Leading XLPE Cable Manufacturer in China

The XLPE Cable or Cross-link polyethylene is a thermoset insulation material. XLPE cables are made through a process of changing molecular structures of the polymer chains to make them more tightly when bound together. It is done by physical means and chemical means.

  • Available in a wide range variety of versions
  • Can stand from low up to extra high voltage.

XLPE Cable

The XLPE cable is manufactured for voltage from low up to high voltage. It is equipped with other insulation materials such as EPR, PVC, and silicone rubber. This is known as cross-linking polyethylene which is chemical resistance and oil resistance at elevated temperatures. XLPE cable for use as a low smoke zero halogen material.

Our XPLE is superior to many insulations, and elongation and offers excellent tensile strength and resistance against impact.  Honest cable manufactured this type of XPLE cable insulation that cannot melt or drip even at a temperature of soldering irons. Aside from that, it increased flow resistance and improved aging properties.  Honest Cable always assure that all of our XLPE cables meet international standard like ISO 9001, SGS, CE, etc. to ensure the quality and durability of products.

Copper Conductor 600V Single-Core XLPE Cable

The copper conductor 600V single core XLPE cable is used for the main power supply. It is installed in cable trunking, cable duct, cable trays, switchgear, and Cable ladders.

Aluminum Conductor 1000V Single-Core XLPE Cable

The aluminum conductor 1000V single core XLPE cable is widely used for substations, power plant, building, sea port, etc. It is available in natural insulations colors.

2 Core to 5 Core XLPE Insulated Cable

Our 2-core to 5-core XLPE insulated cables is normally used for power transmission and distribution. It applies to a size below 16mm and above 35mm

4 Core Aluminum Conductor XLPE Cable

We offer 4 core aluminum conductor XLPE Cable that can be used for low up to ultra-high voltage cable.  These are used for underground, industrial, power stations, etc.

3 Earth Core XLPE Insulated Cable

3 earth core XLPE insulated cables are used to connect appliances like extension cables, power outlet sockets, lamps, and others. It has 3 cores which the live, neutral, and earth.

PVC Sheathed Copper Wire Screened XLPE Cable

The PVC sheathed copper wire screened XLPE cable is available in different insulation colors such as black, blue, red, yellow, green and so on to make it more attractive.

Characteristic of XLPE Cable

The XLPE Cable is combined with different molecular structures such as:

  • Circular Stranded BC Conductor
  • PP wrapping tape
  • PVC overall sheath
  • Inner PVC sheath
  • XLPE insulations
Characteristic of XLPE Cable
XLPE Cable Applications

XLPE Cable Applications

XLPE cables are ideal for transmission and power distribution applications. Using an XLPE Cable is safer than external electrical usage due to its more resistance to corrosion. These are very useful, especially for an application that doesn’t want to replace or inspect the cable frequently such as concrete-filled power line trenches.

These XLPE Cable insulated wire specifications are better sense than other insulated cables. It can support a broad range of voltage from lower up to higher current. We can provide customized XLPE cable to meet your specific needs.

Feature of XLPE Cable

The XLPE cable offers different features for various applications such as:

  • It does not melt easily
  • Long lasting insulations choices
  • Don’t corrode easily when exposed to gasses, salt and corrosive acids
  • Provide high performance
  • Longer service
  • Chemical resistance
  • Water resistance
  • Oil resistance
  • Excellent dialectric strength
  • High insulation resistance
  • Low dissipation functions and many more.
Feature of XLPE Cable
One Stop XLPE Cable Solution for your Business
One Stop XLPE Cable Solution for your Business

We offer XLPE cables for different sizes, colors, designs, and thicknesses. Aside from that, we can provide low MOQ, fast delivery high productivity, affordable price, and quality assurance.

XLPE Cable – The Ultimate FAQ Guide

XLPE is the abbreviation of cross-linked polyethylene, which is a common material for insulation is cables.

This material has come a long way and is becoming more and more popular, especially in high voltage applications.

Its major contender is EPR, which is another thermoset material.

XLPE offers a wide range of benefits that primarily come from its crosslinking.

Polyethylene on its own is a great material for cable insulation and sheathing.

However, crosslinking takes it to the next level and makes it ideal for certain applications.

This material is mostly used for insulation only, so you’ll find it paired with other sheathing materials, most commonly PVC.

However, it’s much different from PVC, especially in terms of an insulator.

What is XLPE Cable?

Any cable that has crosslinked polyethylene insulation is an XLPE cable.

It’s a thermoset material, which means it can only be heated and shaped once.

Polyethylene is either crosslinked physically or chemically, and the process is similar to the vulcanization of rubber.

Chemicals like silane or peroxide produce free radicals that form links/chains between the molecules.

As a result, the stability of the bond between the molecules increases, even when they are exposed to high heat.

On the other hand, in physical crosslinking, the manufacturers use high-energy electron beams or microwave lasers.

