Details of Xav 4X25 Cable
I. Information Related to the Product Itself
(I) Specification Parameters
As a 4-core
Armoured Cable, Xav 4X25 Cable has its specification parameters designed around a 25mm² single-core cross-section, with all indicators meeting the requirements of high-power power transmission.
Current-carrying capacity is one of its core performance parameters. In a standard environment (temperature 25°C, laid in the air), the current-carrying capacity of this cable can reach 80-100A, which can meet the power needs of large equipment. If it is laid directly underground, due to changes in heat dissipation conditions, the current-carrying capacity needs to be multiplied by a correction factor of 0.85-0.9; in high-temperature environments (such as industrial workshops in summer), the correction factor is adjusted to about 0.8, and it can still transmit power stably.
The outer diameter of the cable is about 30-35mm, and the thickness of the armoured layer is about 1.5-2mm. The overall structure is compact, which can not only adapt to laying spaces such as underground pipelines and wall penetration but also provide sufficient mechanical protection through the armoured layer. Its rated voltage is 0.6/1kV, which conforms to the low-voltage and high-power power transmission standards. The DC resistance of the
Copper Conductor is strictly controlled, and the DC resistance per kilometer at 20°C is not more than 0.727Ω, which effectively reduces energy loss during transmission. In addition, the protection level of the armoured layer reaches IP65, which can resist dust intrusion and low-pressure water spray, and adapt to complex environments such as humidity and dust.
(II) Characteristic Uses
With its own performance advantages, Xav 4X25 Cable shows distinct characteristic uses in various scenarios and has become a reliable choice for high-power power transmission.
In industrial factories, it is an ideal
Power Supply Cable for large equipment. For example, heavy machine tools have high power and long running time. This cable can transmit power stably to ensure the precise operation of the machine tools; large compressors have large current fluctuations during startup and operation, and the current-carrying capacity and stability of the cable can avoid shutdowns caused by power supply problems. The main
Power Lines in the workshop also often use this cable to distribute power from the distribution box to various branches to ensure the smooth operation of the entire workshop power system.
In the field of commercial buildings, it is suitable for power supply of large central air-conditioning hosts. The power of central air-conditioning hosts is high, especially during the peak cooling period in summer, which has extremely high requirements for the stability of power transmission. This cable can meet its continuous power supply needs. At the same time, the outgoing line of the standby generator in commercial complexes can also use this cable to quickly transmit generator power to key areas (such as elevators and emergency lighting) in case of sudden power outages.
In municipal engineering, this cable is often used for supporting power lines of underground pipe networks. The underground environment is complex, with problems such as soil extrusion and groundwater erosion. The armoured layer and environment resistance of the cable can ensure long-term stable operation. In addition, this cable is also competent for the main cable of street lamps on urban roads, which needs to withstand ground vehicle vibration and rainwater immersion.
The "Straight Through" feature makes it have obvious advantages in scenarios that require continuous power transmission. For example, for the standby power lines of data centers, even a short transmission interruption may cause huge losses, and this feature can reduce the risk of transmission interruption; for the power supply lines of intensive care units in hospitals, continuous and stable power is the key to ensuring the operation of medical equipment, and this cable can provide reliable support.
(III) Material and Style
In terms of material selection and style design, Xav 4X25 Cable fully combines the needs of high-power transmission and laying in complex environments, achieving the unity of performance and practicality.
In terms of materials, the conductor is made of high-purity electrolytic copper with a purity of more than 99.95%. High-purity copper has excellent conductivity, which can reduce resistance loss during current transmission and ensure efficient power transmission. At the same time, the copper conductor has good ductility and toughness, and is not easy to break even with a certain degree of bending during laying, reducing construction difficulty.
The insulation layer is made of cross-linked polyethylene (XLPE) material, which has strong temperature resistance. The long-term working temperature can reach 90°C, and it can withstand a high temperature of 130°C during short-term overload, and is not easy to have insulation aging. It has high insulation resistance, which can effectively isolate current interference between cores and ensure the safety of power transmission. Moreover, XLPE has good chemical stability and is not easy to be eroded by corrosive gases and moisture in the air, extending the service life of the cable.
