I. Product-Related Information
(1) Specification Parameters
The Nyy Cu/PVC/PVC 4-core 35mm²
Copper DC Power Cable is engineered with precise specification parameters that define its performance capabilities and suitability for a wide range of 直流 (DC) power transmission applications. These parameters ensure the cable can reliably handle medium to high-power DC loads while maintaining stability and safety.
At the core of its design is the 4-core structure, each with a conductor cross-sectional area of 35mm². This configuration is optimized for balanced current distribution in multi-loop DC systems, allowing for efficient parallel power transmission. The 35mm² conductor size strikes a balance between current-carrying capacity and physical dimensions, making it suitable for both indoor and outdoor installations where space may be constrained.
Current-carrying capacity is a critical parameter for
DC cables, as it determines the maximum power the cable can transmit without overheating. Under standard ambient conditions (25℃), each 35mm² core of the
Nyy Cable has a long-term allowable current-carrying capacity of approximately 130A in DC mode. This capacity is derived from rigorous testing to ensure the cable can operate continuously without exceeding safe temperature limits, which is crucial for preventing insulation degradation. The current rating translates to significant power-handling capabilities: in a 750V DC system, each core can transmit approximately 97.5kW (calculated as Power = Voltage × Current, 750V × 130A), and with
4 Cores, the total power capacity reaches 390kW. This makes the cable ideal for large-scale DC applications such as connecting photovoltaic inverters, energy storage systems, and industrial DC machinery.
The cable’s rated DC voltage is typically 1.8kV, though custom versions can be manufactured to meet higher voltage requirements (up to 3kV) for specialized applications. This voltage rating ensures compatibility with common DC power systems, including those found in renewable energy installations, industrial plants, and transportation infrastructure.
Physical dimensions are carefully controlled to balance functionality and installability. The overall outer diameter of the cable is approximately 40mm, which includes the combined thickness of the conductors, insulation, and sheath layers. The
PVC Insulation surrounding each conductor has a thickness of about 1.6mm, providing robust electrical isolation between cores to prevent short circuits and leakage currents. The inner
PVC Sheath, which encloses the 4
Insulated Cores, adds another 2.0mm of thickness, enhancing mechanical protection and structural integrity.
The minimum bending radius of the cable is specified as 10 times its outer diameter, equating to approximately 400mm. This
Flexibility allows the cable to be installed in tight spaces, around corners, or in cable trays without compromising the integrity of the insulation or conductors. It also simplifies routing in complex installations, such as within industrial machinery or building cavities.
Short-circuit withstand capability is another key parameter, ensuring the cable can tolerate transient overloads without failure. The Nyy cable can withstand short-circuit temperatures up to 80℃ for limited durations, providing a safety margin during fault conditions. This allows protective devices (such as fuses or circuit breakers) sufficient time to isolate the fault, minimizing downtime and preventing damage to connected equipment.
Conductor resistance is minimized to reduce power loss during transmission. At 20℃, the maximum DC resistance of each 35mm²
Copper Conductor is ≤0.524Ω/km. This low resistance ensures efficient energy transfer, which is particularly important in long-distance DC lines where losses can accumulate significantly.
Other notable parameters include the cable’s weight (approximately 3.5kg per meter), which influences handling and installation requirements, and its operating temperature range. The cable is designed to operate reliably in temperatures from -30℃ to 70℃, making it suitable for harsh environmental conditions, including cold climates and outdoor installations exposed to direct sunlight.
(2) Characteristic Uses
The Nyy Cu/PVC/PVC 4-core 35mm² copper DC power cable is versatile, with characteristic uses spanning multiple industries that rely on efficient and reliable DC power transmission. Its design attributes—such as high current capacity, durability, and flexibility—make it a preferred choice for applications where performance and cost-effectiveness are paramount.
In the
new energy sector, the cable plays a critical role in photovoltaic (PV)
Power Stations. It serves as the DC connection link between solar panel strings and combiner boxes, as well as between combiner boxes and inverters. PV systems operate in harsh outdoor environments, exposed to extreme temperature fluctuations (-30℃ to 70℃), UV radiation, and moisture. The cable’s PVC sheath resists UV degradation and moisture ingress, ensuring long-term reliability in these conditions. Its 4-core design allows for parallel connection of multiple panel strings, simplifying wiring and reducing installation time.
