10mm²: 19 strands of 0.82mm-diameter wire, stranding pitch 12-14 times the conductor diameter.
16mm²: 37 strands of 0.67mm-diameter wire, stranding pitch 14-16 times the conductor diameter.
25mm²: 37 strands of 0.86mm-diameter wire, stranding pitch 16-18 times the conductor diameter.
35mm²: 54 strands of 0.91mm-diameter wire, stranding pitch 18-20 times the conductor diameter.
10mm²: DC resistance ≤1.83Ω/km, current-carrying capacity ≥60A (ambient temperature 25℃).
16mm²: DC resistance ≤1.15Ω/km, current-carrying capacity ≥85A (ambient temperature 25℃).
25mm²: DC resistance ≤0.74Ω/km, current-carrying capacity ≥120A (ambient temperature 25℃).
35mm²: DC resistance ≤0.53Ω/km, current-carrying capacity ≥160A (ambient temperature 25℃).
10mm² and 16mm²: 1.2-1.5mm insulation thickness.
25mm² and 35mm²: 1.5-1.8mm insulation thickness.
Thermal Stability: Long-term allowable operating temperature of 90℃, with a short-circuit withstand temperature of 250℃ (for 1 second), enabling it to tolerate load fluctuations and short-circuit faults.
Electrical Performance: Dielectric loss tangent (tanδ) ≤0.0005 (20℃, 50Hz), minimizing energy loss; volume resistivity ≥1×10¹⁴Ω·cm, ensuring strong insulation resistance; power frequency withstand voltage ≥10kV/1min (no breakdown), meeting the 0.6/1kV voltage level requirements.
Weather Resistance: After 1200 hours of accelerated UV aging testing (per IEC 60086-4), the insulation retains ≥85% of its original tensile strength, with no cracking or discoloration. It also resists acid and alkali corrosion—after 72 hours of immersion in 5% sulfuric acid or 5% sodium hydroxide solution, tensile strength retention is ≥80%.
10mm²: Outer diameter 22-24mm, unit length weight ≈1.2kg/m.
16mm²: Outer diameter 24-26mm, unit length weight ≈1.6kg/m.
25mm²: Outer diameter 28-30mm, unit length weight ≈2.2kg/m.
35mm²: Outer diameter 30-32mm, unit length weight ≈2.8kg/m.
Minimum Bending Radius: 12 times the cable’s outer diameter (e.g., 264mm for a 22mm diameter 10mm² cable), preventing insulation damage during installation.
Tensile Load Capacity: 1.2kN (10mm²) to 2.5kN (35mm²), ensuring the cable can withstand the tension of spanning 100-140 meters between poles.
Impact Resistance: ≥5kJ/m² (tested by dropping a 1kg weight from 1m height), protecting against accidental impacts from branches or tools.
Fatigue Resistance: After 8000 bending cycles (bending to the minimum radius and back), the conductor’s breaking strength retention rate is ≥90%, with no insulation cracking.
Rural Areas: The 10mm² and 16mm² cross-sections are used for branch lines extending to farmhouses and rural communities. For example, in a rural electrification project covering 500 households, 10mm² cables supply individual homes, while 16mm² cables connect to small agricultural irrigation pumps (5-10kW). The aluminum alloy conductor’s high strength allows spanning across farmland without additional poles, reducing land occupation and construction costs.
Urban Suburbs: The 25mm² and 35mm² cross-sections are used for branch lines in suburban residential areas and small commercial districts. In a suburban community with 1000 households, 25mm² cables supply residential blocks, while 35mm² cables power community centers and small shops. The bundled design reduces the number of lines, simplifying maintenance and improving the aesthetic appearance of the area.
Light Industry (e.g., Textiles, Plastics): 16mm² cables supply enterprises with power requirements of 10-20kW (e.g., weaving machines, plastic injection molding machines). The XLPE insulation’s Chemical Resistance protects against industrial emissions, ensuring stable operation.
