Three Phase Cores: Transmit balanced three-phase power, with cross-sectional areas (CSA) ranging from 10mm² to 240mm². Common configurations include 3×16mm²+2×10mm² (residential) and 3×120mm²+2×70mm² (industrial).
Two Auxiliary Cores: Smaller in CSA (typically 50–60% of phase cores) to serve as neutral (current balancing) and earth (fault protection). For example, a 3×50mm²+2×25mm² cable uses 25mm² cores for neutral/earth, ensuring efficient fault current dissipation.
Conductor | CSA (Phase) | Ampacity (Air, 25°C) | Ampacity (Direct Burial, 25°C) |
Copper | 25mm² | 85–95A | 75–85A |
Copper | 120mm² | 210–230A | 180–200A |
Aluminum | 25mm² | 65–75A | 55–65A |
Aluminum | 120mm² | 160–180A | 140–160A |
Temperature Range: All models operate reliably from -40°C (cold climates) to +90°C (continuous use), with short-term overload capacity up to +130°C (XLPE insulation).
Bending Radius: 10× cable diameter (static) and 15× (dynamic). For a 3×50mm²+2×25mm² Copper Cable (28mm diameter), this means a 280mm static bending radius—ideal for navigating tight spaces in buildings or underground ducts.
Water Resistance: PE-sheathed variants achieve IP67 protection (submersion up to 1m for 30 minutes), while PVC-sheathed models offer IP65 (water jet resistance)—suitable for outdoor installations under eaves or in cable trays.
Copper Conductors (YJV/YJV22):
Purity and Structure: 99.95% pure electrolytic copper, stranded into concentric layers (e.g., 19 strands for 25mm²) to enhance Flexibility. Stranding reduces skin effect (AC resistance) and enables easier installation.
Performance Advantages: Conductivity of 58 MS/m (20°C) minimizes energy loss—critical for long runs (e.g., 500m in industrial plants). Corrosion resistance (natural oxide layer) eliminates the need for additional coatings in most environments.
Cost Consideration: 30–40% more expensive than aluminum but offers lower lifecycle costs due to reduced maintenance and energy savings.
Aluminum Conductors (YJLV/YJLV22/ZR-YLV):
Alloy Composition: AA 6201 (aluminum-magnesium-silicon alloy) for enhanced strength (tensile strength: 120 MPa vs. 70 MPa for pure aluminum). Stranded into compact bundles to improve flexibility.
Performance Tradeoffs: Conductivity of 37 MS/m (20°C) requires larger CSA for equivalent ampacity (e.g., 35mm² aluminum = 25mm² copper). Tin plating (5–10μm) prevents corrosion in humid or saline environments.
Cost Advantage: Lightweight (2.7 g/cm³ vs. 8.96 g/cm³ for copper) reduces transportation costs, making it ideal for rural electrification or budget-constrained projects.
Peroxide Cross-Linking: Molten XLPE is extruded onto conductors and heated to 200–220°C in a continuous vulcanization (CV) tube. Peroxides initiate cross-linking, forming a three-dimensional molecular structure. This method delivers superior thermal stability, suitable for high-load applications.
Silane Cross-Linking: XLPE is pre-mixed with silane additives, extruded, and cured via moisture (90% RH, 60°C) for 24–48 hours. More energy-efficient than peroxide cross-linking, ideal for standard-duty models (e.g., YJLV).
Dielectric Strength: 20–30 kV/mm, ensuring no breakdown at 1KV.
Aging Resistance: Withstands UV radiation and temperature cycles for 20+ years—double the lifespan of PVC Insulation.
Fire Safety: Inherently flame-retardant, meeting IEC 60332-1 (single cable flame test).
PVC Sheath (YJV/YJLV/ZR-YLV):
Formulation: PVC resin (60–70%), plasticizers (20–25% for flexibility), and flame retardants (5–10%). ZR-YLV adds halogen-free flame retardants (aluminum hydroxide) to reduce toxic smoke.
