Voltage Withstand Test: The cable is exposed to 2.0kV (phase-to-neutral) and 3.0kV (phase-to-phase) for 5 minutes without electrical breakdown, confirming its ability to handle transient voltage surges (e.g., during industrial motor startup or grid fluctuations).
Insulation Resistance Test: Using a megohmmeter, insulation resistance is measured at ≥100 MΩ at 20°C, minimizing leakage current and ensuring efficient power transmission—critical for reducing energy loss in large-scale projects.
Short-Circuit Current Test: It withstands a 20 kA short-circuit current for 1 second, protecting connected equipment (e.g., circuit breakers, variable frequency drives) from damage during fault conditions.
Dielectric Loss Test: At 50Hz, the dielectric loss tangent (tan δ) is <0.001, indicating minimal energy waste in the insulation—essential for utilities aiming to meet sustainability targets.
Conductor Size (mm²) | Ampacity at 30°C (Amps) | Ampacity at 40°C (Amps) | Typical Application Load |
50 | 130–150 | 120–140 | 20–30 residential homes (total load: 25–35 kW) |
70 | 160–180 | 150–170 | 10–15 floor office building (total load: 35–45 kW) |
95 | 200–220 | 190–210 | Small manufacturing workshop (total load: 45–55 kW) |
120 | 230–250 | 220–240 | Large warehouse with conveyor systems (total load: 55–65 kW) |
150 | 270–290 | 260–280 | Industrial park with 3–5 small factories (total load: 65–75 kW) |
50mm² conductor: 19 strands of 1.8mm diameter wire
150mm² conductor: 37 strands of 2.3mm diameter wire
Thermal Stability: It operates reliably across -40°C to 90°C, far wider than PVC’s 0°C to 70°C range. This allows use in extreme climates—from Canadian winters (-30°C) to Middle Eastern summers (45°C)—without insulation degradation.
Environmental Resistance: XLPE has a water absorption rate of ≤0.1% after 24 hours of immersion, preventing moisture-induced short circuits. It also resists UV radiation (maintaining 90% tensile strength after 2,000 hours of UV exposure per ISO 4892-3) and industrial pollutants (e.g., oil, dust).
Insulation Thickness: Calibrated to conductor size to meet the 0.6/1kV rating:
50/70mm²: 1.2mm thickness
95/120mm²: 1.4mm thickness
150mm²: 1.6mm thickness
Galvanized Steel Messenger: Tensile strength of 400–500 MPa, enabling 60-meter spans between poles. Ideal for rural areas with wide pole spacing.
Aluminum - Clad Steel Messenger: Lighter than galvanized steel (density: 5.8 g/cm³ vs. 7.8 g/cm³) with similar strength, suitable for coastal regions (resistant to saltwater corrosion).
Sizing Versatility: Five conductor sizes eliminate the need for multiple cable types in mixed-use projects (e.g., a development combining homes, shops, and a small factory).
Lightweight Aluminum Conductors: 30% lighter than copper, reducing pole load and installation labor. A 100-meter 4×150mm² Aluminum Cable weighs 84 kg, vs. 237 kg for copper—lowering transport and handling costs.
Durable XLPE Insulation: 25–30 year service life, matching the lifespan of utility poles—reducing replacement cycles and long-term costs.
Integrated Messenger Option: Extends span length to 60 meters, cutting the number of poles needed in rural areas by 20–30%.
Residential Developments:
Commercial Districts:
Light Industrial Zones:
Rural Electrification:
Aluminum Conductors:
XLPE Insulation:
Messenger Materials:
Helical Core Twisting: The 4 Cores are twisted at a pitch of 15–20 times the outer diameter (300–450mm), reducing wind resistance and ice loading—critical for areas prone to storms.
Symmetrical Layout: Cores are arranged symmetrically around the messenger (if included), ensuring balanced weight distribution and preventing sagging.
Compact Profile: Outer diameter of 22–32mm allows up to 4 cables to be installed on a single utility pole, ideal for dense urban areas.
