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XLPE Cable and Frequently Asked Questions

XLPE Cable, short for Cross-Linked Polyethylene Cable, is an insulated electrical cable renowned for its exceptional electrical properties and mechanical strength. It features a thermosetting insulation material, cross-linked polyethylene, which enhances its resistance to heat, moisture, and environmental stresses.

XLPE cables are vital components in modern electrical power systems. Their low dielectric loss and high current-carrying capacity make them ideal for power transmission and distribution. They are extensively used in underground and submarine cabling due to their robustness and reliability. Moreover, XLPE cables find applications in various industrial settings and renewable energy projects. Their capability to withstand harsh conditions and resist chemical corrosion ensures consistent power supply in diverse environments. As a crucial innovation in cable technology, XLPE cables have revolutionized electrical infrastructure and significantly improved the efficiency and reliability of power networks worldwide.

Characteristics of XLPE Cable

XLPE Cable stands out for its remarkable characteristics, making it a preferred choice for various electrical applications.

XLPE is a thermosetting material formed through the cross-linking of polyethylene molecules. This process imparts superior thermal and mechanical properties to the cable, making it highly resistant to high temperatures, moisture, and chemicals. The cross-linking ensures enhanced electrical performance and durability.

Advantages of XLPE Cable:
&#; Excellent Electrical Properties: XLPE exhibits low dielectric loss, ensuring efficient power transmission and minimal energy wastage.
&#; High Current-Carrying Capacity: Its ability to handle high current loads allows for efficient power distribution.
&#; Superior Thermal Performance: XLPE can withstand elevated operating temperatures, reducing the risk of cable failure.
&#; Resistance to Environmental Stresses: It remains resilient in harsh conditions, including UV exposure and abrasion.
&#; Long Service Life: XLPE cables have a prolonged operational life due to their robust construction and insulation properties.
&#; Easy Installation: The flexibility and lightweight nature of XLPE cables facilitate straightforward installation.

Comparison with other Cable Types (PVC, EPR, etc.):
&#; XLPE vs. PVC: XLPE cables outperform PVC cables in terms of thermal endurance, current-carrying capacity, and environmental resistance, making them more suitable for high-power applications and outdoor installations.
&#; XLPE vs. EPR: While both XLPE and Ethylene Propylene Rubber (EPR) cables offer excellent electrical properties, XLPE cables tend to have higher temperature ratings, longer life expectancy, and better resistance to water treeing, making them preferable for high-voltage applications and critical infrastructure.

Construction of XLPE Cable:

XLPE cables are designed with a robust construction to ensure optimal electrical performance and mechanical strength. The construction involves specific layers and components, each playing a crucial role in the cable&#;s overall functionality.

The basic structure of an XLPE cable consists of the following components arranged from the inside to the outside:
&#; Conductor: The core of the cable is typically made of copper or aluminum conductors, responsible for carrying electrical current.
&#; Insulation: The conductor is surrounded by a layer of Cross-Linked Polyethylene (XLPE) insulation. XLPE&#;s cross-linked structure provides excellent electrical properties and thermal stability.
&#; Screen (optional): In some XLPE cables, an insulation screen may be added to mitigate electric field stresses, thereby reducing partial discharges.
&#; Metallic Screen (optional): For medium and high voltage cables, a metallic screen, such as copper tape or wire, may be applied to provide electromagnetic shielding.
&#; Bedding: The bedding layer, typically made of PVC or LLDPE, protects the cable core and serves as a bedding for the armoring (if applicable).
&#; Armoring (optional): For certain XLPE cables, steel or aluminum wires or tapes are used to provide mechanical protection and additional strength.
&#; Sheath: The outermost layer is the cable sheath, which can be made of PVC, HDPE, or LSZH (Low Smoke Zero Halogen) material, offering protection against moisture, chemicals, and mechanical damage.

Types of XLPE Cables

XLPE cables come in various configurations to cater to different voltage levels and application requirements. The key types of XLPE cables are as follows:

Low Voltage XLPE Cables:
Low voltage XLPE cables are designed for voltages typically up to 1 kV ( volts). They are commonly used in residential, commercial, and industrial applications, providing power distribution within buildings, connecting appliances, and various low-voltage equipment.

Medium Voltage XLPE Cables:
Medium voltage XLPE cables are engineered for higher voltage levels, ranging from 1 kV to 35 kV. They are extensively employed in industrial installations, underground power distribution, and infrastructure projects, serving as feeder cables for substations and power distribution networks.

