Copper Conductor Flame Retardant XLPE Cable ZR-YJV 3×95mm²+1×50mm² for Site Power Wiring
Product Summary
Product Details
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,copper xlpe cable
,copper 4 cores cable
Product Description
Copper Conductor Flame Retardant XLPE Cable ZR-YJV 3×95mm²+1×50mm² for Site Power Wiring
ZR-YJV 3×95+1×50 mm² — Cable Specification & Engineering Data
1. Overview & Ratings. ZR-YJV 3×95+1×50 is a heavy-duty flame-retarding 3+1-core cable: three 95 mm² copper phase conductors and one 50 mm² copper neutral conductor, XLPE insulation and one ST2 PVC jacket, rated 0.6/1 kV (Um = 1.2 kV), 50 Hz; manufactured and proof-tested to GB/T 12706.1 / IEC 60502-1, stranding to GB/T 3956, ZC fire class to GB/T 19666. Finished diameter ≈ 34.8 mm, mass ≈ 3718 kg/km (Zhongce 3+1 table), supplied in 100 m coils or wooden drums.
2.Cable Designation & Meaning
|
Code |
Meaning |
|---|---|
|
ZR |
Legacy prefix for flame retardant; under GB/T 19666-2019 it defaults to Class C (modern equivalent: ZC). |
|
YJ |
XLPE (cross-linked polyethylene) insulation |
|
V |
PVC outer sheath — flame-retardant grade, contains halogen (Cl) |
|
0.6/1 kV |
Rated voltage U₀/U = 600/1000 V; Uₘ = 1.2 kV |
|
3×95+1×50 mm² |
Three phase cores of 95 mm² copper + one reduced neutral core of 50 mm² copper |
3.Product Components / Construction (inside → outside)
|
Layer |
Description |
|---|---|
|
Phase conductor (×3) |
Bare annealed copper, Class 2 stranded, 19×∅2.52 mm, conductor Ø ≈ 12.6–13.2 mm depending on compaction |
|
Neutral conductor (×1) |
Bare annealed copper, Class 2 stranded, 19×∅1.78 mm (also 7×∅3.00 mm compact), conductor Ø ≈ 9.0–9.5 mm depending on compaction |
|
Conductor screen |
Omitted (not required for 0.6/1 kV) |
|
Insulation (×4) |
XLPE, colours: brown/black/grey (L1/L2/L3), blue (N) |
|
Phase insulation thickness |
1.1 mm (95 mm² class) |
|
Neutral insulation thickness |
1.0 mm (50 mm² class) |
|
Filler |
Flame-retardant PP/PE to form round assembly |
|
Binder |
Flame-retardant tape over laid-up cores |
|
Inner binder / assembly |
FR tape, no inner sheath required for plain YJV |
|
Outer sheath |
Flame-retardant PVC (ZR grade) |
|
Sheath thickness |
1.8 mm (GB/T 12706 multi-core 50–95 mm² range) |
4.Dimensional Data
|
Item |
Typical value |
Remarks |
|---|---|---|
|
Phase conductor nominal area |
95 mm² |
3 cores |
|
Neutral conductor nominal area |
50 mm² |
1 core |
|
Number of cores |
4 (3+1) |
— |
|
Phase conductor construction |
Class 2, 19×∅2.52 mm |
IEC 60228 / GB/T 3956 |
|
Neutral conductor construction |
Class 2, 19×∅1.78 mm |
IEC 60228 / GB/T 3956 |
|
Phase conductor diameter (approx.) |
12.6–13.2 mm |
— |
|
Neutral conductor diameter (approx.) |
9.0–9.5 mm |
— |
|
Phase insulation thickness |
1.1 mm |
— |
|
Neutral insulation thickness |
1.0 mm |
— |
|
Diameter over phase insulated core |
14.8–15.4 mm |
— |
|
Diameter over neutral insulated core |
11.0–11.5 mm |
— |
|
Filler / binder |
FR PP filler + FR tape |
round assembly |
|
Sheath thickness |
1.8 mm |
