U-1000 Arvfv 4-Core Aluminum Cable (10-35mm²) with XLPE Insulation, Aluminum Armoring & PVC Sheath for Power Stations

Material and Purity: The conductor is made of high-purity aluminum with a purity of ≥99.5%. High-purity aluminum can reduce the impact of impurities on conductivity, ensure smooth current transmission, and reduce energy loss.

Structure and Process: It is made into a 4-core structure through the compact stranding process. This process makes the structure of the conductor more compact, reduces the gaps inside the conductor, improves the filling factor, and thus enhances the conductivity. At the same time, compact stranding can also improve the Flexibility and mechanical strength of the conductor.

Cross-Section Specifications and Resistance: The cross-sectional specifications cover 10mm², 16mm², 25mm², and 35mm². Conductors of different cross-sections have different DC resistances at 20℃. The DC resistance of 10mm² conductor is ≤1.83Ω/km, 16mm² conductor is ≤1.15Ω/km, 25mm² conductor is ≤0.727Ω/km, and 35mm² conductor is ≤0.524Ω/km. The low resistance value ensures less energy loss during power transmission and improves the efficiency of power transmission.

Bending Radius: The minimum bending radius is 8 times the outer diameter of the cable. This characteristic allows the cable to be flexibly laid in the complex spatial layout of the power station, whether in narrow passages or corners, facilitating installation and reducing construction difficulty.

Material and Temperature Resistance: The insulation layer is made of cross-linked polyethylene (XLPE) material, which can withstand a temperature of up to 90℃. This enables the cable to maintain stable insulation performance in the high-temperature environment that may occur in power stations, without insulation aging or failure due to excessive temperature.

Volume Resistivity: The volume resistivity is ≥1×10¹⁴Ω·cm. The high volume resistivity indicates that it has excellent insulation performance, which can effectively prevent current leakage and ensure the safety of power transmission.

Temperature Adaptability: Under the ambient temperature difference of -40℃ to 90℃, the insulation layer can maintain stable performance without hardening, cracking, or other phenomena. This enables the cable to adapt to temperature changes in different areas of the power station, and can work reliably whether in cold winters or high-temperature environments generated by equipment operation.

Thickness and Eccentricity: The insulation layer has a uniform thickness. The thickness of the insulation layer of cables with different cross-sectional specifications varies. The insulation layer thickness of 10mm² cable is about 1.4mm, 16mm² is about 1.6mm, 25mm² is about 1.8mm, and 35mm² is about 2.0mm. The eccentricity is ≤15%, ensuring that the insulation layer is evenly distributed around the conductor and avoiding insulation hidden dangers caused by local thin insulation.

Partial Discharge Quantity: The partial discharge quantity is ≤10pC. A small partial discharge quantity indicates that the insulation layer is of good quality, reducing insulation aging caused by partial discharge and prolonging the service life of the cable.

Material and Thickness: The armoring layer is made of aluminum material, with a thickness ranging from 0.5mm to 0.8mm depending on the cross-sectional specification. The armoring layer thickness of 10mm² and 16mm² cables is about 0.5mm, and that of 25mm² and 35mm² is about 0.8mm. Aluminum armoring has good mechanical properties and can provide effective mechanical protection for the cable.

Protective Effect: It can resist external mechanical damages such as collision and extrusion, and avoid damage to the internal conductor and insulation layer due to external forces during cable laying and use. At the same time, aluminum material has certain corrosion resistance, which can adapt to the possibly humid environment in the power station and prolong the service life of the cable.

Material and Thickness: The outer sheath is made of polyvinyl chloride (PVC) material, with a thickness of 1.8-2.5mm. The outer sheath thickness of 10mm² and 16mm² cables is about 1.8mm, and that of 25mm² and 35mm² is about 2.5mm.

Performance: It has good acid and alkali resistance and UV resistance. In the power station environment, it may come into contact with some acid and alkali substances, and the PVC outer sheath can resist the erosion of these substances; at the same time, for areas exposed to the outdoors or with UV irradiation, the UV resistance can prevent sheath aging and protect the internal structure of the cable from erosion by the external environment.

Laid in air: The current-carrying capacity of 10mm² cable is about 55A, 16mm² is about 70A, 25mm² is about 90A, and 35mm² is about 110A.

Laid underground: The current-carrying capacity of 10mm² is about 45A, 16mm² is about 58A, 25mm² is about 75A, and 35mm² is about 90A.

Raw material selection: High-purity aluminum ingots with a purity of ≥99.5% are selected to ensure that the quality of raw materials meets the requirements. Strict inspections are carried out on aluminum ingots, including chemical composition analysis, and only qualified aluminum ingots can be used for production.

Wire drawing: The aluminum ingot is drawn into Aluminum Wires of the required diameter through a wire drawing machine. During the wire drawing process, the wire drawing speed and die size are controlled to ensure that the diameter of the Aluminum Wire is uniform, the surface is smooth, and there are no scratches, cracks and other defects.

