and service quality. This feedback is used to identify areas for improvement in manufacturing, packaging, delivery, and customer support.

Customers are invited to participate in product development surveys, providing input on new features or specifications that would better meet their needs (e.g., enhanced chemical resistance, higher temperature ratings, or smaller outer diameter).