I. From the Perspective of the Product Itself
(I) Specification Parameters
120mm² Specification
The 120mm² XLPE copper
Power Cable comes in both 3-core and 2-core structures. In the 3-core structure, each conductor has a cross-sectional area of 120mm², which is suitable for three-phase circuits as a whole; the 2-core structure is suitable for single-phase circuits. The rated voltage of this specification cable covers the medium and low voltage range, usually 0.6/1kV to 10kV, which can meet the needs of different medium and low voltage distribution scenarios.
In terms of current-carrying capacity, the 3-core 120mm² cable has a long-term allowable current-carrying capacity of approximately 280A when laid in air; when laid in soil, it is about 330A. The 2-core 120mm² cable has a long-term allowable current-carrying capacity of about 300A when laid in air and about 350A in soil. The large current-carrying capacity enables it to meet the needs of high-power power transmission.
The thickness of the insulation layer is 1.6mm, which can ensure that the cable has good insulation performance under the rated voltage, effectively block the current, and prevent electric leakage. The outer diameter of the cable varies slightly depending on the number of cores. The outer diameter of the 3-
Core Cable is about 55mm, and that of the 2-core cable is about 48mm.
In terms of bending radius, the static bending radius is not less than 12 times the outer diameter of the cable, and the dynamic bending radius is not less than 20 times the outer diameter of the cable. During installation and laying, this standard must be followed to avoid damage to the cable due to excessive bending.
35mm² Specification
The 35mm² specification also has 3-core and 2-core structures. The 3-core structure has a cross-sectional area of 35mm² per core, suitable for three-phase circuits; the 2-core structure is suitable for single-phase circuits. The rated voltage is the same as that of the 120mm² specification, ranging from 0.6/1kV to 10kV.
In terms of current-carrying capacity, the 3-core 35mm² cable has a long-term allowable current-carrying capacity of about 140A when laid in air and about 170A in soil; the 2-core 35mm² cable has a current-carrying capacity of about 150A in air and about 180A in soil, which is suitable for power transmission of medium-sized loads.
The thickness of the insulation layer is 1.4mm, which can meet the insulation requirements of medium and low voltage distribution systems. The outer diameter of the 3-core cable is about 38mm, and that of the 2-core cable is about 32mm.
In terms of bending radius, the static bending radius is not less than 10 times the outer diameter of the cable, and the dynamic bending radius is not less than 15 times the outer diameter of the cable, which is convenient for operation in different installation environments.
25mm² Specification
The 3-core and 2-
Core XLPE Copper Power Cables of 25mm² specification, the 3-core is suitable for three-phase circuits, the 2-core is suitable for single-phase circuits, with a rated voltage of 0.6/1kV to 10kV.
In terms of current-carrying capacity, the 3-core 25mm² cable has a long-term allowable current-carrying capacity of about 100A when laid in air and about 120A in soil; the 2-core 25mm² cable has a current-carrying capacity of about 110A in air and about 130A in soil, which is suitable for small-scale power distribution needs.
The thickness of the insulation layer is 1.2mm, which can ensure good insulation performance. The outer diameter of the 3-core cable is about 32mm, and that of the 2-core cable is about 26mm.
The bending radius is the same as that of the 35mm² specification, with the static bending radius not less than 10 times the outer diameter of the cable and the dynamic bending radius not less than 15 times the outer diameter of the cable, which is convenient for installation in narrow spaces.
(II) Characteristic Uses
120mm² Specification
The industrial field is an important application scenario for the 120mm² specification cable. Heavy machinery and production lines in large factories are high-power equipment with large and stable power demand. The 3-core 120mm² cable is suitable for three-phase circuits and can provide sufficient and stable power for these equipment, ensuring the continuous progress of production.
In the main power distribution system of large buildings, this specification of cable also plays a key role. For example, large shopping malls, office buildings, hotels, etc., need to efficiently transmit electricity from substations or distribution rooms to various areas. The 3-core 120mm² cable can be used as the main distribution line to meet the power demand of many electrical equipment in the building.
The 2-core 120mm² cable is suitable for power supply of some large single-phase equipment, such as large refrigeration equipment, large electric welders, etc., to ensure the normal operation of these equipment.