Wire Drawing: High-purity aluminum ingots (99.7% purity) are melted at 660°C, extruded into wires of the required diameter (e.g., 1.8mm for 50mm²), and drawn through diamond dies to refine strength.
Stranding: Wires are twisted into conductors using a stranding machine (100–150 RPM). For 50mm², 19 wires are twisted; for 150mm², 37 wires are used.
Anti - Corrosion Coating: Conductors are coated with zinc (hot-dip galvanizing, 5–10μm thickness) or aluminum oxide (anodization, 2–3μm thickness).
Material Preparation: XLPE resin is mixed with cross-linking agents (dicumyl peroxide), antioxidants, and UV stabilizers in a high-speed mixer.
Extrusion: The mixture is fed into an extruder (160–180°C), extruded over the conductor to form the insulation layer (1.2–1.6mm thickness).
Curing: The Insulated Conductor passes through a curing tube (200–250°C) for 5–10 minutes, activating cross-linking to form a three-dimensional polymer network.
Cooling: It is cooled in a water bath (20–30°C) and dried with compressed air.
Core Bundling: 4 Insulated Cores are fed into a bundling machine, twisted at 300–450mm pitch to form a single unit.
Messenger Integration: If included, the messenger is fed into the machine and bonded to the core bundle via molten XLPE extrusion.
Quality Check: The Bundled Cable is measured for outer diameter (22–32mm) and weight per unit length (0.8–1.5 kg/m), with deviations >±5% rejected.
Conductor Tests: Electrical resistance (≤0.387 Ω/km for 50mm², ≤0.214 Ω/km for 150mm²) and tensile strength (≥4.5 kN for 50mm²).
Insulation Tests: Thickness uniformity (±0.1mm), dielectric strength (≥20 kV/mm), and UV resistance (2,000 hours exposure).
Final Cable Tests: Short-circuit current (20 kA for 1 second) and impact resistance (1kg weight dropped from 1m, no insulation damage).
Reels:
Wooden reels (plywood/pine) for domestic shipments:
50/70mm² (500m length): Outer diameter 1.5m, hub diameter 0.5m, weight 60kg.
95/120/150mm² (500m length): Outer diameter 1.8m, hub diameter 0.6m, weight 80kg.
Steel reels (galvanized carbon steel) for international/long-distance shipments:
500m length: Outer diameter 1.8m, hub diameter 0.6m, weight 120kg.
1000m length: Outer diameter 2.2m, hub diameter 0.8m, weight 180kg.
Protective Layers:
Product details: Name, voltage rating, conductor size, insulation type.
Manufacturing info: Batch number, production date, manufacturer contact.
Compliance marks: IEC 60502-1, ANSI/ICEA S-94-649, CE/UL certification.
Handling warnings: “Lift only at reel hubs,” “Store in dry area,” “Do not stack >2 reels.”
Indoor Storage:
Outdoor Storage:
Road:
Rail:
Sea:
20-foot container: 8–10 reels (500m length).
40-foot container: 18–22 reels (500m length).
Air:
Loading Protocols:
Pre - Load Inspection: The logistics team checks reels for pre - existing damage (cracked flanges, torn protective film) and verifies that labels match the shipping manifest. The transport vehicle/container is inspected for cleanliness, structural integrity, and moisture (using a humidity meter for sea containers).
Equipment Setup: For reels weighing ≤80kg (50/70mm²), a forklift with a reel clamp attachment (padded with rubber to avoid scratching) is used. For heavier reels (95–150mm², up to 180kg), a crane with a spreader bar and soft slings is deployed to distribute weight evenly across the reel hub.
Positioning and Securing: Reels are placed with a minimum 10cm gap between them to prevent friction. For road/rail transport, steel straps (12mm thick) are tightened to 70–80 N·m and anchored to the vehicle’s tie - down points. For sea containers, wooden blocks (10×10cm) are nailed to the container floor under each reel, and additional load - restraining bars are installed along the container walls.
Unloading Protocols:
Site Preparation: The unloading area is cleared of debris and leveled (using temporary ramps if the ground is uneven). For industrial sites, safety barriers and warning signs are set up to prevent unauthorized access.