High Voltage XLPE Cables:
High voltage XLPE cables are designed to handle voltages above 35 kV, typically up to 500 kV or more. These cables are crucial components in major power transmission systems, interconnecting large power plants, substations, and transmission grids.

Single Core and Multi-Core XLPE Cables:
XLPE cables can have a single conductor core or multiple cores, typically two, three, or four cores, depending on the application and specific requirements. Single-core cables are suitable for high-voltage transmission, whereas multi-core cables are often used for distribution and industrial applications.

Unarmored and Armored XLPE Cables:
XLPE cables may come with or without armor. Armored XLPE cables have an additional layer of steel or aluminum wires/tapes for mechanical protection, making them suitable for direct burial, underground, or harsh environmental conditions.

Fire Resistant XLPE Cables:
Fire-resistant XLPE cables are designed to maintain functionality during fire incidents. They are widely used in critical applications like emergency lighting, fire alarm systems, and evacuation systems.

Low Smoke Zero Halogen (LSZH) XLPE Cables:
LSZH XLPE cables are designed with a special outer sheath material that emits minimal smoke and no toxic halogen compounds when exposed to fire. They are commonly used in confined spaces, public areas, and buildings where fire safety is a concern.

The choice of the appropriate type of XLPE cable depends on factors such as voltage requirements, installation environment, safety considerations, and specific application needs. Each type of XLPE cable offers distinct advantages, making them a versatile and widely used solution for various electrical power transmission and distribution challenges.

Applications of XLPE Cable

XLPE cables find extensive use in a wide range of electrical power transmission and distribution applications due to their exceptional electrical properties and mechanical strength. Some of the key applications of XLPE cables include:

Power Transmission and Distribution:
XLPE cables are crucial components in high-voltage power transmission systems, interconnecting power plants, substations, and transmission grids. They efficiently transmit electricity over long distances, ensuring minimal power losses and reliable energy delivery.

Underground and Submarine Cabling:
XLPE cables are well-suited for underground and submarine cabling projects due to their robustness and resistance to moisture and environmental stresses. They are used to supply power to urban areas, transportation networks, and offshore installations.

Industrial Applications:
XLPE cables serve various industrial needs, powering machinery, motors, and equipment in factories, mines, and industrial plants. Their high current-carrying capacity and durability make them ideal for heavy-duty applications.

Renewable Energy Projects:
In renewable energy installations, such as wind farms and solar power plants, XLPE cables play a critical role in transmitting generated electricity to the grid. They facilitate the integration of renewable energy sources into the existing power infrastructure.

Building Wiring and Infrastructure:
XLPE cables are extensively used in buildings and infrastructure for electrical wiring, connecting lighting fixtures, outlets, and electrical panels. Their flexibility and ease of installation make them a preferred choice in construction projects.

Railways and Transportation:
XLPE cables are employed in railways and transportation systems, providing power supply to trains, signaling systems, and electrified tracks. Their high reliability and resistance to mechanical stress make them suitable for rail applications.

Oil and Gas Industry:
XLPE cables are utilized in the oil and gas sector for onshore and offshore installations, providing power to pumps, motors, and control systems in harsh and corrosive environments.

Data Centers and Telecommunications:
XLPE cables are also used in data centers and telecommunications infrastructure for power distribution and connection of critical equipment, ensuring continuous and reliable operations.

Fire Safety Systems:
Fire-resistant XLPE cables are employed in fire safety systems, such as emergency lighting, fire alarms, and evacuation systems, to maintain functionality during fire incidents.

The versatility of XLPE cables, combined with their ability to withstand challenging environments, makes them a preferred choice in diverse applications, contributing significantly to the efficiency and reliability of modern electrical systems across industries.

Frequently Asked Questions (FAQs) about XLPE Cable

What are the benefits of XLPE?

The benefits of XLPE make it a preferred choice for applications where electrical insulation, chemical resistance, thermal stability, and mechanical strength are crucial factors. Its versatility and reliability have contributed to its widespread use in power transmission, cable manufacturing, automotive, aerospace, and other industries. XLPE insulation performs at both high and low temperatures. Due to its structure, XLPE is extremely resistant to abrasion and other wear and tear. It also boasts resistance to high-voltage electricity, chemicals, and other hazardous materials. Cross-linked polyethylene insulation is also a more affordable option.

