Detailed Introduction to 25mm², 50mm², 240mm² Single-Core XLPE Cables
I. From the Perspective of the Product Itself
(1) Specification Parameters
The 25mm², 50mm², and 240mm² single-
Core XLPE cables (0.6/1kV) have both commonalities and differences in specification parameters due to their different cross-sectional areas.
In terms of voltage level, all three cables are 0.6/1kV, which means they can operate stably in low-voltage power systems with a rated voltage of 600V and a maximum voltage of 1000V, meeting the electricity standards for general low-voltage scenarios such as building power distribution and industrial equipment connection.
Conductor parameters are an important sign to distinguish the three. They all use high-purity copper as the conductor, with a purity of more than 99.9% and a conductivity of ≥58MS/m, which makes the loss of electricity during transmission extremely low and can efficiently transmit electrical energy to various electrical equipment. The conductor diameter of the 25mm² cable is about 5.6mm, that of the 50mm² is about 8.0mm, and that of the 240mm² is about 17.4mm. As the cross-sectional area increases, the diameter of the conductor also increases accordingly to meet the demand for larger current-carrying capacity.
Current-carrying capacity is a key parameter to measure the transmission capacity of the cable, and there are significant differences in current-carrying capacity among cables of different specifications. The current-carrying capacity of the 25mm² cable is about 80-100A, which can meet the power demand of small motors, household main lines and other electrical equipment in normal temperature environments; the current-carrying capacity of the 50mm² cable reaches 120-150A, which can provide stable power supply for medium-sized air conditioners, workshop equipment, etc.; the current-carrying capacity of the 240mm² cable is as high as 400-450A, which is sufficient to support the high-power demand of large industrial machinery, substation outgoing lines and other equipment.
The insulation layer parameters are excellent. It uses XLPE (cross-linked polyethylene) material. After warm water cross-linking treatment, its temperature resistance range is extended to -40℃ to 90℃, which enables the cable to maintain stable insulation performance in cold winters, hot summers, and occasions with high temperatures in industrial environments. The insulation resistance is ≥1000MΩ·km, and the breakdown field strength is ≥20kV/mm, which can effectively resist the impact of harsh environments such as humidity and oil pollution, prevent current leakage, and ensure the safety of power transmission.
The sheath layer parameters are also relatively good. The black sheath is made of weather-resistant PVC material, which meets the GB/T 2951.5 standard. Its thickness varies according to the cable specifications. The sheath thickness of the 25mm² cable is about 1.8mm, that of the 50mm² is about 2.0mm, and that of the 240mm² is about 2.4mm. The sheath has the characteristics of UV resistance, acid and alkali resistance, and mechanical wear resistance, and can maintain stable performance in various environments such as outdoor exposure or buried laying.
In terms of
Flexibility parameters, the minimum bending radius of the three cables is only 6 times the outer diameter of the cable. The outer diameter of the 25mm² cable is about 10mm, and the minimum bending radius is about 60mm; the outer diameter of the 50mm² cable is about 14mm, and the minimum bending radius is about 84mm; the outer diameter of the 240mm² cable is about 26mm, and the minimum bending radius is about 156mm. This good flexibility makes it suitable for use in complex laying scenarios such as threading in narrow spaces and beam wrapping.
The 25mm², 50mm², and 240mm² single-core XLPE cables (0.6/1kV) have characteristic uses in different fields due to their respective performance characteristics.
The 25mm² cable has a current-carrying capacity of about 80-100A and is suitable for scenarios such as small motors and household main lines. In household electricity use, it can be used as an incoming line to transmit electricity from the community distribution room to the household distribution box, providing power support for various household appliances such as refrigerators, TVs, and washing machines. For small motors in small processing plants, such as grinders and small fans, the 25mm² cable can also meet their power needs and ensure the normal operation of the equipment. In addition, the power distribution system of small shops also often uses this specification of cable to supply power for lighting, cash register equipment, etc.
