In the global electrical infrastructure landscape, grounding systems are not just "supporting components"—they are the final line of defense against electrical faults that can cause equipment destruction, workplace accidents, or even large-scale power outages. With the acceleration of industrialization, the expansion of renewable energy projects (e.g., wind farms, utility-scale solar arrays), and the tightening of global safety standards (such as IEC 60364, NEC 250, and GB 50169), the demand for earthing cables that balance high performance, durability, and compliance has never been higher. A 2024 report by the International Electrotechnical Commission (IEC) noted that over 30% of electrical accidents in industrial settings are caused by inadequate grounding—highlighting the critical role of reliable earthing solutions.
Our Green Yellow Insulated Copper Conductor Earthing Cable, available in 35mm² and 120mm² cross-sectional sizes, is engineered to address this industry need. It is not a generic "one-size-fits-all" product but a targeted solution designed for two distinct user groups: medium-scale operations (e.g., commercial buildings, small industrial facilities) that require the 35mm² variant, and heavy-duty applications (e.g., large factories, renewable energy plants) that depend on the 120mm² model. What sets this cable apart is its seamless integration of three core strengths: high-purity
Copper Conductors for efficient fault current diversion, flame-retardant green-yellow insulation for safety and visibility, and a flexible structure that simplifies installation in complex environments. By aligning with the strictest global standards and focusing on real-world installer pain points (e.g., difficulty bending thick cables, uncertainty about long-term durability), it has become a trusted choice for electrical engineers, contractors, and facility managers across sectors.
The performance of an earthing cable begins with its conductor—and we spare no effort in ensuring our copper meets the highest purity standards. Our cable uses 99.95% high-purity electrolytic copper, produced via a multi-step refining process: raw copper ore is first smelted into blister copper (98-99% pure), then subjected to electrolytic refining, where an electric current passes through a copper sulfate solution to remove impurities (e.g., iron, sulfur, oxygen) and produce a final product with impurity levels below 50ppm (parts per million). This level of purity is non-negotiable: even 0.1% impurities can increase electrical resistance by up to 5%, leading to energy loss during normal operation and overheating during fault events—risks that compromise both safety and efficiency.
To enhance
Flexibility without sacrificing strength, the copper conductor is constructed using a
stranded design (rather than solid copper). For the 35mm² variant, we use 19 strands of 0.5mm-diameter fine
Copper Wire, twisted together at a lay pitch of 10mm (the distance between consecutive twists). For the 120mm² model, we use 61 strands of 0.6mm-diameter wire with a lay pitch of 15mm. This stranded structure offers two key benefits: first, it allows the cable to bend repeatedly without cracking—critical for installations that require navigating around machinery, through narrow conduits, or in confined spaces (e.g., inside power distribution cabinets for large factories). Second, it improves mechanical resilience: unlike solid conductors, which are prone to snapping under tension, our stranded copper can withstand a tensile force of 3.5kN (for 35mm²) and 8kN (for 120mm²) without permanent deformation—ensuring it remains intact during transportation and installation.
We also subject the copper conductor to rigorous performance testing. At 20°C, the DC resistance of the 35mm² variant is ≤0.529Ω/km, and the 120mm² variant is ≤0.153Ω/km—both well below the IEC 60228 Class 5 standard (which allows up to 0.56Ω/km for 35mm² and 0.16Ω/km for 120mm²). This low resistance ensures that fault currents (which can reach tens of kiloamperes) are diverted away from equipment and personnel in milliseconds—fast enough to prevent electric shocks or equipment damage. Additionally, we test the conductor’s corrosion resistance: after 48 hours of exposure to a 5% sodium chloride solution (simulating coastal or humid environments), the copper shows no signs of oxidation or pitting—ensuring long-term performance in harsh conditions.
The green-yellow insulation layer is more than just a visual identifier—it is a multi-functional barrier that protects the copper conductor, ensures safety, and complies with global norms. We use environmentally friendly polyvinyl chloride (PVC) formulated to meet RoHS 2.0 standards (2011/65/EU), which restricts the use of 10 hazardous substances (e.g., lead, cadmium, hexavalent chromium) to levels below 1000ppm. This makes the cable suitable for use in eco-sensitive projects (e.g., LEED-certified commercial buildings) and markets with strict environmental regulations (e.g., the EU, California).