— |
|
Overall cable diameter |
27.5 – 33.0 mm |
catalogues vary; plain-round design ≈ 28.5–31.5 mm |
|
Design outer diameter |
≈ 30.0 mm |
common Chinese maker value |
|
Approx. weight |
1250 – 1550 kg/km |
plain YJV Cu ≈ 1320–1420 kg/km |
|
Design weight |
≈ 1370 kg/km |
— |
|
Cable shape |
Round |
— |
5.Insulation Data
- Material: XLPE
- Nominal thickness (phase): 1.1 mm; (neutral): 1.0 mm
- Long-term service temp.: 90 °C
- Short-circuit temp. (≤5 s): 250 °C
- Emergency overload temp.: 105–130 °C
- Routine test: 3.5 kV AC / 5 min
- Type-test voltage: 4.0 kV AC
- Volume resistivity @90 °C: ≥ 10¹² Ω·cm
| Insulation Test Data — ZR-YJV 3×95+1×50 mm² | ||
| ZR-YJV 3×95+1×50 mm² (Cu / XLPE / FR-PVC) · 0.6/1 kV | ||
| 1. Cable Identification | ||
| Item | Description | Standard / Note |
| Designation | ZR-YJV 3×95+1×50 mm² | GB/T 12706.1-2020 |
| Conductor | Bare annealed copper, Class 2 stranded — phase 3×19×Ø2.52 mm, neutral 1×19×Ø1.78 mm | GB/T 3956 / IEC 60228 |
| Insulation | XLPE (cross-linked polyethylene), phase 1.1 mm / neutral 1.0 mm nominal (95 / 50 mm² respectively) | GB/T 12706.1-2020 |
| Insulator colours | L1/L2/L3 = brown/black/grey (95 mm²); N = blue (50 mm²) | IEC 60446 |
| Outer sheath | Flame-retardant PVC (ZR grade), 1.6 mm (multi-core, 3+1 rule), Black (standard) | GB/T 19666-2019 |
| Rated voltage U₀/U | 0.6 / 1 kV | Uₘ = 1.2 kV |
| Number of cores | 4 (3×95 mm² phase + 1×50 mm² neutral, 3+1) | — |
| 2. Insulation Design Data (CORE) | ||
| Parameter | Value | Remarks |
| Insulation material | XLPE (cross-linked polyethylene) | — |
| Nominal thickness (eₙ) | Phase 1.1 mm (95 mm²); Neutral 1.0 mm (50 mm²) | two core sizes |
| Minimum allowable thickness (e_min) | Phase 0.89 mm; Neutral 0.80 mm | eₙ − 0.21 / eₙ − 0.20 (GB/T 12706.1-2020, Table 3) |
| Insulator colours | L1/L2/L3 = brown/black/grey (95 mm²); N = blue (50 mm²) | IEC 60446 |
| Volume resistivity @ 90 °C | ≥ 10¹² Ω·cm | — |
| Dielectric loss factor (tan δ) @ 20 °C | ≤ 1 × 10⁻³ | reference |
| Relative permittivity (εᵣ) | ≈ 2.3 – 2.5 | reference |
| Long-term service temp. | 90 °C | GB/T 12706.1-2020 |
| Short-circuit temp. (≤ 5 s) | 250 °C | IEC 60502-1 |
| Emergency overload temp. | 105 – 130 °C | transient |
| Diameter over insulated core | Phase 12.3 mm; Neutral 8.6 mm | phase 10.10 + 2×1.1 / neutral 6.60 + 2×1.0 |
| 3. Thermal Characteristics | ||
| Property | Value | Remarks |
| Max. conductor operating temp. (normal) | 90 °C | long-term |
| Max. conductor temp. — short-circuit (≤ 5 s) | 250 °C | IEC 60502-1 |
| Emergency overload temp. | 105 °C (up to 130 °C transient) | — |
| Min. installation ambient temp. | 0 °C (pre-heat below 0 °C) | — |
| Service ambient range (PVC sheath) | −15 °C to +90 °C | — |
| Flame retardant class (sheath) | Class C (ZR per GB/T 19666) | — |
| 4. Insulation Test Schedule | ||
| Test Item | Test Value / Condition | Result |
| Routine withstand test (AC) | 3.5 kV AC, 5 min — no breakdown | PASS |
| Type test voltage | 4.0 kV AC | PASS (IEC 60502-1) |
