Voltage Rating: All models are rated for MV applications, covering 10kV, 20kV, and 35kV— the most common MV grades for urban distribution, industrial power supply, and renewable energy integration. The insulation system (primarily XLPE) is designed to withstand these voltage levels with a safety margin: the dielectric strength of XLPE exceeds 20kV/mm at 25°C, preventing electrical breakdown even under transient voltage spikes (e.g., from lightning or grid switching).
Current-Carrying Capacity: Determined by conductor cross-sectional area (available in 120mm², 150mm², 185mm², 240mm², 300mm², 400mm²) and installation environment. For example, a 240mm² Aluminium Conductor (Class 2 stranded) in the NA2XSY model delivers a rated current of 310A at 90°C (in air) and 280A when buried underground (soil temperature: 20°C, thermal resistivity: 1.5K·m/W). Larger 400mm² conductors reach 420A (air) and 380A (underground), suitable for high-load industrial or renewable energy projects.
Insulation Resistance: Critical for water-blocking performance, insulation resistance (measured at 70°C using a 2500V megohmmeter) exceeds 1000MΩ·km across all models. This high resistance ensures minimal leakage current, even in permanently damp underground conditions, reducing energy loss and the risk of insulation degradation.
Short-Circuit Withstand Capacity: All models can withstand short-circuit currents for 5 seconds without conductor damage: 240mm² conductors handle 25kA at 250°C, while 400mm² conductors tolerate 35kA—protecting the cable during grid faults (e.g., phase-to-phase shorts) and minimizing downtime.
Bending Radius: The stranded aluminium conductor enhances Flexibility, with a minimum bending radius of 12× the cable’s outer diameter for fixed underground installation (e.g., 144mm for a 12mm-diameter 120mm² Na2xsy Cable) and 20× for temporary handling (e.g., during trench laying). This flexibility simplifies installation in tight spaces (e.g., narrow utility trenches beneath city streets).
Impact Resistance: Tested per IEC 60811-1-1, all models withstand a 50J impact (a 5kg weight dropped from 1m) without sheath or insulation damage. The NA2XS2Y, with its double sheath, offers enhanced impact resistance (60J), making it suitable for high-traffic underground areas (e.g., beneath highways).
Temperature Range: Operates reliably in -40°C to 90°C, covering extreme climates—from cold northern regions (e.g., Siberian urban grids) to hot coastal areas (e.g., Middle Eastern solar farms). The XLPE insulation remains stable at low temperatures (no brittleness) and high temperatures (no softening), ensuring consistent performance year-round.
Corrosion Resistance: The aluminium conductor is coated with a zinc-aluminium alloy (per ISO 1461) to prevent oxidation, while the outer sheath (PVC/PE) resists soil corrosion (acidic/alkaline soils, saltwater in coastal areas). The NA2XS(FL)2Y’s low-smoke sheath further resists chemical degradation from industrial contaminants (e.g., oil, solvents in factory trenches).
Material Grade: High-purity aluminium (99.7% minimum purity) is used, with trace amounts of silicon and iron to enhance strength without compromising conductivity. This grade (AA 1350) delivers a conductivity of ≈37MS/m at 20°C—70% of copper’s conductivity—but at 30% of the weight and 40% of the cost, making it ideal for large-scale underground projects where material costs and installation weight are critical.
Stranding Design: Class 2 Stranded Conductors (per IEC 60228) consist of multiple small-diameter Aluminium Wires (0.5-2.0mm) twisted in a helical pattern. The lay length (distance of one full twist) is optimized for flexibility: 12-16× the conductor diameter for 120-240mm² conductors, and 16-20× for 300-400mm² conductors. Stranding also improves heat dissipation, as gaps between wires allow air/water flow during underground operation, preventing localized overheating.
Anti-Corrosion Treatment: After stranding, the conductor is coated with a thin layer of zinc-aluminium alloy (10-15μm thick) via hot-dip galvanizing. This coating acts as a barrier against soil moisture and chemicals, preventing aluminium oxidation (which forms a non-conductive oxide layer that degrades performance). For coastal projects, an additional epoxy resin coating (5μm thick) is available to resist saltwater corrosion.
Inner Water-Blocking Tape: Wrapped around the stranded conductor, this tape is made of non-woven polyester impregnated with water-swellable polymers (sodium polyacrylate). When exposed to moisture, the polymers expand 100-200× their original volume, sealing gaps between conductor strands and preventing water from spreading along the cable core. The tape has a thickness of 0.2-0.3mm and overlaps by 50% to ensure full coverage.