Compact stranding: Multiple aluminum wires are stranded through a compact stranding machine to form a 4-core structure. During the stranding process, the stranding pitch and pressure are precisely controlled to make the conductor structure compact and improve the filling factor. At the same time, ensure that the 4-core conductors are arranged uniformly with good consistency.

Annealing treatment: The Stranded Conductor is annealed, heated to a certain temperature, kept warm for a period of time, and then slowly cooled to eliminate internal stress in the conductor and improve the flexibility and conductivity of the conductor.

Material preparation: High-quality XLPE Insulation Materials are selected, and strict inspections are carried out on the materials to ensure that their performance meets the standards. Before extrusion, the XLPE material is dried to remove moisture in the material to avoid bubbles in the insulation layer.

Extrusion molding: An extruder is used to extrude and coat the XLPE material on the outer layer of the conductor to form an insulation layer. According to different cross-sectional specifications, the parameters of the extruder, such as temperature, speed and pressure, are adjusted to ensure that the thickness of the insulation layer is uniform and meets the design requirements. During the extrusion process, the quality of the insulation layer is monitored in real-time to ensure that the surface is smooth and free of bubbles, cracks and other defects.

Cross-linking treatment: The extruded Insulated Wire core enters the cross-linking pipe for cross-linking treatment. By controlling the temperature, pressure and time, the XLPE material forms a stable three-dimensional network structure, thereby improving its temperature resistance and insulation performance.

Material selection: High-quality aluminum strips are selected as armoring layer materials, and the thickness, width and mechanical properties of the aluminum strips are inspected to ensure they meet the requirements.

Armoring forming: The aluminum strip is armored on the outer layer of the insulated wire core through an armoring machine. During the armoring process, the tension and winding angle of the aluminum strip are controlled to make the armoring layer tightly wrap around the insulated wire core, ensuring the uniformity and firmness of the armoring layer. At the same time, avoid damage to the insulation layer during the armoring process.

Material preparation: PVC materials that meet the requirements are selected, and formula adjustment and mixing are carried out to ensure stable performance of the materials. Inspections are carried out on PVC materials, including acid and alkali resistance, UV resistance, etc.

Extrusion molding: The PVC material is heated and plasticized in an extruder, then extruded and coated on the outer layer of the armoring layer to form an outer sheath. Parameters such as extrusion temperature, speed and pressure are controlled to make the thickness of the outer sheath uniform, closely combined with the armoring layer, with a smooth surface and no bubbles, cracks and other defects.

Raw material inspection: Strict inspections are carried out on aluminum ingots, XLPE Insulation Materials, aluminum strips, PVC outer sheath materials and other raw materials. Only qualified raw materials can enter the production process.

In-process inspection: Quality control points are set in each production link such as conductor manufacturing, insulation layer extrusion, armoring layer processing, and outer sheath extrusion to inspect semi-finished products. For example, inspect the diameter and DC resistance of the conductor, the thickness and eccentricity of the insulation layer, the firmness of the armoring layer, the thickness and surface quality of the outer sheath, etc., to ensure that the product quality of each link meets the requirements.

Finished product inspection: Finished cables need to pass a number of strict tests, including power frequency withstand voltage test (3kV/5min without breakdown), insulation resistance test, partial discharge test, mechanical performance test (such as tensile strength, elongation at break), temperature resistance test, corrosion resistance test, etc. A certain number of samples are taken from each batch of products for comprehensive testing, and only products with all indicators qualified can leave the factory.

Quality traceability: A sound quality traceability system is established to record information such as the source of raw materials, parameters during production, and test results, so that when quality problems occur, they can be traced in a timely manner, the causes can be found, and improvement measures can be taken.

Cable reels: Cables are usually wound on sturdy steel or wooden cable reels. Steel cable reels have high strength and high load-bearing capacity, suitable for cables with large weight and long length; wooden cable reels have low cost, suitable for cables with relatively light weight. The size of the cable reel is determined according to the length and cross-sectional specification of the cable to ensure that the cable can be neatly and tightly wound on it.

Protective materials: A moisture-proof and wear-resistant plastic film is wrapped around the outer layer of the cable. The plastic film can effectively prevent the cable from getting damp and being slightly worn. For cables transported over long distances or exported, a layer of linen or woven bag is wrapped around the outer layer of the plastic film to further enhance the firmness and protective performance of the packaging.

Winding and fixing: The cable is neatly wound on the cable reel, and the tension is controlled during the winding process to avoid loose or excessive stretching of the cable. Special fixing devices are used at both ends of the cable to fix it to prevent the cable from slipping off the cable reel during transportation.