When should XLPE cable be used?

XLPE cable is commonly used in a wide range of applications, including power distribution in buildings, industrial installations, and utility power grids. It is available in various sizes and configurations, including single-core, multi-core, and screened cables. It can also be used for low-voltage, medium-voltage, and high-voltage Cross-Linked Polyethylene applications.

In short, XLPE cable should be used in industries that expose wire and cable to:

• Extreme temperature conditions (high and low)
• High-voltage electrical applications
• Abrasion and stress
• Water and other liquids
• Chemicals and other hazardous materials

XLPE cable can be used for plumbing, mining, and various electrical applications. Cross-linked polyethylene cables can also be found across the chemical industry and within the commercial and residential heating industry. Don&#;t forget about dentists&#; offices and other medical institutions, groundskeeping at stadiums and other venues, and much more.

What&#;s the difference between XLPE insulation and PVC insulation?

XLPE, as explained above, is cross-linked polyethylene material. PVC stands for polyvinyl chloride insulation.

The main difference is that XLPE can be used for high and low-tension applications. Its structure provides great resistance to abrasion, stress, and other wear and tear. PVC insulation cannot withstand as much pressure, meaning it is only suitable for low-tension applications.

Other differences:
&#; XLPE insulation tends to last longer than PVC insulation
&#; Since XLPE doesn&#;t contain chloride, it is more environmentally friendly
&#; XLPE insulation can withstand higher temperatures
&#; Cross-linked polyethylene features more moisture resistance

How does XLPE insulation improve cable performance?

XLPE insulation significantly improves cable performance by offering enhanced electrical, thermal, and mechanical properties. The cross-linked polyethylene undergoes a chemical process that creates a durable, robust insulation material. XLPE insulation reduces dielectric losses, improving cable efficiency during power transmission. Its higher temperature rating ensures stable operation under elevated heat conditions. XLPE&#;s exceptional mechanical strength enhances cable durability and resistance to physical stresses. Moreover, XLPE&#;s resistance to moisture, chemicals, and environmental factors ensures long-term reliability and protection in harsh conditions. With reduced water treeing, a common issue in wet environments, XLPE insulation delivers superior performance, making it a preferred choice for various electrical applications, including power transmission, distribution, and industrial installations.

Conclusion

XLPE cables have emerged as a cornerstone in modern electrical infrastructure, offering a multitude of advantages that ensure efficient power transmission and distribution. Their exceptional electrical properties, high current-carrying capacity, and superior thermal performance make them a preferred choice for various applications. Additionally, their resistance to environmental stresses and extended service life further solidify their reliability in critical installations.

The future prospects for XLPE cable technology are promising. Ongoing research and development efforts aim to push the boundaries of XLPE&#;s capabilities, potentially increasing voltage ratings, improving insulation properties, and exploring eco-friendly materials. Advancements in XLPE cable design and manufacturing techniques will pave the way for more sustainable and efficient electrical networks. As technology evolves, XLPE cables will continue to play a pivotal role in shaping the future of power transmission and distribution, fostering a more resilient and reliable energy landscape.

If you need any custom cable assembly & wire harness, Please contact us now! We are your best partner for customizing wiring harnesses.

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In FPV drones, the electrical wiring and connectors play a crucial role in ensuring that the drone operates efficiently and safely. In this tutorial, we will cover everything you need to know about electrical wires and connectors, including the different types and how the size of wire and connector affects performance.

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What Type of Electrical Wires Should You Use for Your FPV Drone?

There are several types of wires available, the most common type used in FPV drones is silicone stranded wire. Compared to solid core wires, stranded wires are more flexible and easier to work with.

Compared to PVC-insulated wires, Silicone-insulated wire is preferred for RC applications due to its flexibility, especially as multirotor frames and components continue to shrink in size. Silicone wires are also lightweight and can tolerate a wider temperature range, making them more durable in extreme environments. In addition, they are less likely to melt or shrink when exposed to heat during soldering.

Electrical Resistance in Wires

One important factor to consider when choosing wires for your FPV drone is the wire&#;s resistance. Longer or thinner wires will have more resistance, which can lead to voltage drop and power loss (especially so for the battery). This is why wires have a current rating.

To minimize resistance, it&#;s best to keep your wires as short as possible. While thicker wires can also help reduce resistance, they can add weight to your drone.