Either way, the resulting polyethylene is much sturdier than its earlier version.

It essentially rearranges the molecular structure and creates barriers for the links so they don’t break even at higher temperature or under higher pressure.

This material is then used to insulate aluminum or copper conductors.

XLPE CABLE

What are the Characteristics of XLPE Cable?

XLPE offers many useful features as insulation material.

These features are:

Heat Resistance

XLPE offers reliable heat resistance, thanks in part to crosslinking.

Ethylene on its own is also heat-resistant, but when crosslinked, it exhibits even better resistance to heat.

The molecular structure is much stronger, so they do disperse under thermal pressure.

In comparison with most thermoplastics, XLPE as a thermosetting material offers way better heat resistance.

Wide Operating Temperature Range

Since it’s high heat-resistant material, it offers increased stability at high temperatures as well.

This allows it’s normal operating and short-circuit temperature to be higher than thermoplastics.

This is also one of the reasons why this insulation can handle high voltage easily.

The normal operating temperature for XLPE is 90 ℃, whereas the emergency range is up to 130 ℃, and the short circuit is 250 ℃.

High Tensile Strength

XLPE has very high tensile strength, which makes it good for handling mechanical stress as well.

It can withstand abrasion, tear, and wear and is generally long-lasting and durable as a result of its strong molecular structure.

Its strong characteristics make it ideal for use outdoors and in tough conditions where environmental factors may pose the threat of wear and tear.

The addition of carbon black can add further cut-through resistance.

Impact Resistance

As compared with polyethylene, XLPE has even higher impact resistance.

It can withstand mechanical pressure well.

This ensures that the cables do not lose its structural integrity and continues to work even when impacted with heavy force.

Chemical Resistance

XLPE is resistant to chemicals, including acids and alkalis.

It also offers good resistance to oil, especially better than other insulators like PVC and EPR.

Weather Resistance

One of the most important attributes for power cables is being weather-resistant.

Now, weather resistance has mostly to do with the outer sheathing of the cable as that outer layer is the first one to come in contact with weather elements.

However, it’s safe to say that XLPE bolsters the weather resistance of a cable.

The most important aspect of XLPE’s weather resistance is its resistance to water treeing.

Water treeing is the phenomenon where water seeps into the insulation, creating cracks.

It can result in slow damage over time and perhaps even permanent failure.

XLPE offers good water treeing resistance.

In comparison, EPR is better equipped for this kind of protection.

However, XLPE offers better water-treeing resistance than PVC.

Low-Smoke Zero-Halogen

Low-smoke zero-halogen materials are those that don’t produce excessive smoke when on fire and don’t contain any halogens so as to not produce any harmful gases.

XLPE meets both these requirements, which are typically required for many applications in many regulated industries.

What are the Benefits of XLPE Cable?

These cables have become one of the most sought-after materials in the cabling world.

It is one of the three commonly used materials, the others being PVC and EPR.

However, it offers many benefits, some of which the other two do not offer.

XLPE

Support for High-Voltage Applications

XLPE has virtually become a standard insulation material in all high-voltage cables.

This material can carry a high mount of currents and support hundreds of kV applications.

Even EPR cannot come close to the range XLPE offers in terms of high-voltage compatibility.

The voltage rating for XLPE cables can be both low, high, and mega high.

Their voltage range is typically 600V to 36kV.

Mega high voltage cables specifically designed for high-voltage applications with XLPE as insulation can offer as much as 300 kV.

This is the reason why it’s a common material in high voltage power supply cables that carry hundreds of kV to power cities and towns.

On top of that, this material doesn’t require a metallic sheath, which keeps the cables flexible.

Tough Material

XLPE is a tough material that provides adequate mechanical stress and chemical resistance.

It checks all the requirements of what a high-quality insulation material should be.

Whether you’re dealing with outdoor installation, burial wiring, or industrial usage, this kind of insulation offers ample protection from all the potential threats.

This makes XLPE cables extremely reliable too.

They are also some of the most long-lasting cables, as XLPE doesn’t lose its strength with aging.

Low Dielectric Loss

In comparison with PVC and EPR, XLPE has the lowest dielectric losses.

With minimal dissipation, XLPE comes on top as far as being the economical choice is concerned.

This is one of the many reasons why many industries prefer this insulation material over others, as it saves them money in the long run.

It’s highly efficient that way as the dielectric loss is one of the major problems in cabling, especially in the energy industry.

All that electricity that’s inevitably lost can be salvaged by using more efficient cable structures, of which XLPE is a major part.

High Thermal Range

The thermal range of XLPE is fairly wide, which makes it ideal for use in many different parts of the world with both sub-zero and boiling temperatures.

It can be used in industries marked with high temperature working conditions.

High operating temperature for cables is important to maintain their integrity even in case of accidents like a fire.