Energy storage systems (ESS) also benefit from the cable’s capabilities. It is used to transmit power between battery clusters and power conversion systems (PCS), which convert DC power from batteries to AC for grid integration. Battery rooms can be humid, but the cable’s moisture-resistant PVC sheath prevents corrosion of conductors and insulation breakdown. The high current-carrying capacity ensures efficient charging and discharging of large battery banks, supporting the fluctuating power demands of ESS applications.
In industrial settings, the cable is employed in DC-powered equipment such as electrolytic cells, electroplating tanks, and DC motor drives. Electrolytic processes involve corrosive electrolytes, but the cable’s PVC sheath resists chemical splashes, protecting the internal conductors. Its flexibility allows for easy routing around machinery, even in confined spaces, while the 4-core design enables separate control and power circuits to be integrated into a single cable, reducing clutter.
Telecommunications infrastructure relies on the cable for reliable power supply to communication base stations. Base stations require 24/7 uninterrupted DC power from backup batteries, and the cable connects these batteries to power distribution units (PDUs) and radio equipment. The low resistance of the
Copper Conductors ensures minimal voltage drop, maintaining stable power to sensitive electronics, while the PVC insulation prevents interference with signal cables.
Electric vehicle (EV) charging stations use the cable in their DC fast-charging systems. It connects the charging station’s power module to the vehicle connector, transmitting high-power DC to recharge EV batteries quickly. The cable’s ability to handle 130A per core supports the high currents required for fast charging, and its durable sheath withstands frequent handling and exposure to weather.
Rail transportation is another key application area. The cable is used in the DC traction auxiliary systems of subways, light rails, and trams, where it powers lighting, ventilation, and control systems. These environments experience vibration and mechanical stress, but the cable’s
Stranded Conductors and robust sheath absorb shocks, ensuring continuous operation.
In summary, the Nyy Cu/PVC/PVC 4X35mm² cable’s adaptability to diverse environments and power requirements makes it indispensable in renewable energy, industrial, telecommunications, transportation, and EV infrastructure.
(3) Material and Style
The Nyy Cu/PVC/PVC 4-core 35mm² copper DC power cable combines high-quality materials and a functional design to deliver reliable performance in DC power transmission. Each component is selected for its specific properties, ensuring the cable meets electrical, mechanical, and environmental demands.
Conductors: The cable uses high-purity electrolytic copper (purity ≥99.95%) for its conductors. This high purity minimizes electrical resistance, reducing power loss during transmission—a critical factor in DC systems where efficiency is paramount. The copper is drawn into thin wires and stranded together, a process that enhances flexibility.
Stranded Conductors are less prone to breaking than solid conductors when bent or twisted, making the cable easier to install in tight spaces or around obstacles. The stranding also improves heat dissipation by increasing the surface area of conductors, helping to maintain safe operating temperatures under high current loads.
Insulation: Each copper conductor is insulated with a specially formulated PVC (polyvinyl chloride) material designed for DC applications. Unlike standard PVC, this insulation is optimized to resist space charge accumulation—a phenomenon in DC systems where electric charges build up in the insulation, leading to premature aging and breakdown. The insulation has a high volume resistivity (≥10¹⁴Ω·cm), ensuring effective electrical isolation between cores even at high DC voltages. It also exhibits excellent corona resistance, preventing partial discharges that can damage insulation over time. The insulation thickness of 1.6mm provides a balance between electrical safety and cable flexibility.
Sheath: The cable features a dual-layer PVC sheath system. The inner sheath encloses the 4 insulated cores, holding them together and providing a barrier against moisture and dust. The outer sheath, with a thickness of 2.0mm, adds mechanical protection, resisting abrasion, impact, and chemical corrosion. PVC is chosen for its cost-effectiveness, durability, and ease of processing. It withstands exposure to UV radiation, making the cable suitable for outdoor use, and resists common industrial chemicals, oils, and solvents—critical for industrial and EV charging applications. The outer sheath is smooth, reducing friction during installation and allowing the cable to be pulled through conduits or trays with minimal effort.
Style and Structure: The cable has a cylindrical, compact design with a uniform outer diameter of 40mm. The 4 insulated cores are twisted together in a helical pattern to form a round core, which is then encased in the inner and outer sheaths. This twisted design ensures even distribution of stress during bending, preventing core damage. The outer sheath is typically black, a color chosen for its UV resistance and ability to hide dirt, maintaining a professional appearance in visible installations.