Applications: Indoor installations (cable trays, wall cavities) or protected outdoor areas (underground ducts with drainage). Resists water, oil, and mild chemicals but degrades in direct sunlight over time.
PE Sheath (Premium Variants):
Type: High-density polyethylene (HDPE) for rigidity or low-density polyethylene (LDPE) for flexibility. HDPE offers superior Chemical Resistance (to solvents, acids) and UV stability.
Applications: Underground direct burial (resists soil pressure up to 100 kPa) or coastal areas (saltwater corrosion resistance).
Steel Wire Armour (SWA, YJV22/YJLV22):
Construction: Galvanized steel wires (1.2–2.5mm diameter) twisted helically around the sheath at a pitch of 10–15× cable diameter. Wire count varies by cable size (e.g., 16 wires for 25mm², 32 wires for 120mm²).
Protection: Shields against impact (construction equipment), rodent gnawing, and soil compression. Enables direct burial without additional conduit, reducing installation costs by 20–30%.
Target Markets: Commercial buildings (shopping malls, offices) and data centers.
Key Applications: Powering HVAC systems, lighting, and server racks. Copper’s low resistance ensures stable voltage for sensitive equipment (e.g., servers), while PVC sheath simplifies installation in cable trays.
Example: A 3×70mm²+2×35mm² YJV cable powers a 10-story office building, supplying 150A to the main electrical panel.
Target Markets: Industrial plants and underground urban grids.
Key Applications: Direct burial in factory yards or city streets, powering heavy machinery (e.g., compressors, conveyors). SWA protects against accidental digging or vibration, while copper ensures efficient power transmission.
Example: A 3×240mm²+2×120mm² YJV22 cable connects a suburban substation to an industrial park, transmitting 300A over 1km.
Target Markets: Rural residential areas and low-density commercial zones.
Key Applications: Overhead or underground distribution in rural neighborhoods. Aluminum’s low cost and lightweight design reduce installation and material expenses.
Example: A 3×50mm²+2×25mm² YJLV cable supplies power to 50 rural homes, installed on utility poles with minimal support hardware.
Target Markets: Budget-conscious industrial projects and remote infrastructure.
Key Applications: Direct burial in mining sites or remote factories. SWA provides mechanical protection, while aluminum reduces costs for long runs (e.g., 1km in a mine).
Example: A 3×120mm²+2×70mm² YJLV22 cable powers a remote mining camp, transmitting 160A over 800m.
Target Markets: High-rise residential buildings, hospitals, and airports.
Key Applications: Indoor wiring in fire-sensitive areas. Halogen-free flame retardants reduce toxic smoke, complying with NFPA 70 (U.S.) and BS 6387 (UK) fire safety codes.
Example: A 3×25mm²+2×16mm² ZR-YLV cable powers a hospital’s emergency wing, ensuring safe evacuation during fires.
Wire Drawing: Copper rods (12mm diameter) or aluminum alloy rods (15mm diameter) are drawn through diamond dies to reduce strand diameter (e.g., 0.41mm for 25mm² copper). Cold drawing maintains material strength, while lubricants (mineral oil) prevent strand damage.
Stranding: Strands are twisted into concentric layers using a stranding machine. For copper, 19 strands form a 25mm² conductor; for aluminum, 37 strands form a 35mm² conductor. Stranding pitch is 100–150mm to balance flexibility and current distribution.
Annealing (Copper Only): Stranded Copper Conductors are heated to 350–400°C in a nitrogen atmosphere to reduce residual stress, improving conductivity and flexibility.
Material Preparation: XLPE resin is mixed with additives (cross-linking agents, antioxidants) in a twin-screw extruder. For ZR-YLV, halogen-free flame retardants are added at this stage.