Controlled Lifting: The same equipment used for loading is employed, with a spotter guiding the operator to avoid collisions with nearby infrastructure (e.g., utility poles, factory walls). Heavier reels are lowered slowly (10cm per second) to prevent sudden impacts.
Post - Unloading Inspection: The customer’s on - site representative inspects each reel for transit damage (dented flanges, moisture inside the protective film). Photos are taken of any damage, and a joint inspection report is signed with the carrier.
Bill of Lading (BOL): A legal document issued by the carrier that serves as a receipt for the goods, a contract for transportation, and a document of title. For sea shipments, a “clean on board” BOL is required to confirm reels were loaded in good condition.
Commercial Invoice: Details the product name, quantity, unit price, total value, and terms of sale. It includes the Harmonized System (HS) code (3926.90.90 for Insulated power cables) to enable customs authorities to assess import duties.
Certificate of Compliance (CoC): Issued by the manufacturer, this document certifies that the cable meets IEC 60502 - 1, ANSI/ICEA S - 94 - 649, and local standards (e.g., UL for North America, CE for Europe). It includes key test results (insulation resistance, short - circuit current).
Packing List: Itemizes each reel (reel number, conductor size, length, weight) and confirms the total number of packages. This helps customs officials verify that the shipment matches the documentation.
Insurance Certificate: For sea/air shipments, this document provides proof of cargo insurance (typically covering 110% of the shipment value) to protect against damage, loss, or theft during transit.
Order Confirmation: The sales team sends a confirmation email within 24 hours, outlining the order details (conductor size, length, quantity, messenger inclusion) and providing a lead time:
Standard orders (50/70/95mm², in - stock): 2–3 weeks.
Custom orders (120/150mm², with messenger): 3–4 weeks (requires specialized manufacturing).
Production Scheduling: The production team allocates a slot in the manufacturing line, prioritizing urgent orders (e.g., a factory shutdown requiring 150mm² cable for repairs) by adding them to a “fast - track” queue.
Pre - Shipment Notification: Once production is complete and quality control tests are passed, the logistics team sends an email 3–5 days before dispatch, including the tracking number, carrier details, and expected delivery date (EDD).
Online Portal: A secure login on the manufacturer’s website displays the shipment’s location (e.g., “In transit from Houston to Dallas”), transit status (e.g., “Cleared customs in Rotterdam”), and EDD. For sea shipments, it integrates with container tracking platforms like Maersk Line or Hapag - Lloyd.
SMS/Email Alerts: Automated updates are sent at key milestones: “Shipment dispatched from factory,” “Arrived at regional distribution center,” “Out for delivery—expected between 9 AM–3 PM.”
Dedicated Logistics Contact: For large orders (≥50 reels), a dedicated logistics coordinator is assigned to address queries (e.g., “Will the shipment arrive before our project deadline?”) and resolve delays (e.g., rerouting due to a road closure).
Conductor Size | Road (300km, 5 reels) | Rail (1500km, 20 reels) | Sea (Shanghai - Rotterdam, 10 reels) | Air (Dubai - London, 2 reels) |
50mm² | \(350–\)450 | \(1,200–\)1,500 | \(1,800–\)2,200 | \(2,000–\)2,500 |
150mm² | \(600–\)750 | \(2,500–\)3,000 | \(3,500–\)4,000 | \(3,000–\)3,500 |
Basic Coverage (1% of shipment value): Covers damage from accidents, storms, and theft.
Premium Coverage (2% of shipment value): Includes expedited replacement (within 48 hours) for emergency cases and coverage for partial damage (e.g., a single reel damaged in transit).
Online Form: A form on the manufacturer’s website asks for:
Company details (name, address, contact person, phone/email).
Project details (application: e.g., “industrial warehouse expansion,” location: e.g., “Ontario, Canada”).
Sample specifications (conductor size: 50–150mm², length: 1–5m, messenger inclusion: yes/no).
Sales Representative: Direct requests to the assigned sales rep, who can also arrange for customized samples (e.g., 3m lengths with exposed conductors to test termination).
