630mm 500mm XLPE Single Core Power Cable 100% Copper Aluminum Electrical Wire for Conductor PVC Jacketed Power Cables

The specification parameters of 630mm² and 500mm² XLPE single-core Power Cables are precisely designed to adapt to the harsh requirements of medium and high-voltage power transmission. Each parameter has undergone repeated testing and verification to ensure stable operation in various complex scenarios.

The rated voltage is one of the important parameters of this series of cables. Both cables cover medium and high voltage levels such as 10kV, 20kV, and 35kV. The 10kV level is suitable for power transmission in urban distribution networks and industrial parks; the 20kV level can meet the needs of tie lines between medium-sized substations and high-voltage power distribution in large industrial enterprises; the 35kV level is mainly used for connections between regional substations and main power plants, as well as power transmission from large energy bases. This coverage of multiple voltage levels enables the cables to flexibly meet the needs of transmission networks with different voltage levels, eliminating the need to design separate cables for different voltage scenarios and reducing design and procurement costs.

Current-carrying capacity is a key indicator to measure the power transmission capacity of cables. The 500mm² cable, when laid in the air with good convective heat dissipation, has a current-carrying capacity of approximately 650-750A; when laid underground with relatively poor heat dissipation conditions, the current-carrying capacity is about 550-650A. The 630mm² cable has more excellent current-carrying capacity, reaching 780-880A in the air and 680-780A underground. This range of current-carrying capacity allows the 500mm² cable to be adapted to medium-capacity power transmission links such as large transformer outgoing lines and high-voltage switchgear connections. For example, in a medium-sized factory, when connecting a transformer with a capacity of 3000-5000kVA, the 500mm² cable can stably transmit power; while the 630mm² cable can cope with larger capacity power transmission needs, such as connecting a transformer with 8000kVA or more in a large thermal power plant, ensuring efficient power transmission.

The conductivity of the conductor is one of the core performances of the cable. The purity of the Copper Conductor is ≥99.95%. High-purity copper can greatly reduce the resistance during current transmission, with a DC resistance of ≤0.0308Ω/km at 20℃, which means that the Copper Conductor Cable has less energy loss and higher transmission efficiency when transmitting the same current. The purity of the Aluminum Conductor is ≥99.5%, with a resistance of ≤0.0501Ω/km. Although the conductivity of aluminum is lower than that of copper, Aluminum Conductor Cables are a more economical choice in some scenarios that are cost-sensitive and do not have extreme requirements for transmission efficiency. Both conductors have passed strict conductivity tests, including resistance tests at different temperatures and current-carrying capacity tests, to ensure that their conductivity meets relevant standards.

The performance parameters of the XLPE insulation layer are also crucial. The three-dimensional network structure formed after cross-linking treatment enables it to have a temperature resistance range of -40℃ to 90℃, maintaining stable insulation performance in cold northern regions or high-temperature industrial environments. It can withstand high temperatures of 130℃ during short-term overload, which can effectively avoid damage to the insulation layer due to excessive temperature during peak electricity consumption or short-term overload of equipment. The insulation resistance is ≥1000MΩ·km, ensuring insulation strength under high voltage and preventing electric leakage. The dielectric loss tangent value is ≤0.003 (at 20℃), indicating that the energy loss of the insulation layer in the AC electric field is extremely small, further improving the transmission efficiency of the cable.

The thickness of the PVC Sheath is 2.5-4.0mm. The sheath thickness of cables with different specifications varies slightly. The sheath of the 630mm² cable is relatively thicker to provide stronger mechanical protection. The sheath has UV resistance, which can resist long-term irradiation of ultraviolet rays in sunlight when laid outdoors, delaying the aging rate of the sheath. At the same time, its acid and alkali corrosion resistance allows the cable to be used in corrosive environments such as chemical plants and sewage treatment plants. The sheath is mainly black in color, which can not only absorb heat and reduce temperature changes inside the sheath but also blend with the surrounding environment, making it less likely to be damaged by external factors. The surface is printed with specifications, voltage, certification, and other marks, which are printed with wear-resistant ink and remain clearly identifiable after long-term use, facilitating user identification and maintenance.