Semi-Conductive Buffer Layer: Positioned between the water-blocking tape and insulation, this layer is a semi-conductive polyethylene (SCP) compound filled with carbon black. It eliminates air gaps (which can trap moisture) and provides electrical continuity between the conductor and insulation, reducing partial discharge (a major cause of insulation failure). The buffer layer is extruded directly over the tape, ensuring a tight seal.
Outer Sheath Water Resistance: The outer sheath (varies by model) is formulated for maximum moisture barrier performance:
NA2XSY/NA2XS2Y: PVC (polyvinyl chloride) or PE (polyethylene) sheath. PVC offers excellent Chemical Resistance, while PE provides higher impact strength. Both are extruded at 180-200°C to form a dense, homogeneous layer (thickness: 2.5-4.0mm) with no pinholes (tested via helium leak detection).
NA2XS(F)2Y/NA2XS(FL)2Y: Halogen-free flame-retardant (HFFR) PE sheath. In addition to moisture resistance, this sheath contains magnesium hydroxide/aluminium hydroxide additives for flame retardancy, with a thickness of 3.0-4.5mm to balance protection and flexibility.
NA2XSY: Standard XLPE insulation (thickness: 3.5-5.0mm, depending on voltage rating) and single PVC/PE sheath. XLPE is cross-linked via peroxide cross-linking (200-250°C) to enhance high-temperature stability, while the single sheath balances cost and basic protection.
NA2XS2Y: XLPE insulation plus double sheath (inner PE, outer PVC/PE). The inner PE sheath (1.5-2.0mm thick) provides a primary moisture barrier, while the outer sheath (2.0-2.5mm thick) adds mechanical protection against soil pressure and rodent bites.
NA2XS(F)2Y: XLPE insulation (with flame-retardant additives) and double HFFR PE sheath. The insulation’s additives (magnesium hydroxide) reduce flame spread, while the Hffr Sheath self-extinguishes per IEC 60332-1.
NA2XS(FL)2Y: Low-smoke zero-halogen (LSZH) XLPE insulation and double LSZH PE sheath. The insulation and sheath use a combination of flame-retardant additives and smoke suppressants (e.g., molybdenum trioxide), ensuring smoke density (per IEC 61034) of ≤200% and halogen acid gas emission (per IEC 60754) of ≤5mg/g.
Wire Drawing: Aluminium rods (9.5mm diameter, AA 1350 grade) are pulled through diamond dies (at room temperature) to reduce their diameter to 0.5-2.0mm. The drawing process is monitored for wire diameter (via laser gauges) to ensure consistency—variations of ±0.01mm are rejected.
Stranding: Drawn wires are fed into a rotary stranding machine, where they are twisted into Class 2 Stranded Conductors. The machine’s speed (100-200rpm) is adjusted based on conductor size to maintain the correct lay length. After stranding, the conductor is inspected for uniformity (no loose wires) and measured for cross-sectional area (tolerance: ±2%).
Anti-Corrosion Coating: The stranded conductor is passed through a hot-dip galvanizing bath (450°C, zinc-aluminium alloy) to apply the anti-corrosion coating. A air knife removes excess coating, ensuring a uniform thickness (10-15μm). The coated conductor is then cooled in a water bath (20-30°C) to set the coating.
Water-Blocking Tape Wrapping: The coated conductor is fed into a tape-wrapping machine, where the water-swellable tape is applied with 50% overlap. The machine’s tension (5-10N) is controlled to avoid tape damage, and a camera system checks for full coverage (no gaps).
Buffer Layer Extrusion: A single-screw extruder (barrel temperature: 160-180°C) extrudes the semi-conductive PE buffer layer over the taped conductor. The extruder’s speed (5-10m/min) is synchronized with the conductor’s movement to ensure a uniform thickness (0.8-1.2mm). A laser diameter gauge monitors the buffer layer, with automatic speed adjustments for deviations.
XLPE Insulation Extrusion and Cross-Linking: The buffered conductor moves to a second extruder (twin-screw, barrel temperature: 180-220°C) for XLPE insulation extrusion. The insulation thickness is set based on voltage rating (3.5mm for 10kV, 5.0mm for 35kV). After extrusion, the Insulated Conductor enters a cross-linking tube, where it is heated to 200-250°C using high-pressure nitrogen. This activates the peroxide cross-linking agent, transforming the XLPE into a three-dimensional molecular structure. The cross-linked insulation is cooled in a water bath (20-30°C) to stabilize its properties.
