450/750V Earth Cable 120mm2 150mm2 240mm2 Green/Yellow Earth Cable

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2025-08-12 08:57:23

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Detailed Information on 450/750V Earth Cable 120mm², 150mm², 240mm² Green/Yellow

1. Product-Specific Information

1.1 Specification Parameters

The 450/750V green/Yellow Earth Cable series, available in 120mm², 150mm², and 240mm², is engineered to meet global safety standards, providing tailored grounding solutions for diverse electrical systems. While sharing core design principles, each 规格 differs in conductor dimensions to accommodate varying current demands.

Conductor Specifications:

120mm²: Comprises 37 strands of 1.98mm diameter copper, forming a conductor with an overall diameter of 12.4mm. The DC resistance at 20°C is maximum 0.158Ω/km, allowing it to handle fault currents up to 20kA for 1 second.

150mm²: Features 37 strands of 2.2mm diameter copper, resulting in a conductor diameter of 13.8mm. Its DC resistance is ≤0.124Ω/km, with a fault current capacity of 25kA for 1 second.

240mm²: Consists of 61 strands of 2.2mm diameter copper, yielding a conductor diameter of 17.2mm. The DC resistance is ≤0.077Ω/km, capable of withstanding 35kA fault currents for 1 second.

All conductors adhere to Class 2 stranded structure standards (IEC 60228), balancing Flexibility and mechanical strength. This design allows bending without strand breakage, crucial for installation in confined spaces.

Insulation Parameters:

Each cable features a PVC Insulation layer with a thickness of 1.4mm (minimum 1.2mm) for 120mm² and 150mm², and 1.6mm (minimum 1.4mm) for 240mm² to accommodate the larger conductor. The insulation withstands 450/750V (phase-to-earth/phase-to-phase) and exhibits a dielectric strength of ≥15kV/mm, ensuring electrical isolation even during voltage surges.

Mechanical and Thermal Properties:

Bending Radius: 12× outer diameter (OD) for fixed installation, 15× OD for flexible use. The OD varies by 规格: 15.2mm (120mm²), 16.6mm (150mm²), and 20.4mm (240mm²).

Operating Temperature: -15°C to 70°C continuous; 105°C for short-term overloads (≤5 seconds).

Tensile Strength: Insulation Material offers ≥12MPa, with elongation at break ≥150%, resisting tearing during handling.

1.2 Material Composition

Copper Conductors: High-purity electrolytic copper (99.95% purity) is used for its superior conductivity (58 MS/m) and corrosion resistance. Annealing at 400-500°C in a nitrogen atmosphere relieves internal stresses, enhancing ductility for stranding.

PVC Insulation: A specialized compound formulated for grounding applications, containing:

Polyvinyl chloride resin (60-70% by weight) for structural integrity.

Phthalate plasticizers (15-20%) to maintain flexibility at low temperatures.

Calcium-zinc stabilizers (3-5%) for heat resistance, replacing lead-based additives to meet RoHS standards.

Flame retardants (10-15%: aluminum hydroxide and antimony trioxide) to achieve IEC 60332-1-2 flame classification.

The green-yellow 双色 insulation follows IEC 60446, with each color covering 30-70% of the surface in a helical pattern, ensuring universal recognition as a grounding conductor.

1.3 特色用途 by 规格

Each cable 规格 targets specific applications based on current capacity:

120mm²:

Ideal for medium-scale systems such as commercial buildings (shopping malls, hotels) where it serves as the main grounding loop, connecting distribution panels to earth electrodes. It is also used for grounding 中型工业设备 like injection molding machines (50-100kW) and data center server racks, where fault currents are moderate but reliability is critical.

150mm²:

Suited for large industrial machinery in steel mills, chemical plants, and automotive factories, including blast furnaces and assembly line robots. It functions as a grounding 干线 in 10kV-0.4kV substations, linking transformers and switchgear to grounding grids, where 25kA fault current handling is essential.

240mm²:

Designed for high-power infrastructure: large substations, thermal power plants, and wind farms. It grounds turbine generators (1.5MW+) and traction substations in urban rail systems, where 35kA fault currents are possible. Its low resistance (≤0.077Ω/km) ensures compliance with strict grounding resistance standards (<1Ω) in critical facilities.