To ensure that your power system can deliver the required power, make sure your wires are appropriately sized for the components in your drone. Choosing the right size wire will prevent it from becoming a bottleneck in your power system and allow your drone to perform at its best.

Understanding Wire Gauge

Wire gauge refers to the thickness of the electrical wire and is measured in AWG (American Wire Gauge). Choosing the right wire gauge is important to ensure that the wire can handle the current required by the component it is connected to.

In general, the higher the AWG number, the thinner the wire. The lower the AWG number, the bigger the cable size and current capacity. The current rating of a wire is the maximum amount of current that it can safely handle without overheating or becoming damaged.

When building an FPV drone, minimizing weight is important. For instance, here are some commonly used wire gauges for different components on a 6S 5-inch FPV drone:

• 14AWG for Battery XT60 Pigtail
• 18AWG-20AWG for ESC and Motor power wires
• 28AWG for other low power components and signals

When connecting two wires, the maximum current that can be passed through them is limited by the smaller wire. Therefore, if you are extending a wire, it&#;s best to match the wire gauge and use the same AWG wire. Using larger wires than necessary doesn&#;t provide any benefit but extra weight, which is not ideal for an aircraft.

Here&#;s the estimated weight per meter of wire for different AWG number:

• 24 AWG &#; 4.5g
• 20 AWG &#; 7.5g
• 18 AWG &#; 11g
• 16 AWG &#; 20g
• 14 AWG &#; 27g
• 12 AWG &#; 39g
• 10 AWG &#; 61g

Disclaimer: The numbers in this post are a guide only.

Are you interested in learning more about Single-Core and Multi-Core Wiring Harnesses? Contact us today to secure an expert consultation!

Current Rating Look-Up Table

To determine what AWG wires you need, you should first work out your quad&#;s maximum amp draw and then refer to a current rating look-up table. The current rating is normally a continuous current if not specified.

Different electrical wire manufacturers may have different standards and current ratings. Here&#;s one example:

As a general guideline, I personally follow this table based on the burst current requirement (e.g. current draw at full throttle):

• 10AWG Wire: 250A
• 12AWG Wire: 160A
• 14AWG Wire: 110A
• 16AWG Wire: 80A
• 18AWG Wire: 50A
• 20AWG Wire: 30A
• 22AWG Wire: 24A
• 24AWG Wire: 20A

It&#;s important to use the appropriate wire size to minimize voltage drop and power loss due to resistance, and to reduce the risk of overheating. However, in some cases, it may be acceptable to use slightly thinner wires if the wire length is short and the current bursts are only for a short period of time to minimize weight.

In my 6S 5&#; builds, I usually use 14 AWG wires for connecting the battery, even though the maximum current draw might be slightly over the current rating of the 14AWG wire. I don&#;t think this would be a problem because, firstly the wires are quite short; secondly, the current bursts typically only lasts for a couple of seconds, even if you leave it at full throttle for longer, the battery wouldn&#;t be able to keep up anyway. The main reason I prefer 14AWG over 12AWG is because they are easier to solder to the ESC, and can shave a couple of grams off my build.

There&#;s also voltage rating for electrical wires, but it&#;s usually not a concern for RC applications, since the voltage we are dealing with are well below 30V. The wires we use can tolerate much higher voltage (e.g. hundreds of volts or even higher).

Where to Buy Silicon Electrical Wires

Are Red and Black Wires Different?

No, red and black wires are the same wires, just different in colour. You can use any colour wire you want for your drone, but conventionally, red is used for positive power and black is used for ground. Following this convention makes it easier to visualize which wire is which and helps prevent mistakes. There are other colour-coded wires which are typically for signals, but it&#;s totally up to you what color wires to use.

12 AWG

Applications: For XT60 pigtail, high power 5&#;, 6&#;, 7&#; FPV Drone.

14 AWG

Application: for XT60 pigtail, medium power 5&#; FPV Drone.

16 AWG

Application: for XT30 and XT60 pigtail, long range builds (80A burst).

20 AWG

Application: for XT30 on sub250 builds, and motor wire extension for 5&#; builds. 18AWG also works well if you don&#;t mind the slight extra weight.

26AWG-28AWG

Application: for signals, power for your FPV system, receiver etc, basically anything that isn&#;t battery or motor related.

Choosing the Right Connectors for Your FPV Drone

Connectors are an essential component for attaching two components temporally, such as the battery and ESC. You can also use connectors if you don&#;t like soldering.