Sheath Extrusion: For NA2XSY (single sheath) and NA2XS2Y/NA2XS(F)2Y/NA2XS(FL)2Y (double sheath), the insulated conductor is fed into a third extruder (single-screw for PVC/PE, twin-screw for HFFR/LSZH). The sheath material is extruded over the insulation at 180-200°C (PVC) or 190-210°C (PE/HFFR/LSZH). For double-sheath models, a second extruder applies the outer sheath immediately after the inner sheath (cooled to 80-100°C to ensure adhesion).
Armouring (Optional): For projects requiring extra mechanical protection (e.g., rocky soil), a Steel Tape armour layer (0.8-1.2mm thick, galvanized) is helically wrapped around the sheath. The armour is applied with 15-20% overlap using an armouring machine, with tension control (15-20N) to avoid sheath damage.
Quality Testing: After production, each cable undergoes a series of tests:
Electrical Tests: Dielectric strength (20kV/mm for 1min), insulation resistance (≥1000MΩ·km), and partial discharge (≤10pC at 1.73× rated voltage).
Water-Blocking Test: The cable is submerged in water (20°C) for 24 hours, then tested for insulation resistance (no more than 10% drop from initial value).
Mechanical Tests: Impact resistance (50J), bending test (10 cycles at minimum radius), and sheath adhesion (≥15N/10mm).
Flame-Retardant/Low-Smoke Tests (for F/FL models): Vertical flame propagation (IEC 60332-1, self-extinguish in 60s), smoke density (IEC 61034, ≤200%), and halogen acid gas (IEC 60754, ≤5mg/g).
NA2XSY: Ideal for residential districts and small commercial areas (e.g., suburban shopping centers) where fire risk is low and budget is a priority. It is commonly used to connect 10kV substations to residential neighborhoods, delivering power to 500-1000 households per cable. Its single sheath and cost-efficiency make it the most widely used model in urban low-risk zones.
NA2XS2Y: Deployed in high-traffic urban areas, such as beneath city centers, highways, or public squares. The double sheath protects against soil pressure (from heavy vehicles) and rodent bites (common in urban sewers/trenches). For example, in a downtown 20kV distribution project, NA2XS2Y 300mm² cables are used to supply power to skyscrapers, with the double sheath ensuring durability in high-pressure underground trenches.
NA2XS(F)2Y: Suitable for industrial parks with moderate fire risk (e.g., automotive factories, electronics plants). The flame-retardant sheath prevents fire spread in case of equipment malfunctions (e.g., oil leaks from machinery). A 35kV NA2XS(F)2Y 400mm² cable is often used to power industrial main transformers, where flame safety is critical for avoiding production downtime.
NA2XS(FL)2Y: Reserved for high-risk industrial areas, such as chemical plants, oil refineries, or waste treatment facilities. The low-smoke zero-halogen design minimizes toxic fume release in case of fire, protecting workers and equipment in confined underground trenches. For example, in a petrochemical complex, NA2XS(FL)2Y 240mm² cables connect MV generators to process units, ensuring safety during fire emergencies.
All Models: Used in underground renewable energy projects, such as solar farms and wind parks. The water-blocking system protects against groundwater in remote or coastal locations:
Solar Farms: NA2XSY 185mm² cables are buried underground to connect solar inverters to 10kV collection substations, with the water-blocking tape preventing moisture damage in damp soil.
Coastal Wind Farms: NA2XS2Y 240mm² cables (with epoxy-coated conductors) are used to transmit power from offshore wind turbines to onshore grids, resisting saltwater corrosion and wave-induced soil movement.
Hydroelectric Plants: NA2XS(FL)2Y 300mm² cables are deployed in underground tunnels near dams, where the low-smoke feature protects maintenance workers in case of fire.
NA2XS(FL)2Y: The primary choice for critical infrastructure, including
Reel Specifications: Reel dimensions are matched to cable size to avoid over-bending (which could damage the stranded aluminium conductor or water-blocking tape). For 120-180mm² cables (smaller cross-sections), 1.2m-diameter reels (width: 0.8m) are used, holding 500-800m of cable per reel. For 240-400mm² cables (larger cross-sections), 1.8m-diameter reels (width: 1.2m) are preferred, with a capacity of 300-500m per reel. The reel core (central cylinder) has a diameter of 0.4-0.6m, ensuring the cable is coiled with a radius larger than the minimum bending radius (12× outer diameter) to prevent structural damage.
Material Options:
Steel Reels: Used for heavy-duty applications (e.g., 400mm² cables, long-distance truck shipping). Constructed from galvanized steel (thickness: 3-5mm), they resist impact, corrosion, and deformation—critical for transporting cables over rough terrain (e.g., construction site access roads). Steel reels are reusable, and we offer a “reel return program” where customers can return undamaged reels for a 10% credit on their next order.