The armoured layer is made of galvanized steel strip, which has excellent mechanical strength and corrosion resistance. The galvanized layer can prevent the steel strip from rusting and can maintain the protective performance for a long time even in a humid environment. The armoured layer tightly wraps the cable and can resist external mechanical impacts such as extrusion and collision, such as soil pressure during underground laying and instrument collision during construction, providing solid protection for internal cores and insulation layers.
The outer sheath is made of polyvinyl chloride (PVC) material, which has good weather resistance and wear resistance. The
PVC Sheath can adapt to different temperature changes and maintain stable performance in an environment of -15°C to 60°C. At the same time, it can resist ultraviolet radiation and chemical erosion, extending the service life of the cable in outdoor or industrial environments.
In terms of style, the cable has a 4-core structure, and the core colors are clearly distinguished, which are yellow, green, red (phase wires) and blue (neutral wire) respectively, facilitating quick identification and wiring during construction. The armoured layer adopts an interlocking armoured design, which has good
Flexibility and does not affect the bending and laying of the cable. The overall shape is cylindrical with a smooth surface and a black color, which is resistant to dirt and can blend with industrial, municipal and other environments. The surface of the cable is printed with model, cross-section, rated voltage, manufacturer and other marks, which is convenient for later maintenance and traceability.
(IV) Production Process
The production process of Xav 4X25 Cable is rigorous and standardized, and each link is carried out to improve performance and reliability, ensuring that the product meets high-power transmission standards.
The production of
Copper Conductors is a basic link. High-quality electrolytic copper rods are selected, and the copper rods are drawn into
Copper Wires with a diameter suitable for 25mm² cross-section through a continuous wire drawing process. During the wire drawing process, the wire drawing speed (about 8-10m/s) and die precision are strictly controlled to ensure uniform diameter of the copper wires. Subsequently, multiple copper wires are stranded to form a conductor in a concentric stranding way. During stranding, the tension is kept uniform to enhance the mechanical strength and conductivity of the conductor.
The insulation extrusion link is crucial. The XLPE material is put into an extruder, heated and melted at a temperature of 120-150°C, and uniformly coated on the surface of the copper conductor through a precision mold to form an insulation layer with a thickness of about 1.4mm. During the extrusion process, an online thickness gauge is used to monitor the thickness of the insulation layer in real time to ensure that the deviation does not exceed ±0.1mm, avoiding the impact of uneven thickness on insulation performance. After that, the
Insulated Core is cross-linked, and the XLPE molecules form a three-dimensional network structure through steam cross-linking to improve temperature resistance and insulation strength.
The cabling process needs to ensure that the cores are arranged neatly. The 4 insulated cores are stranded in a symmetrical way, and the stranding pitch is controlled at 16-20 times the outer diameter of the cable to reduce friction between cores. During the stranding process, polypropylene filling rope is added to make the cable shape round, and then a layer of polyester tape is wrapped to enhance structural stability.
The armoured layer is made by the galvanized steel strip longitudinal wrapping process. The galvanized steel strip with a thickness of 0.3-0.5mm is continuously longitudinally wrapped outside the cabled core through special equipment. The overlapping width of the steel strip is 15%-20% of the width of the steel strip, and it is firmly connected by high-frequency welding to form a closed armoured protective layer. After welding, cooling treatment is carried out to ensure that the steel strip is closely attached to the core.
Outer sheath extrusion is the last protective process. The PVC material is heated to 160-180°C in an extruder to melt, and uniformly coated on the armoured layer to form an outer sheath with a thickness of about 2mm. After extrusion, it is quickly cooled and shaped through a cold water tank to make the sheath tightly attached to the armoured layer. During the production process, samples of each batch of cables need to be taken for voltage withstand test (applying 3kV voltage for 5 minutes without breakdown), insulation resistance test (not less than 1000MΩ), etc., to ensure qualified quality.
II. General Product Information
(I) Packaging
The packaging of Xav 4X25 Cable focuses on protecting the cable from damage during transportation and storage, and the packaging method is designed in combination with its armoured structure characteristics.