Mechanical Processing: 25mm² cables power medium-sized machinery (20-30kW, e.g., lathes, milling machines). The aluminum alloy conductor’s high current-carrying capacity handles the intermittent high loads of these machines without overheating.
Medium-Density Zones (300-500 households): 25mm² cables supply each zone, supporting residential loads (air conditioners, refrigerators) and small public facilities (streetlights, playground equipment). The 4-core design balances three-phase loads, preventing neutral line overload and voltage deviation (≤2% of rated voltage).
High-Density Zones (500+ households): 35mm² cables handle higher loads, including large public facilities (community hospitals, shopping centers) and multiple high-rise buildings. The XLPE insulation’s thermal stability ensures the cable operates safely even during peak summer demand (when air conditioner use is high).
Household Power Supply: 10mm² cables connect individual farmhouses, supporting basic loads (lighting, televisions, small appliances). The aluminum alloy conductor’s tensile strength allows spanning across fields, reducing the number of poles needed.
Agricultural Equipment: 16mm² cables power irrigation pumps (5-15kW) and grain dryers. The XLPE insulation’s chemical resistance protects against pesticide residues and soil moisture, ensuring reliable operation during planting and harvesting seasons.
Wire Preparation: Aluminum alloy wires (of the required diameter for each cross-section) are unwound from spools and passed through a wire straightener to remove any kinks. The wires are then fed into a stranding machine.
Concentric Stranding: The stranding machine arranges the wires in concentric layers around a central wire. The number of layers and strands depends on the cross-section (e.g., 19 strands for 10mm², 54 strands for 35mm²). The stranding pitch is controlled by the machine’s speed to ensure the conductor is compact and flexible.
Annealing: After stranding, the conductor is passed through an annealing furnace (300-350℃) to reduce internal stress and improve flexibility. The annealing process also enhances the conductor’s conductivity by optimizing the grain structure of the aluminum alloy.
Quality Inspection: The Stranded Conductor is inspected for diameter, roundness, and strand alignment. A sample is tested for DC resistance and tensile strength to ensure compliance with specifications.
Material Preparation: XLPE compound pellets (HDPE + cross-linking agents + additives) are dried in a dehumidifying dryer (80℃ for 4 hours) to remove moisture. The dried pellets are then fed into a single-screw extruder.
Extrusion: The extruder melts the XLPE compound (160-180℃) and extrudes it onto the stranded conductor. The extrusion die is designed to control the insulation thickness (1.2-1.8mm, depending on the cross-section). A laser diameter gauge continuously monitors the insulation thickness, adjusting the extruder speed automatically to maintain precision (tolerance ±0.1mm).
Cross-Linking: The Insulated Conductor is passed through a continuous vulcanization (CV) tube, where it is heated to 180-200℃ using hot air. This heat activates the peroxide cross-linking agents, transforming the XLPE’s molecular structure into a three-dimensional network. The CV tube is 20-30 meters long, ensuring sufficient time for cross-linking.
Cooling and Inspection: The cross-linked insulated conductor is cooled in a water bath (20-30℃) to stabilize the insulation. The conductor is then inspected for surface defects (e.g., bubbles, scratches) and insulation thickness. A sample is tested for insulation resistance and power frequency withstand voltage.
Bundling: Four insulated cores (3 phase + 1 neutral) are fed into a bundling machine, which arranges them in a parallel configuration. A polyethylene adhesive is applied between the cores to hold them together, and the bundle is passed through a sizing die to ensure a uniform outer diameter (22-32mm).
Optional Sheath Extrusion: For Sheathed Cables, the bundled cores are fed into a second extruder, where HDPE is extruded over the bundle at 150-170℃. The sheath thickness (1.5-2.0mm) is controlled by the die size and extruder speed (12-18m/min). The sheathed cable is cooled in a water bath and inspected for sheath thickness and surface quality.
Marking: The cable is marked with product information (specification, voltage rating, manufacturer name) using a laser printer, with markings repeated every 500mm.
Electrical Tests:
DC Resistance Test: Measures the conductor resistance using a micro-ohmmeter (must meet ≤1.83Ω/km to ≤0.53Ω/km).
