Voltage Rating: 0.6/1KV. This dual rating defines the cable’s safe operating limits: 0.6KV for phase-to-earth (or phase-to-neutral) connections and 1KV for phase-to-phase connections. It aligns with the most common LV voltage range for distributing power from substations to end-users, compatible with 230V (Europe/Asia) and 120V (North America) residential systems via transformers.
Conductor Type and CSA:
Copper Conductor (Standard): The 50mm² copper conductor is made from 99.95% pure electrolytic copper, stranded into 37 strands (0.41mm each) for Flexibility. Key electrical properties:
Resistivity: 1.72×10⁻⁸ Ω·m (20°C), ensuring minimal energy loss (≤1.5% per 100 meters).
Ampacity: 110–130A (at 25°C ambient temperature, direct burial). This capacity supports the combined load of 50–80 households (each with a peak load of 2–3kW) or a small commercial complex (e.g., 10–15 retail stores).
Aluminum Conductor (Cost-Effective Alternative): The 50mm² aluminum conductor is alloyed with magnesium and silicon (AA 6201) for enhanced strength, stranded into 19 strands (0.58mm each). Key properties:
Resistivity: 2.82×10⁻⁸ Ω·m (20°C), with ampacity of 85–100A (25°C, direct burial)—suitable for low-to-medium load areas (e.g., rural residential neighborhoods).
Cost Advantage: 30–40% lower material cost than copper, with lighter weight (2.7 g/cm³ vs. 8.96 g/cm³ for copper) to simplify handling.
Short-Circuit Current Rating: Up to 25kA for 1 second. This ensures the cable can withstand transient fault currents (e.g., from accidental digging or equipment malfunctions) without melting or structural damage, maintaining network stability during emergencies.
Overall Diameter: Varies by conductor type:
Copper conductor (50mm²): 18–20mm (PVC insulation: 1.2–1.5mm; PVC sheath: 1.5–2.0mm).
Aluminum conductor (50mm²): 17–19mm (slightly smaller due to aluminum’s lower density).
Weight:
Copper conductor: 0.55–0.60 kg/m (100m reel: 55–60kg).
Aluminum conductor: 0.25–0.30 kg/m (100m reel: 25–30kg).
Tensile Strength:
Copper conductor: ≥4.5kN (per 100m), sufficient to withstand pulling forces during duct installation (up to 50 meters without intermediate pull points).
Aluminum conductor: ≥2.8kN (per 100m), supported by its alloy composition to avoid stretching or breaking.
Minimum Bending Radius: 10× cable diameter (static installation) and 15× cable diameter (dynamic bending). For a 19mm-diameter Copper Cable, this means a static bending radius of 190mm—allowing it to navigate around underground obstacles (pipes, utility lines) without damaging insulation or sheath.
Advantages: Exceptional conductivity (58 MS/m at 20°C) minimizes energy loss, critical for long underground runs (up to 500 meters). Copper’s natural corrosion resistance (forms a thin, stable oxide layer) eliminates the need for additional coatings in most soil types. Its stranded design enhances flexibility, making it easy to pull through ducts or bend around obstacles.
Applications: Preferred for high-load areas (dense residential neighborhoods, commercial complexes) where reliability and low energy loss are priorities.
Advantages: Cost-effective and lightweight, reducing material and transportation costs. The AA 6201 alloy adds strength (tensile strength: 120 MPa) and corrosion resistance, while a thin tin plating (5–10μm) further protects against moisture in acidic or saline soils.
Limitations: Higher resistivity than copper requires larger CSA for equivalent ampacity (e.g., 70mm² aluminum = 50mm² copper). Requires compatible terminals (aluminum-copper transition lugs) to prevent galvanic corrosion when connected to copper-based equipment.
Applications: Ideal for cost-sensitive projects (rural electrification, low-density residential areas) with moderate load demands.
Composition: PVC resin (60–70%), plasticizers (20–25%, e.g., dioctyl phthalate) for flexibility, stabilizers (5–10%, e.g., calcium-zinc) to prevent heat/UV degradation, and flame retardants (3–5%, e.g., aluminum hydroxide).
Electrical Performance: Dielectric strength of 15–20 kV/mm easily withstands the 0.6/1KV voltage rating. Volume resistivity ≥1×10¹⁴ Ω·cm ensures no leakage current, even in moist soil.
Environmental Resistance: Operates reliably in temperatures from -15°C to +70°C—compatible with temperate, subtropical, and mild tropical climates. Resists moisture absorption (<0.1% by weight after 24 hours immersion), preventing insulation breakdown in waterlogged soil.
