Detailed Description of 600/1000V Low-Voltage XLPE 35mm² 4-Core Aluminum Power Cable
I. Core Information of the Product Itself
(I) Analysis of Specification Parameters
The specification parameters of the 600/1000V low-voltage cross-linked polyethylene (XLPE) 35mm² 4-core
Aluminum Power Cable are crucial for its efficient operation in low-voltage distribution systems, with each parameter meticulously designed and strictly controlled.
Voltage Level: The rated voltage of this cable is 600/1000V, which clearly defines its application range in the low-voltage distribution field. Among them, 600V refers to the rated voltage between the core and the ground or the shielding layer, and 1000V refers to the rated voltage between cores. This design enables it to be compatible with low-voltage power grids with AC 50Hz or 60Hz, providing stable power transmission for various low-voltage electrical equipment and lines. Whether in residential electricity use or industrial low-voltage distribution scenarios, it can meet the voltage requirements of power transmission and ensure the normal operation of electrical equipment.
Core Structure and Cross-Section Specification: It adopts a 4-core structure design, including 3 phase lines and 1 neutral line. This structure perfectly meets the needs of three-phase four-wire distribution systems. In the three-phase four-wire system, the 3 phase lines are responsible for transmitting electrical energy, and the neutral line plays a role in balancing the three-phase voltage and providing a single-phase circuit, which can well cope with the distribution scenarios of mixed three-phase balanced loads and single-phase loads. Each core has a conductor cross-sectional area of 35mm², and this cross-sectional specification determines the current-carrying capacity of the cable. When laid in air, its current-carrying capacity is approximately 110A, which can meet a certain scale of electricity demand, such as the total electricity consumption of 30-50 households or the power supply for small and medium-sized motors with power ≤55kW.
Conductor Parameters: The conductor is made of high-purity aluminum with a purity of ≥99.7%. High-purity aluminum is the basis for ensuring the conductive performance of the cable. After optimized annealing treatment, the conductive performance of the
Aluminum Conductor is significantly improved. At 20℃, its DC resistance is ≤0.814Ω/km, fully meeting the requirements of GB/T 12706.1-2020. The low DC resistance can reduce energy loss during current transmission and improve the efficiency of power transmission. At the same time,
Aluminum Conductors have the characteristics of light weight, with a weight of about 250kg per kilometer, which is 40% lighter than
Copper Cables of the same specification. This advantage not only reduces the cost of the cable during transportation but also reduces the labor intensity during installation, making the laying process more convenient.
Insulation Layer Parameters: The insulation layer is made of XLPE material with a temperature resistance of 90℃. Through the peroxide cross-linking process, XLPE forms a three-dimensional network molecular structure, which endows the insulation layer with excellent performance. Its volume resistivity is ≥1×10¹⁴Ω・cm, with excellent electrical insulation performance, which can effectively prevent current leakage and ensure the safety of power transmission. In addition, the insulation layer also has good aging resistance and chemical corrosion resistance. Within the ambient temperature range of -40℃ to 90℃, it will not harden or soften, and can adapt to complex environments such as humidity, dust, acid, and alkali, ensuring the long-term stable operation of the cable.
Sheath Layer Parameters: The sheath layer is usually made of polyvinyl chloride (PVC) or halogen-free low-smoke flame-retardant materials, with a thickness of ≥1.8mm.
PVC Sheath has good mechanical strength, weather resistance, and insulation performance, which can resist external impact, ultraviolet erosion, and certain chemical corrosion, protecting the internal structure of the cable from damage. Halogen-free low-smoke flame-retardant materials have more advantages in terms of safety. In case of fire, they will not release toxic and harmful gases and a large amount of smoke, reducing harm to personnel and equipment, and are suitable for places with high requirements for fire safety, such as high-rise buildings, hospitals, and schools.
Other Key Parameters: The bending radius of the cable is not less than 12 times the outer diameter of the cable. This parameter ensures that the cable can adapt to different terrains and installation requirements during laying, facilitating construction in complex environments. At the same time, the insulation thickness deviation of the cable is ≤0.1mm, ensuring the uniformity of the insulation layer and avoiding potential safety hazards caused by local weak insulation. In the power frequency withstand voltage test, it can withstand 3kV/5min without breakdown, and the partial discharge test is ≤10pC. These parameters fully prove the stability and reliability of the cable's electrical performance.