Trade Shows: Samples are available at industry events (e.g., International Electrical and Electronics Fair), where attendees can handle the cable, inspect the insulation, and discuss technical specifications with engineers.
In - stock samples (1m, standard specs): Shipped within 1–2 business days.
Custom samples (5m, with messenger): Shipped within 3–4 business days.
Physical Specifications: A 1m sample of 95mm² cable, for example, has 1.4mm XLPE insulation, 37 strands of 1.8mm Aluminum Wire, and (if requested) a 16mm² galvanized steel messenger.
Testing: Samples undergo abbreviated quality control tests, including:
Visual inspection (no insulation cracks, uniform stranding).
Insulation resistance test (≥100 MΩ at 20°C).
Tensile strength test (≥7.5 kN for 95mm² conductor).
Included Documentation: Each sample package contains:
A “Sample Test Report” summarizing the test results and batch number.
A product brochure with technical specifications, application guidelines, and compliance certificates.
A compatibility guide listing recommended termination tools and hardware (e.g., “Use crimp connectors rated for aluminum conductors”).
Sample Costs: Standard 1m samples are free for potential customers with a confirmed project (e.g., a utility company planning a rural electrification initiative). Custom samples (5m, with messenger) cost \(50–\)100 per sample, which is fully refundable if the customer places an order of ≥500 meters within 30 days.
Shipping Costs: Domestic shipping (within the same country) is free via courier (FedEx, UPS). International shipping costs \(20–\)60 per sample, depending on the destination (e.g., \(20 to Mexico, \)60 to Australia). Urgent international samples (24 - hour delivery) cost \(100–\)150.
Installation Manual: Every order includes a 60 - page, illustrated manual (available in print and digital formats) with:
Step - by - step instructions for aerial installation (e.g., “Tensioning the messenger for 60 - meter spans,” “Weatherproofing conductor connections to utility poles”).
Diagrams of recommended tools (cable tensioners, insulation strippers, crimping tools) and safety equipment (insulated gloves, hard hats, fall protection).
Troubleshooting tips for common issues (e.g., “Resolving excessive cable sag,” “Fixing insulation damage during termination”).
Technical Hotline: A 24/7 toll - free hotline connects customers to certified electrical engineers with expertise in aerial cable systems. For example, if an installer encounters difficulty terminating a 150mm² conductor, the engineer can provide real - time guidance via phone or video call, including step - by - step photos of the process.
On - Site Support: For orders ≥1000 meters or complex projects (e.g., installing 120mm² cable in a high - wind coastal industrial zone), the manufacturer dispatches a technical specialist to the job site for 1–3 days. The specialist:
Trains the installation team on proper handling techniques (e.g., avoiding kinks in rigid 150mm² cable).
Inspects the first 100 meters of installed cable for compliance with standards (e.g., checking messenger tension, insulation integrity).
Addresses on - site challenges (e.g., adjusting the cable path to avoid existing Power Lines).
Material Defects: Defects in the aluminum conductor (e.g., premature corrosion due to a faulty anti - corrosion coating) or XLPE insulation (e.g., cracking or degradation before the 15 - year mark).
Workmanship Errors: Problems arising from poor manufacturing, such as uneven insulation thickness (deviating more than ±0.1mm from specs), weak bonding between the messenger and core bundle, or strand breakage in the conductor.
Damage from improper installation (e.g., over - tensioning the cable beyond the messenger’s tensile strength, using incompatible termination hardware).
Misuse (e.g., using the cable for voltages exceeding 0.6/1kV, burying the aerial cable underground).
Environmental damage from natural disasters (e.g., tornadoes snapping utility poles, floods submerging the cable) or vandalism (e.g., intentional cutting of the cable).
The customer notifies the after - sales team within 48 hours of discovering the defect, providing the order number, installation date, photos/videos of the damage, and a detailed description of the issue.
A technical specialist reviews the claim and may request a 1 - meter sample of the defective cable for laboratory testing to determine the cause of the issue.
