Low Voltage Armoured Power Cable: Comprehensive Product Guide

1. Product Overview

2. Technical Specifications

2.1 Core Electrical Parameters

• Voltage Rating: 0.6/1kV (IEC standard)

• Frequency Range: 50/60Hz

• Insulation Resistance: >100 MΩ/km at 20°C

• Dielectric Strength: Withstands 3.5kV test for 5 minutes

2.2 Conductor Details

• Material: High-purity electrolytic copper (≥99.95%)

• Stranding: Class 2 flexible stranding per IEC 60228

• Surface Treatment: Tinned or bare copper options

• Current Ratings (at 30°C ambient):

• 4x16mm²: 70-85A

• 4x50mm²: 150-180A

• 4x70mm²: 185-220A

• 4x95mm²: 230-275A

• 4x120mm²: 265-315A

• 4x150mm²: 310-370A

2.3 Insulation System

• Primary Insulation: XLPE (Cross-linked Polyethylene)

• Temperature Range: -30°C to +90°C continuous operation

• Advantages: Excellent dielectric properties, high thermal stability, resistance to electrical treeing

• Insulation Thickness:

• 16mm²: 0.7-0.9mm

• 50mm²: 0.9-1.1mm

• 70mm²: 1.0-1.2mm

• 95mm²: 1.1-1.3mm

• 120mm²: 1.2-1.4mm

• 150mm²: 1.3-1.5mm

2.4 Cable Construction

• Core Identification: Colored insulation (brown, black, grey, blue)

• Core Lay-up: SZ or helical stranding with appropriate fillers

• Inner Sheath: PVC (1.0-1.5mm thickness)

• Armour:

• Type: Steel wire armour (SWA) or Steel Tape armour (STA)

• Purpose: Mechanical protection against impact, crushing, and rodent damage

• Outer Sheath:

• Material: PVC (Polyvinyl Chloride)

• Thickness: 1.5-2.5mm depending on cable size

• Color: Black standard (other colors available)

2.5 Mechanical Properties

• Minimum Bending Radius:

• Static installation: 10-12 times cable diameter

• Dynamic installation: 15-20 times cable diameter

• Weight per Meter:

• 4x16mm²: ~1.2 kg/m

• 4x50mm²: ~3.0 kg/m

• 4x70mm²: ~4.1 kg/m

• 4x95mm²: ~5.5 kg/m

• 4x120mm²: ~6.7 kg/m

• 4x150mm²: ~8.2 kg/m

3. Product Features and Benefits

3.1 Electrical Performance

• High Conductivity: Copper Conductors minimize power loss

• Superior Insulation: XLPE provides excellent dielectric strength and thermal stability

• Reliable Earthing: Armour serves as effective earth path when properly terminated

3.2 Mechanical Protection

• Steel Armour: Resists impact, crushing, and rodent damage

• Robust Sheathing: PVC outer sheath protects against abrasion and environmental factors

• Flexible Design: Class 2 stranding allows for easier installation

3.3 Environmental Resistance

• Weather Resistant: Suitable for outdoor installation

• Chemical Resistant: Resistant to oils, greases, and many chemicals

• Flame Retardant: PVC materials offer flame retardant properties

4. Applications

4.1 Industrial Applications

• Factory Power Distribution: Main feeder and sub-main circuits

• Motor Connections: Power supply for heavy machinery

• Process Control Systems: Reliable power for automation equipment

4.2 Commercial Buildings

• High-Rise Developments: Vertical distribution through risers

• Shopping Centers: Power distribution across large floor spaces

• Data Centers: Critical power circuits with high reliability requirements

4.3 Infrastructure Projects

• Road and Rail: Lighting and power systems

• Tunnel Systems: Emergency and main power circuits

• Water Treatment: Submersible pump connections

4.4 Utility Networks

• Secondary Distribution: From transformers to consumer connections

• Renewable Energy: Connecting solar panels and wind turbines

• Emergency Systems: Backup power circuits

5. Production Process

5.1 Raw Material Selection

• Copper Rod: High-purity copper (99.95%+) for optimal conductivity

• XLPE Compounds: Specialized formulations meeting IEC standards

• Steel for Armour: High-tensile steel wire or tape

• PVC Compounds: Formulated for durability and environmental resistance

5.2 Manufacturing Steps

1. Wire Drawing: Copper rod drawn to required diameter

2. Stranding: Multiple wires twisted together to form conductors

3. Insulation Extrusion: XLPE applied using specialized extrusion equipment

4. Cross-linking: Insulation cured using steam, dry heat, or electron beam

5. Core Assembly: Insulated Cores twisted together with fillers

6. Inner Sheathing: PVC extruded over core assembly

7. Armouring: Steel wire or tape applied helically

8. Outer Sheathing: Final PVC layer extruded over armour

9. Quality Testing: Comprehensive testing throughout production

5.3 Quality Control

• Conductor Testing: Diameter, resistance, stranding checks

• Insulation Testing: Thickness, dielectric strength, thermal stability

• Mechanical Testing: Bending, impact, and crush resistance

• Final Inspection: Dimensional checks, visual inspection, packaging verification