The outer diameter of the cable also varies with specifications. The outer diameter of the 500mm² cable is approximately 40-45mm, and that of the 630mm² cable is about 45-50mm. The size of the outer diameter affects the laying method and required space of the cable. When designing cable trenches, cable trays, and other laying channels, the outer diameter of the cable must be fully considered. In addition, the weight of the cable is also an important parameter. Copper Conductor Cables are relatively heavy, with 500mm² Copper Conductor Cables weighing about 10-12kg per meter and 630mm² copper conductor cables weighing about 13-15kg per meter; Aluminum Conductor Cables are lighter, with 500mm² aluminum conductor cables weighing about 4-5kg per meter and 630mm² aluminum conductor cables weighing about 5-6kg per meter, which has a certain impact on transportation and installation.

630mm² and 500mm² XLPE single-core power cables, with their excellent performance and diverse specifications, have irreplaceable characteristic applications in many fields and can meet the needs of large-capacity power transmission in different scenarios.

In the field of substations, 500mm² cables are suitable for incoming and outgoing lines of medium-sized substations. Medium-sized substations are important hubs for regional power distribution, needing to convert high-voltage electricity into medium and low-voltage electricity for distribution to various users. The transmission capacity of their incoming and outgoing lines is moderate, and the current-carrying capacity of 500mm² cables can perfectly match. At the same time, 500mm² cables also play an important role in the main transmission lines in industrial parks. Industrial parks gather a large number of industrial enterprises with large and relatively concentrated electricity loads. The main transmission lines need to stably and reliably transmit power to various enterprises. 500mm² cables can meet this demand and can be connected to transformers with a capacity of less than 5000kVA, providing continuous power support for enterprises in the park.

630mm² cables perform prominently in ultra-large capacity scenarios such as large substations and thermal power plants. Large substations undertake the task of power transmission and distribution in a wider range with huge transmission capacity. The high current-carrying capacity of 630mm² cables can carry the power output of transformers with 8000kVA and above, ensuring efficient transmission of power from substations to various regions. Thermal power plants are the core places for power production. The electricity generated by generators needs to be transmitted to the step-up station through cables and then connected to the power grid. 630mm² cables can cope with the high-current and high-voltage transmission environment in power plants, ensuring smooth power production and transmission.

The distribution trunk lines of high-rise buildings are another important application scenario for both cables. With the development of urban construction, there are more and more high-rise buildings, and their internal power demand is also increasing. Transmitting power from the bottom distribution room to high floors requires large-capacity and high-reliability cables, and 500mm² and 630mm² cables can meet this demand. The single-core structure design makes the cable easier to lay in dense cable trenches or cable trays, unlike Multi-Core cables which are difficult to arrange due to their complex structure. The characteristic that the bending radius is not less than 12 times the outer diameter allows the cable to flexibly turn in the narrow space of high-rise buildings, adapting to complex wiring environments. In addition, the optional flame-retardant PVC sheath can meet the fire protection requirements of high-rise buildings, which can delay the spread of flames in case of fire, gaining valuable time for personnel evacuation and fire fighting and rescue.

In long-distance power transmission projects, aluminum conductor cables have significant advantages. The density of aluminum is about 1/3 of that of copper, so aluminum conductor cables are much lighter than copper conductor cables, which greatly reduces transportation costs and installation difficulty. During long-distance laying, the lighter weight makes the traction and erection of cables easier, reducing the requirements for construction equipment. At the same time, the price of aluminum is relatively low, and the procurement cost of aluminum conductor cables is also lower than that of copper conductor cables. For long-distance power transmission projects with limited budgets, aluminum conductor cables are a more economical choice.

Copper conductor cables are mostly used in scenarios with strict requirements for transmission efficiency. The conductivity of copper is about 1.6 times that of aluminum. When transmitting the same current, copper conductor cables have lower resistance and less energy loss. In places with high requirements for energy efficiency, such as data centers and precision manufacturing factories, copper conductor cables can reduce energy loss during power transmission and reduce operating costs. At the same time, copper has good mechanical properties and strong fatigue resistance. In environments with frequent current fluctuations or vibrations, copper conductor cables have a longer service life and higher reliability.