Markings on the outer sheath provide essential information for identification and traceability, including the cable type (Nyy Cu/PVC/PVC), specification (4X35mm²), rated voltage (1.8kV DC), manufacturer’s logo, and production date. These markings are printed in durable ink that remains legible throughout the cable’s service life, facilitating maintenance and compliance checks.
Overall, the material selection and design of the Nyy cable prioritize performance, durability, and ease of installation, making it a practical choice for demanding DC power applications.
(4) Production Process
The manufacturing of the Nyy Cu/PVC/PVC 4-core 35mm² copper DC power cable involves a series of precise steps, each controlled to ensure the final product meets strict quality standards for electrical performance and mechanical integrity.
Copper Conductor Manufacturing: The process begins with high-purity electrolytic copper rods (99.95% purity). These rods are inspected for impurities and surface defects before being cleaned to remove oxides and contaminants. The rods are then drawn through a series of diamond dies in a wire drawing machine, reducing their diameter to form thin
Copper Wires (typically 0.2–0.5mm in diameter). Drawing increases the wire’s tensile strength while maintaining conductivity.
The drawn wires undergo annealing, a heat treatment process performed in a controlled nitrogen atmosphere at 500–600℃. Annealing relieves internal stresses from drawing, restoring ductility to the copper. This step is critical for ensuring the conductors can be bent and twisted during installation without breaking.
Multiple annealed wires are then stranded together in a stranding machine to form 35mm² conductors. Stranding uses a planetary stranding process, where wires are twisted in layers around a central wire, ensuring a compact, circular cross-section. This structure enhances flexibility and current-carrying capacity by improving heat dissipation.
Insulation Extrusion: Each 35mm² stranded conductor is fed into an extrusion line to apply the PVC insulation. The PVC compound, formulated for DC applications, is first dried to remove moisture (moisture content <0.05%)—moisture can cause insulation defects like voids or bubbles. The dried PVC pellets are fed into a single-screw extruder, where they are melted at 160–180℃.
The molten PVC is forced through a crosshead die, which shapes the insulation around the conductor. The die is precision-engineered to ensure a uniform 1.6mm thickness. After extrusion, the
Insulated Conductor is cooled in a water bath to solidify the PVC, then passed through a diameter gauge to verify insulation thickness. Conductors with insulation defects (e.g., uneven thickness, pinholes) are rejected.
Cabling: The 4 insulated conductors are gathered and fed into a cabling machine, where they are twisted together at a specified lay length (typically 15–20 times the cable diameter). Twisting ensures the cable has a round, stable shape and prevents core movement during installation. A filling material (polypropylene rope) is sometimes added between cores to fill gaps, ensuring a compact structure. A polyester binding tape is wrapped around the twisted cores to hold them together.
Sheath Extrusion: The cabled core is then passed through a sheath extrusion line. The PVC sheath material, blended for UV and
Chemical Resistance, is dried and melted in an extruder. The molten PVC is extruded over the cabled core, forming the inner and outer sheaths in a single pass (total thickness 2.0mm). The extrusion die is designed to ensure the sheath fully encapsulates the cores without gaps, providing a moisture-tight seal. The
Sheathed Cable is cooled in a water bath and dried.
Quality Testing: After production, each cable undergoes rigorous testing:
Electrical tests: Insulation resistance (measured with a megohmmeter, ≥1000MΩ·km at 20℃), DC withstand voltage (3kV for 5 minutes without breakdown), and conductor resistance (≤0.524Ω/km at 20℃).
Cables passing all tests are labeled with production details and prepared for packaging.
II. General Product Information
(1) Packaging
The Nyy Cu/PVC/PVC 4X35mm² cable is packaged to protect it during storage, transportation, and handling, ensuring it reaches customers in pristine condition.
For standard lengths (100m or 500m reels), heavy-duty wooden reels are used. These reels are made from durable hardwood (e.g., pine) with flanges to prevent the cable from unwinding. The cable is tightly wound onto the reel, with a moisture-resistant plastic film wrapped around it to shield against dust and water. Steel bands secure the cable to the reel, and a tag attached to the flange lists the cable type, length, specification, batch number, and manufacturer details.
For shorter lengths (10–50m), the cable is coiled and wrapped in thick plastic sheeting, then placed in corrugated cardboard boxes. The boxes are reinforced with wooden edges to prevent crushing and labeled with the same information as reels.