Extrusion: Molten XLPE is extruded onto conductors via a crosshead die, with insulation thickness controlled to 1.2–2.5mm (depending on voltage rating). An online laser gauge monitors thickness, ensuring compliance with IEC 60502-1 (minimum 1.2mm for 0.6/1KV).
Cross-Linking: Conductors move to a CV tube (peroxide method) or humid chamber (silane method) to complete cross-linking. Cooling water baths (20–25°C) set the insulation, preventing deformation.
Core Twisting: The 3 Phase Cores and 2 auxiliary cores are twisted together in a cabling machine. Twisting pitch is 200–300mm to reduce crosstalk and improve flexibility.
Binder Application: A polyester tape is wrapped around the twisted cores to hold them together, preventing movement during sheathing.
Sheath Extrusion: PVC or PE resin is extruded over the binder via a single-screw extruder (160–180°C for PVC, 180–200°C for PE). Sheath thickness ranges from 1.5–3.0mm, with a laser gauge ensuring uniformity.
Wire Spooling: Galvanized steel wires are loaded onto armouring machines, with tension controlled to 50–100N to avoid wire breakage.
Helical Wrapping: Wires are twisted around the sheath at a pitch of 10–15× cable diameter. A servo motor ensures consistent pitch, preventing wire overlap (a common cause of weak points).
Binding Tape: A final polyester tape is wrapped over the armour to protect the sheath and prevent wire fraying.
Electrical Tests:
Insulation Resistance: A 2.5kV DC megohmmeter measures resistance between cores and earth—minimum 100 MΩ (20°C).
Dielectric Strength: Cables are submerged in water and subjected to 2kV AC for 1 minute—no breakdown allowed.
Partial Discharge: For high-voltage tolerance, cables are tested at 1.73kV (phase-to-phase) with partial discharge ≤10 pC.
Mechanical Tests:
Impact Test: A 1kg weight is dropped from 1m onto the cable—no conductor exposure or insulation cracking.
Tensile Test: A 1m sample is pulled until break—minimum breaking force: 4.5kN (copper), 2.8kN (aluminum).
Bending Test: Cables are bent around a mandrel (10× diameter) 10 times—no insulation damage.
Environmental Tests:
UV Aging: Samples are exposed to UV light (1000 hours) to simulate 10 years of outdoor use—no sheath degradation.
Salt Spray: For coastal models, samples are exposed to 5% saltwater (500 hours)—no corrosion on aluminum or steel.
Steel Reels: Used for YJV22/YJLV22 (armoured, heavyweight). Reels have a diameter of 1.2–2.0m, flange thickness of 15–30mm, and load capacity of 500–2000kg. Galvanized steel prevents corrosion during sea shipping.
Wooden Reels: Used for YJV/YJLV/ZR-YLV (lightweight). FSC-certified pine reels (1.0–1.5m diameter) are treated with anti-rot chemicals for outdoor storage.
Protection Layers:
Inner layer: 200-micron PE film to repel dust and moisture.
Outer layer: PVC shrink wrap (for sea shipping) or tarpaulin (for domestic trucking) to prevent water ingress.
Labeling: Each reel has two metal tags with:
Product info: Model (e.g., YJV22 3×50+2×25), conductor material, length, CSA.
Logistics info: Order number, destination, weight, dimensions.
Safety info: Symbols for "heavy load" (crane use only), "keep dry," and "flame-retardant" (for ZR-YLV models). For Armoured Cables, additional labels warn against "cutting with unprotected tools" to prevent steel wire injury.
Cardboard Drums: Used for lengths 50m–100m. Drums have a diameter of 500–800mm and height of 600–1000mm, made from triple-walled corrugated cardboard (400-lb test strength) with a polyethylene (PE) liner to block moisture. The cable is coiled loosely inside, with foam end caps to prevent shifting during transit.