The 50mm² cable has a current-carrying capacity of 120-150A and can meet the power supply needs of medium-sized air conditioners, workshop equipment, etc. In the counters of shopping malls, various display lights, small refrigerators, air conditioners and other equipment are concentrated. The 50mm² cable can provide stable power for these equipment to ensure the normal operation of the counters. The main line of the strong electric well in the office building also mostly uses 50mm² cables to distribute electricity to the distribution boxes on each floor, and then distribute it from the distribution boxes to each office to meet the electricity needs of office equipment such as computers, printers, and air conditioners. In some small and medium-sized workshops, the 50mm² cable can also be competent for the power transmission work of medium-power equipment such as lathes and milling machines.
The 240mm² cable has a current-carrying capacity of up to 400-450A and can support high-power demands such as large industrial machinery and substation outgoing lines. In the factory production line, large stamping machines, injection molding machines and other equipment have huge power. The 240mm² cable can be used as the main line for power transmission to ensure the normal operation of these equipment and the continuous production of the production line. The backup
Power Line of the data center is also inseparable from the 240mm² cable. When the main power supply fails, the backup power supply quickly supplies power to the servers, switches and other equipment in the data center through this cable to avoid data loss and business interruption. In the outgoing line part of the substation, it is necessary to convert high-voltage electricity to low-voltage electricity and then transmit it to various power consumption areas. The 240mm² cable can efficiently complete this task by virtue of its large current-carrying capacity.
In addition, the three cables also perform well in outdoor temporary power supply scenarios. During construction, various construction machinery such as tower cranes and concrete mixers need temporary power supply. Due to the limited space of the construction site and the need to move the equipment, the flexibility of the cable is crucial. The single-core design and small bending radius of these three cables enable them to adapt to this complex environment. During exhibition layout, various display equipment and lighting facilities also need temporary power supply. Frequent movement and bending are a test for the performance of the cable, and their characteristics of not being easy to crack after repeated bending can ensure stable power supply during the exhibition.
(3) Material and Style
Material
The material selection of 25mm², 50mm², and 240mm² single-core XLPE cables (0.6/1kV) is closely related to their performance, and each part of the material has its unique role.
The conductor is made of high-purity copper with a purity of more than 99.9%. High-purity copper has excellent conductivity, which is the key to ensuring low loss in power transmission. At the same time, copper has good ductility and toughness. During the production of the cable, it can be drawn into
Copper Wires of different diameters, and it is not easy to break during laying, so it can adapt to various complex installation environments. In addition, copper has good chemical stability and is not easy to be corroded, which can prolong the service life of the cable.
The insulation layer uses XLPE (cross-linked polyethylene) material. After warm water cross-linking treatment, its molecular structure forms a three-dimensional network structure. This structure makes XLPE material have
High Heat Resistance and can maintain stable performance in the temperature range of -40℃ to 90℃. Compared with ordinary polyethylene, the cross-linked XLPE insulation layer has higher mechanical strength, better impact resistance and wear resistance, and can effectively resist damage from the external environment. At the same time, its excellent insulation performance ensures that no leakage occurs during power transmission, ensuring electrical safety.
The sheath layer is made of weather-resistant PVC material, which meets the GB/T 2951.5 standard. PVC material has good chemical corrosion resistance and can resist the erosion of acids, alkalis, oils and other substances, making it suitable for use in various complex chemical environments. Its UV resistance makes the cable not age quickly due to sunlight when exposed outdoors, prolonging the service life of the cable. In addition, the
PVC Sheath also has good mechanical strength and wear resistance, which can protect the internal conductor and insulation layer of the cable from mechanical damage.
Style
The three cables are consistent in style and also show certain characteristics.
Overall, they all have a single-core design and are in the shape of a cylindrical long strip. The single-core design reduces the 束缚 of
Multi-Core stranding, making the cable softer and more flexible, more convenient in bending and moving, and especially suitable for use in narrow spaces and scenarios that require frequent movement.