Sample lengths (1–5m) are packaged in small cardboard boxes with foam padding to prevent bending. Each sample includes a technical data sheet.
For export shipments, wooden reels are heat-treated to comply with ISPM 15 standards, preventing pest infestation. Palletization is used for bulk orders, with multiple reels secured to a wooden pallet and wrapped in stretch film for stability.
(2) Transportation
Transportation of the Nyy cable is managed to minimize damage and ensure timely delivery, with methods tailored to distance and destination.
Domestic transport primarily uses road vehicles. Flatbed trucks carry large reels, secured with chains and chocks to prevent movement. Enclosed trucks are used for shorter lengths or in inclement weather to protect against rain and extreme temperatures. Drivers are trained to avoid sudden stops that could shift loads.
Long-distance or international transport uses rail or sea freight. Railcars carry palletized reels, while sea shipments use shipping containers. Containers are climate-controlled if needed to avoid temperature extremes that could affect PVC properties.
Air freight is available for urgent orders, with small reels or coils packed in lightweight boxes to meet airline weight limits.
Throughout transport, the cable is protected from physical damage: reels are handled with forklifts using proper lifting points, and coils are not dropped. Moisture barriers (e.g., tarpaulins) prevent water exposure, and UV covers shield against sunlight during transit.
(3) Shipment
The shipment process is streamlined to ensure efficiency and transparency:
(4) Samples
Samples of the Nyy 4X35mm² cable are available to customers for evaluation:
Request process: Samples are requested via email, phone, or the manufacturer’s website, specifying length (1–3m) and intended application.
(5) After-sales Service
Comprehensive after-sales support ensures customer satisfaction throughout the cable’s lifecycle:
Technical support: Engineers provide installation guidance (e.g., bending radius, termination methods) and troubleshooting via phone, email, or on-site visits.
free of charge, with all associated shipping costs covered by the manufacturer.
Maintenance guidance: Customers receive detailed manuals outlining best practices for cable maintenance, including periodic inspection schedules (e.g., checking for sheath damage, insulation integrity, and secure terminations) and cleaning procedures to remove dirt or debris that could affect performance.
Training programs: For large-scale projects or industrial clients, on-site training sessions are available to educate electricians and maintenance staff on proper installation techniques, safety protocols, and identification of potential issues. These sessions can be customized to focus on specific applications, such as PV system integration or EV charging station setup.
Feedback mechanism: The manufacturer actively solicits customer feedback through surveys and follow-up calls to identify areas for improvement. This input is used to refine production processes, enhance material formulations, or develop new features that better meet market needs.
In cases of non-warranty issues (e.g., damage due to improper installation or accidental mishandling), the after-sales team offers cost-effective repair services or replacement options, ensuring minimal downtime for the customer. Emergency support is available 24/7 for critical applications, such as hospital backup power systems or data center infrastructure, to address urgent issues promptly.
Overall, the after-sales service program is designed to build long-term customer relationships by providing ongoing support, ensuring the cable performs optimally throughout its service life, and addressing any concerns with professionalism and efficiency.
Conclusion
The Nyy Cu/PVC/PVC 4-core 35mm² copper DC power cable represents a harmonious blend of performance, durability, and cost-effectiveness, making it a versatile solution for DC power transmission across diverse industries. Its precise specification parameters—including high current-carrying capacity, robust insulation, and flexible design—enable reliable operation in environments ranging from harsh outdoor renewable energy installations to controlled industrial settings.
The careful selection of materials, from high-purity copper conductors to DC-optimized PVC insulation and sheath, ensures the cable meets stringent electrical and mechanical requirements. The manufacturing process, characterized by rigorous quality control at every stage, guarantees consistency and reliability in every unit produced.
Complemented by thoughtful packaging, efficient transportation, transparent shipment processes, accessible sampling options, and comprehensive after-sales support, the cable offers a complete solution that addresses not only the technical needs of customers but also their practical concerns regarding handling, installation, and long-term maintenance.
Whether powering solar farms, energy storage systems, industrial machinery, telecommunications infrastructure, EV charging stations, or rail transportation auxiliaries, the Nyy Cu/PVC/PVC 4X35mm² cable stands as a testament to engineering excellence, providing a stable and efficient backbone for modern DC power systems.
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