Cardboard Boxes: Used for lengths <50m. Boxes are double-walled, with internal dividers to separate the cable from sharp edges (e.g., staples). Each box is sealed with water-activated tape (more durable than standard packing tape) and labeled with a clear plastic tag indicating length, model, and handling instructions (e.g., "Do Not Stack Over 2 Boxes").
Recyclable Materials: Steel reels are 100% recyclable, and wooden reels are sourced from FSC-certified forests (ensuring responsible logging). PE film and cardboard drums/boxes are also fully recyclable, with clear sorting labels to guide waste management.
Reuse Programs: Customers can return intact steel/wooden reels for a 5% discount on their next order. Returned reels are inspected, cleaned, and repurposed for future shipments—reducing material waste by 30% annually.
Bio-Based Alternatives: PVC shrink wrap is being phased out in favor of corn starch-based shrink film, which biodegrades within 12 months in soil. For sea shipments, traditional plastic dunnage is replaced with recycled paper padding, further lowering plastic usage.
Truck Delivery:
Lightweight Models (YJV/YJLV/ZR-YLV): Shipped via light commercial vehicles (5–10 ton capacity) with climate-controlled cargo areas. For example, a 100m reel of YJLV 3×25+2×16 (35kg) can be transported in batches of 20 reels per truck, with delivery times of 1–3 business days for urban areas and 3–5 days for rural regions.
Heavyweight Models (YJV22/YJLV22): Transported via flatbed trucks (20–30 ton capacity) with reinforced beds. Reels are secured with steel straps (12mm width) and wooden blocks to prevent rolling. For long-distance domestic trips (e.g., cross-country in the U.S. or Europe), GPS tracking is provided, allowing customers to monitor shipment location in real time.
Courier Services: For urgent orders (e.g., emergency repairs to a hospital’s electrical system), 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 up to $5,000 per shipment.
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 batches):
Container Preparation: Reels are stacked in a single layer (to avoid crushing lower reels) with wooden dunnage between them. Humidity packs (500g each) are placed in the container to absorb moisture—critical for tropical destinations where humidity exceeds 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 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 both weight and volume), and shipments are prioritized for quick customs clearance. A 100m reel of YJV 3×50+2×25 (65kg) costs approximately $800 to ship via air from Germany to Singapore, with delivery times of 2–5 business days.
Customs Compliance:
All international shipments include a complete set of documentation to avoid delays:
Commercial Invoice: Details product description (e.g., "YJV22 0.6/1KV 3×120+2×70 copper cable"), quantity, unit price, total value, and country of origin.
Packing List: Specifies package dimensions, weight, and contents (e.g., "10 reels of YJLV22, 200m each, total weight 1,800kg").
Certificate of Origin: Required for preferential tariff rates (e.g., EU-Mercosur Free Trade Agreement) to reduce import duties.
Compliance Certificates: Includes IEC 60502-1, UL 1569 (North America), or BS 6346 (UK) certifications to verify the cable meets the importing country’s electrical standards. For example, shipments to the U.S. require UL listing, while those to the EU need CE marking per the Low Voltage Directive (2014/35/EU).
Order Placement: Customers can place orders via multiple channels:
Online Portal: The company’s website allows customers to select model, conductor material, CSA, length, and quantity, with real-time inventory updates (e.g., "YJV 3×25+2×16: 50 reels in stock"). Orders are processed instantly, and a confirmation email is sent within 5 minutes, including an order number and estimated lead time.
Sales Team: For large or custom orders (e.g., 500 reels of ZR-YLV 3×50+2×25 for a high-rise project), customers can contact the sales team via phone or email. The team provides a detailed quote (including shipping costs and volume discounts) within 24 hours and assists with technical 选型 (e.g., recommending YJV22 over YJV for underground installation in rocky soil).
Production Lead Time:
In-Stock Items: Standard models (e.g., YJV 3×16+2×10, YJLV 3×25+2×16) are shipped within 1–2 business days.