In terms of color, all three cables adopt black sheaths. Black has good dirt resistance, is not easy to show dirt during use, and reduces the trouble of cleaning. At the same time, black has good concealment in the outdoor environment, can blend with the surrounding environment, and reduce visual abruptness. In addition, the black sheath can also absorb more heat, which helps the cable to dissipate heat to a certain extent.
The surface of the cable is printed with clear marks, including model, specification, voltage level, manufacturer, production date and other information. These marks not only facilitate users to identify the basic parameters of the cable during procurement and use, but also facilitate later maintenance and management. The printing of the marks uses wear-resistant ink to ensure that it will not fall off easily during long-term use.
(4) Production Process
The production process of 25mm², 50mm², and 240mm² single-core XLPE cables (0.6/1kV) is rigorous and complex, ensuring the quality and performance of the products.
Conductor Production: First, high-purity copper raw materials are selected, and impurities are removed through smelting to improve the purity of copper. Then, the copper liquid is made into copper rods through a continuous casting process, and the diameter of the copper rods depends on the specifications of the cable. Next, the copper rod is drawn into a copper wire of the required diameter by using a wire drawing equipment. During the wire drawing process, it is necessary to control the drawing speed and tension to ensure the quality of the copper wire. Finally, multiple copper wires are twisted together according to certain rules to form a conductor. The twisting process can enhance the flexibility and mechanical strength of the conductor.
Insulation Layer Extrusion: The produced conductor is cleaned and dried to remove oil and moisture on the surface to ensure a tight bond between the insulation layer and the conductor. Subsequently, the XLPE material is added to the extruder and heated to melt it. The molten XLPE material is evenly wrapped around the conductor through an extrusion die to form an insulation layer. During the extrusion process, it is necessary to accurately control the temperature, pressure and speed of the extruder to ensure that the insulation layer has a uniform thickness and a smooth surface. After extrusion, the cable is subjected to warm water cross-linking treatment. The cable is put into warm water, and under specific temperature and time conditions, the XLPE molecules undergo a cross-linking reaction to form a three-dimensional network structure, thereby improving the performance of the insulation layer.
Sheath Extrusion: The cable core after insulation layer treatment needs to be cleaned and dried again. Then, the PVC material is added to another extruder and heated to melt. The molten PVC material is wrapped around the insulation layer through an extrusion die to form a sheath. During the extrusion process, parameters such as temperature, pressure and speed also need to be controlled to ensure that the sheath has a uniform thickness, a flat surface, and is closely combined with the insulation layer. For cables of different specifications, the corresponding extrusion dies need to be replaced to ensure that the size of the sheath meets the requirements.
Cooling and Solidification: The cable after sheath extrusion needs to be cooled through a cooling water tank to make the sheath solidify and form quickly. During the cooling process, it is necessary to control the change of water temperature to avoid cracks and other defects in the sheath due to too fast cooling speed.
Mark Printing: The cooled cable passes through printing equipment, and marks such as model, specification, voltage level, and manufacturer are printed on the surface of the sheath. During the printing process, it is necessary to ensure that the marks are clear and firm.
Finished Product Inspection: The produced cables need to undergo strict inspection. Inspection items include the DC resistance of the conductor, the insulation resistance and breakdown field strength of the insulation layer, the thickness and mechanical properties of the sheath, the appearance quality of the cable, etc. For cables of different specifications, parameters such as their current-carrying capacity should also be tested separately. Only cables that pass all inspection items can leave the factory for sale.
Wire Take-up and Packaging: The qualified cables after inspection are wound on the cable reel by the wire take-up equipment, and a suitable cable reel is selected according to the length and specification of the cable. During the winding process, it is necessary to ensure that the cables are arranged neatly to avoid twisting and knotting. Finally, the cable reel is packaged to protect the cable from damage during transportation and storage.