35mm² Specification
The 35mm² specification cable is widely used in power distribution of medium-sized industrial equipment. For equipment such as small and medium-sized machine tools, fans, water pumps, etc., with moderate power, the 3-core 35mm² cable can meet their three-phase power supply needs and ensure the stable operation of the equipment.
This specification of cable is also commonly used in branch power distribution of commercial buildings. For branch lines on each floor of large shopping malls and power distribution in office areas of office buildings, the 3-core 35mm² cable can distribute power from the main line to various power points, providing power for lighting, air conditioning, office equipment, etc.
The 2-core 35mm² cable can be used for power supply of some medium-sized single-phase equipment, such as medium-sized air conditioners, elevator auxiliary equipment, etc.
25mm² Specification
The 25mm² specification cable is widely used in civil power distribution. In the branch power distribution of residential communities, electricity is distributed from the main line to each household. The 2-core 25mm² cable is suitable for single-phase circuits and can meet the power demand of household appliances and lighting.
This specification of cable is also often used for power supply of small equipment in small industrial workshops. For example, equipment such as small lathes and grinders have small power. The 3-core 25mm² cable can provide three-phase power, and the 2-core can be used for single-phase small equipment.
In addition, the 25mm² specification cable can also meet the power transmission needs in the power distribution of some small public facilities, such as community activity centers and small supermarkets.
(III) Material and Style
Conductor Material
The conductors of the three specifications of cables are all made of high-purity copper with a purity of more than 99.9%. High-purity copper has excellent conductivity, which can reduce resistance, reduce energy loss during power transmission, and improve power transmission efficiency. At the same time,
Copper Conductors have good ductility and mechanical strength, and are not easy to break during the production, installation and use of the cable, which can ensure the structural stability of the cable.
Insulation Layer Material
The insulation layer is made of cross-linked polyethylene (XLPE). XLPE is a polyethylene material that has undergone cross-linking treatment and has excellent performance. It has strong temperature resistance, with a long-term service temperature of up to 90℃. In abnormal situations such as short circuits, it can maintain certain insulation performance at higher temperatures, improving the safety and reliability of the cable. XLPE has stable insulation performance, high insulation resistance, and low dielectric loss, which can effectively prevent current leakage and ensure the safety of power transmission. In addition, XLPE also has good anti-aging performance and chemical corrosion resistance, which can resist the erosion of environmental factors such as moisture, acid and alkali, and extend the service life of the cable.
Sheath Material
The sheath of the cable usually uses polyvinyl chloride (PVC) or polyethylene (PE).
PVC Sheath has good mechanical strength and corrosion resistance, which can protect the internal structure of the cable from external mechanical damage and environmental erosion, and the cost is relatively low. PE sheath has better
Flexibility and low-temperature resistance, and can maintain good performance in cold environments, making it suitable for use in low-temperature areas.
Style Design
The three cables are all cylindrical in overall shape with a compact structure. The three conductors of the 3-core cable are twisted together, and the outside is sequentially wrapped with an XLPE insulation layer and a sheath; the 2-core cable is formed by twisting two conductors and then wrapping them with an insulation layer and a sheath. The color of the cable is usually black, which has good dirt resistance and weather resistance, and can maintain a relatively stable appearance in various laying environments. The surface of the cable is smooth and flat, without obvious protrusions or depressions, which is convenient for operations such as pipe threading and dragging during installation.
(IV) Production Process
Conductor Production
First, high-purity copper ingots are smelted to remove impurities, obtaining pure copper water. Then, the copper water is cast into copper rods through a continuous casting process, and the diameter of the copper rods is adjusted according to the specifications of the
Cable Conductor. Next, the copper rod is drawn into
Copper Wires of the required diameter by a wire drawing process. During the wire drawing process, it is necessary to accurately control the drawing speed, temperature and lubrication conditions to ensure the dimensional accuracy and mechanical properties of the copper wire. For cables of different specifications, a corresponding number of copper wires are twisted according to a certain twisting method. Twisting can improve the flexibility and filling coefficient of the conductor, reduce the skin effect, and ensure the conductive performance of the conductor.