For signals, it&#;s less of a problem and you can use any connector you want. However, when it comes to battery or any high current applications, it&#;s crucial to choose the right type of connector, because like wires, connectors also have a current limitation.

Here is a general guideline for the continuous and burst current ratings of some commonly used connectors:

• JST connector: 5A (10A)
• 2mm bullet connectors: 20A (40A)
• XT30: 30A (60A)
• XT60: 60A (180A)

While it&#;s tempting to overcompensate and use larger connectors, it&#;s not always necessary and can add unnecessary weight to your drone. In some cases, it may even have a negative impact on your drone&#;s performance. For example, when it comes to micro drones such as Tiny Whoops, there&#;s a debate about whether XT30 connectors or BT2.0 / A30 connectors are the better option. While XT30 connectors have a lower resistance than PH2.0, BT2.0 and A30, but the benefits are hardly noticeable while it&#;s much heavier, some argue that BT2.0 and A30 are the optimal choices because they provide a good compromise between weight and performance. You can learn more about these connectors for micro drones in my testing: https://oscarliang.com/micro-battery-connectors-testing/

By choosing the appropriate connector based on your drone&#;s specific needs, you can ensure that your drone operates safely and efficiently.

Where to Buy LiPo Battery Connectors

Two of the most popular battery connectors used in FPV drones are the XT60 and XT30 connectors. These connectors share the same design but come in different sizes and are rated for different maximum currents. According to the official datasheet, the XT60 connector is rated for a maximum current of 60 amps, while the XT30 connector is rated for a maximum current of 30 amps. These ratings are designed to ensure safe operation of the connectors under specific conditions.

However, recent test has shown that the XT30 connector can actually support a much higher continuous current of up to 60 amps without any problems, as long as the wires connected to it are large enough. This means that you can safely use an XT30 connector for applications that require higher currents, as long as you follow the appropriate safety precautions.

On the other hand, the XT60 connector has also been put to the test, and it has been found that it can safely handle burst currents of up to 180 amps for 10 seconds without any problems. This makes it a reliable choice for a typical FPV drones without the need to upgrade to heavier and bulkier connectors.

XT60 Connectors

XT60 14AWG Pigtail

Comes with wires soldered on.

XT30 Connectors

XT30 16AWG Pigtail

Comes with wires soldered on.

Tips for Using Wires and Connectors

What Gauge Wires for Extending Capacitor?

When extending a capacitor in your FPV drone, the recommended wire gauge will depend on the size of the capacitor and the amount of current it will be handling. But in general, the length of the wires are more important than the wire gauge.

For smaller capacitors (under uF), you can use thinner wires such as 18AWG or 20AWG (like the motor wires). For larger capacitors (over uF), it&#;s best to use thicker wires such as 16AWG. It&#;s important to keep the wire as short as possible to minimize resistance.

You can learn more about why and how to add capacitor in your drone in this article.

Soldering Techniques

Proper soldering techniques are important for creating strong, reliable electrical connections in your drone. Techniques for soldering wires and connectors include tinning, splicing, and using heat shrink tubing to protect the connection. It is important to avoid common soldering mistakes such as overheating the wire, creating cold joints, or using too much solder.

You can learn about how to solder wires and connectors in this tutorial.

Proper Cable Management

When routing wires in your drone, it&#;s important to keep them as short as possible to reduce the risk of interference and voltage drops. If the wires are too long, you can twist them to keep them neat and tidy, which also help against interference.

When connecting wires and components, ensure that they are securely fastened and will not come loose during flight. Loose wires can cause significant damage to your drone during flight and potentially lead to a crash.

It&#;s also important to avoid resting cables on top of the flight controller, apart from potentially causing interference, it could also be hitting the gyro which affect flight performance. Instead, try to route cables underneath or around the FC.

Finally, to help prevent damage to your battery lead solder joints during crashes, it&#;s recommended to secure the battery lead to the frame using zip ties. This provides stress relief and prevents pulling the solder joints during a crash.

More Info and Discussion

We have a similar topics on the forum if you&#;d like to learn more about this subject and like to comment.

Edit History

• May &#; Article created
• Apr &#; Article revised
• Nov &#; Added product shopping options
• Mar &#; Updated guide, added &#;Tips&#; section, updated product links, changed page URL

For more information, please visit signal cable vs power cable.