Detailed Information on 4X50mm² Low Voltage XLPE PVC Insulated Copper Power Cable
1. Specification Parameters
The 4X50mm² low voltage XLPE PVC insulated
Copper Power Cable is engineered with precise specifications to ensure reliable performance in low-voltage distribution systems. These parameters are critical to its functionality, safety, and compatibility with various applications.
Conductor Specifications: The cable comprises 4 individual
Copper Conductors, each with a cross-sectional area of 50mm². The copper used is of high purity (minimum 99.95%), ensuring excellent electrical conductivity. Each conductor is stranded, consisting of 37 strands of 1.3mm diameter
Copper Wires. This stranding design enhances
Flexibility, allowing the cable to be bent and maneuvered more easily during installation, especially in confined spaces. The conductor resistance at 20°C is ≤0.383Ω/km, which is well within the limits specified by international standards, ensuring minimal energy loss during power transmission.
Insulation Parameters: Each copper conductor is insulated with cross-linked polyethylene (XLPE). The insulation thickness is 1.0mm, providing effective electrical isolation. XLPE insulation has a dielectric strength of ≥20kV/mm, ensuring that it can withstand the voltage stresses encountered in low-voltage applications. The insulation resistance of the XLPE layer exceeds 1000MΩ·km at 20°C, preventing leakage current and ensuring safe operation. Additionally, the XLPE insulation is resistant to water treeing, a common issue in humid environments that can degrade insulation performance over time.
Sheath Parameters: The outer sheath is made of polyvinyl chloride (PVC), with a thickness of 1.8mm. This
PVC Sheath has a tensile strength of ≥12MPa and an elongation at break of ≥150%, making it tough and resistant to mechanical damage. It is also resistant to a wide range of chemicals, including acids, alkalis, and oils, which helps protect the internal components of the cable in various environments. The PVC sheath is UV-stabilized, providing some degree of protection against ultraviolet radiation when used in outdoor applications.
Voltage Rating: The cable is rated for 0.6/1kV, where 0.6kV is the phase-to-earth voltage and 1kV is the phase-to-phase voltage. This rating makes it suitable for use in low-voltage distribution systems, including residential, commercial, and industrial applications. It can operate at frequencies of 50Hz or 60Hz, ensuring compatibility with different power grids around the world.
Current-Carrying Capacity: The current-carrying capacity (ampacity) of the cable varies depending on the installation method. When installed in air (at an ambient temperature of 30°C), the ampacity is approximately 165A. When directly buried in soil (at an ambient temperature of 25°C), the ampacity is around 145A. These values are sufficient to meet the power demands of medium-sized equipment and facilities, ensuring that the cable does not overheat under normal operating conditions.
Temperature Ratings: The XLPE insulation allows the cable to operate at a maximum continuous temperature of 90°C. In the event of a short circuit (lasting up to 5 seconds), the cable can withstand temperatures up to 250°C without suffering permanent damage. The PVC sheath has a maximum operating temperature of 70°C, which is well within the range of typical operating conditions for the cable.
Mechanical Parameters: The minimum bending radius for fixed installation is 12 times the outer diameter of the cable, while for dynamic installation (where the cable may be subject to movement), it is 20 times the outer diameter. This flexibility allows for easier installation in various settings. The cable has a maximum pulling tension of 15kN, which is sufficient to withstand the forces encountered during installation.
2. Characteristic Uses
The 4X50mm² low voltage XLPE PVC insulated copper power cable is versatile and finds application in a wide range of low-voltage distribution scenarios, thanks to its unique combination of properties.
Industrial Applications: In industrial plants, this cable is commonly used to connect medium-sized motors, production lines, and distribution control cabinets. The high current-carrying capacity and robust construction make it suitable for powering machinery and equipment that require a reliable power supply. For example, in a manufacturing facility, it can be used to supply power to conveyor belts, pumps, and processing machines. The XLPE insulation's ability to withstand high temperatures ensures that the cable can operate safely even in the warm environments often found in industrial settings.
