1. Product-Specific Details
1.1 Specifications and Parameters
SWA (Steel Wire Armoured)
Armoured Power Cables with
4 Cores and conductor sizes of 25mm², 35mm², 50mm², and 70mm² come with a set of precise specifications and parameters that ensure their optimal performance in low-voltage (LV) power distribution systems.
The voltage rating of these cables is typically 0.6/1kV, which is standard for LV applications. This rating indicates that the cable can withstand a phase-to-earth voltage of 0.6kV and a phase-to-phase voltage of 1kV, making it suitable for distributing power in various settings where low-voltage electricity is required.
For the conductor size, each of the 25mm², 35mm², 50mm², and 70mm² options has specific current-carrying capacities. The 25mm² conductor can handle currents up to approximately 85A under normal operating conditions. As the conductor size increases, the current-carrying capacity rises. The 35mm² conductor can carry around 110A, the 50mm² around 145A, and the 70mm² can support up to approximately 185A. These values may vary slightly depending on factors such as the installation environment (ambient temperature, ventilation) and the method of installation (direct burial, in cable trays, etc.).
The XLPE insulation used in these cables has a thickness that is proportionate to the conductor size. For the 25mm² conductor, the insulation thickness is usually around 1.0mm. For 35mm², it increases to about 1.1mm, 50mm² has 1.2mm, and 70mm² features insulation thickness of approximately 1.4mm. This ensures that the insulation can effectively withstand the electrical stress and prevent leakage current.
The steel wire armouring (SWA) layer has its own set of parameters. The steel wires used are typically galvanized to enhance corrosion resistance. The number and diameter of the steel wires depend on the overall size of the cable. For 25mm² cables, the SWA may consist of 7 wires with a diameter of 0.8mm each. As the cable size increases, the number or diameter of the wires increases. For
70mm² Cables, it might have 12 wires with a diameter of 1.2mm, providing sufficient mechanical strength.
The outer sheath, available in PVC or LSZH, has varying thicknesses.
PVC Sheaths for 25mm² cables are around 1.8mm thick, while for 70mm² cables, they can be up to 2.4mm. LSZH sheaths, being designed for specific fire safety, have similar thickness ranges to ensure protection. The overall diameter of the cables also increases with conductor size. A 25mm² 4-core
Swa Cable has an overall diameter of approximately 22mm, while a 70mm² one can be around 32mm.
1.2 Special Purpose
These SWA armoured
Power Cables are designed to serve a wide range of special purposes across different industries and applications, thanks to their unique combination of features.
In industrial facilities, they are widely used to power heavy machinery and equipment. Factories with production lines, such as automotive manufacturing plants, rely on these cables to supply electricity to robotic arms, welding machines, and conveyor systems. The SWA layer protects the cables from the constant vibrations, impacts, and abrasion caused by the movement of machinery. The XLPE insulation ensures that even in the high-temperature environment of industrial operations, the cables maintain their electrical performance, preventing overheating and power loss.
In infrastructure projects, such as construction sites, these cables are essential for temporary and permanent power distribution. They can be directly buried underground to connect temporary power sources to construction equipment like cranes, concrete mixers, and power tools. The armouring provides protection against the rough handling and potential damage from construction materials and heavy vehicles. The 4-core design is ideal for three-phase power systems commonly used in construction, ensuring balanced power supply.
Commercial buildings, including shopping malls, office complexes, and hotels, utilize these cables for their main power distribution. The choice between PVC and LSZH sheaths depends on the building's safety requirements. In areas where fire safety is critical, such as high-rise buildings and hospitals, LSZH
Sheathed Cables are preferred. They prevent the release of toxic gases and dense smoke in case of a fire, allowing for safer evacuation and reducing damage to equipment.
Utilities sector also benefits from these cables. They are used in distributing power from substations to residential areas or commercial zones. The direct burial capability of SWA cables makes them suitable for laying underground, avoiding the need for expensive
Overhead Lines. The durability of the cables ensures a long service life, reducing maintenance costs for utility companies.
Transportation infrastructure, such as airports, railway stations, and ports, relies on these cables for reliable power supply. Airports use them to power lighting systems, baggage handling equipment, and runway lighting. Railway stations need a stable power supply for signaling systems, escalators, and ticket counters, where the SWA cables' resistance to mechanical stress ensures uninterrupted operation.
1.3 Materials and Styles
The materials used in SWA armoured
Power Cables are carefully selected to meet the demands of their applications, and they come in various styles to suit different installation requirements.
The conductors are made of high-quality copper, known for its excellent electrical conductivity. Copper ensures minimal resistance, allowing for efficient power transmission with low energy loss. The
Copper Conductors are stranded to enhance
Flexibility, making the cables easier to bend and install in tight spaces. Stranding also helps in withstanding repeated flexing, which is important in applications where the cable needs to be moved or routed around obstacles.