Easy Installation

XLPE cables typically have a decent bending radius, although that varies greatly from cable to cable (it depends on numbers of factors).

The bending radius combined with the lightweight makes these cables easy to install.

 XLPE CABLE

It’s also worth mentioning that XLPE cables can be installed vertically as opposed to cables with oil in their construction.

Therefore, there are no height limitations when it comes to the installation of XLPE cables.

Similarly, it does not always require flame for joining and fitting operations.

What are the Applications of XLPE Cable?

XLPE cables are primarily used as power cables to supply energy.

However, they are not limited to the energy sector.

Other industries, especially those that require high-voltage cables, also use cables with XLPE insulation.

The list of industries relying on XLPE cables is very widely.

Here are some of the major applications/industries:

  • Energy sector (Power supply, HVDC, distribution, etc.)
  • Mining
  • Agriculture
  • Marine Shipboard
  • Chemical production

What is the Difference Between XLPE Cable & PVC Cable?

XLPE and PVC (polyvinyl chloride) are two of the most common materials used for insulation.

While XLPE primarily serves as insulation, PVC serves as both insulation and sheath.

However, there are many differences between the two, even if we compare them both as just insulators.

The difference between the two also results in different applications.

Some applications, particularly low voltage ones, may make do with both PVC and XLPE, while others have conditions that only XLPE can accommodate.

XLPE Cable

Here are the key differences between these two types of cables (cables with XLPE insulation and cables with PVC insulation):

XLPE is Halogen-free

PVC contains chlorine (Cl), which is a halogen, while XLPE contains no halogens.

That is the most basic molecular difference between the two materials, but it’s also an important one.

In applications that may have a likelihood of fire, XLPE is clearly a better option and perhaps even a mandated requirement.

Many industries and official standards require cable materials to be halogen-free, which essentially eliminates the possibility of the use of PVC.

The chlorine in PVC poses a threat of harmful gases in case of a fire.

This makes XLPE a far safer option.

XLPE is Better for High-Voltage

XLPE is much better at carrying higher amounts of current, so it can support high voltage applications (upwards of 100 kV).

On the other hand, PVC is ideal for low-voltage applications only.

It may not be suitable for insulating conductors with a voltage rating of over 100 kV.

XLPE is Tougher

Overall, XLPE is way sturdier than PVC.

While both materials offer abrasion resistance, wear resistance, tear resistance, and impact resistance, XLPE comes on top in comparison with PVC.

The crosslinking makes it better at resisting mechanical pressure and chemical agents.

XLPE also has a higher operating temperature, thanks, again, to the crosslinking, which binds the molecular structure even at higher temperatures.

For instance, under short circuit conditions, PVC has a max temperature of 160 ℃ whereas XLPE has a max temperature of 250 ℃.

PVC is Cheaper

Economically, PVC is a better option as it is cheap and readily available.

Since XLPE requires crosslinking, it is a little more expensive to produce than PVC.

That said, XLPE proves cost-effective in the long run because of its lower dielectric loss.

PVC is More Water-Resistant

XLPE is water-resistant to a good extent, but for continuous exposure to water, PVC is a better option.

PVC serves as an important insulation and sheathing material in boat cables.

What is the Standard of XLPE Cable?

Standards are extremely important when considering cables.

International standardization bodies have designed common standards for cables defining the structure, materials, capacities, and applications.

These standardizations also help ensure safety for the premises and structures where the cables are being used.

XLPE CABLE

There are several standard systems that have specific standards for electric cables, which include XLPE as insulation material.

For instance, the British Standard BS 5467 specifies the insulation materials for power cables for voltage ratings of up to 3kV.

XLPE meets the insulation requirements set by this specific standard.

Technically, HEPR or hard ethylene propylene rubber also meets the standard, but it is XLPE that is commonly used.

IEC 62076 and IEC 60502 also include specifications for extruded insulation that XLPE meets.

The IEC 62076 lays out the specification for cables extruded insulation and for voltage rating of 150 kV and up to 500 kV in a fixed installation.

The IEC 60502 standard lays out specifications for similar cables but for the voltage rating of 1 kV to 30 kV.

You can find more information about insulation and other specifications in the standards followed in your region.

IEC and BS standards are followed internationally, but there are regional and national standardization bodies as well.

In addition to standards, also look out for certifications such as CE and ROHS, which help assess the safety of the cables.

What are the Cable Types of XLPE Cable?

Conclusion

XLPE is an exceptionally strong and protective insulation material, particularly for high voltage cables.

It has become the most common material for such cables on account of its high thermal range, mechanical strength, and corrosion resistance from numbers of environmental factors.

Therefore, XLPE cables are used in a variety of industries, mainly for power supply and distribution.

It is the crosslinking that makes it so tough against so many environmental threats.

Quality of the insulation is, of course, an important consideration.

The cables can only be reliable if they have quality components and meet the required standards.

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