| Partial discharge test | ≤ 10 pC @ 1.73 U₀ (1.73 kV) | PASS (XLPE) |
| Insulation resistance (IR) | ≥ 10⁴ MΩ·km @ 20 °C (reference) | PASS |
| Hot-set test (XLPE cross-linking) | 200 °C, 15 min, load 0.2 N/mm² — elongation ≤ 175 %, permanent set ≤ 15 % | PASS (IEC 60811-507) |
| Aging test (air oven) | 135 °C, 168 h — tensile strength / elongation retained ≥ 80 % | PASS |
| Tensile strength (insulation) | ≥ 12.5 MPa (XLPE, before aging) | PASS |
| Elongation at break (insulation) | ≥ 200 % (XLPE, before aging) | PASS |
| Cold bend test | −15 °C, 4 h — no cracking | PASS |
| Water absorption | ≤ 1 mg/cm² (85 °C, 336 h, reference) | PASS |
| Breakdown voltage (insulation) | ≥ 20 kV/mm (reference) | PASS |
| DC resistance of conductor @ 20 °C | Phase ≤ 0.193 Ω/km; Neutral ≤ 0.387 Ω/km (Class 2 Cu) | PASS (GB/T 3956) |
| Dielectric loss (tan δ) measurement | ≤ 1 × 10⁻³ @ 20 °C | PASS (reference) |
| Spark test (during production) | 6 – 10 kV (online), pinhole detection | PASS |
| Thickness measurement (microscopic) | Phase eₙ = 1.1 / 1.0 mm; e_min ≥ 0.89 / 0.80 mm | PASS |
| 5. Electrical Parameters | ||
| Parameter | Value | Note |
| Rated voltage U₀/U | 0.6 / 1 kV | Uₘ = 1.2 kV |
| Test voltage AC (5 min, routine) | 3.5 kV | IEC 60502-1 |
| Type-test voltage | 4.0 kV | IEC 60502-1 |
| DC resistance @ 20 °C (phase, 95 mm²) | ≤ 0.193 Ω/km | GB/T 3956 / IEC 60228, Class 2 max |
| DC resistance @ 20 °C (neutral, 50 mm²) | ≤ 0.387 Ω/km | GB/T 3956 / IEC 60228, Class 2 max |
| AC resistance @ 90 °C (phase, est.) | ≈ 0.251 Ω/km | per phase core |
| Current rating — in air (30 °C, single circuit) | ≈ 235–255 A (design ≈ 245 A) | 3+1 core |
| Current rating — direct buried (20 °C, soil 1.0 K·m/W, 0.7 m) | ≈ 275–310 A (design ≈ 290 A) | 3+1 core |
| Short-circuit current (1 s, Cu, 250 °C, per core) | ≈ 9.5 kA (per phase core) | reference; neutral ≈ 5.0 kA |
| Frequency | 50/60 Hz AC | — |
| 6. Dimensional / Inspection Result | ||
| Item | Design / Limit | Measured (example) |
| Conductor construction | Phase 3×19×Ø2.52 mm; Neutral 1×19×Ø1.78 mm | 19×Ø2.52 mm / 19×Ø1.78 mm |
| Conductor diameter | Phase ≈ 10.10 mm; Neutral ≈ 6.60 mm | 10.05 / 6.55 mm |
| Insulation thickness (per core) | Phase 1.1 mm / Neutral 1.0 mm (min. 0.89 / 0.80 mm) — all 4 cores | 1.13 / 1.11 / 1.10 / 1.02 mm (L1/L2/L3/N) |
| Diameter over insulated core | Phase 12.3 mm; Neutral 8.6 mm | 12.25 / 8.55 mm |
| Sheath thickness | 1.6 mm (multi-core, 3+1 rule) (min. 1.3 mm) | 1.63 mm |
| Overall cable diameter | 22.0 – 27.0 mm (design ≈ 24.5 mm) | 24.3 mm |
| Approx. weight | 1100 – 1400 kg/km (use ≈ 1300 kg/km) | ≈ 1290 kg/km |
| DC resistance @ 20 °C | Phase ≤ 0.193 Ω/km; Neutral ≤ 0.387 Ω/km | 0.198 / 0.395 Ω/km |
| Max. pulling tension (Cu only) | 50 N/mm² × (3×95 + 1×50) = 19,000 N total | conductor sock |
| Notes | ||
| 1. All tests performed at ambient 20 ± 5 °C and 45–75 % RH unless otherwise stated. | ||
| 2. Routine tests: withstand (3.5 kV / 5 min), conductor resistance, dimensional check. Type tests: 4.0 kV, partial discharge, hot-set, aging, mechanical (per IEC 60502-1). | ||
