I. Core Information of the Product Itself
(I) Analysis of Specification Parameters
The specification parameters of the IEC 60502-1 copper XLPE insulated PVC sheathed galvanized steel tape armoured 0.6/1kV
Power Cable (model N2xby) are the foundation for its stable operation in various complex environments. Each parameter has undergone rigorous design and testing to meet the power transmission needs of different scenarios.
Voltage Level: The rated voltage of this cable is 0.6/1kV, where 0.6kV represents the rated voltage between the core and the ground or the shielding layer, and 1kV represents the rated voltage between cores. This voltage level enables it to perfectly adapt to AC 50/60Hz low-voltage power grids, widely used in medium and low-voltage distribution systems in industrial, municipal and other fields, providing stable power transmission for medium and high-power equipment clusters and underground laying scenarios. Whether it is power supply for factory production lines or urban street lamp lines, it can meet the voltage requirements and ensure the safety and reliability of power transmission.
Conductor Parameters: The conductor is made of high-purity electrolytic copper with a purity of ≥99.95%. This high-purity copper material provides a solid guarantee for the conductive performance of the cable. The conductor made by the compact stranding process not only has a tight structure, reducing the gaps inside the conductor, but also improves the filling coefficient of the conductor, reduces the impact of the skin effect, thereby improving the conductive efficiency. The number of cores (N) and cross-sectional specifications (xmm²) can be flexibly combined, with common specifications such as 2×16mm², 3×25mm², 4×50mm², 4×120mm², 4×240mm², etc.
There are differences in the DC resistance of conductors of different specifications at 20℃. The DC resistance of the 4×240mm² specification is ≤0.018Ω/km, while that of the 2×16mm² specification is ≤0.988Ω/km. A lower DC resistance means less energy loss during power transmission, which can improve the efficiency of power transmission. In terms of current-carrying capacity, when laid in air, the 4×240mm² specification can reach 480A, which is sufficient to meet the power needs of large equipment; small-sized cables can also provide corresponding current-carrying capacity according to their cross-sectional size, adapting to the power supply of equipment with different powers.
Insulation Layer Parameters: The insulation layer is made of cross-linked polyethylene (XLPE) material with a temperature resistance of 90℃, which has excellent electrical insulation performance and heat resistance. The thickness of the insulation layer increases with the increase of the conductor cross-sectional specification, ranging from 2.0mm to 4.5mm. A thicker insulation layer can better resist the effect of the electric field for large cross-sectional cables, reducing the risk of insulation breakdown. Its volume resistivity is ≥1×10¹⁴Ω·cm, ensuring a good insulation effect and effectively preventing current leakage.
At the same time, the insulation layer can withstand an ambient temperature difference of -40℃ to 90℃. In the cold northern winter and hot southern summer, it can maintain stable insulation performance without hardening, cracking or softening due to temperature changes. The insulation eccentricity is ≤15%, ensuring that the insulation layer is evenly distributed around the conductor, avoiding insulation defects caused by local thin insulation. The partial discharge amount is ≤10pC, indicating that the insulation layer is of good quality, reducing insulation aging caused by partial discharge and prolonging the service life of the cable.
Armour Layer Parameters: The middle galvanized steel tape armour has a thickness of 0.5-0.8mm. The galvanizing treatment makes the steel tape have good corrosion resistance, which can resist the erosion of corrosive substances such as moisture and salt in the soil. The existence of the armour layer significantly improves the mechanical performance of the cable, increasing the cable's mechanical impact resistance by 60%, which can effectively resist soil extrusion, stone collision during underground laying and mechanical damage during construction, protecting the internal conductor and insulation layer of the cable from damage.
Sheath Layer Parameters: The outer polyvinyl chloride (PVC) sheath has a thickness of 1.8-2.5mm. PVC material has good acid and alkali resistance, and can maintain stable performance in environments containing acid and alkali without being corroded. At the same time, its UV resistance enables the cable to resist the irradiation of ultraviolet rays in sunlight when laid outdoors, slowing down the aging rate of the sheath. The flame spread rate of the sheath is ≤0.5m/min, passing the IEC 60332-1 flame retardant test. In case of fire, it can delay the spread of flames, buying time for personnel evacuation and fire rescue.