Marking information: Relevant product information is clearly marked on the side and end of the cable reel, including product name, model specification (U-1000 Arvfv 4-core, 10-35mm²), length, weight, production batch number, implementation standard, production date, manufacturer name, address and contact information, etc. These marking information are convenient for customers to quickly identify the product when receiving and inspecting the goods, and also facilitate product traceability and management.

For road transportation, trucks with robust chassis and reliable braking systems are chosen. The loading process is supervised to ensure cable reels are lifted using appropriate lifting equipment (e.g., cranes with soft slings) to avoid damage to the reels or cables. Each reel is positioned securely on the truck bed, with wooden blocks or steel wedges placed between reels to prevent rolling.

For railway transportation, flatbed railcars with secure lashing points are used. Cable reels are fastened using steel chains and turnbuckles, ensuring a minimum of four anchor points per reel to withstand train vibrations and sudden stops.

For sea freight, containers are inspected for moisture, rust, or sharp edges before loading. Cable reels are stacked in a way that distributes weight evenly, with dunnage materials (e.g., plywood) placed between layers to prevent friction. Containers are also fitted with moisture-absorbing desiccants to protect against humidity during long voyages.

Drivers or logistics personnel are provided with detailed manifests specifying the cable type, quantity, and destination. They are instructed to avoid rough terrain and maintain steady speeds (typically ≤60 km/h for road transport) to minimize jolting.

GPS tracking systems are installed on vehicles to monitor transit routes and ensure adherence to scheduled stops. For long-distance shipments, daily checks are conducted to inspect lashings, reel integrity, and weatherproofing (e.g., tarpaulins for open trucks during rain).

In case of extreme weather (e.g., temperatures below -15℃ or above 40℃), transportation is rescheduled or equipped with climate-control measures (e.g., insulated containers) to prevent thermal stress on the cables.

Upon arrival, unloading is performed using the same careful lifting techniques as loading. A designated receiving team verifies the shipment against the manifest, checking for visible damage such as dented reels, torn sheaths, or displaced markings. Any discrepancies or damage are documented with photographs and reported immediately to the manufacturer.

Upon receiving an order, the sales team confirms specifications (e.g., cable length, cross-section) with the customer and forwards the details to the production department. A unique order number is assigned for tracking, and customers receive an order acknowledgment with an estimated delivery date (typically 7–14 business days for standard orders, 21 days for custom configurations).

Once production is complete and cables pass quality inspections, the logistics team schedules shipment based on the customer’s preferred method (road, rail, or sea). For urgent orders, expedited shipping options (e.g., air freight for small quantities) are available at an additional cost, with 24-hour tracking provided.

Customers are notified 48 hours before shipment, including the carrier’s name, tracking number, and expected delivery window. A proforma invoice and packing list are emailed, with hard copies included in the shipment.

For international shipments, the documentation team prepares commercial invoices, certificates of origin (ISO-compliant), and material safety data sheets (MSDS) for PVC and XLPE components. These documents are validated by customs brokers to ensure compliance with import regulations in the destination country (e.g., CE marking for the European Union, UL certification for North America).

Customers can request free samples (up to 5 meters) for testing purposes. Samples are shipped within 3 business days of the request, accompanied by a test report detailing key parameters (e.g., insulation resistance, conductor resistivity). Customized samples (e.g., specific lengths or markings) may incur a nominal fee, which is refundable upon placing a bulk order.

A dedicated technical support team is available 24/7 via phone or email to assist with installation queries, such as recommended bending techniques or compatibility with connectors. Installation guides (in multiple languages) are provided with each shipment, including step-by-step diagrams for stripping insulation and terminating cables.

Warranty coverage includes a 5-year guarantee against manufacturing defects. In case of a claim, customers are instructed to provide photos of the issue and the batch number; the manufacturer arranges for replacement or repair within 10 business days of validation.

After delivery, customers receive a satisfaction survey to rate aspects like product quality, delivery time, and support. Feedback is reviewed quarterly by the quality assurance team, with actionable insights implemented to enhance processes (e.g., improving packaging based on damage reports).

The cable complies with international standards such as IEC 60502-1 (Low-voltage Power Cables with extruded insulation) and ASTM B230 (Aluminum wire for electrical purposes). It is also certified by regulatory bodies including the International Electrotechnical Commission (IEC) and Underwriters Laboratories (UL) for use in power station applications.

The PVC Sheath is RoHS-compliant, containing no lead, cadmium, or hexavalent chromium. The manufacturing process is ISO 14001-certified for environmental management, with waste materials (e.g., aluminum scrap, insulation trimmings) recycled through authorized partners.

Safety certifications include flame-retardancy ratings (IEC 60332-3) and smoke density tests (IEC 61034), ensuring the cable meets fire safety requirements in enclosed spaces like power station control rooms.

Customers receive a compliance pack with each order, including test certificates, material declarations, and traceability records. These documents are also accessible via a secure online portal, allowing customers to verify product authenticity and performance data at any time.