XLPE (cross-linked polyethylene) is chosen as the
Insulation Material for its superior properties. Compared to traditional
PVC Insulation, XLPE has better thermal stability, enabling it to operate at higher temperatures. It is also resistant to chemical degradation, making it suitable for environments where exposure to oils, solvents, or other chemicals is possible. The cross-linking process gives XLPE a three-dimensional molecular structure, enhancing its mechanical strength and durability.
The steel wire armouring is made of galvanized steel. Galvanization involves coating the steel wires with a layer of zinc, which acts as a barrier against corrosion. This is crucial, especially for cables installed underground or in damp environments, as it prevents rusting and ensures the longevity of the armouring layer. The steel wires are helically wrapped around the
Insulated Cores, providing uniform protection around the entire circumference of the cable.
The outer sheath materials, PVC and LSZH, each have distinct advantages. PVC is a cost-effective option with good resistance to moisture, UV radiation, and many chemicals. It is flexible and easy to process, making it suitable for general-purpose applications. LSZH, on the other hand, is a halogen-free material that, when exposed to fire, emits very little smoke and no toxic gases like hydrogen chloride. This makes it ideal for enclosed spaces where fire safety is a top priority.
In terms of styles, these cables are primarily 4-core, but within that, there are variations based on the sheath material (PVC or LSZH). Additionally, there are options for different armouring configurations, although the standard is helically wrapped steel wires. Some specialized versions may have additional layers, such as a bedding layer between the insulated cores and the armouring to provide extra cushioning and protection. The cables are also available in different colors for easy identification, with the cores color-coded according to international standards (e.g., brown, black, grey for phases and blue for neutral).
1.4 Production Process
The production of SWA
Armoured Power Cables involves a series of precise and controlled processes to ensure quality and performance.
The first step is conductor manufacturing. High-purity copper rods are drawn through a series of dies to reduce their diameter and form thin wires. These wires are then stranded together using a stranding machine. The stranding process is done in a specific pattern to ensure the conductor has the desired flexibility and current-carrying capacity. For 4-
Core Cables, four such
Stranded Conductors are prepared.
Next is the insulation extrusion. The
Stranded Copper Conductors are passed through an extrusion machine where XLPE compound is melted and applied around each conductor to form the insulation layer. The extrusion process is carefully controlled to ensure uniform thickness of the insulation. After extrusion, the
Insulated Conductors undergo a cross-linking process. This can be done using either chemical cross-linking (where the XLPE is heated in a vulcanization tube) or radiation cross-linking (using electron beams). Cross-linking transforms the linear polymer structure into a three-dimensional network, giving XLPE its excellent thermal and mechanical properties.
Once the insulated cores are ready, they are twisted together to form a 4-core cable core. This twisting is done to ensure the cores are properly bundled and to enhance the cable's flexibility. A bedding layer, usually made of PVC or non-woven material, is then applied around the twisted cores to provide a smooth surface for the armouring.
The steel wire armouring is applied next. Galvanized steel wires are helically wrapped around the bedding layer using an armouring machine. The tension and pitch of the wrapping are precisely controlled to ensure the armouring is uniform and provides adequate protection. The armouring process also ensures that the steel wires are firmly secured without damaging the underlying layers.
After armouring, the outer sheath is extruded. For PVC sheaths, PVC compound is melted and extruded over the
Armoured Core. For LSZH sheaths, a halogen-free compound is used in the extrusion process. The extrusion parameters, such as temperature and pressure, are adjusted based on the sheath material to ensure proper adhesion and uniform thickness.
Once the sheath is applied, the cables undergo a series of testing processes. These include electrical tests such as insulation resistance test, voltage withstand test, and continuity test to ensure electrical performance. Mechanical tests, such as tensile strength and elongation tests on the sheath and armouring, are also conducted. Additionally, fire tests are performed on LSZH sheathed cables to verify their low smoke and zero halogen properties. Only after passing all these tests are the cables spooled onto reels for distribution.
2. General Product Information
2.1 Packaging
The packaging of SWA armoured power cables is designed to ensure their protection during storage, handling, and transportation.
For smaller lengths, typically up to 100 meters, the cables are spooled onto wooden reels. These reels have flanges to prevent the cable from slipping off. The reels are made of sturdy plywood or solid wood, ensuring they can withstand the weight of the cable. The cable ends are sealed with heat-shrinkable caps to prevent moisture, dust, and debris from entering the cable core. Each reel is labeled with essential information, including the cable type, conductor size, number of cores, length, voltage rating, material of sheath, and compliance with standards (such as IEC, BS).