(II) Characteristics and Core Advantages
The 600/1000V low-voltage XLPE 35mm² 4-core aluminum power cable has significant characteristics and core advantages in the market, making it an ideal choice in the field of low-voltage distribution.
1. Excellent Comprehensive Cost-Effectiveness: Aluminum conductors have obvious cost advantages over
Copper Conductors, which can significantly reduce the purchase cost of cables. In large-scale distribution projects, this cost advantage is more prominent, which can effectively reduce the total investment of the project. At the same time, although the conductivity of aluminum is slightly lower than that of copper, through the selection of high-purity materials and optimized process treatment, the conductive performance of the cable can meet the needs of low-voltage distribution. Moreover, the low-loss characteristic of the XLPE insulation layer (dielectric loss tangent ≤0.003) further reduces energy waste during power transmission. Taking the transmission of 100A current as an example, the annual loss per kilometer of cable is about 80 kWh lower than that of traditional
PVC Insulated Cables. Long-term use can save a lot of electricity expenses, improving the cost-effectiveness of the product as a whole.
2. Good Environmental Adaptability: The insulation layer and sheath layer materials of the cable enable it to adapt to various complex environments. The insulation layer maintains stable performance within a wide temperature range of -40℃ to 90℃, which can cope with climate differences in different regions, and can work normally both in cold northern regions and hot southern regions. The sheath layer has good weather resistance and corrosion resistance, which can resist the erosion of environmental factors such as ultraviolet rays, humidity, dust, and oil stains, and is suitable for various scenarios such as outdoors, industrial plants, and underground. In addition, the cable supports various laying methods such as underground, pipe threading, and overhead, further enhancing its applicability in different environments.
3. Optimized Structural Design: The 4-core structure design fits the needs of the three-phase four-wire distribution system, eliminating the need for separate laying of neutral lines, simplifying the laying process, and reducing installation time and material costs. The application of compact stranding technology in conductor manufacturing not only reduces the skin effect, improves the conductivity efficiency, but also enhances the mechanical strength of the conductor, making the cable more resistant to wear and stretching during laying and use. The three-layer co-extrusion equipment is used in the production of the insulation layer to ensure the uniformity of the insulation layer thickness, avoid local insulation defects, and improve the electrical safety of the cable.
4. Reliable Safety Performance: The cable strictly follows national standards during production and undergoes a number of rigorous tests. The power frequency withstand voltage test (3kV/5min without breakdown) and partial discharge test (≤10pC) ensure the reliable electrical insulation performance of the cable, reducing the risk of safety accidents such as short circuits and electric leakage. For cables with halogen-free low-smoke flame-retardant sheaths, they can effectively inhibit the spread of flames and reduce the release of toxic gases in case of fire, buying time for personnel evacuation and fire rescue, and improving the overall safety.
(III) Characteristic Uses and Application Scenarios
With its excellent performance and characteristics, the 600/1000V low-voltage XLPE 35mm² 4-core aluminum power cable is widely used in many fields.
1. Building Distribution Field: In multi-storey residential buildings, office buildings, commercial complexes and other buildings, this cable is often used as the floor distribution trunk line. The strong electric well of the building is an important channel for cable laying. The current-carrying capacity of 35mm² can meet the power demand of each floor or multiple floors. For example, in a 30-storey residential building, this cable is laid as the trunk line in the strong electric well of each unit, which can distribute electricity from the distribution room to the distribution boxes on each floor, and then from the distribution boxes to each household. Its 4-core structure is compatible with the three-phase four-wire demand of household electricity, ensuring the normal use of lighting, air conditioning, household appliances and other equipment. At the same time, the weather resistance and mechanical strength of the cable can adapt to the environment inside the building, such as temperature changes and slight vibrations.