Wooden Reels: For lighter cables (120-180mm²) or short-distance rail shipping, wooden reels (pine or birch) are used. They are treated with anti-mold chemicals (per ISPM 15) to prevent fungal growth (which could transfer moisture to the cable sheath) and lined with a 0.2mm-thick polyethylene (PE) film to create a moisture barrier. Wooden reels are cost-effective and eco-friendly, as they are fully recyclable after use.
Protective Layers: Every coiled cable is wrapped in three protective layers to shield against moisture, dust, and abrasion:
Inner PE Film: A 0.15mm-thick PE film is tightly wrapped around the coiled cable to seal out dust and prevent direct contact with the reel (avoiding sheath scratches).
Waterproof Kraft Paper: For outdoor storage or rainy-season shipping, a layer of wax-impregnated kraft paper (thickness: 0.1mm) is applied over the PE film. This paper repels water and prevents condensation from forming on the cable surface—critical for preserving the water-blocking tape’s swellable properties (moisture exposure before installation would render it ineffective).
Outer PP Woven Bag: A heavy-duty polypropylene (PP) woven bag (weight: 120g/m²) is slipped over the entire reel, with drawstrings at both ends to secure it. The bag resists tearing during loading/unloading and provides UV protection (preventing PVC/PE sheath degradation if the reel is temporarily stored outdoors).
Labeling: Each reel features two weather-resistant labels (one on the reel face, one on the side) with permanent ink, including:
Cable details: Model (e.g., NA2XS(FL)2Y), conductor size (e.g., 240mm²), voltage rating (e.g., 20kV), length (e.g., 500m), batch number, and manufacturing date.
Handling instructions: “Do Not Stack Over 2 Layers,” “Keep Dry,” “Minimum Bending Radius: 144mm,” and “Store in Temperature: -10°C to 40°C.”
Compliance marks: IEC 60502-2, GB/T 12706.2, CE (for European markets), and UL (for North American markets, if applicable).
Emergency contact: Our technical support hotline and local distributor contact information, for quick assistance during delivery.
Container Preparation: Containers are inspected for damage (e.g., rust holes, broken seals) and lined with a 0.3mm-thick PE moisture barrier film to block saltwater vapor. A 500g desiccant bag (silica gel) is placed in each corner of the container to absorb humidity—critical for preventing condensation on the cable sheath (which could lead to mold growth or sheath degradation during long sea voyages, typically 25-40 days).
Reel Loading: Reels are loaded vertically into the container using a gantry crane (equipped with soft nylon slings to avoid reel damage). For 20ft containers, 4-6 steel reels (240mm² cables) or 8-10 wooden reels (120mm² cables) fit, depending on reel size. For 40ft containers, capacity doubles. Reels are separated by 100mm-thick wooden blocks (treated per ISPM 15) to prevent friction between them, and steel straps (grade 80, width: 25mm) are used to secure each reel to the container’s floor and side rails. The straps are tightened to 5kN tension—enough to hold reels in place during rough seas (up to 15° container tilt).
Documentation Placement: A waterproof envelope (attached to the container’s interior wall) holds all shipping documents, including:
Commercial invoice (with HS code 7326.90.90 for MV power cables).
Packing list (detailing reel count, cable model, length, and gross/net weight).
Certificate of Conformity (CoC) to IEC 60502-2/GB/T 12706.2.
Fumigation certificate (for wooden reels, per ISPM 15).
Test reports (electrical, water-blocking, and flame-retardant tests for F/FL models).
Sample Packaging: Cables are cut to the requested length, coiled into a small cardboard tube (diameter: 150mm, length: 300mm) lined with PE film, and sealed with waterproof tape. The tube is placed inside a double-walled corrugated cardboard box (thickness: 5mm) with foam padding (density: 30kg/m³) to prevent bending. A “Sample – Fragile” label is affixed to the box, and a copy of the sample test report is included.
Repair Segment Packaging: Longer repair segments (50-100m) are coiled onto small plastic reels (diameter: 600mm) and wrapped in PE film + kraft paper. The reel is placed in a wooden crate (plywood, thickness: 12mm) with steel corners for impact resistance. The crate is labeled with “Repair Part – Urgent” and includes installation instructions tailored to underground repair (e.g., jointing with water-blocking connectors).
Truck Transportation: For domestic or short-distance shipments (≤500km), we use heavy-duty flatbed trucks (capacity: 30-40 tons) equipped with air suspension (to reduce vibration) and weather-resistant tarpaulins (PVC-coated, thickness: 0.5mm) to shield reels from rain, dust, and UV radiation. Key safeguards include:
Reel Securing: Reels are placed on anti-slip rubber mats (thickness: 10mm) and secured with steel chains (grade 80, breaking strength: 80kN) and ratchet binders. For double-reel loads, wooden spacers (200×200×100mm) are placed between reels to prevent rubbing.