Commercial Buildings: Commercial buildings such as shopping malls, hotels, and office complexes rely on this cable for their electrical distribution needs. It is used in the main
Power Lines for 中央空调 systems, elevators, and lighting. The
Multi-Core design is particularly advantageous in these settings, as it allows for the transmission of both phase and neutral conductors in a single cable, simplifying installation and reducing the amount of space required. The PVC sheath's resistance to mechanical damage makes it suitable for installation in areas with high foot traffic or where the cable may be exposed to occasional impacts.
Residential Communities: In residential areas, the cable is used as a distribution trunk line, connecting the main transformer to the distribution cabinets in individual buildings. It can handle the power demands of multiple households, supplying electricity to appliances, lighting, and heating systems. The cable's flexibility makes it easy to install in the confined spaces of residential buildings, such as in walls, ceilings, and under floors. Additionally, the XLPE insulation's resistance to water treeing ensures that it can operate reliably in the humid environments often found in residential basements and crawl spaces.
Municipal Engineering: Municipal projects such as street lighting systems, traffic signal facilities, and small pumping stations also utilize this cable. Its ability to be installed in both indoor and outdoor environments, along with its resistance to UV radiation and chemical corrosion, makes it suitable for these applications. For example, in street lighting, the cable can be buried underground or installed on poles, providing a reliable power supply to the lights. In traffic signal systems, it ensures that the signals receive a consistent power supply, contributing to road safety.
Temporary Power Supplies: The cable is also useful for providing temporary power in construction sites and outdoor events. Its flexibility and durability make it easy to deploy and retrieve, and its high current-carrying capacity can meet the power needs of temporary facilities such as construction trailers, lighting, and power tools.
3. Material and Style
The materials used in the 4X50mm² low voltage XLPE PVC insulated copper power cable are carefully selected to ensure optimal performance, durability, and safety. The cable's style is designed to facilitate easy installation and integration into various electrical systems.
Conductor Material: The conductors are made of high-purity electrolytic copper. Copper is chosen for its excellent electrical conductivity, which minimizes energy loss during power transmission. It also has good thermal conductivity, allowing heat generated during operation to be dissipated efficiently, reducing the risk of overheating. The copper is annealed, which softens the material and increases its flexibility, making the conductors easier to strand and the cable easier to install.
Insulation Material: The insulation layer is made of cross-linked polyethylene (XLPE). XLPE is a thermosetting polymer that is created by cross-linking polyethylene molecules, which gives it superior properties compared to traditional polyethylene. It has excellent thermal stability, allowing it to operate at higher temperatures without melting or degrading. XLPE also has good
Chemical Resistance, making it resistant to attack from oils, solvents, and other chemicals. Additionally, it is resistant to water absorption, which helps maintain its insulation properties in humid environments.
Sheath Material: The outer sheath is made of polyvinyl chloride (PVC). PVC is a thermoplastic polymer that is known for its durability, flexibility, and chemical resistance. It provides a tough outer layer that protects the internal components of the cable from mechanical damage, moisture, and UV radiation. The PVC used in the sheath is formulated to be flame-retardant, which helps prevent the spread of fire in the event of a cable fault.
Cable Style: The cable has a round, compact design, with the 4
Insulated Conductors twisted together to form a
Single Core. This twisted design helps to reduce electromagnetic interference (EMI) and crosstalk between the conductors. The overall diameter of the cable is approximately 22mm, which makes it easy to handle and install in various conduit sizes and spaces. The cable is typically black in color, which helps it blend into outdoor environments and provides some degree of UV protection.
4. Production Process
The production of the 4X50mm² low voltage XLPE PVC insulated copper power cable involves several stages, each of which is carefully controlled to ensure the quality and reliability of the final product.
Conductor Stranding: The first step in the production process is the stranding of the
Copper Conductors. High-purity copper rods are drawn through a series of dies to reduce their diameter to 1.3mm, forming individual copper wires. These wires are then stranded together using a planetary stranding machine. The machine twists the wires at a controlled pitch, ensuring that they are evenly distributed and form a tight, uniform conductor. The stranding process enhances the flexibility of the conductor and improves its ability to withstand bending and flexing during installation.