Insulation Resistance Test: Applies 1kV DC to the insulation using a megohmmeter (≥1×10¹⁴Ω·cm).
Power Frequency Withstand Test: Submerges the cable in water for 24 hours, then applies 10kV AC for 1 minute (no breakdown).
Partial Discharge Test: Applies 1.73kV AC (1.5× rated voltage) and measures partial discharge (≤10pC).
Mechanical Tests:
Tensile Test: Measures the conductor’s tensile strength (220-260MPa) and insulation’s tensile strength (≥12MPa) using a universal testing machine.
Impact Test: Drops a 1kg weight from 1m onto the cable (no insulation damage).
Bending Test: Bends the cable to 12× its outer diameter 10 times (no cracks or conductor breakage).
Spooling: Cables that pass all tests are spooled onto wooden or steel reels (diameter 1.2-1.8 meters) with a maximum length of 1000 meters per reel. The reels are labeled with product details (specification, length, manufacturing date, batch number) and stored in a dry warehouse until shipment.
Wooden Reels: Made of pine wood (moisture content ≤15%) to prevent warping. Each reel has a diameter of 1.2-1.5 meters (for 10-25mm² cables) or 1.5-1.8 meters (for 35mm² cables), a width of 0.6-0.9 meters, and a central steel axle (diameter 50mm) to facilitate unwinding. The inner surface of the reel is lined with a 2mm-thick foam pad to prevent the cable’s XLPE insulation from rubbing against the wood, which could cause scratches.
Steel Reels: Used for long-distance or sea shipments, made of galvanized steel (zinc coating thickness ≥80μm) to resist corrosion. They have the same dimensions as wooden reels but are more durable, with a load capacity of up to 3 tons (suitable for 1000 meters of 35mm² cable, which weighs 2800kg).
Primary Tag: Attached to the reel’s axle, it includes detailed product information: product name (ABC Aerial Bundled Cable 0.6/1kV - 4×10/16/25/35mm²), conductor type (aluminum alloy), insulation material (XLPE), sheath type (with/without), reel weight (cable + reel), length (1000 meters), manufacturing date, batch number, and manufacturer contact details (address, phone, email).
Secondary Tag: Affixed to the outer PE film, it features simplified information (product name, specification, length) and a QR code. Scanning the QR code links to the cable’s test reports, certification documents (e.g., IEC 60502-1, RoHS), and installation guidelines on the manufacturer’s online portal.
Storage Environment: The reels should be stored in a dry, well-ventilated warehouse with a temperature range of -5℃ to 40℃ and relative humidity ≤75%. The warehouse floor must be flat and made of concrete to prevent reel tipping.
Reel Placement: Reels are placed on wooden blocks (height 100mm) to elevate them off the ground, avoiding moisture absorption from the floor. When storing multiple reels, a minimum distance of 300mm is required between each reel to allow air circulation and prevent collision damage.
Prohibitions: Reels should not be stacked, as the weight of upper reels can crush the lower ones. The warehouse must be free from direct sunlight, heat sources (e.g., heaters), and corrosive substances (e.g., chemicals), which can degrade the XLPE insulation and aluminum alloy conductor.
Storage Period: The recommended maximum storage period is 12 months from the manufacturing date. If storage exceeds 12 months, the cable must undergo re-testing before installation. The re-testing includes insulation resistance measurement (≥1×10¹³Ω·cm, a slight reduction from the original ≥1×10¹⁴Ω·cm due to long-term storage), visual inspection of the XLPE insulation for cracks or discoloration, and DC resistance testing of the aluminum alloy conductor to ensure no corrosion has increased resistance beyond the standard range (≤1.90Ω/km for 10mm², ≤1.20Ω/km for 16mm², ≤0.78Ω/km for 25mm², ≤0.56Ω/km for 35mm²).