(II) Characteristics and Core Advantages
The IEC 60502-1 copper XLPE insulated PVC sheathed galvanized steel tape armoured 0.6/1kV power cable (model N2xby) has significant characteristics and core advantages in the market due to its unique design and excellent performance.
1. Excellent Electrical Performance: The high-purity electrolytic
Copper Conductor combined with the compact stranding process ensures that the cable has good conductive performance. The low DC resistance reduces energy loss during power transmission. The XLPE insulation layer has high volume resistivity and low partial discharge, which can effectively prevent current leakage, ensure the insulation reliability of the cable, and reduce the risk of short circuits, leakage and other faults. These excellent electrical performances enable the cable to maintain efficient and stable power transmission during long-term operation.
2. Strong Mechanical Performance: The design of the galvanized steel tape armour layer greatly improves the mechanical strength and impact resistance of the cable, enabling it to adapt to complex laying environments such as underground and pipe threading, and resist external mechanical damage. Whether it is collision during construction or soil extrusion during use, the armour layer can provide effective protection for the cable, prolonging the service life of the cable.
3. Good Environmental Adaptability: The insulation layer of the cable can withstand a large temperature range, from -40℃ to 90℃, and can work normally under different climatic conditions. The acid and alkali resistance and UV resistance of the PVC sheath enable the cable to operate stably in industrial environments containing corrosive substances and municipal engineering with outdoor sunlight. In addition, the corrosion resistance of the galvanized steel tape also enhances the adaptability of the cable in humid, salty and other environments.
4. Reliable Flame Retardant Performance: The PVC sheath has passed the IEC 60332-1 flame retardant test, with a low flame spread rate. In case of fire, it can play a certain flame retardant role, reducing the spread range of the fire and protecting the safety of personnel and equipment. This feature makes the cable have high application value in places with certain fire safety requirements, such as factory workshops and underground pipe corridors.
5. Flexible Specification Combination: The flexible combination of the number of cores and cross-sectional specifications can meet the power transmission needs of different scenarios. Whether it is the power supply of small equipment or the main cable of large production lines, a suitable specification can be found, improving the versatility and applicability of the cable.
(III) Characteristic Uses and Application Scenarios
Due to its excellent performance and diverse specifications, the IEC 60502-1 copper XLPE insulated PVC sheathed galvanized steel tape armoured 0.6/1kV power cable (model N2xby) is widely used in many fields.
1. Industrial Plants: In industrial production, this cable is an indispensable power transmission equipment. Cables with specifications of 4×120mm² and above can be used as the main cable of the production line to provide stable power for large motors, machine tools and other equipment. The environment of the factory workshop is complex, with equipment vibration, oil pollution and other conditions. The armour layer of the cable can resist mechanical damage caused by vibration, and the PVC sheath can resist oil corrosion, ensuring the continuous and stable operation of the production line. For example, in the welding workshop of an automobile manufacturing factory, high-power welding equipment requires a large amount of electricity. The 4×240mm² specification cable can meet its power needs and can work for a long time in an environment full of oil and mechanical vibration.
2. Municipal Engineering: This cable is often used in street lamp lines, traffic signal lines and other municipal engineering. The 2×50mm² model cable is suitable for underground street lamp lines. When laid underground, the armour layer can prevent damage to the cable caused by rat and ant bites and soil extrusion. The UV resistance and acid and alkali resistance of the PVC sheath adapt to outdoor environmental changes. In urban road reconstruction projects, the use of this cable can ensure the stable power supply of the street lamp system and reduce problems such as street lamp failure due to cable faults.
3. Underground Pipe Corridors: Underground pipe corridors are an important part of urban infrastructure, with a humid internal environment and possibly various corrosive gases and liquids. The cable can adapt to this humid environment, and can further resist the erosion of groundwater when laid with pipes, providing power support for ventilation, drainage, monitoring and other equipment in the pipe corridor. In the comprehensive pipe corridor, the armour layer and sheath layer of the cable work together to ensure the safety and reliability of power transmission and ensure the normal operation of the pipe corridor.
4. Commercial Buildings: The power distribution systems of large shopping malls, office buildings and other commercial buildings also use this cable. In the lines from the underground power distribution room to the distribution boxes on each floor of these buildings, appropriate specifications of cables can be selected according to the power load. The flame retardant performance and mechanical performance of the cable can meet the requirements of commercial buildings for fire safety and power supply stability, ensuring the normal operation of lighting, air conditioning, elevators and other equipment in the building.