II. From the Perspective of General Product Information
(1) Packaging
To ensure that 25mm², 50mm², and 240mm² single-core XLPE cables (0.6/1kV) are not damaged during transportation and storage, their packaging methods are carefully designed.
Different packaging methods are adopted for cables of different lengths and specifications. Short-length cables (such as less than 100 meters) are usually packaged in reels, which are made of cardboard or plastic, light and easy to carry. The cable is neatly wound on the reel and wrapped with plastic film to prevent the cable from being eroded by dust and moisture. Both ends of the reel are provided with baffles to prevent the cable from slipping during transportation.
For long-length cables (such as more than 100 meters), cable reels are used for packaging. There are two types of cable reels: wooden and iron. Wooden cable reels have low cost and light weight, and are suitable for short-distance transportation and packaging of small batches of cables; iron cable reels have high strength and large load-bearing capacity, and are suitable for long-distance transportation and packaging of large batches of cables, which can better protect the cables from extrusion and collision.
In the packaging process, the cable is tightly wound on the cable reel. During the winding process, it is necessary to control the tension to ensure that the cable is arranged neatly and avoid twisting and knotting. After winding, a layer of plastic film is wrapped around the outer layer of the cable. The plastic film has good moisture-proof and dust-proof performance, which can protect the surface of the cable from pollution. For cables that need to be stored for a long time, a layer of linen or canvas is wrapped around the outer layer of the plastic film to enhance the protective effect and prevent the cable from direct sunlight, rain soaking and mechanical damage.
Detailed labels are fixed on the cable reels or reels, indicating the model, specification, length, voltage level, manufacturer, production date, implementation standard and other information of the cable, which is convenient for users to identify and check during receipt and storage.
(2) Transportation
The transportation of 25mm², 50mm², and 240mm² single-core XLPE cables (0.6/1kV) needs to follow certain norms and requirements to ensure the quality and safety of the cables.
The choice of transportation mode depends on the transportation distance, quantity and customer requirements. Short-distance transportation (such as in the city or surrounding areas) generally uses truck transportation. Truck transportation has high flexibility and can directly deliver the cables to the customer's designated location, which is suitable for small batches and emergency transportation needs. For long-distance transportation (such as across provinces and cities), railway transportation or long-distance road transportation can be chosen. Railway transportation has the advantages of large capacity, fast speed and good stability, and is suitable for the transportation of large quantities of cables; long-distance road transportation can realize door-to-door service, with strong flexibility, but the transportation cost is relatively high.
During transportation, the following points should be noted: First, when loading cables, the cable reels or reels should be placed stably on the transport tool to avoid tilting and collision. For iron cable reels, steel wire ropes or chains can be used to fix them on the transport vehicle to prevent movement during transportation; for wooden cable reels and reels, ropes can be used for fixing. Second, the cable should avoid direct sunlight and rain soaking during transportation. If necessary, a tarpaulin can be used for covering. Direct sunlight will cause aging of the cable sheath, and rain soaking may affect the insulation performance of the cable. Third, during transportation, the cable should be avoided from severe vibration and impact to prevent damage to the insulation layer and sheath of the cable. On roads with poor conditions, it is necessary to drive slowly to reduce the impact of vibration on the cable. Finally, transport personnel should be familiar with the characteristics and transportation requirements of the cable, regularly check the fixing of the cable and the integrity of the packaging, and deal with problems in a timely manner.
(3) Delivery
The delivery process of 25mm², 50mm², and 240mm² single-core XLPE cables (0.6/1kV) is standardized and systematic to ensure customers receive qualified products on time.
Order Confirmation: Once a customer places an order, the sales team verifies details within 24 hours, including cable specifications, quantity, delivery date, and destination. A formal order confirmation is sent to the customer, outlining terms such as payment conditions and quality guarantees, ensuring mutual understanding.