If the claim is approved:
For minor defects (e.g., a small insulation tear), the manufacturer ships a replacement insulation patch or a 5 - meter repair section of cable, along with step - by - step repair instructions.
For major defects (e.g., widespread conductor corrosion), the manufacturer arranges for a certified technician to visit the site, remove the defective cable section, and install a new section—all at no cost to the customer, including shipping and labor.
Preventive Maintenance Packages:
Annual Inspection Service: A team of technicians visits the customer’s site to conduct a comprehensive check, including:
Visual inspection of the cable (looking for insulation cracks, messenger corrosion, and signs of animal damage).
Electrical testing (measuring insulation resistance and conductor continuity using portable test equipment).
Mechanical checks (adjusting messenger tension if sag exceeds 5% of the span length, tightening loose clamps on utility poles).
5 - Year Comprehensive Maintenance Plan: This package includes annual inspections plus additional services tailored to the cable’s environment:
For coastal areas: Annual cleaning of the messenger and conductors with a corrosion - inhibiting solution.
For industrial zones: Inspection of the insulation for chemical damage and application of a protective coating every 2 years.
For high - wind areas: Reinforcement of messenger clamps and additional tension checks every 6 months.
Repair Services:
Minor Repairs:
Insulation Tears: For tears ≤5mm, technicians clean the area with isopropyl alcohol and apply a heat - shrinkable XLPE patch (matching the cable’s insulation thickness). The patch is heated to 120–150°C to form a waterproof seal, restoring insulation integrity. This repair takes 30–60 minutes per tear and costs \(100–\)150.
Loose Messenger Connections: Technicians re - tension the messenger to the correct specifications (400–500 MPa for galvanized steel) and replace worn clamps. This takes 1–2 hours per connection and costs \(150–\)200.
Major Repairs:
Conductor Damage: If a conductor strand breaks (e.g., due to accidental impact from construction equipment), the defective section (2–3 meters) is cut out, and the remaining ends are stripped of insulation (15–20mm of insulation removed from each end). A compression connector—made of the same aluminum alloy as the conductor to prevent galvanic corrosion—is crimped onto the ends using a hydraulic crimper (calibrated to 12–15 kN of force). The joint is then insulated with a dual-layer heat-shrinkable tube: an inner layer (filled with adhesive) for moisture sealing and an outer layer (XLPE material) for mechanical protection. Electrical tests (continuity and insulation resistance) are conducted to confirm the repair’s integrity. This repair takes 3–4 hours and costs \(500–\)700, depending on the conductor size (e.g., \(500 for 50mm², \)700 for 150mm²).
Insulation Failure: For widespread insulation degradation (e.g., due to chemical exposure in industrial zones or UV damage in desert climates), the entire affected cable section (typically 50–100 meters) is replaced. Technicians first disconnect the old cable from utility poles and terminations, then use a cable puller to thread the new cable between poles—ensuring the same tension and alignment as the original installation. The new cable is terminated using weatherproof connectors, and a final voltage withstand test (2.0kV for 1 minute) is performed. This repair costs \(1,200–\)2,000 per 100 meters, including the new cable and labor (higher for larger sizes: \(1,200 for 50mm², \)2,000 for 150mm²).
Emergency Repair Service: For critical failures that disrupt power (e.g., a cable break causing an outage in a manufacturing plant or residential neighborhood), the manufacturer offers 24/7 emergency service. A team of certified technicians is dispatched within 4–8 hours of the call (depending on location: 4 hours for urban areas, 8 hours for rural regions). The team carries specialized equipment (portable generators, emergency cable sections, and testing tools) to restore power as quickly as possible. Emergency repairs cost 50% more than standard repairs (e.g., \(750–\)1,050 for conductor damage), but customers with the 5-Year Comprehensive Maintenance Plan or extended warranty receive free emergency service.
Before/after photos of the cable or repair site.
Detailed notes on the work performed (e.g., “Replaced 70m of 95mm² cable due to insulation failure”).
Test results (insulation resistance, continuity, voltage withstand) before and after the work.
Recommendations for future care (e.g., “Schedule quarterly tension checks for this section in high-wind areas”).
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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