5. Energy Field: In the low-voltage distribution systems of small hydro
Power Stations and wind farms, this cable can be used to transmit electric energy from generators to transformers or distribution devices. Its good environmental adaptability can adapt to outdoor natural environments such as wind, sun and rain, and the armour layer can protect the cable from damage during installation and use.
(IV) Production Process and Quality Control
The high quality of the IEC 60502-1 copper XLPE insulated PVC sheathed galvanized steel tape armoured 0.6/1kV power cable (model N2xby) benefits from advanced production processes and strict quality control systems.
1. Conductor Manufacturing Process: First, high-purity electrolytic copper ingots are selected and made into copper rods through smelting, rod casting and other processes. The copper rod is drawn into a single wire of the required diameter on a wire drawing machine. During the wire drawing process, the wire drawing speed and die size are strictly controlled to ensure that the diameter of the single wire is uniform. Then, multiple single wires are stranded by a compact stranding machine. During stranding, the stranding pitch and pressure are precisely controlled to make the conductor structure tight and improve the filling coefficient. The
Stranded Conductor needs to be annealed, heated to a certain temperature, kept warm for a period of time and then slowly cooled to eliminate internal stress in the conductor and improve the
Flexibility and conductivity of the conductor.
2. Insulation Layer Extrusion Process: Three-layer co-extrusion equipment is used for the extrusion of the XLPE insulation layer, that is, the conductor shielding layer, insulation layer and insulation shielding layer are extruded at the same time. This process can make the layers closely combined, reduce interface defects and improve insulation performance. Before extrusion, the XLPE material needs to be strictly dried to remove moisture in the material to avoid bubbles in the insulation layer. During the extrusion process, parameters such as extrusion temperature, speed and pressure are precisely controlled. According to different conductor cross-sectional specifications, the thickness of the insulation layer is ensured to be uniform and meet the requirements. The extruded
Insulated Wire core is cross-linked through a cross-linking tube. By controlling the cross-linking temperature, pressure and time, the XLPE material forms a stable three-dimensional network structure, thereby obtaining excellent heat resistance and insulation performance.
3. Armour Layer Manufacturing Process: The armour layer uses galvanized steel tape, which is wrapped on a fully automatic wrapping machine. During the wrapping process, the tension, wrapping angle and overlap of the steel tape are precisely controlled to ensure that the steel tape gap is ≤0.5mm, so that the armour layer uniformly and tightly wraps the outer layer of the insulated wire core. The galvanized steel tape has good corrosion resistance, which can protect the cable from corrosion in complex environments. After wrapping, the armour layer is inspected to ensure that there are no defects such as looseness, wrinkles and damage.
4. Sheath Layer Extrusion Process: The sheath layer is made of PVC material and extruded in an extruder. Before extrusion, the PVC material needs to be mixed and plasticized to ensure uniform material. During the extrusion process, the extrusion temperature is controlled between 160-180℃. This temperature range can ensure that the PVC material is fully plasticized, while avoiding material aging due to excessive temperature. By controlling the extrusion speed and die size, the thickness of the sheath layer is ensured to be uniform, the surface is smooth, free of bubbles, cracks and other defects, and closely combined with the armour layer.
5. Quality Control Process: From the purchase of raw materials, strict inspections are carried out on electrolytic copper, XLPE
Insulation Materials, galvanized steel tapes, PVC sheath materials, etc. Only raw materials that meet the quality standards can enter the production process. During the production process, quality control points are set for each process to inspect semi-finished products, such as the diameter of the conductor, DC resistance, thickness of the insulation layer, eccentricity, wrapping quality of the armour layer, thickness of the sheath layer, etc.
Finished cables need to undergo a number of strict tests, including power frequency withstand voltage test (3kV/5min without breakdown), partial discharge test (≤10pC), insulation resistance test, armour adhesion test (≥15N/cm), flame retardant performance test and more than 20 other tests. A certain number of samples are taken from each batch of products for testing. Only after all indicators are qualified can they leave the factory, accompanied by a complete test report to ensure that the product quality meets the requirements of the IEC 60502-1 standard.