The green-yellow color is mandated by IEC 60446 (International Standard for Identification of Conductors) and GB 7947 (Chinese Standard for Color Identification of Wires and Cables) for earthing conductors. This distinct dual color ensures that electricians and maintenance personnel can quickly locate the grounding system—even in cluttered electrical enclosures with dozens of cables (e.g., in data centers or industrial control rooms). Unlike surface-coated cables, where the color fades over time, our insulation integrates the green-yellow pigment into the PVC compound during manufacturing. To verify durability, we subject the cable to 1000 hours of UV exposure testing (per ISO 4892-3) and 500 cycles of thermal aging (from -30°C to 70°C)—after which the color remains vibrant, with no peeling or fading. This long-term visibility is critical for safety inspections: in many regions (e.g., the EU under CE regulations), non-identified or faded earthing cables can result in project shutdowns or fines.
Safety is paramount, so the insulation is engineered to be
flame-retardant and self-extinguishing. It meets the requirements of IEC 60332-1-2 (Vertical Flame Propagation Test for
Insulated Wires and Cables): when exposed to a 1kW flame for 60 seconds, the cable stops burning within 60 seconds of the flame being removed, with no flame propagation beyond 50mm from the test point. Additionally, it has low smoke density (measured at ≤75% opacity after 4 minutes, per IEC 61034) and low toxicity—releasing no halogen gases (e.g., chlorine, bromine) during combustion. This is especially important in enclosed spaces (e.g., underground tunnels, hospitals, or high-rise buildings), where smoke and toxic fumes pose a greater risk to human life than the fire itself.
The insulation also offers excellent thermal stability. For the standard variant, the operating temperature range is -25°C to 70°C (continuous use), with short-term tolerance up to 105°C (e.g., during installation or temporary overloads). For customers in extreme environments (e.g., cold climates in Canada or hot regions in the Middle East), we offer a high-temperature version with an operating range of -40°C to 90°C—achieved by adding heat-resistant additives to the PVC compound. To validate thermal durability, we test the insulation’s tensile strength and elongation before and after 1000 hours of aging at 100°C: the tensile strength retention is ≥80%, and elongation retention is ≥70%—far exceeding the IEC 60245 requirement of ≥70% and ≥60%, respectively.
The
PVC Insulation is designed to withstand the most common environmental stressors. It has high moisture resistance: when submerged in deionized water at 23°C for 24 hours, the insulation resistance (measured at 1000V DC) remains ≥100MΩ—preventing water from seeping into the conductor and causing corrosion or short circuits. It is also resistant to common industrial chemicals: exposure to mineral oil (ISO VG 32), 5% hydrochloric acid, and 5% sodium hydroxide for 24 hours results in no swelling, cracking, or loss of performance. For applications with higher chemical exposure (e.g., refineries, chemical plants), we offer a custom version with chlorinated polyethylene (CPE) insulation— which provides superior resistance to oils, solvents, and strong acids.
The two cross-sectional sizes of our earthing cable are tailored to address distinct application needs—each optimized for current-carrying capacity, flexibility, and compatibility with specific equipment. Below is a detailed breakdown of their performance, ideal use cases, and technical advantages.
The 35mm² cable is designed for medium-current grounding systems, where a balance of performance and cost-effectiveness is key. Its key technical parameters include:
Current-Carrying Capacity: At 25°C (ambient temperature), it can carry a continuous current of 115A; at 40°C (common in industrial environments), this drops to 95A—meeting the needs of most medium-sized equipment.
Fault Current Tolerance: It can withstand a fault current of 60kA for 1 second and 45kA for 5 seconds—fast enough to trigger protective devices (e.g., circuit breakers, fuses) before damage occurs.
Physical Dimensions: The outer diameter is 12.0mm ±0.5mm, and the weight is 0.42kg/m—light enough for easy handling by a single installer. The minimum bending radius is 60mm (5x the outer diameter), allowing it to fit into tight spaces (e.g., between electrical panels and wall-mounted equipment).
Ideal Applications:
Commercial Buildings: Grounding for large HVAC systems (e.g., 1000-ton chillers), elevator control panels, and backup generators (≤100kVA). In a 50-story office tower, for example, the 35mm² cable can connect the main electrical panel to the building’s earth rod network—ensuring fault currents from elevator motors or HVAC compressors are safely diverted.
Small to Medium Industrial Facilities: Grounding for industrial motors (20-50kW), packaging machinery, and welding equipment. A car parts manufacturer, for instance, might use it to ground robotic welding arms—preventing electrical interference that could affect weld quality.
Renewable Energy (Small-Scale): Grounding for residential solar arrays (>10kW) and small commercial solar inverters (50-100kW). In a 5MW rooftop solar project, the 35mm² cable can connect each inverter to the site’s grounding grid—ensuring safety during lightning strikes or inverter faults.