Cost Advantage: 30–50% lower cost than XLPE insulation, making the YKY cable accessible for budget-constrained projects without compromising basic performance.
Composition: PVC resin (65–75%), carbon black (2–3%) for UV resistance (critical if the cable is exposed during installation), plasticizers (15–20%) for flexibility, and impact modifiers (5–8%, e.g., acrylics) to enhance mechanical durability.
Mechanical Protection: Withstands soil pressure up to 80 kPa (equivalent to 8 meters of soil depth), preventing deformation of the Insulated Conductor. Resists root penetration from trees and shrubs (a common issue in residential areas) and impact from small rocks during installation.
Chemical Resistance: Unaffected by common soil contaminants, including fertilizers (nitrates, phosphates), detergents, and mild industrial runoff. In saline soils (coastal areas), it maintains integrity for 10+ years—outperforming uncoated polyethylene sheaths.
Flame Retardancy: Meets IEC 60332-1 (single cable flame test), self-extinguishing within 60 seconds of removing the flame. This reduces fire risks in underground ducts shared with other cables or near residential/commercial buildings.
Neighborhood Feeder Cables: The cable connects LV substations to underground distribution boxes (typically placed every 200–300 meters in residential areas). From these boxes, smaller cables (2.5mm²–10mm² BVR) distribute power to individual homes. The 110–130A ampacity of copper YKY cables supports 50–80 households, eliminating the need for parallel cables and reducing duct space.
New Housing Developments: In greenfield projects, the cable is installed during construction, either in ducts or via direct burial (0.7–1.0 meters depth per IEC 60364). Its flexibility allows it to follow the layout of roads and housing blocks, avoiding obstacles like water pipes or sewage lines.
Rural Electrification: Aluminum YKY cables are preferred for rural areas, where low population density and budget constraints make cost-effectiveness a priority. The 85–100A ampacity powers 30–50 rural homes, with its lightweight design simplifying installation in remote areas with limited equipment.
Small Shopping Centers/Office Parks: The cable connects to main electrical panels in commercial buildings, powering stores, offices, and HVAC systems. The PVC sheath’s chemical resistance ensures longevity in areas where soil may be contaminated by parking lot runoff (oil, deicing salts) or cleaning agents.
Apartment Complexes: For mid-rise apartments (5–10 floors), the cable supplies power to basement distribution boards, which then feed elevators, lighting, and tenant units. Its flame-retardant sheath reduces fire risks in underground parking garages adjacent to the cable ducts.
Public Facilities: Used in parks, schools, and hospitals to power outdoor lighting, irrigation systems, and emergency generators. The cable’s moisture resistance ensures reliable operation in damp soil (e.g., park grounds) or near water features.
Small Workshops/Warehouses: The cable transmits power from LV substations to industrial distribution panels, powering machinery (e.g., lathes, compressors) and lighting. The PVC sheath’s impact resistance withstands occasional damage from forklifts or construction equipment during maintenance.
Logistics Hubs: In distribution centers, the cable powers conveyor belts, loading dock equipment, and HVAC systems. Its ampacity supports the high load of multiple machines running simultaneously, while its flexibility allows installation around warehouse pillars and storage areas.
Food Processing Facilities: For low-risk food plants (e.g., bakery, beverage bottling), the cable is installed in stainless steel ducts to meet hygiene standards. The PVC insulation and sheath are non-toxic and easy to clean, complying with food safety regulations (e.g., FDA 21 CFR Part 177).
Wire Drawing:
Copper: 99.95% pure copper rods (12mm diameter) are drawn through diamond dies to reduce strand diameter to 0.41mm. The drawing process is done at room temperature (cold drawing) with mineral oil lubrication to prevent strand damage.
Aluminum: AA 6201 alloy rods (15mm diameter) are drawn to 0.58mm strands, with intermediate annealing (300–350°C) to soften the alloy and improve ductility.
Stranding:
Copper conductors: 37 strands are twisted in a concentric pattern (1 central strand + 6 strands in layer 1 + 12 strands in layer 2 + 18 strands in layer 3) using a stranding machine. The stranding pitch is 100–120mm, optimizing flexibility and current distribution.
Aluminum conductors: 19 strands are twisted in a concentric pattern, with a stranding pitch of 80–100mm to enhance stability.
Annealing (Copper Only): Stranded Copper Conductors are heated to 350–400°C in a nitrogen atmosphere (to prevent oxidation) and cooled slowly. Annealing reduces residual stress from drawing, improving flexibility and conductivity.