2. Industrial Plant Scenarios: In industrial production, this cable can be used as the power supply line for small and medium-sized motors (power ≤55kW). There are many equipment in industrial plants, and the environment is relatively complex, which may have vibrations, oil stains, dust and other conditions. The aluminum conductor of the cable is light in weight, which is convenient for laying and installation in the plant; the chemical corrosion resistance and aging resistance of the XLPE insulation layer can resist the erosion of oil stains and dust; the mechanical strength of the sheath layer can withstand the slight vibration during the operation of the equipment, ensuring the stable power supply of the motor and the continuity of production. For example, in the mechanical processing workshop, the motor used to drive lathes, milling machines and other equipment can meet its power demand and environmental adaptation requirements by using this cable for power supply.
3. Municipal Engineering: This cable is often used in the distribution network of street lamp systems, green belt irrigation equipment and other municipal engineering. The street lamp system is distributed on both sides of the road, requiring the cable to have good weather resistance to adapt to the outdoor natural environment such as wind, sun and rain. The sheath layer of this cable can resist the influence of ultraviolet rays and temperature changes, ensuring the normal lighting of street lamps. Green belt irrigation equipment is usually installed outdoors and may involve humid environments. The moisture-proof and corrosion-resistant properties of the cable's insulation layer and sheath layer can ensure the stable power supply of the irrigation equipment, ensuring the smooth progress of greening irrigation work.
4. Agricultural Production Field: This cable also has certain applications in agricultural production scenarios such as modern agricultural greenhouses and small farmland irrigation systems. The lighting, ventilation, temperature control and other equipment in agricultural greenhouses need stable power supply, and the 4-core structure and appropriate current-carrying capacity of the cable can meet the needs of these equipment. The power of equipment such as water pumps in farmland irrigation systems is relatively small, and the current-carrying capacity of this cable is sufficient to support its operation, and its weather resistance can adapt to the environmental conditions of outdoor farmland, providing power guarantee for agricultural production.
(IV) Production Process and Quality Control
The excellent quality of the 600/1000V low-voltage XLPE 35mm² 4-core aluminum power cable comes from advanced production processes and strict quality control systems.
1. Conductor Manufacturing Process: First, high-purity aluminum ingots are selected and made into aluminum rods through smelting, rod casting and other processes. The aluminum rod is processed into a single wire by a continuous extrusion machine. During the processing, the diameter and tolerance of the single wire are strictly controlled to ensure uniform quality of the single wire. Then, the compact stranding process is used to strand multiple single wires into a conductor. By precisely controlling the stranding pitch and pressure, the structure of the conductor is made more compact, the filling coefficient of the conductor is improved, the skin effect is reduced, and the conductive performance is enhanced. The
Stranded Conductor needs to be annealed, heated to a certain temperature, kept for a period of time, and then slowly cooled to eliminate the internal stress generated during processing, improve the
Flexibility and conductivity of the conductor, and ensure that the conductor is not easy to break during laying and use.
2. Insulation Layer Extrusion Process: Three-layer co-extrusion equipment is used for the extrusion of the insulation layer, that is, the conductor shielding layer, the insulation layer and the 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 defects such as bubbles in the insulation layer. During the extrusion process, parameters such as extrusion temperature, speed and pressure are precisely controlled to ensure that the thickness of the insulation layer is uniform with a deviation of ≤0.1mm. The extruded insulation layer should undergo a cross-linking reaction through a cross-linking tube. By controlling the cross-linking temperature, pressure and time, the XLPE material forms a stable three-dimensional network structure to obtain excellent insulation performance and temperature resistance.
3. Cabling Process: The 4
Insulated Cores are stranded into a cable according to a certain pitch. During the stranding process, it is necessary to ensure that the cores are arranged neatly with uniform tension to avoid excessive friction and extrusion between the cores. When cabling, a filling rope can be placed in the center of the cable core to ensure the roundness of the cable core, facilitating the subsequent extrusion of the sheath. At the same time, a layer of non-woven fabric or other isolation materials is wrapped around the outer layer of the cable core to fix the core and prevent the sheath material from penetrating into the cable core.