In addition, these two types of cables can also play an important role in some special environments, such as places with high temperature, high humidity, and strong corrosion. The temperature resistance and moisture resistance of the XLPE insulation layer, as well as the corrosion resistance of the PVC sheath, enable the cable to operate stably in these harsh environments, ensuring continuous power supply. For example, they can be seen in high-temperature workshops of metallurgical factories, humid environments by the sea, and corrosive areas of chemical plants.

In terms of Conductor Materials, the copper conductor is made of high-purity electrolytic copper with a purity of ≥99.95%. High-purity electrolytic copper has extremely low impurity content, which can minimize resistance and improve conductivity. Electrolytic copper is refined to remove impurities such as iron, lead, and zinc, which can seriously affect the conductivity of copper. Therefore, high purity is the key to ensuring the excellent performance of Copper Conductors. At the same time, high-purity copper has good ductility and plasticity, which is convenient for extrusion, stranding, and other processing techniques, and can form a conductor with a stable structure and smooth surface.

The aluminum conductor is made of high-purity aluminum rod with a purity of ≥99.5%. Although the conductivity of aluminum is not as good as that of copper, high-purity aluminum can ensure its basic conductivity and meet the needs of medium and high-voltage power transmission. The aluminum rod is subjected to strict purification processes to reduce impurities such as silicon and iron, which can lead to a decrease in the mechanical and conductive properties of aluminum. High-purity aluminum has good toughness and is not easy to break during wire drawing and bunch stranding, which can ensure the integrity and consistency of the conductor.

The insulation layer is made of cross-linked polyethylene (XLPE) material. XLPE is a polyethylene material that has undergone cross-linking treatment, and its performance has been greatly improved compared with ordinary polyethylene. The uncross-linked polyethylene molecules have a linear structure, with poor heat resistance and mechanical strength. However, the three-dimensional network structure formed after cross-linking makes XLPE have excellent heat resistance, aging resistance, and mechanical strength. XLPE has good chemical stability and is not easily corroded by acids, alkalis, oils, and other chemicals, and can maintain stable insulation performance in various harsh environments. At the same time, XLPE has a small dielectric constant and low dielectric loss, which is beneficial to improve the transmission efficiency of the cable.

The PVC sheath is made of high-quality polyvinyl chloride material, added with antioxidants, ultraviolet absorbers, flame retardants, and other additives. Polyvinyl chloride itself has good mechanical properties and insulation performance. By adding antioxidants, it can delay the oxidative aging of the sheath and extend its service life; ultraviolet absorbers can absorb ultraviolet rays in sunlight to protect the sheath from being damaged by ultraviolet rays; the addition of flame retardants makes the sheath have certain flame retardant performance, which can inhibit combustion in case of fire. The PVC sheath has strong corrosion resistance and can resist the erosion of acid and alkali substances in the soil, industrial waste gas, etc., protecting the internal structure of the cable from damage.

In terms of appearance, both cables have a single-core structure and are cylindrical overall. The single-core structure makes the cable more flexible, convenient for bending and laying, especially in narrow spaces, single-Core Cables are easier to operate than Multi-Core Cables. The color of the cable is mainly determined by the PVC sheath, mainly black. Black not only has good weather resistance but also can absorb heat, reduce temperature changes inside the sheath, and avoid sheath aging caused by severe temperature fluctuations.

According to the different conductor materials, they can be divided into copper conductor type and aluminum conductor type. The cross-section of the copper conductor cable is purplish red, which is the natural color of copper, with a smooth surface and no burrs or scratches. The cross-section of the aluminum conductor cable is silvery white, also with good surface quality. Both types of conductors have undergone strict surface treatment. The surface of the copper conductor may be tinned to enhance its oxidation resistance; the surface of the aluminum conductor will form a dense oxide film to prevent further oxidation and corrosion.

There are also certain differences in the styles of insulation layers. Although they all use XLPE materials, they can be divided into dry cross-linked and wet cross-linked according to different cross-linking processes. The dry cross-linked XLPE insulation layer has higher purity and more stable performance, suitable for scenarios with high insulation requirements; the wet cross-linked XLPE insulation layer has relatively low cost and is widely used in some ordinary scenarios. The insulation layer has a uniform thickness, closely fits the conductor, and has no bubbles, wrinkles, or other defects, ensuring good insulation effect.