Material Preparation: PVC resin, plasticizers, stabilizers, and flame retardants are mixed in a high-speed mixer (1000–1500 RPM) at 80–90°C to form a homogeneous compound. The compound is then cooled to 40–50°C and granulated for extrusion.
Extrusion: The compound is fed into a single-screw extruder (L/D ratio 25:1) heated to 160–180°C. The molten PVC is extruded onto the Stranded Conductor via a crosshead die, with insulation thickness controlled to 1.2–1.5mm (monitored by an online laser gauge).
Cooling and Sizing: The insulated conductor is pulled through a water bath (20–25°C) to cool and set the insulation. A sizing die ensures the outer diameter of the insulation is uniform (±0.1mm), preventing thin spots that could lead to electrical breakdown.
Material Preparation: PVC resin, carbon black, plasticizers, and impact modifiers are mixed in a high-speed mixer (800–1200 RPM) at 70–80°C, then granulated.
Extrusion: The insulated conductor is fed into a second single-screw extruder (L/D ratio 20:1) heated to 150–170°C. The molten PVC sheath is extruded over the insulation, with thickness controlled to 1.5–2.0mm (laser gauge monitoring).
Printing and Cooling: A laser printer applies product identification (cable type, CSA, voltage rating, manufacturer name) to the sheath. The cable is then cooled in a water bath (15–20°C) to set the sheath and ensure dimensional stability.
Electrical Testing:
Insulation Resistance Test: A 1kV DC megohmmeter measures insulation resistance between conductor and sheath. Minimum resistance: ≥100 MΩ (at 20°C) for both copper and Aluminum Cables.
Dielectric Strength Test: The cable is submerged in water and subjected to 2kV AC for 1 minute. No breakdown or arcing confirms insulation integrity.
Conductor Resistance Test: A micro-ohmmeter measures conductor resistance—must be ≤0.344Ω/km (copper) or ≤0.568Ω/km (aluminum) at 20°C.
Mechanical Testing:
Impact Test: A 1kg weight is dropped from 1m onto the sheath. The cable is then tested for electrical continuity—no loss of continuity indicates sheath durability.
Tensile Test: A 1-meter sample is pulled until the conductor breaks. Breaking force must exceed 4.5kN (copper) or 2.8kN (aluminum).
Cold Bend Test: The cable is cooled to -15°C for 4 hours, then bent around a mandrel (10× diameter) 10 times. No cracks in insulation or sheath confirm low-temperature flexibility.
Environmental Testing:
Water Immersion Test: The cable is submerged in 23°C water for 24 hours. Insulation resistance must remain ≥100 MΩ.
Soil Corrosion Test: Samples are buried in simulated acidic (pH 4) and saline (3.5% NaCl) soil for 30 days. No sheath degradation or conductor corrosion is allowed.
Certification: After passing all tests, the cable is certified to IEC 60227 (global), BS 6004 (UK), and ANSI/UL 44 (North America). Certification documents are provided to customers to facilitate regulatory approval for underground installation projects. For example, in the EU, the CE marking is added to confirm compliance with the Low Voltage Directive (2014/35/EU), while in North America, UL listing ensures adherence to local electrical codes (NEC 2023).
Plastic Reels: Used for Aluminum Conductor Cables (lighter weight) and domestic shipments. Made from high-density polyethylene (HDPE), these reels are impact-resistant (withstanding drops of up to 0.5m) and water-resistant, making them suitable for outdoor storage. Key specifications:
100m reel (aluminum): Diameter 800mm, flange thickness 100mm, weight 15kg.
200m reel (aluminum): Diameter 1000mm, flange thickness 120mm, weight 25kg.
Wooden Reels: Used for Copper Conductor Cables (heavier weight) and international shipments. Constructed from FSC-certified pine, reels are treated with anti-rot chemicals to prevent degradation in humid climates. Key specifications:
100m reel (copper): Diameter 900mm, flange thickness 150mm, weight 30kg.
200m reel (copper): Diameter 1200mm, flange thickness 180mm, weight 45kg.
Boxes are made from double-walled corrugated cardboard (300-lb test strength) with foam inserts at both ends to prevent the cable from shifting. The box interior is lined with a PE bag to protect against moisture.
Each box is labeled with a clear plastic tag indicating:
Cable details: Length (e.g., 50m), conductor type (copper/aluminum), CSA (50mm²), and voltage rating (0.6/1KV).
Handling instructions: “Keep Dry,” “Do Not Stack,” and “Cut Edge—Handle with Gloves” (to prevent injury from sharp cable ends).
HDPE reels and PE film are fully recyclable, and the company offers a take-back program for used reels (customers receive a 5% discount on their next order when returning intact reels).