6. Packaging and Transportation

6.1 Standard Packaging

• Cable Drums:

• Wooden drums (plywood or solid wood)

• Steel flanged drums for heavier cables

• Drum sizes from 600mm to 1250mm diameter

• Lengths per Drum:

• 4x16mm²: 500-1000 meters

• 4x50mm²: 300-600 meters

• 4x70mm²: 250-500 meters

• 4x95mm²: 200-400 meters

• 4x120mm²: 150-300 meters

• 4x150mm²: 100-250 meters

6.2 Transportation Guidelines

• Handling Instructions:

• Use proper lifting equipment for cable drums

• Avoid dropping or impacting drums

• Store in dry, level area

• Transport Modes:

• Road transport for local and regional deliveries

• Sea freight for international shipments

• Rail transport for long-distance land movement

6.3 Storage Recommendations

• Indoor Storage: Preferred to protect from weather

• Outdoor Storage: Possible with adequate covering

• Shelf Life: Up to 2 years under proper storage conditions

7. Ordering and Shipping

7.1 Ordering Information

• Required Details:

• Cable type and specifications

• Core configuration and size

• Quantity required

• Special requirements (color, length, etc.)

• Order Confirmation:

• Detailed order acknowledgment

• Technical datasheet

• Delivery schedule

7.2 Lead Times

• Standard Products: 7-14 working days

• Large Quantities: 2-4 weeks

• Custom Products: 4-6 weeks

7.3 Shipping Process

• Documentation:

• Commercial invoice

• Packing list

• Certificate of conformity

• Test reports

• Shipping Terms:

• EXW (Ex Works)

• FOB (Free On Board)

• CIF (Cost, Insurance, Freight)

• DDP (Delivered Duty Paid)

8. Sample Policy

8.1 Sample Availability

• Standard Samples: Available upon request

• Sample Lengths: 1-5 meters typical

• Lead Time: 3-5 working days

8.2 Sample Order Process

• Request Submission: Product details, address, purpose

• Approval Process: Evaluation based on product and availability

• Delivery: Standard or expedited shipping options

8.3 Sample Evaluation

• Testing Parameters:

• Visual inspection

• Dimensional checks

• Electrical testing if required

• Feedback Mechanism:

• Evaluation form

• Technical support contact

9. Installation Guidelines

9.1 Preparation

• Site Assessment: Check route, obstacles, environmental conditions

• Tool Preparation: Cable pullers, sheaves, cutting tools, termination kits

• Safety Equipment: Gloves, safety glasses, ear protection

9.2 Installation Procedures

• Unreeling: Use proper equipment to prevent drum damage

• Routing: Maintain minimum bending radius

• Pulling: Use appropriate tension, avoid sharp bends

• Termination: Follow manufacturer guidelines for connectors and lugs

• Earthing: Properly bond and earth armour at both ends

9.3 Safety Considerations

• Lockout/Tagout: Ensure power is disconnected

• Personal Protective Equipment: Use appropriate safety gear

• Compliance: Follow local electrical codes and regulations

10. After-Sales Support

10.1 Warranty

• Standard Warranty: 12-24 months against manufacturing defects

• Claim Process:

• Notification within warranty period

• Provide order details and photos

• Technical evaluation

• Resolution (repair, replacement, or refund)

10.2 Technical Support

• Application Assistance: Help with cable selection and system design

• Installation Guidance: On-site or remote support

• Troubleshooting: Technical experts available to resolve issues

10.3 Maintenance Recommendations

• Regular Inspections: Visual checks, insulation resistance testing

• Preventive Measures: Address potential issues before they become problems

• Record Keeping: Maintain installation and maintenance records

11. Quality Assurance

11.1 Certifications

• International Standards: IEC, BS, VDE compliance

• Quality Management: ISO 9001 certified processes

• Environmental Management: ISO 14001 compliance

11.2 Testing Procedures

• Type Tests: Conducted on new product designs

• Routine Tests: Performed on every cable manufactured

• Special Tests: Conducted at customer request

12. Conclusion