Insulation Layer Extrusion
The extrusion molding process is used to wrap the XLPE insulation layer around the conductor. First, XLPE granular material is added to the hopper of the extruder. After being heated and melted, the molten XLPE material is transported to the mold through the screw of the extruder. The size of the mold is accurately designed according to the cable specifications to ensure uniform thickness of the insulation layer. During the extrusion process, the extrusion temperature (generally between 130-190℃), extrusion speed and pressure are strictly controlled, so that the molten XLPE material evenly coats the surface of the conductor to form a continuous and dense insulation layer. After extrusion, the insulation layer is cross-linked, usually by peroxide cross-linking. By heating, the XLPE molecules form a three-dimensional network structure, thereby significantly improving its heat resistance, mechanical strength and insulation performance.
Cabling Process
For 3-core cables, the three
Insulated Cores are twisted according to a certain twisting direction and pitch; for 2-core cables, the two insulated cores are twisted. The size of the twisting pitch will affect the flexibility and structural stability of the cable, and needs to be reasonably set according to the cable specifications. During the twisting process, in order to ensure the roundness and filling rate of the cable, some inert filling materials, such as polypropylene ropes, are filled between the cores. The filling material can also play a buffering role, reducing mutual friction and extrusion between the cores and protecting the insulation layer from damage.
Sheath Extrusion
A sheath is extruded on the outer layer of the cabled cable. PVC or PE material is added to the extruder, heated and melted, and then evenly coated on the outer layer of the cabled cable through an extrusion mold. The extrusion parameters are controlled to ensure that the sheath has uniform thickness, a smooth surface, and is closely combined with the internal cabling structure without defects such as bubbles and impurities. The extrusion of the sheath can further enhance the mechanical protection performance and environmental erosion resistance of the cable.
Quality Inspection
Strict quality inspection is carried out in each link of the production process. For the conductor, parameters such as its diameter, resistivity, and tensile strength are tested; for the insulation layer, properties such as its thickness, insulation resistance, voltage resistance, and thermal elongation are tested; for cabling and sheathing, the appearance, size, roundness, and the tensile strength and elongation at break of the sheath are tested. The finished cable also needs to undergo partial discharge tests, aging tests, etc., to ensure that the product meets relevant standards and technical requirements. Only cables that pass all tests can leave the factory for sale.
II. From the Perspective of General Product Information
(I) Packaging
Packaging Materials
Different packaging materials are used according to the specifications and lengths of the cables. Due to its large cross-sectional area and heavy weight, the 120mm² specification cable is usually packaged with steel cable reels, which have high strength and strong bearing capacity, and are suitable for long-distance transportation and packaging of long-length cables. Cables of 35mm² and 25mm² specifications can use wooden cable reels, which have low cost and light weight, and are suitable for medium and short-distance transportation and small-batch delivery.
Packaging Method
When packaging, the cable is neatly wound on the cable reel, arranged tightly and flatly without twisting or overlapping. The outer layer is wrapped with a plastic film to play a role in moisture-proof and dust-proof. For steel cable reels, strong baffles are added on the sides to prevent the cable from slipping; baffles are also added on the sides of wooden cable reels to ensure the stability of the cable during transportation and storage. A shaft sleeve is installed at the central shaft hole of the cable reel to facilitate handling and loading/unloading with equipment such as forklifts and cranes.
Packaging Marks
The side and end face of the cable reel are clearly marked with product name (XLPE Copper Power Cable), specification parameters (120mm², 35mm², 25mm² and number of cores), length, rated voltage, implementation standard, production date, production batch number, manufacturer's name, address, contact information and other information. The marks are clear and firm, which is convenient for users to identify and trace.
(II) Transportation
Transportation Mode
Choose a suitable transportation mode according to the transportation distance, quantity of cables and customer needs. For long-distance transportation with large quantities, railway transportation is adopted, which has large transport capacity, low cost and good stability, and can effectively ensure the safety of the cable. For medium and short-distance transportation, road transportation is adopted, which has high flexibility and can realize door-to-door service, facilitating customers to receive goods. For urgent orders or small batches of samples, air transportation or car express can be used to shorten the transportation time.