The 120mm² cable is a heavy-duty solution for high-current environments, where reliability and durability are non-negotiable. Its technical parameters reflect this focus:
Current-Carrying Capacity: At 25°C, it can carry 220A continuously; at 40°C, it carries 180A—enough to support large equipment with high power demands.
Fault Current Tolerance: It withstands 120kA for 1 second and 90kA for 5 seconds—making it suitable for high-voltage systems where fault currents can be extremely large.
Physical Dimensions: The outer diameter is 20.0mm ±0.8mm, and the weight is 1.35kg/m. To maintain flexibility despite its size, we use a tighter strand lay (15mm) and a thicker insulation layer (3.0mm). The minimum bending radius is 240mm (12x the outer diameter)—still manageable with the use of cable bending tools.
Ideal Applications:
Heavy Industry: Grounding for large industrial machinery (e.g., 100kW+ motors, metal presses, and industrial furnaces). A steel mill, for example, might use the 120mm² cable to ground a 200kW rolling mill—diverting fault currents that could otherwise damage the mill’s control system or cause downtime.
High-Voltage Equipment: Grounding for power transformers (≥500kVA), medium-voltage switchgear (10-35kV), and outdoor substations. In a utility substation, the cable connects the transformer’s neutral point to the substation’s grounding grid—ensuring safety during voltage surges or transformer faults.
Renewable Energy (Large-Scale): Grounding for utility-scale solar arrays (>100MW) and wind turbines (>2.5MW). A 200MW wind farm, for instance, would use the 120mm² cable to ground each turbine’s nacelle (which houses the generator and converter)—protecting against lightning strikes and electrical faults in the turbine’s system.
While our earthing cable is designed for ease of installation, following best practices is critical to ensure optimal performance, compliance with safety standards, and long-term reliability. Below is a step-by-step guide to installation, based on IEC 60364 and local electrical codes.
Before beginning installation, take the following steps to avoid errors or safety hazards:
Inspect the Cable: Check the cable reel for damage (e.g., cuts in the insulation, kinks in the conductor) that may have occurred during shipping. Verify that the size (35mm²/120mm²) and insulation type (PVC/CPE) match the project’s requirements. For outdoor installations, confirm that the cable is rated for UV exposure (standard for our PVC insulation).
Prepare Tools and Materials: Gather the necessary equipment: a hydraulic crimping tool (rated for 35mm² or 120mm² copper conductors), Copper Cable lugs (DT-35 for 35mm², DT-120 for 120mm²), heat-shrink tubing (rated for 105°C), a wire brush (for cleaning conductor surfaces), and a ground resistance tester (e.g., Fluke 1625).
Evaluate the Installation Site: Map the grounding path to avoid obstacles (e.g., water pipes, gas lines) and ensure the cable can be routed without exceeding the minimum bending radius. For outdoor installations, choose a path that avoids standing water or areas with high chemical exposure. Test the soil’s resistivity (aim for ≤100Ω·m); if it is too high, use a ground enhancement compound to lower resistance.
Cut the Cable to Length: Measure the distance between the grounding point (e.g., equipment terminal, earth rod) and the main grounding bus, then add 10cm of extra length to account for bending. Use a sharp cable cutter (not pliers) to make a clean cut—avoid crushing the conductor.
Prepare the Conductor: Strip 15mm of insulation from the end of the cable using a wire stripper (set to the correct diameter to avoid nicking the Copper Strands). Use a wire brush to clean the exposed conductor—removing any oxidation or dirt that could increase resistance.
Crimp the Cable Lug: Slide the appropriate cable lug onto the cleaned conductor, ensuring it is fully seated. Use the hydraulic crimping tool to apply the correct pressure (3 tons for 35mm², 8 tons for 120mm²)—follow the tool manufacturer’s guidelines to avoid under-crimping (which causes loose connections) or over-crimping (which damages the conductor).
Insulate the Termination: Slide a piece of heat-shrink tubing over the crimped lug, covering both the lug and the insulation-cable junction. Use a heat gun to shrink the tubing—apply heat evenly to avoid bubbles or gaps. For outdoor or humid environments, use adhesive-lined heat-shrink tubing for extra moisture protection.
Secure the Cable: Use cable clips or ties to secure the cable to walls, conduits, or cable trays—spacing clips every 50cm for horizontal runs and every 30cm for vertical runs. Avoid over-tightening the clips, as this can compress the insulation and damage the conductor.
After installation, conduct two critical tests to verify performance:
Insulation Resistance Test: Use a 1000V megohmmeter to measure the resistance between the copper conductor and the ground. The reading should be ≥100MΩ—lower values indicate moisture or damage to the insulation.