Insulation Extrusion: After stranding, each copper conductor is insulated with XLPE. The insulation extrusion process involves feeding the conductor into an extruder, where molten XLPE is applied around the conductor. The extruder is equipped with a die that controls the thickness and shape of the insulation layer. The temperature of the extruder is carefully controlled to ensure that the XLPE is properly melted and applied evenly. After extrusion, the insulated conductor passes through a cooling water bath to solidify the XLPE. The XLPE is then cross-linked using either a chemical process (with peroxide initiators) or radiation (using electron beams), which transforms it into a thermosetting material with enhanced properties.
Cabling: Once the individual conductors are insulated, they are twisted together to form the
Multi-Core Cable. This is done using a cabling machine, which twists the 4 insulated conductors at a controlled lay length. The lay length is typically between 16 and 20 times the diameter of the cable, which helps to ensure the stability of the cable structure and reduce EMI. During cabling, a filler material (usually a polypropylene rope) may be added to fill the gaps between the conductors, ensuring a round and
Compact Cable core.
Sheath Extrusion: The cabled core is then passed through another extruder to apply the PVC sheath. The PVC is melted in the extruder and applied around the cabled core, forming a continuous outer layer. The thickness of the sheath is controlled by the extruder die, ensuring that it meets the specified requirements. After extrusion, the sheath is cooled in a water bath to solidify it. The cooling process is carefully controlled to prevent the formation of cracks or other defects in the sheath.
Quality Control Testing: Throughout the production process, various quality control tests are performed to ensure that the cable meets the required standards. These tests include:
Only cables that pass all these tests are approved for release.
5. Packaging
The packaging of the 4X50mm² low voltage XLPE PVC insulated copper power cable is designed to protect the cable during storage, transportation, and handling, ensuring that it arrives at the installation site in good condition.
Reel Packaging: The cable is typically wound onto wooden or steel reels for large-length deliveries. The reels are designed to accommodate the cable's length and weight, with flanges to prevent the cable from slipping off during transportation. The size of the reel depends on the length of the cable; for example, a 500m length of cable is usually wound onto a reel with a diameter of 1200mm and a width of 600mm. The cable is secured to the reel with steel strapping to prevent it from unwinding during handling.
Protective Wrapping: The cable on the reel is wrapped with a layer of moisture-resistant plastic film to protect it from dust, dirt, and moisture. This wrapping also helps to prevent damage to the cable's sheath during transportation and storage. For long-term storage, additional protective measures may be taken, such as wrapping the reel in a heavy-duty tarpaulin.
Labeling: Each reel is labeled with detailed information about the cable, including:
Compliance marks, indicating that the cable meets relevant international standards (such as IEC, CE, or UL).
Small-Length Packaging: For smaller lengths of cable (such as 50m or 100m), the cable may be packaged in coils and placed in cardboard boxes. The boxes are labeled with the same information as the reels, and the coils are wrapped in plastic to protect them from damage.
6. Transportation
The transportation of the 4X50mm² low voltage XLPE PVC insulated copper power cable requires careful planning and handling to ensure that the cable is not damaged during transit.
Mode of Transportation: The choice of transportation mode depends on the distance, quantity, and urgency of the delivery. For short distances, road transportation is typically used, with the cable reels loaded onto trucks. For longer distances, rail or sea transportation may be more cost-effective. Air transportation is used for urgent deliveries, although it is more expensive.
Loading and Unloading: When loading and unloading the cable reels, proper equipment and techniques are used to prevent damage. Forklifts or cranes with appropriate lifting attachments are used to move the reels. The reels are lifted from the center to avoid putting stress on the flanges, and they are secured to the transport vehicle to prevent movement during transit.
Environmental Protection: During transportation, the cable reels are protected from extreme weather conditions. For example, they may be covered with tarpaulins to protect them from rain, snow, and direct sunlight. In hot climates, measures may be taken to prevent the cable from overheating, such as avoiding exposure to direct sunlight for extended periods.
Handling Instructions: The transport vehicle and handling personnel are provided with clear instructions on how to handle the cable reels. This includes information on the maximum stacking height, the proper lifting points, and the need to avoid dropping or impacting the reels.
7. Delivery
The delivery process of the 4X50mm² low voltage XLPE PVC insulated copper power cable is designed to ensure that the cable is delivered to the customer on time and in good condition.