Wooden reels are sourced from FSC-certified forests, ensuring responsible forestry practices. Unused wood scraps from reel production are repurposed into packaging filler (e.g., wooden blocks for pallet stabilization).
PVC shrink wrap is being phased out in favor of bio-based shrink films (made from corn starch), which biodegrade within 12 months in soil—reducing plastic waste in landfills.
Truck Delivery:
Small orders (1–5 reels): Delivered via light commercial vehicles (5–10 ton capacity) with climate-controlled cargo areas (to prevent moisture buildup in humid weather). Delivery times: 1–3 business days for urban areas, 3–5 days for rural areas.
Large orders (10+ reels): Shipped via flatbed trucks (20–30 ton capacity) with waterproof tarps and pallet stabilization (wooden blocks + stretch film). For long-distance domestic trips (e.g., cross-country in the U.S. or Europe), GPS tracking is provided to customers, allowing real-time monitoring of shipment location.
Courier Services: For urgent orders (e.g., emergency repairs to Underground Cables), courier services (e.g., DHL, FedEx) are used. Small custom-cut lengths (≤10m) are packed in padded envelopes and delivered within 24–48 hours, with insurance coverage for damage during transit.
Sea Freight:
The majority of international orders are shipped via sea freight, as it is cost-effective for heavy reels. Reels are loaded into 20ft or 40ft shipping containers (FCL for large orders, LCL for small orders). Inside the container:
Reels are stacked in a single layer (to avoid crushing lower reels) with wooden dunnage between them to prevent rolling.
Humidity packs (500g each) are placed in the container to absorb moisture (critical for shipments to tropical regions, where humidity levels exceed 80%).
Transit times: 2–4 weeks for regional shipments (e.g., Europe to North Africa), 4–8 weeks for intercontinental shipments (e.g., China to Brazil), and 6–10 weeks for transoceanic shipments (e.g., U.S. to Australia).
Air Freight:
For time-sensitive international projects (e.g., a construction deadline in Singapore), air freight is used. Reels are packed in lightweight aluminum frames to reduce weight (air freight costs are calculated by weight and volume), and shipments are prioritized for quick customs clearance. Transit times: 2–5 business days, but costs are 5–8 times higher than sea freight.
Customs Compliance:
All international shipments include a complete set of documentation to avoid delays:
Commercial Invoice: Details product description, quantity, unit price, total value, and country of origin (e.g., “Made in Germany” or “Made in China”).
Packing List: Specifies package dimensions, weight, and contents (e.g., “5 reels of 50mm² copper YKY cable, 100m each”).
Certificate of Origin: Required for preferential tariff rates (e.g., EU-Mercosur Free Trade Agreement) to reduce import duties.
Compliance Certificates: Includes IEC/UL/BS certifications and test reports to verify the cable meets the importing country’s electrical standards (e.g., SABS certification for South Africa, JIS certification for Japan).
Order Placement: Customers can place orders via multiple channels:
Online Portal: The company’s website allows customers to select conductor type, length, quantity, and delivery address, with real-time inventory updates (e.g., “50mm² copper YKY: 100 reels in stock”). Orders are processed instantly, and a confirmation email is sent within 5 minutes.
Sales Team: For large or custom orders (e.g., 100 reels of 200m aluminum YKY cable), customers can contact the sales team via phone or email. The team provides a detailed quote (including shipping costs and lead times) within 24 hours and assists with technical 选型 (e.g., recommending copper vs. aluminum for a coastal project).
Production Lead Time:
In-Stock Items: Shipped within 1–2 business days (for standard lengths: 100m, 200m).
Custom Orders: Production lead time of 5–7 business days (for non-standard lengths or specialized sheath formulations, e.g., extra-thick PVC for acidic soil). Customers receive weekly progress updates (e.g., “Production 70% complete—scheduled for shipping on [date]”).
Shipping Notification: When the order ships, customers receive an email with:
Tracking Number: For domestic orders, a link to the courier’s tracking page (e.g., UPS, DPD) to monitor delivery status. For international orders, a container number and link to the shipping line’s tracking system (e.g., Maersk, CMA CGM).
Delivery Instructions: A reminder to inspect the packaging for damage upon receipt and contact the company within 48 hours if defects are found.
Sample Availability: Samples are available in 1-meter lengths for both copper and aluminum conductors. Customers can request up to 3 samples per order, with options for standard or extra-thick PVC sheath (for harsh soil conditions).
Sample Request Process:
Online: Customers can request samples via the website’s “Sample Request” page, providing their shipping address and project details (e.g., “Underground installation in coastal Florida—need to test corrosion resistance”).