Route Planning: Drivers are provided with routes avoiding rough roads, low bridges, and construction zones—critical for 1.8m-diameter reels (which require clearances of ≥3m). Real-time GPS tracking is available, and customers receive daily location updates.
Temperature Control: For shipments in extreme climates (≤-10°C or ≥40°C), trucks are equipped with heated/cooled containers to prevent sheath brittleness (in cold) or softening (in heat). For example, in Siberian winter shipments, containers are heated to 5°C to keep the XLPE insulation flexible.
Rail Transportation: For longer land distances (>500km, e.g., China to Central Asia), rail transportation is cost-effective and stable. We use flatcar rail wagons (capacity: 60 tons) with reinforced floors to support heavy steel reels. Additional measures include:
Reel Fastening: Reels are bolted to the wagon’s floor using steel brackets (welded to the wagon) and secured with turnbuckles. This prevents lateral movement during train acceleration/deceleration.
Transit Monitoring: A dedicated rail supervisor inspects the wagons at key junctions (e.g., border crossings) to check reel security and tarpaulin integrity. Transit time is typically 3-7 days for cross-country shipments, with ETA updates sent to customers every 48 hours.
Vessel Selection: We choose vessels with dedicated “cable-friendly” cargo holds—ventilated, humidity-controlled (≤60% RH), and free from sharp edges that could damage reels. For F/FL models (flame-retardant), we book cargo holds with fire suppression systems (CO₂-based) to meet IMO’s IMDG Code (Class 9, miscellaneous dangerous goods).
Loading/Unloading: Containers are loaded onto vessels using gantry cranes with spreader bars (to avoid container tilting). We coordinate with the shipping line to prioritize container placement in the lower cargo hold (to minimize movement during rough seas). Unloading at the destination port is supervised by our local agent, who checks for container damage (e.g., dents, water ingress) before releasing the shipment.
Customs Clearance Support: To avoid delays, our in-house customs team prepares all required documents (including certificate of origin, HS code classification, and import permits) 7 days before the vessel arrives. For European Union destinations, we handle EORI registration and comply with REACH regulations (ensuring no restricted substances in cable materials). For North America, we assist with FDA registration (for hospital-related shipments) and CBP entry filings.
Carrier Partnerships: We work with DHL, FedEx, and UPS to secure priority air cargo space—typically delivering to major airports (e.g., Frankfurt, Shanghai Pudong, New York JFK) within 2-5 days.
Regulatory Compliance: Air shipments comply with IATA’s Dangerous Goods Regulations (DGR)—cables are classified as “non-dangerous” but require a Material Safety Data Sheet (MSDS) detailing insulation and sheath materials. For F/FL models, additional fire safety documentation is provided to meet airline requirements.
Cost Structure: Air freight costs 4-6 times more than sea freight (e.g., \(2.50/kg vs. \)0.50/kg for 240mm² cables), but we offer a 15% discount for emergency orders related to critical infrastructure (hospitals, subway systems).
Order Confirmation (Day 1-2): A sales representative sends a detailed order confirmation (via email and PDF) within 24 hours of order placement. The document includes:
Cable specifications: Model, conductor size, voltage rating, length per reel, and quantity.
Pricing: Unit price, total cost, payment terms (e.g., 30% advance, 70% against B/L copy), and currency (USD/EUR/CNY).
Production timeline: Scheduled start date, quality testing date, and estimated shipment date (typically 15-20 days for standard orders, 7-10 days for urgent orders).
Customer acknowledgment: A signature line for the customer to confirm specifications and timeline—required before production begins.
Production Scheduling (Day 3-4): The production planning team allocates resources (raw materials, machinery, labor) to the order. If any materials (e.g., LSZH sheath compound for NA2XS(FL)2Y) are out of stock, the customer is notified immediately, and alternative delivery dates are proposed. A production schedule with daily milestones is shared with the customer (e.g., “Day 5: Conductor stranding; Day 8: Water-blocking tape application”).
Production & Quality Checks (Day 5-18): Manufacturing proceeds per Section 1.3, with daily quality checks documented in a “Production Quality Log.” Key milestones (e.g., insulation extrusion, sheath application) are photographed and sent to the customer via a secure portal. If a quality issue arises (e.g., sheath pinhole detected during helium leak testing), production is paused, and the customer is consulted on corrective actions (e.g., re-extruding the sheath, adjusting the extrusion temperature).