Road Transportation: The most common mode for domestic shipments within 500km. Flatbed trucks (load capacity 10-15 tons) are used, equipped with steel rails and adjustable wooden supports to secure the reels. Each truck can carry 6-8 wooden reels (for 10-25mm² cables) or 4-6 steel reels (for 35mm² cables), depending on weight. The reels are placed parallel to the truck’s length, and steel straps (breaking strength ≥5 tons) are tightened over the reel flanges, anchored to the truck’s rails to prevent lateral movement. Rubber anti-slip pads (thickness 10mm) are placed between the reels and the truck bed to reduce vibration, which could loosen the cable windings or scratch the XLPE insulation. The maximum speed for road transport is limited to 60km/h on highways and 30km/h on rural roads to minimize jolting.
Rail Transportation: Ideal for domestic long-distance shipments (over 500km) or cross-border transport within regions with interconnected rail networks (e.g., Europe, North America). Specialized freight railcars (load capacity 20-30 tons) are used, featuring reinforced floors and lashing points. Reels are secured using the same steel strap and anti-slip pad method as road transport, but with additional wooden wedges (oak, thickness 50mm) inserted between reels to prevent longitudinal movement during train acceleration or braking. Rail transport offers lower vibration than road transport, reducing the risk of insulation wear, and typically has a transit time 30% faster than long-haul road transport for distances over 1000km.
Sea Transportation: The primary mode for international shipments. Reels are loaded into 20-foot or 40-foot shipping containers: a 20-foot container can hold 8-10 wooden reels (10-25mm²) or 5-7 steel reels (35mm²), while a 40-foot container doubles this capacity. Before loading, the container floor is lined with moisture-absorbing desiccants (silica gel packets, 500g each, placed every 1.5 meters) to control humidity and prevent condensation—condensation can corrode steel reels or cause the XLPE insulation to absorb moisture, leading to insulation degradation. Reels are secured to the container’s internal lashing rings using steel chains (breaking strength ≥8 tons) and turnbuckles, which are tightened to eliminate slack. For shipments to high-humidity regions (e.g., Southeast Asia) or extreme-temperature areas (e.g., the Middle East), the container is fitted with a temperature-humidity logger that records conditions every 2 hours. This data is provided to the customer upon delivery to verify the cable was transported in suitable environments (temperature 0℃-35℃, humidity ≤80%).
Air Transportation: Rarely used for full-size reels due to weight and volume constraints (a 1000-meter steel reel of 35mm² cable weighs ~3000kg). However, it may be used for small quantities (e.g., 50-100 meters) or emergency replacements. The cable is cut into shorter lengths and packaged in heavy-duty fiberboard boxes (lined with foam) to meet airline weight limits (≤50kg per box). Air freight is costly (8-10 times more than sea transport) and is only recommended for urgent cases, such as repairing a damaged cable in a critical power distribution network.
Commercial Invoice: Details the product description (ABC Aerial Bundled Cable 0.6/1kV - 4×10/16/25/35mm²), quantity, unit price, total value, currency, and terms of sale (e.g., FOB, CIF).
Packing List: Specifies the number of reels, reel material (wood/steel), weight per reel, total weight, container number, and dimensions of each reel.
Certificate of Origin (COO): Issued by a local chamber of commerce, verifying the cable was manufactured in the stated country (required for tariff calculation and trade agreement compliance, e.g., EU’s Generalized System of Preferences).
Compliance Certificates: Includes IEC 60502-1 (low-Voltage Cable standard), RoHS (restriction of hazardous substances), and country-specific certifications (e.g., UL for the U.S., CSA for Canada, TÜV for Germany). For wooden reels, a phytosanitary certificate (issued by the national plant protection organization) is required to prevent the spread of pests.
Bill of Lading (B/L): For sea transport, this document serves as a contract of carriage and proof of ownership, issued by the shipping line. For air transport, an Air Waybill (AWB) is provided instead.
Shipment Departure: An email is sent when the cable leaves the manufacturer’s warehouse, including the tracking number, carrier details, and a link to the tracking portal.
In-Transit Update: A message is sent halfway through the journey (e.g., when the container is midway across the ocean) to confirm progress and reconfirm the ETA. If any delays occur (e.g., port congestion, bad weather), the team immediately notifies the customer and provides a revised ETA.