For longer lengths, up to 500 meters or more, heavy-duty steel reels are used. These reels are designed to handle the increased weight of longer cables. They have a central axle for easy lifting and transportation using forklifts or cranes. The steel reels are also coated with anti-corrosive paint to prevent rusting, especially during long-term storage or sea transportation.
Both wooden and steel reels are wrapped with a layer of waterproof plastic film to protect the cables from moisture during transit. For export shipments, the reels are often placed in wooden crates that comply with ISPM 15 standards, ensuring they are treated to prevent the spread of pests. This is crucial for international transportation, as it avoids delays in customs clearance.
2.2 Transportation
Transporting SWA armoured power cables requires careful planning to ensure they reach their destination in good condition.
For domestic transportation, trucks with flatbed or curtain-sided trailers are commonly used. The reels are secured onto the trailer using steel straps and wooden blocks to prevent movement during transit. The straps are tightened around the reels and anchored to the trailer to withstand sudden stops and turns. For larger steel reels, forklifts are used to load and unload them onto the trucks.
International transportation often involves sea freight, especially for large quantities. The reels are loaded into shipping containers, either 20-foot or 40-foot, depending on the size and quantity of the cables. The reels are arranged in the container to maximize space utilization while ensuring they are stable. They are secured using dunnage bags or steel braces to prevent shifting during the voyage, which can cause damage to the cables or the container.
Air freight is used for urgent orders, although it is more expensive. Due to the weight and size of the cables, air freight is typically limited to smaller reels or shorter lengths. During air transportation, the reels are packaged in lightweight but sturdy crates to meet airline weight restrictions.
Regardless of the transportation method, the cables are handled with care to avoid bending them beyond their minimum bending radius, which could damage the armouring or insulation. Transportation companies are instructed to avoid exposing the cables to extreme temperatures, as excessive heat or cold can affect the properties of the sheath and insulation materials.
2.3 Delivery
The delivery process of SWA armoured power cables is designed to be efficient and reliable, ensuring customers receive their orders on time.
When an order is placed, the manufacturer processes it and schedules production based on the availability of materials and the order quantity. Once the cables are produced and tested, they are prepared for delivery. The delivery time depends on the customer's location and the transportation method chosen. For domestic orders, delivery can take 2-5 business days using road transport. International orders shipped by sea may take 2-6 weeks, depending on the destination port. Air freight can reduce the delivery time to 3-7 business days for international destinations.
The manufacturer provides the customer with a tracking number once the shipment is dispatched. This allows the customer to monitor the progress of their delivery online, providing transparency and peace of mind. For large orders, the manufacturer may coordinate with the customer to schedule the delivery at a convenient time, ensuring that there is adequate space and equipment to unload the reels.
Upon delivery, the customer is required to inspect the cables for any visible damage. If there is any damage during transit, it should be reported immediately to the manufacturer and the transportation company for claims processing.
2.4 Samples
Manufacturers of SWA armoured power cables often provide samples to customers to allow them to evaluate the product before placing a large order.
Samples are typically short lengths of the cable, ranging from 1 to 5 meters, depending on the customer's request. They include all the features of the full-length cables, such as the 4-core configuration, XLPE insulation, SWA layer, and the chosen sheath material (PVC or LSZH). This allows customers to test the cable's physical properties, such as flexibility, and check the quality of the materials and construction.
To request a sample, customers can contact the manufacturer's sales team, providing details such as the conductor size, sheath material, and any specific requirements. The manufacturer may charge a nominal fee for the sample, which is often refundable if a subsequent order is placed. The sample is shipped using courier services, ensuring quick delivery, usually within 3-5 business days for domestic customers and 5-10 business days for international customers.
2.5 After-sales Service
Comprehensive after-sales service is provided to ensure customer satisfaction and address any issues that may arise with the SWA armoured power cables.
Manufacturers offer technical support to customers, providing guidance on installation, maintenance, and troubleshooting. Their team of engineers is available to answer questions regarding the cable's performance, compatibility with other equipment, and proper handling. This can be done through phone, email, or video conferences, ensuring timely assistance.
In case of any defects in the cables that are due to manufacturing errors, the manufacturer offers a warranty. The warranty period typically ranges from 1 to 5 years, depending on the product and the customer's agreement. If a defect is identified within the warranty period, the manufacturer will replace the defective cables or provide a refund, depending on the customer's preference.
For customers facing issues during installation or use, the manufacturer may dispatch technical personnel to the site to assess the problem and provide solutions. This is especially valuable for large-scale projects where the proper functioning of the cables is critical.
Manufacturers also maintain a record of customer orders and interactions, allowing them to provide personalized service. They may follow up with customers after delivery to ensure the cables are performing as expected and to gather feedback for continuous improvement of their products and services.
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