Transportation Precautions
Before transportation, check whether the packaging is intact and whether the cable reel is firm. During transportation, the cable reel must be placed horizontally, and tilting, inverting or stacking are strictly prohibited to prevent the cable reel from rolling and colliding, which may cause damage to the cable. The transport vehicle should drive smoothly, avoiding violent operations such as sudden braking and sharp turns, to reduce the shaking of the cable reel. At the same time, measures should be taken to prevent rain, sun and moisture. A rain cloth can be covered on the cable reel to prevent the cable from being affected by bad weather. Special lifting equipment is used for loading and unloading, and handle with care to avoid impact and damage to the cable and cable reel.
Transportation Fixation
Use steel wire ropes or iron chains to fix the cable reel on the carriage of the transport vehicle. The fixed points are selected at the solid parts of the cable reel, such as the flange of the steel reel or the reinforcing ribs of the wooden reel, to ensure reliable fixation. For long-distance transportation, buffer materials such as wooden boards and rubber pads are placed between the cable reels to reduce mutual collision and friction.
(III) Delivery
Delivery Process
After the customer places an order and makes payment, the sales department will transmit the order information to the warehouse and production department. Stock products are directly packaged and shipped after checking the specifications and quantities; customized products are transferred to the warehouse after production and passing inspection, and then packaged and shipped. Contact the transportation company to determine transportation matters, and inform the customer of the transportation company name, license plate number, waybill number, estimated arrival time and other information before delivery to facilitate the customer's preparation for receiving goods.
Delivery Time
For regular specification cables in stock, they will be shipped within 1-3 working days after receiving the order and confirming payment. Customized products are usually shipped within 7-15 working days according to the production cycle, and the specific time is communicated and confirmed with the customer.
Delivery Tracking
After the cable is shipped, track the transportation status and keep abreast of the location and progress of the goods. If there are abnormal situations such as transportation delays, the customer will be notified immediately and coordinate with the transportation company to ensure that the goods arrive as soon as possible.
(IV) Samples
Sample Provision
To facilitate customers to understand the product quality and performance, the company can provide samples of various specifications and core numbers, with a sample length of generally 1-2 meters, for customers to check the appearance, structure, material, etc.
Sample Cost
Samples are provided free of charge, and the express fee is borne by the customer. For large customers with clear cooperation intentions or long-term partners, the express fee can be reduced or exempted.
Sample Delivery
After receiving the sample request, the samples will be prepared and properly packaged within 1-2 working days, with clear marks of specifications and core numbers, etc., sent by reliable express, and the customer will be informed of the express tracking number for inquiry.
(V) After-sales Service
Quality Assurance
The product quality guarantee period is 1-3 years. During the guarantee period, for quality problems caused by non-human factors, such as aging of the insulation layer, damage to the sheath, breakage of the conductor, etc., free repair or replacement services will be provided.
Technical Support
A professional technical team provides technical support through phone calls, emails, online consultations, etc. Customers can consult technical personnel at any time when encountering problems in installation, laying, and use. For complex technical issues, on-site guidance by technical personnel can be arranged to ensure the correct installation and normal operation of the cable.
Fault Handling
If customers find faults during use, they should notify the company in a timely manner. The company will respond within 24 hours, send personnel to understand the situation, analyze the causes, and formulate solutions. For faults requiring on-site handling, technical personnel will be dispatched promptly to minimize losses caused by cable faults.
Customer Feedback
Multiple customer feedback channels are set up, such as customer service hotlines, emails, and online message boards. The company attaches great importance to customer opinions and suggestions, sorts out and processes feedback in a timely manner, and continuously improves product quality and service levels based on feedback to enhance customer satisfaction.
In conclusion, the 120mm², 35mm², and 25mm² XLPE copper power cables (3-core and 2-core) have their own advantages in terms of specification parameters, characteristic uses, material styles, and production processes, and can meet the power transmission needs of different scenarios. Meanwhile, comprehensive general information services including packaging, transportation, delivery, samples, and after-sales provide customers with all-round guarantees, making them an ideal choice in medium and low-voltage distribution systems.
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