The styles of PVC sheaths can be divided into ordinary sheath type and flame-retardant sheath type according to whether they have flame-retardant performance. The ordinary sheath type is suitable for general places and can provide basic mechanical protection and weather resistance; the flame-retardant sheath type adds more flame retardants on the basis of the ordinary sheath, with better flame retardant performance, suitable for high-rise buildings, shopping malls, hospitals, and other places with high fire protection requirements. The surface of the sheath is printed with clear marks, including the cable's specifications, rated voltage, manufacturer, certification marks, etc. These marks are made by embossing or debossing processes and can remain clear after long-term use.

In addition, according to different laying methods, they can also be divided into overhead type, direct burial type, and pipe 穿 type, etc. The sheath of the overhead Type Cable may be thicker to enhance wind resistance, ultraviolet resistance, and other properties; the sheath of the direct burial type cable has better soil corrosion resistance; the pipe 穿 type cable has better Flexibility, convenient for laying in pipes. Cables of different styles have slight differences in Structure and Performance to adapt to different laying environments and usage needs.

The production process of 630mm² and 500mm² XLPE single-core power cables is complex and precise, and each link needs to be strictly controlled to ensure that the quality and performance of the products meet relevant standards and usage requirements.

Copper conductor manufacturing: First, high-purity electrolytic copper ingots are put into a melting furnace for melting, and the melting temperature is controlled at about 1083℃ to completely melt the copper ingots. During the melting process, inert gas is introduced for degassing treatment to remove gases such as hydrogen in the copper water, and refining agents are added to remove impurities. The molten copper water is cast into copper rods through a continuous casting machine, and the diameter of the copper rods is determined according to the specifications of the final conductor. Then, the copper rod is drawn through a wire drawing machine, and the copper rod is drawn into Copper Wires with a smaller diameter through a series of wire drawing dies with different apertures. During the wire drawing process, the copper wire will undergo work hardening due to plastic deformation, so annealing treatment is required. Annealing is carried out in a continuous annealing furnace, heating the copper wire to 300-500℃ and keeping it for a certain time to eliminate internal stress and restore its flexibility and conductivity. Finally, multiple annealed copper wires are stranded using the compact stranding process, which can improve the filling factor of the conductor, reduce the outer diameter of the conductor, and enhance the mechanical strength of the conductor. During the stranding process, the stranding pitch and tension are strictly controlled to ensure the structural stability of the conductor.

Aluminum conductor manufacturing: The manufacturing process of Aluminum Conductors is similar to that of copper conductors, but there are some differences. First, high-purity aluminum rods are drawn through a wire drawing machine to form Aluminum Wires of the required diameter. Due to the relatively poor toughness of aluminum, the speed and tension during the wire drawing process are more strictly controlled to avoid breaking of the Aluminum Wire. The drawn aluminum wire also needs to be annealed, and the annealing temperature is generally 200-300℃ to improve its mechanical properties. Then, the aluminum wires are stranded using the bunch stranding process, which can keep a certain gap between the aluminum wires, facilitating heat dissipation. The surface of the Stranded Aluminum Conductor will undergo oxidation resistance treatment, usually using anodic oxidation to form a dense oxide film, improving its corrosion resistance.

The extrusion of the XLPE insulation layer adopts the dry cross-linking process. First, XLPE particles are uniformly mixed with cross-linking agents, antioxidants, and other additives, and then added to the extruder. The temperature of the extruder is controlled in sections, gradually increasing from the feeding section to the die section to ensure proper melting and plasticization of the material. The molten XLPE is then extruded onto the conductor through a specially designed cross-head die, which ensures uniform thickness and concentricity of the insulation layer. The extrusion speed is carefully synchronized with the conductor feeding speed to maintain consistent insulation thickness, typically ranging from 5mm to 10mm depending on the voltage rating.

After extrusion, the cable enters a continuous vulcanization (CV) tube for cross-linking. The CV tube is divided into three zones: preheating, cross-linking, and cooling. In the preheating zone, the cable is heated to around 120-150℃ to prepare for cross-linking. The cross-linking zone maintains a temperature of 180-200℃ under high pressure (0.8-1.2MPa) using nitrogen as the heating medium, which triggers the cross-linking reaction. The duration of cross-linking is precisely controlled based on the insulation thickness, usually 15-30 minutes, to ensure complete formation of the three-dimensional molecular structure. Finally, the cable is cooled in the cooling zone using water or air to stabilize the cross-linked structure, with the temperature gradually reduced to ambient levels to prevent thermal stress.