Arrival at Destination: The customer is notified when the shipment reaches the destination port/terminal, along with instructions for customs clearance (if the customer is handling it themselves) or confirmation that clearance is in progress (if the manufacturer’s broker is assisting).
Final Delivery: A “Delivery Scheduled” message is sent 24-48 hours before the cable is delivered to the customer’s site. On the delivery day, the driver contacts the customer 1 hour before arrival to coordinate unloading.
Electrical Tests:
DC resistance (measured with a micro-ohmmeter, e.g., ≤0.74Ω/km for 25mm²).
Insulation resistance (measured with a megohmmeter at 1kV, ≥1×10¹⁴Ω·cm).
Power frequency withstand test (10kV AC for 1 minute, no breakdown).
Partial discharge test (≤10pC at 1.73kV AC).
Mechanical Tests:
Tensile strength (≥220MPa for aluminum alloy conductor, ≥12MPa for XLPE insulation).
Impact resistance (no damage after 1kg weight drop from 1m height).
Bending resistance (no cracks after bending to 12× outer diameter 10 times).
Visual and Dimensional Tests:
Inspection of insulation and sheath thickness (using a micrometer).
Outer diameter measurement (e.g., 28-30mm for 25mm²).
Surface quality check (no bubbles, scratches, or unevenness).
Express Courier: For international customers, DHL or FedEx is used, with a delivery time of 3-5 business days.
Local Courier: For domestic customers, a local service (e.g., UPS) is used, with a delivery time of 1-2 business days.
On-Site Delivery: For customers near the manufacturer’s facility, the sales team can deliver the sample in person, along with a technical representative.
Thicker HDPE sheath (for harsh industrial environments).
Higher-strength aluminum alloy conductor (for areas with high wind loads).
Halogen-Free XLPE insulation (for sensitive environments like hospitals).
Installation Guidance: Detailed drawings, video tutorials, and on-site support for complex installations (e.g., spanning 140-meter gaps).
Troubleshooting: Analysis of issues like insulation breakdown or conductor overheating, with tailored solutions (e.g., recommending heat-shrink sleeves for minor damage).
Performance Optimization: Recommendations to reduce line loss (e.g., adjusting load current) or extend lifespan (e.g., installing vibration dampers in windy areas).
Monthly: Visual inspection of insulation and poles for damage.
Quarterly: Insulation resistance testing (≥1×10¹³Ω·cm).
Annual: Partial discharge testing and conductor temperature measurement (≤90℃).
Minor Sheath Damage: Clean the area, apply adhesive primer, and use a heat-shrink sleeve.
Major Insulation Damage: Cut out the damaged section and splice with a compression connector.
Replacement: Free replacement of defective cables, including shipping and installation.
Repair: Free repair materials and technical guidance.
Refund: Full refund for irreparable defects.
Improper Installation: This includes bending the cable beyond its minimum bending radius (12× outer diameter), over-tensioning the cable during installation (exceeding the 1.2-2.5kN tensile load range), using incompatible termination materials (e.g., copper lugs on aluminum alloy conductors), or failing to follow the manufacturer’s installation guidelines.
Negligence or Misuse: Examples include ignoring routine maintenance (e.g., not cleaning the cable surface in industrial zones with heavy pollution), allowing vegetation to grow into the cable (causing sheath tearing), or using the cable for applications outside its rated parameters (e.g., using a 0.6/1kv Cable in a 10kV system).
External Events: Damage from natural disasters (earthquakes, floods, hurricanes), vandalism (intentional cutting or scratching), bird pecking (unless the customer purchased the optional bird-proofing kit), or lightning strikes (unless the cable is equipped with the optional surge protection accessory).
Unauthorized Modifications: Any changes to the cable (e.g., stripping the XLPE insulation, adding non-manufacturer-approved sheaths, or splicing the cable with non-compliant materials) void the warranty.