II. General Product Information
(I) Packaging Standards
To ensure that the IEC 60502-1 copper XLPE insulated PVC sheathed galvanized steel tape armoured 0.6/1kV power cable (model N2xby) is not damaged during transportation and storage, strict packaging standards are adopted.
1. Cable Reels: Cables are usually wound on sturdy steel or wooden reels. The size of the reels is designed according to the specifications and length of the cables. The diameter and width of the reels can ensure that the cables are neatly and tightly wound, avoiding loosening and mutual friction during transportation. Both sides of the reel are provided with high-strength flanges. The thickness and strength of the flanges are calculated to withstand the weight of the cable and the impact force during transportation, preventing the reel from deformation. For large-section and long-length cables, steel reels are generally used to ensure sufficient load-bearing capacity; for small-section and short-length cables, wooden reels can be used for easy handling.
2. Fixing and Protection: After the cable is wound on the reel, high-strength steel strips or steel wires are used to fasten the cable on the reel to prevent the cable from sliding during transportation. The outer layer of the cable is wrapped with a moisture-proof and wear-resistant plastic film or linen to protect the sheath layer of the cable from scratches and wear. For exported or long-distance transported cables, a rain cover is added outside the reel to prevent rainwater and moisture from entering the cable and affecting its performance. A protective device is provided at the central shaft hole of the reel to avoid damage to the reel during hoisting.
3. Identification Information: Relevant product information is clearly marked on the sides and ends of the reel, including product name, model specification (N2xby), rated voltage (0.6/1kV), number of cores and cross-sectional specification, length, weight, production batch number, execution standard (IEC 60502-1), production date, manufacturer name, address and contact information, etc. This identification information helps customers quickly identify the basic situation of the product when receiving and inspecting the cable, and also facilitates product traceability and quality tracking.
4. Packaging Inspection: After the cable packaging is completed, quality inspectors will inspect the packaging, checking the firmness of the reel, the fixing of the cable, the integrity of the protective materials, and the accuracy of the identification information, etc., to ensure that the packaging meets the requirements and provide guarantee for the safe transportation and storage of the cable.
(II) Transportation and Storage Specifications
1. Transportation Requirements:
Road Transportation: Use special freight vehicles, such as flatbed trucks or box trucks. When loading cable reels, ensure that the reels are placed stably and firmly fixed on the vehicle with steel wire ropes or chains to prevent rolling, tilting or collision during transportation. During transportation, abide by traffic rules, avoid violent operations such as sudden braking and sharp turns, and reduce the impact on the cable. During long-distance transportation, regularly check the fixing of the cable reels and handle problems in a timely manner.
Railway Transportation: Select appropriate railway freight cars, place the cable reels reasonably, and leave a certain gap between the reels to avoid mutual extrusion. Use special fixing devices to fix the reels in the carriage to prevent movement due to vibration during train operation.
Sea Transportation: For cables transported by ship, place the reels in a ventilated and dry cargo hold to avoid moisture. Place moisture-proof materials such as wooden boards under the reels and fix the reels to the fixed points of the cabin with ropes to prevent displacement or collision due to bumpy during navigation. Additionally, implement waterproofing measures to avoid direct contact between the cable reels and water.
2. Storage Specifications:
Storage Environment: The warehouse should be dry, well-ventilated, and free from corrosive gases, dust, and direct sunlight. The temperature in the warehouse should be maintained between -15℃ and 40℃, with a relative humidity not exceeding 75%. Install temperature and humidity meters to monitor the environment regularly, and take ventilation or dehumidification measures when necessary.
Placement of Reels: Cable reels must be stored vertically to prevent deformation of the reel or damage to the cable caused by horizontal pressure. A distance of at least 0.5 meters should be kept between adjacent reels to facilitate air circulation and ease of handling. For reels stored for an extended period, rotate them every 3 months to change the stress points on the cable, preventing permanent deformation or insulation aging.
Protection Measures: Cover the cable reels with waterproof and dustproof tarpaulins to protect them from moisture and dust accumulation. Avoid placing heavy objects on or near the reels to prevent accidental damage. For cables with a storage period exceeding 12 months, conduct a pre-use inspection, including checking the appearance of the sheath and insulation, and testing the insulation resistance, to ensure they meet operational requirements.