The PVC sheath extrusion process follows the insulation layer application. PVC compound, mixed with plasticizers, stabilizers, and flame retardants, is fed into a separate extruder. The extrusion temperature is set between 160-190℃ to achieve optimal flow properties. The molten PVC is extruded over the XLPE insulation layer through a sheath die, forming a tight and uniform protective layer. The sheath thickness is designed to provide mechanical protection, with 630mm² cables typically having a thicker sheath (3.5-4.0mm) compared to 500mm² cables (2.5-3.0mm).

During extrusion, the sheath is bonded to the insulation layer using a bonding agent or through controlled temperature profiling, ensuring no delamination occurs during handling or installation. The surface of the sheath is embossed with identification marks, including cable type, size, voltage rating, and manufacturer information, using a counter-rotating roller system that imprints the text while the PVC is still malleable.

Throughout the production process, in-line quality control measures are implemented. Laser diameter gauges continuously monitor the conductor, insulation, and sheath dimensions, with automatic adjustments made to the extrusion parameters if deviations are detected. Spark testers check for insulation and sheath defects by applying a high-voltage pulse (10-30kV) as the cable passes through, ensuring no pinholes or cracks are present.

After production, finished cables undergo rigorous offline testing. These tests include:

To ensure safe transportation and storage, 630mm² and 500mm² XLPE Cables are packaged on sturdy wooden or steel reels. The reels are designed with flanges of sufficient height (300-500mm) to prevent cable damage, and the barrel diameter is sized to maintain a minimum bending radius (12 times the cable outer diameter) during storage.

Each reel can hold 200-500 meters of cable, depending on the cross-sectional area. The cable is wound tightly with uniform tension to avoid loose layers, which could cause abrasion during transit. A moisture-resistant barrier, typically a polypropylene film, is wrapped around the cable to protect against humidity. For long-term storage or marine transport, the entire reel is enclosed in a heavy-duty plastic bag and secured with steel bands.

Reel markings include:

Smaller lengths (50-100 meters) may be supplied in wooden crates lined with foam to prevent movement, with similar protective measures and labeling.

Cables are transported using flatbed trucks, container ships, or railcars, depending on the destination. For overland transport, reels are secured to the truck bed using steel chains and wedges to prevent rolling, with a maximum of 3-4 reels per truck to avoid overloading. Container shipments use 40-foot high-cube containers, with reels stacked vertically (where possible) and braced with timber to prevent shifting during sea transport.

Temperature control is critical during transportation:

Handling equipment must be suitable for the reel weight (up to 5 tons), with forklifts or cranes equipped with spreader bars to avoid damaging the reel flanges. The cable ends are sealed with waterproof caps to prevent moisture ingress, and a handling eye is fitted to each reel for safe lifting.

Orders are processed through a dedicated sales system, with confirmation provided within 24 hours of receipt. Custom specifications (e.g., flame-retardant sheaths, special colors) require additional lead time (7-10 days) for material sourcing and production scheduling.

Standard delivery times are:

Each shipment includes:

Customers are provided with a tracking number to monitor shipment progress, and delivery is confirmed with a signed proof of delivery document.

Samples (1-2 meters in length) are available upon request, free of charge for qualified customers. Sample processing takes 3-5 working days, with shipping costs borne by the customer. Samples include a certificate of analysis detailing key parameters (conductor resistance, insulation thickness, test results) to verify compliance with specifications.

Custom samples (e.g., special insulation thicknesses) may incur tooling charges, which are refundable upon placement of a bulk order.

The cables come with a 2-year warranty against manufacturing defects, covering materials and workmanship. In the event of a warranty claim, technical staff will conduct an on-site inspection within 48 hours of notification to determine the cause of failure.

Technical support includes:

For out-of-warranty issues, repair or replacement services are offered at a discounted rate, with a 10-year product lifecycle support commitment. A dedicated after-sales hotline is available 24/7 to address urgent queries.