1.4 Manufacturing Process

Production follows stringent protocols to ensure consistency across all 规格:

Copper Strand Production:

High-purity copper rods are drawn through diamond dies to achieve the required strand diameters (1.98mm, 2.2mm). Strands undergo annealing to restore ductility, ensuring they withstand stranding forces without fracturing.

Stranding:

Strands are twisted using planetary stranding machines, with a pitch of 12-16× strand diameter to ensure tight interlock. For 240mm², 61 strands are layered concentrically to maintain uniformity.

Insulation Extrusion:

Molten PVC (160-190°C) is extruded onto the Stranded Conductor via a crosshead die, ensuring uniform thickness. A dual-color die injects green and yellow insulation simultaneously, forming the helical pattern required by IEC 60446.

Quality Testing:

Each batch undergoes:

Electrical tests (insulation resistance ≥100MΩ·km; 2500V AC withstand for 5 minutes).

Flame tests (IEC 60332-1-2: self-extinguishing within 60 seconds).

Dimensional checks (strand count, insulation thickness, OD).

2. General Product Information

2.1 Packaging

Packaging varies by 规格 to optimize handling and protection:

120mm² and 150mm²: Spooled onto wooden reels (300mm core) with 100m or 250m lengths. Reels are wrapped in moisture-resistant paper and shrink-wrapped.

240mm²: Supplied on steel reels (400mm core) with 50m or 100m lengths, due to increased weight (≈12kg/10m).

Bulk orders are palletized: 10 reels (120/150mm²) or 5 reels (240mm²) per pallet, secured with steel strapping and stretch-wrapped. Pallets include labels with 规格，length, batch number, and handling instructions.

2.2 Transportation and Handling

Loading/Unloading: Use cranes or forklifts with padded tines to avoid reel damage. Steel reels (240mm²) require lifting via core holes.

Transport: Secure reels horizontally on trucks with ratchet straps (≥5000kg strength). Cover with tarps to protect from UV and moisture.

Storage: Store in dry warehouses (5-30°C, ≤70% humidity). Avoid stacking reels to prevent flange warping. Keep away from chemicals and heat sources.

2.3 Ordering and Delivery

MOQ: 100m for 120/150mm²; 50m for 240mm². Bulk discounts apply for orders >10,000m.

Customization: Available reel sizes (e.g., 500m) and additional testing (e.g., salt spray for marine use).

Lead Times: In-stock items ship within 48 hours; custom orders take 7-10 days. International delivery: 3-5 days (Europe), 7-10 days (Asia), 30-40 days (sea freight).

2.4 Samples and After-Sales

Samples: 1m samples provided free (shipping cost borne by customer), including test certificates.

Warranty: 10-year coverage for material defects. Excludes damage from improper installation or overcurrent.

Technical Support: Engineers assist with termination methods (compression lugs, exothermic welding) and code compliance (e.g., BS 7671, NF C 15-100).

2.5 Certifications

All cables comply with:

IEC 60245-1 (PVC Insulated Cables)

IEC 60228 (Class 2 conductors)

IEC 60332-1-2 (flame retardancy)

IEC 60446 (color coding)

CE marking (EU Low Voltage Directive)

Certificates and test reports (SGS, Intertek) are available upon request.

3. Environmental Considerations

Recyclability: Copper Conductors are 100% recyclable; production uses 80% recycled copper, reducing energy use by 85% vs. virgin material.

PVC Management: Post-Industrial PVC scrap is recycled into new insulation.

Packaging: Wooden reels use FSC-certified timber; stretch film is biodegradable.

4. Comparison with Alternatives

Aluminum Conductors: Lower cost but higher resistance (1.6× copper) and prone to corrosion, requiring special terminations.

XLPE Insulation: Withstands higher temperatures (90°C) but is stiffer and 30% more expensive than PVC, unnecessary for 70°C applications.

Single-Strand Copper: Cheaper but inflexible, unsuitable for tight bends.

The green/yellow PVC-insulated copper series balances cost, performance, and versatility, making it the preferred choice for most grounding applications.

This comprehensive range ensures that regardless of the project scale—from commercial buildings to power plants—there is a precisely engineered grounding solution to meet safety and performance requirements.