(III) Shipping and Delivery Process
1. Order Confirmation: Upon receiving the customer's order, the sales team verifies the details, including cable model (N2xby), specifications (core number and cross-section), quantity, delivery date, and destination. A formal sales contract is signed, specifying quality standards, pricing, payment terms, and liability for breach of contract. The production department adjusts the production schedule based on the order to ensure timely completion.
2. Pre-Shipment Inspection: Before dispatch, quality inspectors conduct a comprehensive check of the cables. This includes verifying the conformity of the model, specifications, and length with the order; inspecting the appearance for scratches, cracks, or damage to the sheath, armour, and insulation; and reviewing accompanying documents such as test reports and certificates of compliance to ensure they meet IEC 60502-1 standards.
3. Logistics Arrangement: Based on the delivery location and urgency, select the appropriate transportation mode. For domestic shipments, road or railway transport is preferred; for international orders, sea freight is commonly used, with air freight available for urgent requests. The logistics team coordinates with carriers to confirm the shipping schedule, route, and tracking information, and secures cargo insurance to cover potential loss or damage during transit.
4. Shipment Notification: Once the cables are shipped, the customer is promptly informed via email or phone, providing details such as the waybill number, carrier contact information, estimated arrival time, and a copy of the shipping documents. The sales team remains in contact with the customer to address any queries during transportation.
5. Delivery and Acceptance: Upon arrival at the destination, the customer or their designated representative conducts an on-site inspection. They check the integrity of the packaging, the consistency of the cable model and quantity with the order, and any visible damage. If discrepancies or damage are found, the customer must notify the supplier within 48 hours, providing photos and written documentation as evidence. After successful verification, the customer signs the delivery receipt to confirm acceptance. In case of non-conformity, the supplier arranges for replacement or repair in accordance with the contract terms.
(IV) Sample Services
To assist customers in evaluating the suitability of the IEC 60502-1 copper XLPE insulated PVC sheathed galvanized steel tape
Armoured Cable (model N2xby), the following sample services are offered:
1. Provision of Samples: Customers can request free samples of standard specifications (up to 5 meters in length) by contacting the sales department. The customer is responsible for the freight charges. Samples are dispatched within 3 working days of the request, accompanied by a sample test report detailing key parameters such as conductor resistance, insulation thickness, and flame retardancy.
2. Customized Samples: For customers requiring non-standard specifications (e.g., special core configurations or sheath colors), customized samples can be produced. The customer provides detailed technical requirements, and the R&D team designs and manufactures the samples accordingly. A nominal fee may apply for customization, which is refundable upon placement of a bulk order.
3. Testing Support: The technical team offers assistance with sample testing, including guidance on conducting insulation resistance tests, voltage withstand tests, and mechanical performance checks. If required, the supplier can arrange for third-party laboratory testing at the customer's expense, with the test results provided in a formal report.
(V) After-Sales Service
The supplier is committed to providing comprehensive after-sales support to ensure customer satisfaction:
1. Quality Warranty: The cable comes with a 2-year warranty from the date of delivery. During this period, if the cable fails due to manufacturing defects (e.g., insulation breakdown or armour detachment under normal use), the supplier provides free replacement or repair. Damage caused by improper installation, mechanical abuse, or environmental factors beyond the cable's design scope is not covered under warranty but can be repaired at a reasonable cost.
2. Technical Assistance: A dedicated technical hotline and email support are available to address customer inquiries. The technical team provides guidance on cable installation, including proper laying methods, bending radius requirements, and termination techniques. For large-scale projects, on-site technical support can be arranged to supervise installation and resolve any on-site issues.
3. Complaint Handling: Customer complaints are registered and addressed within 24 hours. The after-sales team investigates the cause of the issue, and a solution is proposed within 3 working days, which may include replacement, repair, or compensation as per the contract. Feedback from complaints is used to improve production processes and quality control.
4. Maintenance Guidance: The supplier provides a maintenance manual outlining recommended inspection intervals, cleaning methods, and signs of potential failure to help customers extend the cable's service life. Regular follow-up calls are made to key customers to assess performance and address any emerging concerns.
By adhering to strict production standards, comprehensive quality control, and customer-centric services, the IEC 60502-1 copper XLPE insulated PVC sheathed galvanized steel tape armoured 0.6/1kV power cable (model N2xby) ensures reliable and safe power transmission across diverse industrial and municipal applications.
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