Ground Resistance Test: Use a four-point ground resistance tester to measure the resistance of the entire grounding system. For commercial buildings and small industrial facilities, the resistance should be ≤4Ω; for heavy industry and renewable energy projects, it should be ≤1Ω. If the resistance is too high, add additional earth rods or apply ground enhancement compound.
Our Green Yellow Insulated Copper Conductor Earthing Cable is certified to meet or exceed the requirements of leading international standards—ensuring compatibility with projects worldwide and compliance with local regulations. Below is an overview of key certifications and standards:
The cable complies with multiple IEC standards, including:
IEC 60228: Specifies requirements for conductors of Insulated Cables. Our copper conductor meets Class 5 (stranded) requirements, ensuring low resistance and high flexibility.
IEC 60245-2: Covers Flexible Cables with PVC insulation and sheathing. Our cable meets the "60245 IEC 53" classification, which mandates flame retardancy, low smoke density, and resistance to moisture.
IEC 60332-1-2: Requires the cable to be flame-retardant, as tested by the vertical flame propagation method.
IEC 60446: Mandates the green-yellow color for earthing conductors—ensuring visual identification across global markets.
EU (CE Marking): The cable bears the CE mark, indicating compliance with the Low Voltage Directive (2014/35/EU) and the RoHS 2.0 Directive (2011/65/EU). This allows it to be sold and used in all 27 EU member states, as well as EFTA countries (e.g., Switzerland, Norway).
North America (UL/CSA): A custom version of the cable is certified to UL 44 (Standard for Rubber-Insulated Wire and Cable) and CSA C22.2 No.245 (Canadian Standard for Flexible Cables). This variant uses a flame-retardant PVC that meets UL 94 V-0 requirements and is suitable for use in the U.S. and Canada.
China (GB Standards): The cable complies with GB 7947 (Color Identification of Wires and Cables) and GB 50169 (Code for Design of Earthing of Electrical Installations)—making it suitable for Chinese projects, including state-owned industrial facilities and renewable energy plants.
RoHS 2.0: The cable is free of 10 restricted substances (e.g., lead, mercury, hexavalent chromium) at levels below 1000ppm—meeting the strictest global environmental regulations.
REACH: It is compliant with the EU REACH Regulation (EC No. 1907/2006), which restricts the use of substances of very high concern (SVHCs). We provide a full REACH declaration upon request, listing all materials used in the cable.
We maintain a strict quality control (QC) system throughout the manufacturing process—from raw material sourcing to final product testing—to ensure every reel of cable meets our high standards. Below is an overview of our QC procedures:
Copper: Every batch of electrolytic copper is tested for purity using a spectrometric analyzer—only batches with ≥99.95% purity are accepted. We also test for mechanical properties (tensile strength, elongation) to ensure the copper can withstand stranding without breaking.
PVC Insulation: We source PVC from certified suppliers and test each batch for flame retardancy (per IEC 60332-1-2), thermal stability (at 100°C for 1000 hours), and RoHS compliance (using a X-ray fluorescence analyzer).
During manufacturing, we conduct real-time tests to catch defects early:
Conductor Stranding: We use a laser diameter gauge to measure the diameter of each copper strand—ensuring consistency. We also check the lay pitch every 100 meters to maintain flexibility.
Insulation Extrusion: A laser thickness gauge monitors the insulation thickness (3.0mm for 35mm², 4.0mm for 120mm²) to ensure it meets specifications. We also check the green-yellow color using a spectrophotometer—ensuring it matches the IEC 60446 standard.
Resistance Testing: Every 100 meters of conductor is tested for DC resistance using a micro-ohmmeter—rejecting any sections with resistance above the IEC 60228 limit.
Before shipping, every reel of cable undergoes a battery of tests:
耐压测试 (Withstand Voltage Test): The cable is subjected to 3000V AC for 5 minutes—no breakdown or leakage indicates 合格 (pass).
Flame Retardancy Test: A sample from each reel is tested per IEC 60332-1-2—only reels that pass the flame propagation requirement are shipped.
Mechanical Test: Samples are bent 180° 500 times (at the minimum bending radius) to ensure the insulation does not crack or the conductor does not break.
Labeling Check: We verify that each reel is labeled with the size, standard, batch number, and manufacturing date—allowing full traceability if issues arise.
Our earthing cable has been trusted by customers across industries to solve their grounding challenges. Below are two real-world examples of how it has delivered value:
A leading renewable energy developer in Germany installed 200 units of 2.5MW wind turbines in a 500MW wind farm. The project required an earthing cable that could withstand high fault currents, resist harsh weather (cold winters, strong winds), and be easy to install in the turbine nacelles (confined spaces).