4. Sheath Layer Extrusion Process: According to product requirements, PVC or halogen-free low-smoke flame-retardant materials are selected as sheath materials, and the sheath materials are dried before extrusion. An extruder is used to coat the sheath material on the cabled core, and parameters such as extrusion temperature and speed are controlled to ensure that the sheath layer has uniform thickness, smooth surface, and no bubbles, cracks and other defects. The thickness of the sheath layer is ≥1.8mm to ensure that it has sufficient mechanical strength and protective performance.
5. Quality Control Process: From the purchase of raw materials, strict inspections are carried out on aluminum ingots, XLPE
Insulation Materials, sheath materials and other raw materials. 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, and pitch of the cable. Finished cables need to undergo a series of performance tests, including power frequency withstand voltage test, partial discharge test, insulation resistance test, mechanical performance test (such as tensile strength, elongation at break), flame retardant performance test (for flame-retardant
Sheath Cables), etc. A certain number of samples are taken from each batch of products for testing, and only after all indicators are qualified can they leave the factory, accompanied by a detailed product quality inspection report to ensure that the product quality meets national standards and design requirements.
II. General Product Information
(I) Packaging Standards
To ensure that the cable is not damaged during transportation and storage, the 600/1000V low-voltage XLPE 35mm² 4-core aluminum power cable adopts strict packaging standards.
1. Cable Reels: Cables are usually wound on wooden or steel reels. The size of the reel is designed according to the length and diameter of the cable to ensure that the cable can be neatly and tightly wound on the reel, avoiding loosening and mutual friction during transportation. Both sides of the reel are provided with solid 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 longer cables, large steel reels are generally used to ensure sufficient load-bearing capacity; for short-length cables, small wooden reels can be used for easy handling and storage.
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 material, such as 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: Clear marking of relevant product information is made on the sides and ends of the reel, including product name, model specification (600/1000V low-voltage XLPE 35mm² 4-core aluminum power cable), length, weight, production batch number, implementation standard (GB/T 12706.1-2020), production date, manufacturer's 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 status of the cable reels and handle any problems promptly.
Railway Transportation: Choose appropriate railway freight cars and arrange the cable reels reasonably, leaving sufficient gaps between reels to avoid mutual extrusion. Use special fixing devices to secure the reels in the carriage to prevent movement due to vibration during train operation.
Waterway Transportation: For cables transported by ship, place the reels in a well-ventilated and dry cargo hold to prevent moisture. Place wooden boards or other moisture-proof materials under the reels and fix them to the ship's fixtures with ropes to prevent displacement or collision due to bumpy during navigation. Meanwhile, take rainproof and moisture-proof measures to avoid cable immersion in water.
2. Storage Specifications:
Storage Location: Select a dry, well-ventilated, cool warehouse free from corrosive gases and dust. The warehouse floor should be flat and solid, preferably with a moisture-proof layer to prevent ground moisture from eroding the cables. Avoid direct sunlight and keep away from heat sources (such as heaters and stoves) in the warehouse to prevent aging of the cable sheath and insulation layer.
Storage Method: Cable reels should be stored vertically, not horizontally, to prevent reel deformation or cable extrusion. Maintain a certain distance between reels, generally not less than 0.5 meters, to facilitate ventilation and handling. For cables stored for a long time, regularly turn them to change the stress points of the cables and prevent deformation or insulation layer aging caused by long-term static placement.
Temperature and Humidity Control: The temperature in the warehouse should be controlled between -15℃ and 40℃, with a relative humidity not exceeding 75%. Install thermometers and hygrometers as needed to regularly monitor temperature and humidity changes in the warehouse. Take ventilation and dehumidification measures when necessary to ensure the storage environment meets the requirements.
Time Limit Requirements: The storage period of the cable is generally 2 years. Cables beyond the storage period must undergo sampling inspection before use, including insulation resistance testing and appearance inspection, and can only be used after passing the inspection to ensure the cable performance meets the usage requirements.
(III) Delivery and Shipment Process
1. Order Processing: After receiving the customer's order, the sales staff will communicate with the customer in a timely manner to confirm information such as product model specifications, quantity, delivery date, delivery location, and transportation method, and sign a formal sales contract. The contract clarifies the rights and obligations of both parties, including product quality standards, prices, payment methods, and liability for breach of contract. The production department formulates production plans and arranges production schedules according to the order requirements to ensure production is completed within the specified delivery period.