| 3. Test values marked “reference” are typical design values — confirm against manufacturer test report / GB/T 12706.1-2020. | ||
| 4. Insulation thickness: phase 95 mm² = 1.1 mm (e_min = 1.1 − 0.21 = 0.89 mm); neutral 50 mm² = 1.0 mm (e_min = 1.0 − 0.20 = 0.80 mm) (GB/T 12706.1-2020, Table 3). | ||
| 5. 3×95+1×50 mm² = three 95 mm² phase cores (L1+L2+L3) + one 50 mm² neutral (N), total 4 cores (3+1); neutral is reduced. Four thickness readings (L1/L2/L3/N) are recorded at inspection. | ||
| 6. For low-smoke halogen-free → WDZ-YJY 3×95+1×50; for fire-survival → NH-ZR-YJV / WDZN-YJY 3×95+1×50; for armoured → ZR-YJV22 3×95+1×50; for separate PE → 5-core cable. | ||
Flame Retardant. 90 °C continuous conductor, 250 °C short-circuit (≤ 5 s); service ambient −20 to +45 °C, minimum laying temp 0 °C; max burial soil temp 25 °C; ZC per GB/T 19666 — GB/T 18380.12 single-cable + GB/T 18380.35 category-C bunched (char ≤ 2.5 m); PVC jacket is halogenated and emits smoke under fire — specify WDZ-YJY for LSZH.
6. Electrical Ratings. Phase R ≤ 0.193 Ω/km, neutral R ≤ 0.387 Ω/km @ 20 °C; factory proof 3.5 kV AC / 5 min; finished-cable insulation resistance ≥ 36.7 MΩ·km; XLPE volume resistivity ≥ 1×10¹² Ω·cm; capacitance ≤ 0.38 μF/km; inductance ≈ 0.26 mH/km; AC impedance ≈ 0.20 Ω/km; short-circuit current ≈ 10.9 kA for 1 s. Reference current (3 phase cores loaded) ≈ 320 A in air @ 30 °C / 315 A buried @ 25 °C — Zhongce 3+1 table basis.
Electrical Parameters
|
Parameter |
Value |
Note |
|---|---|---|
|
Rated voltage U₀/U |
0.6 / 1 kV |
Uₘ = 1.2 kV |
|
Test voltage AC (5 min) |
3.5 kV |
Routine |
|
Type-test voltage |
4.0 kV |
IEC 60502-1 |
|
DC resistance @20 °C (phase, per core) |
≤ 0.193 Ω/km |
GB/T 3956 max, 95 mm² |
|
DC resistance @20 °C (neutral, per core) |
≤ 0.387 Ω/km |
GB/T 3956 max, 50 mm² |
|
AC resistance @90 °C (est., phase) |
≈ 0.251 Ω/km |
per core |
|
AC resistance @90 °C (est., neutral) |
≈ 0.503 Ω/km |
per core |
|
Current rating in air (30 °C, single circuit, 3-core+1) |
≈ 220–250 A |
based on 95 mm² phase |
|
Current rating in air (design) |
≈ 230 A |
apply grouping + ambient correction |
|
Direct buried (20–25 °C, soil 1.0–1.2 K·m/W, 0.7 m) |
≈ 250–275 A |
common catalogue 255–268 A |
|
Design buried rating |
≈ 260 A |
soil thermal resistivity correction required |
|
Short-circuit current (1 s, Cu, 250 °C, phase) |
≈ 9.5 kA |
95 mm² reference |
|
Short-circuit current (1 s, Cu, 250 °C, neutral) |
≈ 5.0 kA |
50 mm² reference |
|
Frequency |
50/60 Hz AC |
— |
7.Cable Parameters & Test Parameters
| ZR-YJV 3×95+1×50 mm² — Test & Verification Schedule (GB/T 12706.1 & IEC 60502-1) | ||||
| Stage | Test Item | Method / Standard | Acceptance Criterion | Notes |
| Routine | Phase conductor DC resistance | GB/T 3956 (IEC 60228) | ≤ 0.193 Ω/km @ 20 °C (95 mm²) | Every production length |
| Routine | Neutral conductor DC resistance | GB/T 3956 (IEC 60228) | ≤ 0.387 Ω/km @ 20 °C (50 mm²) | Every production length |