Challenge: The previous cable used by the developer was a 120mm² solid-copper model, which was difficult to bend in the nacelles—leading to 30% longer installation times and occasional conductor damage. Additionally, it failed to meet the fault current requirement (120kA for 1 second) during testing.
Solution: The developer switched to our 120mm²
Stranded Copper Cable. Its flexible design (61 strands, 15mm lay pitch) allowed installers to route it through the nacelles without damage, cutting installation time by 25%. The cable also passed the 120kA fault current test with no issues.
Result: The wind farm has been operational for 3 years, with zero grounding-related faults. The developer reported a 15% reduction in maintenance costs, as the cable’s UV-resistant insulation has shown no signs of aging—even after exposure to harsh German winters.
A major automotive manufacturer in Shanghai needed to ground 50 units of 50kW robotic welding arms in its assembly plant. The application required a cable that could handle the welding equipment’s high current demands, resist spatter from welding (heat and metal debris), and maintain low resistance to prevent electrical interference (which affects weld quality).
Challenge: The factory’s previous cable was a 35mm²
Aluminum Conductor model, which had high resistance (≥0.8Ω/km) and was prone to corrosion from welding fumes. This led to frequent weld defects and monthly maintenance checks.
Solution: The factory replaced the
Aluminum Cable with our 35mm² copper cable. The high-purity copper conductor (0.529Ω/km resistance) reduced electrical interference, improving weld quality by 40%. The flame-retardant PVC insulation also withstood welding spatter—eliminating the need for protective sleeves.
Result: The factory reduced maintenance checks from monthly to quarterly, saving 20,000 RMB annually. Weld defects dropped by 35%, leading to a 5% increase in production efficiency. The factory has since standardized on our cable for all new welding lines.
In a competitive market for earthing cables, our product stands out for its unique combination of performance, compliance, and flexibility. Below are its key market advantages, along with the customization services we offer to meet specific customer needs:
Superior Conductivity: Compared to aluminum or low-purity Copper Cables, our 99.95% Pure Copper Conductor offers 8-10% lower resistance—ensuring faster fault current diversion and lower energy loss.
Longer Lifespan: The UV-resistant, Flame-Retardant Insulation and corrosion-resistant copper extend the cable’s lifespan to 20-25 years—twice that of generic cables (10-15 years). This reduces replacement costs and downtime for customers.
Global Compatibility: With certifications for IEC, CE, UL, CSA, and GB standards, our cable is suitable for projects in over 100 countries—eliminating the need for customers to source different cables for different regions.
Cost-Effective: While our cable is priced slightly higher than generic models, its longer lifespan and lower maintenance costs result in a 30% lower total cost of ownership over 10 years.
We understand that every project has unique requirements, so we offer a range of customization options:
Length: Standard reels are 100m, 200m, or 500m—but we can produce reels up to 1000m for large-scale projects (e.g., solar farms, industrial campuses).
Insulation Type: In addition to standard PVC, we offer CPE (for Chemical Resistance) and LSOH (low smoke zero halogen) insulation (for enclosed spaces like 地铁 tunnels or hospitals).
Color: While green-yellow is standard, we can produce cables in green, yellow, or black (with green stripes) for customers with unique identification needs—minimum order quantity (MOQ) applies.
Special Coatings: For marine or coastal applications, we offer a tin-plated copper conductor (instead of bare copper) for enhanced corrosion resistance against saltwater.
Our Green Yellow Insulated Copper Conductor Earthing Cable (35mm² & 120mm²) is more than just a cable—it is a comprehensive safety solution engineered to meet the evolving needs of the global electrical industry. By combining high-purity electrolytic copper (for efficient conductivity), flame-retardant green-yellow PVC (for safety and visibility), and a flexible stranded design (for easy installation), it addresses the core challenges of grounding systems: safety, reliability, and compliance.
Whether you are installing a grounding system for a commercial building, a heavy industrial facility, or a large-scale renewable energy project, our cable offers the performance and peace of mind you need. Its compliance with global standards ensures compatibility across markets, while its long lifespan and low maintenance costs deliver long-term value.
We are committed to providing not just a product, but a partnership. Our team of electrical engineers is available 24/7 to provide technical support, and our customization services ensure the cable meets your project’s unique needs. Contact us today to request a sample, get a quote, or discuss how our earthing cable can enhance the safety and efficiency of your electrical system.
English
Español
Portugues
Pусский
Français
العربية
ไทย
Indonesia
Tiếng Việt
Telefon
Posta