For long-length cables (100 meters and above), wooden cable reels are used for packaging. The wooden reels are made of larch, with a load-bearing capacity of more than 500kg. The diameter of the reel surface is designed to be 1.2-1.5m according to the length of the cable. The cable is neatly wound on the wooden reel, and the winding tension is controlled at 50-80N to avoid deformation of the armoured layer due to over-tightening or looseness due to over-loosening. Both sides of the wooden reel are equipped with baffles with a thickness of 20mm, and rubber buffer strips are added at the edges of the baffles to prevent the cable from colliding with the baffles during transportation. The outer layer of the cable is wrapped with a moisture-proof wrapping film with a thickness of 0.05mm and a winding overlap rate of 50%, which can effectively isolate moisture and dust. The surface of the wooden reel is printed with model, length, weight, production batch number and other information with waterproof ink, and pasted with warning signs such as "Up" and "Anti-pressure".
Short-length cables (10-50 meters) are packaged in high-strength wooden boxes. The wooden boxes are made of multi-layer plywood with a thickness of 15mm, and a 5mm thick pearl cotton buffer layer is laid inside. The cable is coiled into a disc with a diameter of about 30cm and fixed in the wooden box with strapping to avoid shaking during transportation. Desiccants (50g per box) are placed in the box to prevent the cable from getting damp. Product information and transportation warning signs are printed on the outside of the box, and hand holes are opened on the side for easy manual handling.
The packaging materials meet environmental protection requirements, and the wooden packaging has been fumigated to meet export quarantine standards. All packages have passed the drop test (no damage when dropped from a height of 1.2m) before leaving the factory to ensure transportation safety.
(II) Transportation
The transportation of Xav 4X25 Cable needs to combine its weight and armoured characteristics, select an appropriate transportation method and take protective measures.
The transportation method is selected according to the transportation distance and quantity. For short-distance transportation (within 300 kilometers), trucks with hydraulic tailboards are used, and anti-skid rubber pads are laid in the carriage to prevent the cable reels from sliding. A single truck can load 8-10 wooden reel packaged cables. When loading, the wooden reels are separated by wooden strips to prevent mutual collision. For long-distance transportation (more than 300 kilometers), railway flat cars are selected, and the wooden reels are fixed on the carriage load-bearing frame through steel wire ropes. Rubber pads are set at the fixed points to avoid the steel wire ropes from damaging the wooden reels. Large quantities of export transportation use container shipping, with vents set in the containers to control the humidity below 60%.
Targeted protective measures should be implemented during transportation. When transporting in rainy days, the cables are completely covered with rainproof cloth. The edges of the rainproof cloth hang down to the bottom of the carriage and are compacted with sandbags to prevent rainwater from seeping in. When transporting in high-temperature weather, avoid the cables being exposed to the sun for a long time. A sunshade can be installed on the top of the carriage to control the temperature in the carriage not to exceed 40°C. When loading and unloading, a forklift is used. The length of the forklift arm is not less than 1.2m. After inserting into the center hole of the wooden reel, it is lifted slowly to avoid an inclination angle of more than 15°. It is strictly forbidden to use steel wire ropes to directly bind the outer sheath of the cable for hoisting to prevent damage to the sheath and armoured layer.
Regular inspections are required during transportation. Stop every 200 kilometers to check the fixing of the cables, and reinforce them in time if they are loose. The driving speed of the transport vehicle does not exceed 80km/h to avoid displacement of the cable reels caused by sudden braking.
(III) Shipment
The shipment process of Xav 4X25 Cable is standardized and orderly to ensure that the cables are delivered on time and accurately.
In the order confirmation link, after receiving the order, the sales staff checks the product model, quantity, delivery address, delivery time and other information with the customer within 2 hours. After confirmation, an order number is generated and entered into the system. At the same time, check the customer's payment status, and arrange stock preparation after collecting the advance payment (usually 30% of the total amount) according to the contract agreement.
The stock preparation process is efficiently connected. Warehouse managers retrieve the inventory according to the order number, and transfer the cables to the inspection area after checking that the cable identification is consistent with the order information. Quality inspectors conduct random inspections on the cables, including appearance (no damage to the sheath, no looseness of the armoured layer), insulation resistance (measured with a megohmmeter not less than 1000MΩ), and length (error not exceeding ±0.5%). After passing the random inspection, an outgoing inspection report is issued. The stock preparation cycle is usually 1-2 working days, and the stock preparation cycle for customized products with special specifications is determined according to the production progress.