2. Stock Preparation and Inspection: Before shipment, warehouse managers retrieve the corresponding cable products from the inventory according to the order information or notify the production department to send the newly produced cables to the warehouse. Quality inspectors conduct a comprehensive inspection of the cables to be shipped, including checking the model specifications, length, appearance, and accompanying documents (such as quality inspection reports and certificates of conformity) to ensure they are consistent with the order requirements and meet quality standards.
3. Shipping Arrangement: Based on the customer's delivery location and requirements, select the appropriate transportation method. For domestic shipments, road or railway transportation is usually chosen; for international shipments, sea or air transportation is selected. Contact the logistics company to confirm the transportation details, such as the departure time, route, and arrival time, and sign a transportation agreement to clarify the responsibilities of both parties for cargo loss or damage during transportation.
4. Shipment Notification: After the cables are shipped, the sales staff promptly notify the customer of the shipment information, including the waybill number, transportation method, estimated arrival time, and contact information of the logistics company. Provide the customer with a copy of the shipping documents for their reference and inquiry.
5. Delivery and Acceptance: When the cables arrive at the destination, the customer or their agent should inspect the goods on-site. Check whether the packaging is intact, whether the quantity and model specifications of the cables match the order, and whether there is any damage to the cable appearance. If any problems are found, they should promptly communicate with the sales staff and provide relevant photos and documents as evidence. After passing the inspection, the customer signs the delivery receipt to confirm acceptance. If there are quality problems or discrepancies, handle them in accordance with the contract terms, such as returning, replacing, or reissuing the goods.
(IV) Sample Services
To help customers better understand the performance and quality of the 600/1000V low-voltage XLPE 35mm² 4-core aluminum power cable, the following sample services are provided:
1. Sample Provision: Customers can apply for samples by contacting the sales staff. The company provides free samples of a certain length (usually 1-5 meters) for customers to test and evaluate. The customer is responsible for the freight of the samples. For special specifications or longer samples, a certain sample fee may be charged, which can be deducted from the formal order payment after the customer places an order.
2. Sample Customization: If the customer has special requirements for the cable, such as specific sheath materials or flame retardant grades, the company can provide customized sample services. The customization process requires the customer to provide detailed technical parameters and requirements, and the company's technical department designs and produces samples accordingly. Customized samples may involve additional mold fees and processing fees, which are negotiated and confirmed by both parties.
3. Sample Testing Support: The company can provide relevant technical data and test reports of the samples, including parameters such as conductor resistance, insulation thickness, and withstand voltage performance, to assist customers in conducting performance tests. If the customer needs to send the samples to a third-party testing institution for inspection, the company can provide necessary cooperation and support.
(V) After-Sales Service
The company is committed to providing customers with comprehensive after-sales services to ensure the smooth use of the 600/1000V low-voltage XLPE 35mm² 4-core aluminum power cable:
1. Quality Guarantee: The product has a warranty period of 2 years from the date of acceptance. During the warranty period, if the cable has quality problems due to non-human factors (such as insulation breakdown, conductor breakage, etc.), the company provides free repair or replacement services. For quality problems caused by improper use or installation by the customer, the company can provide maintenance services at a reasonable cost.
2. Technical Support: A professional technical team is available to provide customers with technical consulting services, including cable laying guidance, installation precautions, and fault diagnosis. Customers can contact the technical support hotline or email for assistance, and the technical staff will respond in a timely manner and provide solutions. For large-scale projects, the company can send technical personnel to the site for guidance and training.
3. Complaint Handling: Establish a sound complaint handling mechanism. After receiving customer complaints, the after-sales staff will record and verify the situation in a timely manner and give a reply within 24 hours. For complex problems, a special working group will be set up to conduct an in-depth investigation and propose a solution within 3-5 working days to ensure customer satisfaction.
4. Regular Follow-Up: Conduct regular follow-up visits to customers who have purchased the product to understand the cable usage and performance, collect customer feedback and suggestions, and provide maintenance and maintenance guidance. This helps to improve product quality and service levels and establish long-term and stable cooperative relationships with customers.
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