Pre-Shipment Inspection (PSI) (Day 19-20): Before shipment, a third-party inspection agency (e.g., SGS, TÜV) conducts a PSI to verify:
Cable specifications (model, size, length) match the order.
Test reports (electrical, water-blocking, flame-retardant) are valid and meet standards.
Packaging complies with ISO 4883 and ISPM 15 (for wooden reels).
Shipment Dispatch (Day 21): Once approved, the shipment is dispatched, and the customer receives a “Shipment Confirmation Package” via email, including:
Bill of Lading (B/L) or Air Waybill (AWB).
Commercial invoice and packing list.
PSI report and test certificates.
Tracking number (for real-time shipment monitoring).
Incoterms Options:
EXW (Ex Works): Customer collects the cable from our factory (Jiangsu, China) and handles all transportation, customs, and insurance. Ideal for customers with their own logistics teams.
FOB (Free On Board): We deliver the cable to the designated port (Shanghai, Ningbo, Qingdao) and load it onto the customer’s vessel. Customer covers sea freight, insurance, and destination customs.
CIF (Cost, Insurance, and Freight): We cover transportation to the destination port and provide basic marine insurance (coverage for loss/damage due to shipwreck, fire, or piracy). Customer handles destination customs and inland transport.
DDP (Delivered Duty Paid): We handle all aspects (transportation, customs, duty payment) and deliver the cable to the customer’s warehouse. Most convenient for customers without local logistics support (additional 5% service fee applies).
Payment Terms:
Standard: 30% advance payment upon order confirmation, 70% balance against a copy of the B/L (sea) or airway bill (air).
Long-Term Customers: For customers with a 2+ year partnership, we offer 50% advance, 50% balance within 30 days of delivery (subject to credit approval).
Sample Orders: 100% payment upon sample confirmation (sample cost is credited toward bulk orders if placed within 3 months).
Replacement: We ship a replacement cable within 7 days (free of charge for manufacturing or transportation-related issues).
Repair: For minor damage (e.g., small sheath scratch), we send a repair kit (including water-blocking tape, sheath repair compound, and instructions) and dispatch a technician if needed.
Refund: For major issues (e.g., non-compliant insulation), we provide a full refund within 5 working days, including any associated transportation or installation costs.
Sample Inquiry: The customer contacts our sales team via email, phone, or our online portal, specifying:
Cable model (e.g., NA2XS(FL)2Y), conductor size (e.g., 240mm²), voltage rating (e.g., 20kV), and length (10-20m, standard sample length).
Intended test purpose (e.g., water-blocking performance, flame retardancy, electrical conductivity).
Delivery address and preferred courier (DHL, FedEx, UPS).
Sample Quotation: Within 24 hours, the sales team provides a sample quotation, including:
Sample cost: 50% of the bulk unit price (e.g., \(200 for a 10m NA2XS(FL)2Y 240mm² sample, compared to \)400 for 10m in bulk).
Shipping cost: Calculated based on destination (e.g., \(50 to Europe, \)80 to North America).
Delivery time: 5-7 days (production: 3-4 days, shipping: 2-3 days).
Sample Production & Delivery: Upon receiving the customer’s sample payment, we produce the sample using the same production process as bulk orders (to ensure consistency). The sample is packaged per Section 2.1.3 and shipped via the customer’s preferred courier. A tracking number is sent to the customer, and the sample includes a “sample test guide” with recommended test procedures (per IEC standards) and contact information for our technical team.
Test Guide & Resources: The sample test guide includes step-by-step instructions for common tests:
Water-Blocking Test: Submerge the sample in 20°C water for 24 hours, then measure insulation resistance (should remain ≥1000MΩ·km).
Flame-Retardant Test (F/FL models): Perform a vertical flame test (IEC 60332-1) – the sample should self-extinguish within 60 seconds.
Electrical Conductivity Test: Use a multimeter to measure the aluminium conductor’s resistance (should be ≤0.028264Ω·mm²/m at 20°C).
Additional resources (e.g., video tutorials for test setup) are available on our customer portal.
Technical Consultation: Our team of electrical engineers (with 5+ years of Mv Cable experience) is available via video call, phone, or email to:
Answer questions about sample testing (e.g., “How to properly measure insulation resistance after water submersion?”).
Interpret test results (e.g., “A 5% drop in insulation resistance is within acceptable limits for underground use”).
Recommend bulk order adjustments (e.g., “If you need higher flame retardancy, we can increase the HFFR additive ratio in the sheath”).
Third-Party Testing Arrangement: If the customer requires certified testing (e.g., for project approval by a local authority), we can arrange for the sample to be tested at an accredited third-party lab (TÜV, Intertek, SGS) at a 20% discount (due to our bulk lab partnerships). The lab provides a certified test report within 10 days, which can be used for project documentation.