Technical Support Team: For complex projects (e.g., acidic soil in a mining area), the technical team can provide customized samples (e.g., aluminum conductors with extra tin plating) and a testing guide to evaluate key properties (insulation resistance, sheath flexibility).
Sample Cost and Shipping:
Free Samples: For customers planning to place a bulk order (≥10 reels), samples are free, with shipping costs covered by the company.
Low-Cost Samples: For small customers or first-time inquiries, samples cost $10–20 per piece (refundable if a bulk order is placed within 30 days). Shipping is via standard courier, with delivery times of 2–5 business days.
Technical Support:
24/7 Hotline: A toll-free hotline is available for urgent technical issues (e.g., “The cable sheath is damaged during installation—what should I do?”). Certified electrical engineers respond within 1 hour, providing step-by-step guidance (e.g., “Use heat-shrinkable sleeves to repair small tears; replace the cable if damage exceeds 10% of sheath thickness”).
Online Resources: The company’s website features a “Support Center” with:
Installation Videos: Step-by-step guides for direct burial (e.g., “How to Prepare Soil for YKY Cable Installation”) and duct pulling (e.g., “Choosing the Right Cable Puller for 50mm² YKY Cable”).
FAQs: Answers to common questions (e.g., “Can YKY cable be installed in frozen soil?”—yes, if pre-warmed to ≥-5°C to maintain sheath flexibility).
Datasheets: Detailed technical specifications (ampacity charts, soil compatibility guides) for both copper and aluminum conductors.
Installation Training:
On-Site Training: For large customers (e.g., electrical contracting firms, utility companies), the company provides on-site training sessions. Led by experienced trainers, sessions cover:
Safe handling of reels (avoiding over-tensioning during unwinding, using gloves to prevent cuts).
Proper installation techniques (direct burial depth, duct sizing, termination to distribution boxes).
Compliance with local codes (e.g., NEC 300.5 for underground cables in the U.S., IEC 60364-5-52 for Europe).
Virtual Training: For customers in remote areas, live virtual training is offered via Zoom, with 3D models demonstrating installation scenarios (e.g., navigating around underground pipes).
Warranty Coverage:
Standard Warranty: The YKY cable comes with a 10-year warranty (copper conductor) or 8-year warranty (aluminum conductor) against manufacturing defects (e.g., insulation breakdown, sheath cracking). The warranty covers:
Replacement of defective cables (free of charge, including shipping).
Labor costs for reinstallation (if the defect is reported within 5 years of purchase).
Warranty Claim Process: To file a claim, customers provide:
A copy of the order invoice.
Photos/videos of the defect (e.g., cracked sheath, exposed conductor).
A test report from a certified lab confirming the defect is manufacturing-related (not installation error).
Claims are processed within 5 business days, with replacement cables shipped via expedited courier to minimize project delays.
Maintenance and Recycling:
Maintenance Guidelines: Customers receive a “Cable Maintenance Guide” with recommendations for long-term performance:
Annual Visual Inspections: Check for sheath damage (e.g., cuts, cracks) in areas prone to digging (e.g., near construction sites). Use a cable locator to mark the cable’s path, preventing accidental damage.
Soil Testing: Every 3–5 years, test soil pH and salinity (especially in coastal or industrial areas). If soil becomes acidic (pH <5) or saline (NaCl >5%), apply a protective coating (e.g., PVC tape) to the cable sheath.
Load Monitoring: Use a clamp meter to monitor conductor current—ensure it does not exceed the cable’s ampacity (110–130A for copper, 85–100A for aluminum) to prevent overheating.
Recycling Program: For end-of-life cables (after 10–15 years of service), the company offers a recycling program:
Collection: Customers can drop off old cables at designated collection centers or request a free pickup for large quantities (≥500kg).
Processing: Cables are shredded to separate conductors (copper/aluminum) from PVC insulation/sheath. Conductors are melted and recast into new metal rods (95% recycling efficiency), while PVC is processed into plastic pellets for non-electrical applications (e.g., garden edging).
Incentives: Customers who recycle old cables receive a 10% discount on their next YKY cable order, encouraging sustainable practices.
Công ty TNHH Công nghệ Cáp Hongtai
E-mail: export@qlcables.com
sales@qlcables.com
Tel/WhatsApp:+86-18032066271
Thêm khu vực phát triển công nghiệp Xiaokou, Hạt Ningjin, Thành phố Xingtai ， tỉnh Hà Bắc, Trung Quốc
Bản quyền © Công ty TNHH Công nghệ Cáp Hongtai Hỗ trợ kỹ thuật:Công nghệ Ronglida
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