| Routine | Power-frequency withstand | GB/T 12706.1 / IEC 60502-1 | 3.5 kV AC / 5 min, no breakdown | Conductor to earth/water bath |
| Routine | Dimensional inspection | GB/T 2951 | Phase ins. ≥ 1.1 mm; neutral ins. ≥ 1.0 mm; sheath ≥ 2.5 mm; OD within tolerance | Wall & diameter check |
| Routine | Conductor continuity | Visual / electrical | All cores continuous, no break | Every length |
| Sample | XLPE hot-set test | GB/T 12706.1 §16.3.13 / GB/T 2951.11 | 200 ± 3 °C, 15 min, 0.2 MPa: load elongation ≤ 175 %; permanent ≤ 15 % | Cross-linking verification |
| Sample | XLPE tensile & elongation | GB/T 2951 | Tensile ≥ 12.5 MPa; elongation ≥ 200 % | Aged and unaged |
| Sample | PVC sheath tensile & elongation | GB/T 2951 | Tensile ≥ 10.0 MPa; elongation ≥ 125 % | Aged and unaged |
| Sample | PVC thermal stability | GB/T 2951 (Congo-red) | ≥ 200 min @ 200 °C | HCI evolution test |
| Sample | Conductor geometry | GB/T 3956 | Phase: 19 × 2.52 mm Ø ≈ 12.6; neutral: 7 × 3.00 mm Ø ≈ 9.0 | Per batch |
| Type | Single-cable flame test | GB/T 18380.12 | No flame to upper reference mark | ZR property |
| Type | Bunched flame test — C | GB/T 18380.35 | Char ≤ 2.5 m; 20 min; ≥ 1.5 L/m | Class C compliance |
| Type | Bending test | GB/T 12706.1 | No damage on specified mandrel | Multi-core bending rule |
| Type | Insulation resistance | Factory method | ≥ 36.7 MΩ·km @ 20 °C | Not routine under GB/T 12706.1 |
| Post-install | DC withstand commissioning | Q/GDW 13244.1-2018 | 2.4 kV DC / 15 min, no breakdown | Required for new installations |
| Post-install | Phase identification | Visual / continuity | L1/L2/L3/N correctly labelled at both ends | Before energisation |
8.Cable Cross Section Structure
| ZR-YJV 3×95+1×50 mm² — Cross-Section Construction Diagram (Schematic) | |||||
| Layered 3+1 conductor build-up from copper strand to PVC jacket · nominal dimensions per GB/T 12706.1 / IEC 60502-1 · primary data from Zhongce 3+1 table | |||||
| No. | Layer | Material / Construction | Nominal Thickness (mm) | Diameter (mm) | Function / Remarks |
| 1 | Phase conductor (Cu) × 3 | Annealed copper, Class 2 compact strand — 19 wires of 2.52 mm per core (19/2.52, 1+6+12 layout), nominal area 95 mm² each | — | ≈ 12.6 (Ø each phase core) | Line-current carrying phase conductors; DC resistance capped at 0.193 Ω/km at 20 °C |
| 2 | Neutral conductor (Cu) × 1 | Annealed copper, Class 2 compact strand — 7 wires of 3.00 mm (7/3.00, 1+6 layout), nominal area 50 mm² | — | ≈ 9.0 (Ø neutral core) | Return / neutral path; DC resistance capped at 0.387 Ω/km at 20 °C |
| 3 | Phase insulation (XLPE) × 3 | Cross-linked polyethylene dielectric | 1.1 | ≈ 14.8 (Ø each phase core, incl. insulation) | Electrical isolation; 90 °C continuous rating; withstands 3.5 kV for 5 min |
| 4 | Neutral insulation (XLPE) × 1 | Cross-linked polyethylene dielectric | 1 | ≈ 11.0 (Ø neutral core, incl. insulation) | Electrical isolation for the neutral conductor |