Did the sample meet your test requirements?
Are there any adjustments needed for the bulk order (e.g., thicker sheath, higher voltage rating)?
What is your expected timeline for placing a bulk order?
Installation Manual: Every bulk order includes a detailed installation manual (available in English, Spanish, French, German, and Chinese) covering:
Pre-Installation Checks: Inspecting the cable for damage (sheath scratches, water-blocking tape exposure), verifying reel labels (model, size, voltage), and checking storage conditions (should be stored in a dry, 10-30°C environment).
Handling Guidelines: Minimum bending radius (12× outer diameter for fixed installation), lifting procedures (use soft slings to avoid sheath damage), and avoiding dragging the cable over rough surfaces (to prevent water-blocking tape damage).
Trench Preparation: Trench depth (≥0.7m for residential areas, ≥1.0m for roadways), backfill material (sand or fine gravel to avoid sheath abrasion), and drainage (installing perforated pipes to prevent water accumulation in the trench).
Jointing & Termination: Step-by-step instructions for jointing (using compression joints compatible with aluminium conductors) and termination (using MV cable lugs), with emphasis on sealing joints to maintain water resistance (e.g., using heat-shrinkable sleeves with water-blocking adhesive).
Post-Installation Testing: Insulation resistance test, phase continuity test, and (for F/FL models) a visual inspection of the (e.g., using heat-shrinkable waterproof sleeves).
Post-Installation Testing: Recommended tests after installation, including insulation resistance measurement (to confirm no damage during laying) and phase continuity testing (to ensure correct conductor connection).
On-Site Technical Support: For large-scale or complex projects (e.g., urban subway power networks, industrial park underground grids), we offer on-site technical support:
Pre-Installation Site Assessment: A certified technician visits the project site before installation to inspect trench conditions (e.g., soil type, moisture level), verify cable routing plans (to avoid conflicts with other utilities), and provide customized installation recommendations (e.g., “Use sand backfill instead of gravel in clay soil to reduce sheath abrasion”).
Installation Supervision: During critical installation phases (e.g., cable pulling, jointing), the technician remains on-site to monitor compliance with the installation manual, address real-time issues (e.g., cable getting stuck in the trench), and ensure joint sealing meets water-blocking standards.
Training for Installation Teams: The technician conducts a 1-day on-site training session for the customer’s installation team, covering hands-on skills such as proper cable bending, joint compression, and waterproof sleeve application. Training materials (e.g., step-by-step video guides, checklists) are provided for future reference.
Cost Coverage: The customer covers the technician’s travel and accommodation costs, but the technical support and training services are provided free of charge for orders exceeding \(50,000. For smaller orders, a flat fee of \)500/day applies.
Covered Defects:
Conductor Defects: Issues such as aluminium wire breakage (due to poor stranding), inconsistent cross-sectional area (beyond ±2% tolerance), or reduced conductivity (below 37MS/m at 20°C) caused by substandard raw materials or manufacturing errors.
Water-Blocking System Defects: Failure of the water-blocking tape (e.g., no swelling when exposed to moisture) or buffer layer (e.g., delamination from the conductor) leading to moisture ingress and insulation resistance drop (below 1000MΩ·km within the warranty period).
Insulation & Sheath Defects: Degradation of XLPE insulation (e.g., cracking, peeling) or outer sheath (e.g., premature aging, pinholes) due to faulty extrusion or cross-linking, resulting in electrical breakdown or moisture penetration.
Flame-Retardant/Low-Smoke Defects (F/FL Models): Failure to meet flame-retardant standards (e.g., not self-extinguishing within 60 seconds per IEC 60332-1) or excessive smoke/halogen emission (exceeding IEC 61034/60754 limits) due to incorrect additive ratios in the sheath material.
Exclusions: The warranty does not cover damage caused by:
Improper installation (e.g., bending below the minimum radius, using incompatible joint materials).
External factors (e.g., rodent bites, construction equipment impact, soil corrosion from unforeseen chemical contaminants).
Unauthorized modifications (e.g., cutting and re-jointing the cable without our technical approval).
Warranty Claim Process:
Claim Submission: The customer submits a warranty claim via our online portal or email, including:
Proof of purchase (order confirmation, delivery receipt).
Photos/videos of the defect (showing the cable model, batch number, and issue).
A brief description of the problem (e.g., “Insulation resistance dropped to 500MΩ·km after 2 years of underground use”).
Claim Review: Our quality team reviews the claim within 24 hours. If additional information is needed (e.g., test reports), we request it from the customer.