Transportation arrangements are accurately connected. The logistics specialist selects the optimal transportation method according to the delivery address, confirms the delivery time window with the customer (accurate to half a day), and notifies the customer of the arrival information 24 hours in advance, including the license plate number of the transport vehicle, the driver's contact information, and the estimated arrival time. For urgent orders, a special vehicle can be arranged for transportation to ensure delivery within 24 hours.
Shipment tracking is fully visualized. The location of the goods is monitored in real time through the logistics management system, and the transportation progress information is pushed to the customer every 6 hours. In case of delays due to traffic control, bad weather, etc., communicate with the customer immediately and provide solutions (such as changing the transportation route, urgently allocating spare goods). After the goods are delivered, assist the customer in checking the quantity and appearance. After confirmation, the customer signs for receipt, and the receipt is uploaded to the system for archiving in real time.
(IV) Samples
Xav 4X25 Cable provides sample services to help customers understand product performance in advance.
The sample application process is simple. Customers can apply through the official website, phone, email, etc., stating the required number of samples (usually no more than 2 meters) and purpose (such as testing, trial). When applying, it is necessary to provide company name, contact person, contact information and other information, and the sample application will be responded to within 1 working day.
Sample preparation is strictly standardized. Samples are cut from mass-produced qualified products with a length of 1.5 meters, retaining the complete armoured layer and sheath. Both ends of the sample are sealed with insulating 封头 to prevent the core from getting damp. A sample label is attached to the sample, indicating product model, production batch number, cutting date and other information, as well as a copy of the product test report.
Samples are sent by express. The packaging is a hard plastic pipe (diameter 50mm). The sample is put into the pipe, and both ends are fixed with foam plugs to prevent bending during transportation. The express waybill is marked with "Sample" and "Handle with Care", and the next-day delivery service is selected to ensure that the sample is delivered within 48 hours. Samples are provided free of charge, and the express fee is to be paid by the customer.
Sample tracking service is considerate. After the sample is sent, the customer is sent the express waybill number and logistics inquiry link. Within 3 working days after the customer receives the sample, the sales staff will make a return visit to understand the sample usage and answer relevant questions. If the customer needs further performance testing (such as bending resistance test), guidance on testing methods can be provided.
(V) After-sales Service
The after-sales service system of Xav 4X25 Cable is perfect, providing customers with full-cycle support.
In terms of quality assurance, the product warranty period is 2 years, calculated from the date of customer's signature. Within the warranty period, if the cable fails due to its own quality problems (such as insulation layer breakdown, armoured layer falling off), the customer can apply for after-sales service with the purchase contract and fault photos. After receiving the application, the after-sales specialist will respond within 2 hours and arrange technical personnel to arrive at the site for inspection within 48 hours. After confirming the quality problem, the customer will be provided with a new cable for free, and the round-trip transportation cost will be borne.
The technical support team consists of engineers with more than 5 years of experience, providing 7×24-hour consulting services. When customers are in the cable selection stage, engineers provide selection suggestions and current-carrying capacity calculation tables according to equipment power and laying environment; during laying, on-site guidance can be provided, such as bending radius requirements (not less than 12 times the outer diameter of the cable) and armoured layer grounding methods; during use, they answer questions about maintenance, such as regular inspection cycles (recommended once every 6 months) and sheath cleaning methods.
Maintenance services are aimed at cables that have exceeded the warranty period. After inspection by technical personnel, maintenance plans and cost quotations are provided, and maintenance is carried out after customer confirmation. Maintenance contents include sheath repair and armoured layer reinforcement, and a 3-month warranty is provided after maintenance. For cables that cannot be repaired, a trade-in service can be provided, and old cables are recycled at a discount based on weight.
The regular return visit mechanism is normalized. After the customer uses the cable for 3 months, 6 months, and 12 months, after-sales personnel will make return visits to record the cable operation status and collect customer opinions. Product and service optimization is carried out based on return visit data. For example, in response to the problem of humid environment reflected by customers in a certain area, a moisture-proof coating is added to the sheath in subsequent production. At the same time, the electronic version of the "Cable Maintenance Manual" is pushed to customers to provide professional maintenance knowledge.
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