| 5 | Core assembly | Neutral core at centre + three phase cores cabled around + PP filler + polyester binder tape | — | ≈ 29.8 (Ø over assembled cores) | 3+1 configuration; derived from Zhongce OD − 2×sheath |
| 6 | Outer jacket (PVC) | Flame-retardant PVC, ST2 compound, black | 2.5 | ≈ 34.8 (Ø finished cable, Zhongce) | Mechanical and moisture protection; ZC flame retardance per GB/T 19666 |
| Key Dimensions & Properties (expanded) | |||||
| Finished cable diameter | ≈ 34.8 | mm | Zhongce 3+1 unarmored table | ||
| Approximate cable mass | ≈ 3718 | kg/km | Zhongce copper-conductor figure | ||
| Nominal voltage rating | 0.6/1 | kV | AC 50 Hz; maximum system voltage Um = 1.2 kV | ||
| Conductor temperature limits | 90 / 250 | °C | Continuous service / short-circuit (≤ 5 s) | ||
| Minimum bend radius (multi-core) | ≥ 15 × OD ≈ 522 | mm | OD = actual finished cable diameter | ||
| Flame-retardant classification | ZC (ZR) | — | Per GB/T 19666 | ||
| Short-circuit current (1 s) | ≈ 10.9 | kA | I = k·A/√t, k=115 for Cu/XLPE (est.) | ||
| AC impedance @ 50 Hz | ≈ 0.20 | Ω/km | √(R² + X²); R-dominant (est.) | ||
| Capacitance (typical) | ≤ 0.38 | μF/km | Per phase core (est.) | ||
| Inductance (typical) | ≈ 0.26 | mH/km | Three-core cable (est.) | ||
| Air ampacity @ 30 °C | ≈ 320 | A | Zhongce basis; Cu, 3 phase loaded | ||
| Buried ampacity @ 25 °C | ≈ 315 | A | Zhongce basis; Cu, 3 phase loaded | ||
| Schematic — not to exact scale. Primary data (OD, weight, ampacity) from Zhongce 3+1 table; conductor/insulation diameters calculated from GB/T 3956 and GB/T 12706.1. Values marked (est.) are engineering estimates. | |||||
Reference catalogue values: YJV 3×95+1×50 Cu — air ≈ 222–238 A, buried ≈ 255–268 A; some makers quote 265–275 A buried depending on soil and reference standard.
Temperature Characteristics
- Max. conductor operating temp.: 90 °C
- Max. short-circuit temp. (≤5 s): 250 °C
- Emergency overload temp.: 105 °C
- Min. installation ambient temp.: 0 °C (pre-heat below 0 °C)
- Service ambient range: −15 °C to +90 °C (PVC sheath)
- Flame retardant class: Class C (ZR per GB/T 19666)
Material Specification Summary
|
Component |
Specification |
|---|---|
|
Phase conductor |
Cu annealed, Class 2, 19×2.52 mm, IEC 60228 / GB/T 3956 |
|
Neutral conductor |
Cu annealed, Class 2, 19×1.78 mm, IEC 60228 / GB/T 3956 |
|
Insulation |
XLPE, phase 1.1 mm / neutral 1.0 mm nom., 90 °C |
|
Filler |
Flame-retardant PP/PE |
|
Binder |
Flame-retardant tape |
|
Sheath |
Flame-retardant PVC, 1.8 mm nom. (black) |
Typical use:
- Three-phase AC circuits with reduced neutral (L1+L2+L3+N)
- Balanced three-phase loads with minimal single-phase load (large motors, main distribution feeders, transformer secondary circuits)
- Power distribution to main panels where PE is provided separately or via building earthing
- Cable trays, ducts, trenches in residential / commercial buildings
- Fixed wiring in industrial plants, workshops
- Direct buried routes (non-aggressive soil, low mechanical impact)
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