Damage from bird pecking, moderate wind loads (up to 20m/s), and accidental negligence (e.g., a single cable damaged during routine maintenance).
Emergency repair costs, including after-hours technical support and expedited shipping of replacement parts.
Annual professional maintenance inspections (conducted by the manufacturer’s technicians) to identify potential issues early.
Theoretical Modules (6 hours):
Overview of the cable’s design (aluminum alloy conductor, XLPE insulation, bundled structure) and performance parameters (current-carrying capacity, tensile load, bending radius).
Safety guidelines, including PPE requirements (arc-flash suits for high-voltage termination, cut-resistant gloves for cable handling) and lockout/tagout procedures to prevent electrical accidents.
Understanding site-specific challenges (e.g., spanning wide gaps, working in narrow urban lanes) and how to address them with the cable’s features.
Hands-On Sessions (10 hours):
Cable unwinding and handling: Learning to control reel tension (using a tensioning device) to avoid tangling, and practicing safe lifting of reels with forklifts or cranes.
Bending and spanning: Using 5-meter cable samples to practice bending to the minimum radius (e.g., 264mm for 22mm diameter 10mm² cable) and spanning gaps of up to 30 meters between training poles.
Termination: Step-by-step instruction on stripping XLPE insulation (without damaging the conductor), crimping aluminum alloy-compatible lugs, and testing the termination for resistance (must be ≤0.1Ω).
Troubleshooting installation issues: Identifying and fixing common problems, such as cable sagging (adjusted with tensioners) or minor insulation scratches (repaired with heat-shrink sleeves).
Theoretical Modules (4 hours):
Routine maintenance schedule: Explaining the purpose of monthly, quarterly, and annual tasks (e.g., why insulation resistance testing is critical for detecting moisture ingress).
Equipment operation: Training on using tools such as megohmmeters (calibrating the device, interpreting readings), infrared thermometers (identifying hot spots that indicate overloading), and partial discharge analyzers (detecting early insulation degradation).
Environmental adaptation: Tailored guidance for maintaining cables in different environments—for example, cleaning the XLPE insulation every 2 months in industrial zones to remove corrosive deposits, or rinsing the cable with fresh water every 3 months in coastal areas to prevent salt spray damage.
Case Study Workshops (2 hours):
Analyzing real-world maintenance scenarios (e.g., “a 25mm² cable in an industrial park with reduced insulation resistance—how to identify and fix the cause”).
Developing a customized maintenance plan for the customer’s specific project (e.g., a rural electrification project with 10km of 10mm² and 16mm² cables).
Advanced Technical Modules (8 hours):
Current-carrying capacity calculations: Teaching engineers to adjust the cable’s rated current based on ambient temperature (e.g., reducing capacity by 8% for temperatures above 30℃) and installation method (e.g., aerial vs. underground).
Voltage drop analysis: Using the manufacturer’s design software to calculate voltage drop for long cable runs (e.g., a 140-meter span of 35mm² cable) and recommending solutions (e.g., increasing conductor cross-section or adding a voltage regulator).
Compatibility with other equipment: Ensuring the cable works with pole-mounted transformers, circuit breakers, and surge protectors—for example, selecting the correct transformer tap based on the cable’s impedance (typically 0.15-0.3Ω/km for 10-35mm² cross-sections).
Design Workshops (6 hours):
Designing a multi-cross-section distribution network: Using the 4×10/16/25/35mm² cables to power a mixed-use development (residential, commercial, small industrial) while minimizing costs and line loss.
Optimizing pole placement: Using the cable’s 100-140m span capability to reduce the number of poles, balancing infrastructure costs with structural safety.
Hongtai Cable Technology Co., Ltd
E-mail: export@qlcables.com
sales@qlcables.com
Tel/whatsapp:+86-18032066271
Tambahkan ： Zona Pengembangan Industri Xiaokou, Kabupaten Ningjin, Kota Xingtai ， Provinsi Hebei, Cina
Hak Cipta © Hongtai Cable Technology Co., Ltd Dukungan Teknis:Teknologi Ronglida
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