Order Processing: When a customer places an order, the manufacturer processes the order promptly, checking the availability of the cable and scheduling production if necessary. The customer is provided with an estimated delivery date, which is based on the order quantity and the manufacturer's production schedule.
Delivery Scheduling: The manufacturer coordinates with the customer to schedule the delivery at a time that is convenient for them. This may involve delivering the cable to a construction site, a warehouse, or another specified location. The customer is notified in advance of the delivery, allowing them to make arrangements to receive the cable.
Delivery Inspection: Upon delivery, the customer is given the opportunity to inspect the cable reels for any damage. The customer checks the packaging, the labels, and the cable itself to ensure that it matches the order and is in good condition. Any issues or discrepancies are noted and addressed promptly.
Documentation: Along with the cable, the customer receives a set of documentation, including:
8. Samples
The manufacturer provides samples of the 4X50mm² low voltage XLPE PVC insulated copper power cable to customers who wish to evaluate the product before placing a large order.
Sample Availability: Samples are typically available in lengths of 1-5 meters. They are provided free of charge, although the customer may be responsible for shipping costs. The samples are representative of the full-length cable, allowing the customer to inspect the quality of the materials, the construction, and the overall appearance.
Sample Request Process: Customers can request samples by contacting the manufacturer's sales department. The request includes information such as the desired sample length and the intended application. The manufacturer processes the request and ships the samples promptly.
Sample Testing: Customers can perform various tests on the samples to evaluate their performance. This may include checking the conductor resistance, the insulation resistance, and the mechanical properties of the sheath. The samples can also be visually inspected to assess the quality of the insulation and the sheath.
9. After-Sales Service
The manufacturer provides comprehensive after-sales service to ensure customer satisfaction and to address any issues that may arise with the 4X50mm² low voltage XLPE PVC insulated copper power cable.
Technical Support: A team of technical experts is available to provide support and advice to customers. This includes answering questions about the cable's installation, operation, and maintenance. The technical support team can also provide guidance on troubleshooting any problems that may occur.
Warranty: The cable is covered by a warranty, which typically lasts for 12-24 months from the date of delivery. The warranty covers defects in materials and workmanship, ensuring that the customer receives a high-quality product. If a defect is found during the warranty period, the manufacturer will replace or repair the cable free of charge.
Repair and Replacement: In the event that the cable is damaged or fails outside the warranty period, the manufacturer may offer repair or replacement services. The cost of these services depends on the extent of the damage and the age of the cable.
Feedback and Continuous Improvement: The manufacturer values customer feedback and uses it to continuously improve the product and the service. Customers are encouraged to provide feedback on their experience with the cable, including any issues or suggestions for improvement. This feedback is reviewed by the manufacturing and engineering teams to identify areas for enhancement, ensuring that future iterations of the cable meet evolving customer needs and industry standards.
Training and Education: To assist customers in maximizing the performance and lifespan of the cable, the manufacturer offers training sessions and educational materials. These may include workshops on proper installation techniques, maintenance best practices, and safety guidelines. The training is designed for electricians, contractors, and facility managers, equipping them with the knowledge to handle the cable correctly and avoid common installation errors that could compromise its performance.
Emergency Support: In cases of urgent issues, such as unexpected cable failures that disrupt power supply, the manufacturer provides emergency support. A dedicated hotline is available 24/7 to address urgent queries, and technical teams can be dispatched to the site if necessary to assess the problem and recommend solutions. This rapid response helps minimize downtime and ensures that power is restored as quickly as possible.
In summary, the 4X50mm² low voltage XLPE PVC insulated copper power cable is a high-quality, versatile solution for low-voltage distribution systems. Its precise specification parameters, durable materials, and advanced production process ensure reliable performance in a wide range of applications, from industrial plants to residential communities. The comprehensive packaging, transportation, and delivery processes protect the cable during transit, while the availability of samples allows customers to evaluate the product before purchase. The manufacturer’s commitment to after-sales service, including technical support, warranty coverage, and continuous improvement, ensures that customers receive ongoing assistance and can rely on the cable for long-term, safe operation. Whether used in permanent installations or temporary power supplies, this cable stands out for its combination of efficiency, durability, and adaptability, making it a trusted choice for electrical professionals worldwide.
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