Custom Orders: Non-standard CSA (e.g., 3×185+2×95) or specialized sheathing (e.g., PE-sheathed YJV22) have a lead time of 5–7 business days. Customers receive weekly progress updates (e.g., "Production 60% complete—scheduled for shipping on [date]") to align with project timelines.
Shipping Notification: When the order ships, customers receive an email with:
Tracking Details: For domestic orders, a link to the courier’s tracking page (e.g., UPS, DPD); 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 to report any issues within 48 hours. For Armoured Cables, additional notes advise using a forklift (not manual labor) to unload reels.
Delivery Inspection: Upon delivery, customers are advised to:
Check for external damage (e.g., cracked reels, torn shrink wrap). If damage is found, take photos and notify the company immediately to initiate a replacement or refund.
Verify product details (model, CSA, length) against the order invoice. Any discrepancies (e.g., wrong conductor material) are resolved within 3 business days, with replacement cables shipped via expedited delivery.
Sample Availability: Samples are available in 1-meter lengths for all models and CSA sizes. Customers can request up to 3 samples per order, with options for different sheathing (PVC vs. PE) or conductor materials (copper vs. aluminum) to compare performance.
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 Texas—need to test corrosion resistance of YJLV22").
Technical Support: For complex projects (e.g., mining sites with acidic soil), the technical team can provide customized samples (e.g., tin-plated aluminum YJLV22) 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 YJV22 cable sheath is damaged during direct burial—how to repair?"). Certified electrical engineers respond within 1 hour, providing step-by-step guidance (e.g., "Use heat-shrinkable sleeves with adhesive lining to seal the damage; replace the cable if the tear exceeds 50mm in length").
Online Resources: The company’s website features a "Support Center" with:
Installation Videos: Step-by-step guides for direct burial (e.g., "Soil Preparation for YJV22 Cable"), cable tray installation (e.g., "Securing YJV Cable in Industrial Cable Trays"), and termination (e.g., "Connecting YJLV to Copper Terminals").
FAQs: Answers to common questions (e.g., "Can ZR-YLV be used in Outdoor Cable trays?"—yes, but avoid direct sunlight to extend sheath life).
Datasheets: Detailed technical specifications (ampacity charts, temperature resistance curves) and compatibility guides (e.g., "Aluminum Cable Termination Best Practices").
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 (using proper lifting equipment to avoid back injury).
Correct installation techniques (direct burial depth of 0.7–1.0m per IEC 60364, cable bending radius compliance).
Compliance with local codes (e.g., NEC 300.5 for Underground Cables in the U.S., AS/NZS 3000 for Australia).
Virtual Training: For customers in remote areas, live virtual training is offered via Zoom, with 3D models demonstrating complex installation scenarios (e.g., navigating YJV22 around underground pipes).
Warranty Coverage:
Standard Warranty: The series comes with a 15-year warranty for copper-conductor models (YJV/YJV22) and 12-year warranty for aluminum-conductor models (YJLV/YJLV22/ZR-YLV) 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., exposed conductor, cracked sheath).
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 Inspections: Check for sheath damage (e.g., cuts, abrasions) in high-risk areas (e.g., near construction sites, tree roots). Use a cable locator to mark the cable’s path, preventing accidental digging.
Temperature Monitoring: For industrial applications, use an infrared thermometer to monitor cable temperature—ensure it does not exceed 90°C (continuous use) to avoid insulation degradation.
Corrosion Checks: In coastal or industrial areas, inspect Aluminum Conductors annually for signs of corrosion (white powdery deposits). Clean affected areas with a mild detergent and apply anti-corrosion grease.
Recycling Program: For end-of-life cables (after 15–20 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 insulation/sheath. Conductors are melted and recast into new metal rods (95% recycling efficiency), while XLPE/PVC is processed into plastic pellets for non-electrical applications (e.g., garden edging, traffic cones).
Incentives: Customers who recycle old cables receive a 10% discount on their next order, encouraging sustainable practices and reducing landfill waste.
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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