Defect Verification: For complex claims, we may arrange for a third-party lab (e.g., TÜV) to test a sample of the defective cable at our cost. The lab’s report determines if the defect is manufacturing-related.
Resolution: Approved claims are resolved within 7 days, with three options for the customer:
Replacement: We ship a new cable of the same model/size, covering all transportation costs.
Repair: For localized defects (e.g., a single joint failure), we send a repair kit and dispatch a technician to fix the issue on-site.
Refund: For irreparable defects (e.g., widespread insulation degradation), we provide a full refund of the defective cable’s cost, plus any associated installation costs (if the defect is discovered within 1 year of installation).
Preventive Maintenance Schedule: We provide a customized maintenance plan based on the cable’s application and environment, with recommended intervals for inspections and tests:
Quarterly Checks: Visual inspection of above-Ground Cable segments (e.g., trench openings, junction boxes) for signs of damage (e.g., sheath cracks, water accumulation).
Semi-Annual Tests: Measurement of insulation resistance (using a 2500V megohmmeter) to detect early signs of moisture ingress or insulation degradation. For F/FL models, a simplified flame-retardant test (using a small propane torch) is recommended if the cable is in a high-fire-risk area.
Annual Comprehensive Inspection: A detailed assessment including:
Conductor temperature monitoring (using infrared thermometers) to check for overheating (indicative of poor connections or overloading).
Trench condition inspection (e.g., checking for erosion, standing water) and drainage system maintenance.
Joint inspection (checking for leaks, corrosion, or abnormal heating).
Troubleshooting Support: If the customer encounters issues (e.g., power loss, high leakage current), we offer multiple support channels:
24/7 Technical Hotline: Our team of engineers is available 24 hours a day, 7 days a week via phone or WhatsApp to provide immediate guidance. Common issues resolved via the hotline include:
“Insulation resistance is low—how to identify if it’s moisture ingress or conductor damage?”
“The cable is overheating at the joint—what steps to take to fix it?”
Remote Diagnostics: For complex issues, we use video calls to view the cable and installation site, guiding the customer through diagnostic tests (e.g., phase continuity checks, voltage drop measurements). We also accept data logs from the customer’s monitoring system (e.g., temperature, current) to analyze performance trends.
On-Site Troubleshooting: If remote support is insufficient (e.g., a major fault in a subway power cable), we dispatch a technician to the site within 48 hours (for domestic customers) or 72 hours (for international customers). The technician diagnoses the issue, provides a detailed report, and implements a solution (e.g., replacing a damaged cable segment, repairing a faulty joint).
Maintenance Training: We offer annual maintenance training workshops (in-person at our factory or online via webinar) for the customer’s maintenance team. The training covers:
Proper use of testing equipment (e.g., megohmmeters, infrared thermometers).
Identification of early warning signs (e.g., discolored sheath indicating overheating, musty odor indicating moisture ingress).
Emergency response procedures (e.g., isolating a faulty cable segment to prevent power outages in other areas).
Feedback Collection Channels:
Post-Delivery Survey: Within 1 week of delivery, customers receive a short online survey (8 questions) covering satisfaction with packaging, delivery timeliness, and product quality.
Quarterly Check-Ins: For long-term customers (orders exceeding $100,000), our account managers conduct quarterly phone calls to discuss cable performance, installation challenges, and future project needs.
Annual Customer Summit: We host an annual virtual summit for key customers, where they can share feedback directly with our product development, manufacturing, and support teams. The summit also includes presentations on new product enhancements (e.g., improved water-blocking tape, higher-temperature-resistant XLPE insulation).
Feedback Analysis & Action:
All feedback is compiled into a monthly “Customer Feedback Report” and reviewed by our senior management team. Feedback is categorized by type (e.g., product quality, service, delivery) and prioritized based on frequency and impact.
For product-related feedback (e.g., “The NA2XS2Y sheath is prone to scratching in rocky soil”), our R&D team conducts tests to validate the issue and develops solutions (e.g., increasing sheath thickness from 3.0mm to 3.5mm for rocky soil applications).
For service-related feedback (e.g., “On-site technical support took too long to arrive”), we adjust our processes (e.g., expanding our network of international technicians to reduce response times).
Feedback Follow-Up:
Customers who provide critical feedback (e.g., reporting a product defect) receive a follow-up within 2 weeks to inform them of the actions we are taking.
After implementing a solution (e.g., launching an enhanced sheath material), we notify relevant customers and offer them a free sample of the improved product for testing.
We publish an annual “Customer Feedback & Improvement Report” highlighting key feedback trends, actions taken, and future improvement plans. This report is shared with all customers to demonstrate our commitment to transparency and continuous improvement.
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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