Inventory Check & Production Scheduling: The warehouse team checks stock levels for the ordered specifications. If in stock, cables are reserved immediately. For out-of-stock items, the production department schedules manufacturing based on the order priority, aligning with the confirmed delivery timeline.
Pre-Delivery Inspection: Before dispatch, quality inspectors conduct random sampling tests on the cables. Key checks include conductor resistance (ensuring compliance with IEC 60228), insulation integrity (using a 5kV megohmmeter for resistance ≥1000MΩ), and sheath thickness (verified with a micrometer). Only cables passing all tests proceed to packaging.
Packaging & Labeling: Cables are packaged according to their length—short reels for ≤100m and iron/wooden drums for longer lengths. Each package is labeled with the customer’s name, order number, cable type (e.g., 25mm² XLPE), and safety symbols (e.g., “Handle With Care”).
Logistics Coordination: The logistics team selects carriers based on delivery urgency and distance. For urgent orders, express couriers (e.g., DHL, FedEx) are used, while bulk shipments rely on freight forwarders for cost efficiency. A detailed packing list is shared with the carrier and customer, facilitating smooth customs clearance if applicable.
Dispatch Notification: Upon shipment, the customer receives a dispatch email with the tracking number, estimated arrival date, and contact details of the logistics provider. The sales team monitors the shipment until delivery, addressing any delays proactively.
(4) Samples
To assist customers in evaluating product suitability, the company offers sample services for 25mm², 50mm², and 240mm² single-core XLPE cables:
Sample Request Process: Customers can request samples via the company website, email, or phone, specifying the desired 规格 (e.g., 50mm²) and quantity (typically 1–5 meters). The sales team confirms the request within 48 hours, including details on sample fees and delivery time.
Sample Preparation: Samples are manufactured using the same production line as bulk orders to ensure consistency. Each sample includes a test report certifying key parameters, such as current-carrying capacity (e.g., 120A for 50mm² at 30°C ambient temperature) and flame retardancy (if applicable).
Delivery & Cost: Samples are shipped via express mail, with delivery times ranging from 3–7 days depending on the destination. Sample costs (including production and shipping) are refundable if the customer places a bulk order within 3 months, encouraging long-term partnerships.
Feedback Collection: After delivery, the sales team follows up to gather customer feedback on sample performance, such as flexibility during bending tests or compatibility with their installation tools. This input is shared with the R&D team to refine product design if needed.
(5) After-Sales Service
The company provides comprehensive after-sales support to ensure customer satisfaction:
Warranty Coverage: All cables come with a 10-year warranty against manufacturing defects. If a cable fails due to material or 工艺 issues (e.g., insulation breakdown under normal operating conditions), the company offers free replacement or repair within 7 days of receiving the fault report.
Technical Assistance: A dedicated technical hotline (available 24/7) provides guidance on installation, such as recommended bending radii (6× cable diameter) and termination methods using heat-shrinkable sleeves. For large projects, on-site technical teams can assist with installation supervision upon request.
Complaint Handling: Any customer complaints are logged in a tracking system, with a response within 4 hours. For urgent issues (e.g., cable damage during transit), a replacement is dispatched immediately, and the company coordinates with the logistics provider to resolve liability.
Maintenance Guidelines: Customers receive a digital manual outlining maintenance best practices, such as periodic insulation checks (annually using a megohmmeter) and protection against rodent damage in underground installations. The company also offers optional annual inspection services for critical infrastructure projects.
Product Updates: Customers on the mailing list receive notifications about product upgrades, such as enhanced UV-resistant sheaths or higher temperature-rated XLPE insulation, ensuring they stay informed about advancements that may benefit their operations.
This end-to-end service framework—from product design to post-purchase support—reinforces the reliability of 25mm², 50mm², and 240mm² single-core XLPE cables, making them a trusted choice for low-voltage power distribution worldwide.
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