KYJV-450/750V
KYJV XLPE Insulated PVC Sheathed Control Cable — 450/750 V
XLPE insulation for control circuits in hot plant, high fault levels and long de-rated runs.
KYJV swaps PVC/A insulation for cross-linked polyethylene, moving the continuous conductor rating from 70 °C to 90 °C and the short-circuit limit from 160 °C to 250 °C for 5 s. The cross-section, core count and 450/750 V rating stay the same as KVV, so the change is a thermal upgrade rather than a dimensional one: the cable is marginally lighter because XLPE has a density near 0.92 g/cm³ against roughly 1.4 g/cm³ for PVC compound.
Two situations justify it. The first is ambient heat — a tray across a steel mill roof or a Middle East substation where de-rating a PVC cable forces a larger cross-section that costs more than the XLPE upgrade. The second is fault energy, where a control circuit near a high short-circuit level benefits from the 250 °C limit. Voltcore cross-links the insulation in-line and checks the degree of cross-linking by hot-set test on every production batch.
Specification
| Item | Value |
|---|---|
| Rated voltage U0/U | 450/750 V (0.6/1 kV on request) |
| Conductor | Class 2 stranded plain annealed copper, IEC 60228 |
| Number of cores | 2 – 61 |
| Cross-section range | 1.5 – 16 mm² |
| Insulation | XLPE (cross-linked polyethylene), 90 °C rated |
| Sheath | PVC ST1 black; ST2, LSZH or flame-retardant grades available |
| Max. continuous conductor temperature | 90 °C |
| Short-circuit conductor temperature | 250 °C for 5 s maximum |
| Test voltage | 3.5 kV rms for 5 min, no breakdown |
| Minimum bending radius | 15 × cable overall diameter (unarmoured) |
| Installation temperature | Not below 0 °C |
| Core identification | Numbered print or colour coded |
Layer-by-layer construction
Listed from the conductor outward. Read this alongside the specification table — the two together tell you whether the cable will survive its installation method.
- 1. ConductorStranded plain annealed copper, Class 2 to IEC 60228
- 2. InsulationXLPE extruded and cross-linked per core, 0.7–1.0 mm wall, heat-resistant to 90 °C continuous
- 3. Lay-upCores stranded in concentric layers with a controlled lay length
- 4. FillerNon-hygroscopic polypropylene fillers to hold the circular section
- 5. BinderPolyester tape over the bundle before sheathing
- 6. SheathBlack PVC ST1, 1.2–1.8 mm nominal; the sheath still governs the 70 °C outer surface limit
Reference dimensions and weights
| Cores × cross-section (mm²) | Conductor structure (No./mm) | Insulation thickness (mm) | Sheath thickness (mm) | Approx. overall diameter (mm) | Approx. weight (kg/km) | Max. DC resistance at 20 °C (Ω/km) |
|---|---|---|---|---|---|---|
| 4×1.5 | 7/0.52 | 0.7 | 1.2 | 9.0 | 138 | 12.1 |
| 4×2.5 | 7/0.68 | 0.7 | 1.2 | 10.1 | 196 | 7.41 |
| 4×4 | 7/0.85 | 0.8 | 1.4 | 12.0 | 280 | 4.61 |
| 4×6 | 7/1.04 | 0.8 | 1.4 | 13.3 | 380 | 3.08 |
| 4×10 | 7/1.35 | 1.0 | 1.6 | 16.7 | 590 | 1.83 |
| 4×16 | 7/1.70 | 1.0 | 1.8 | 19.4 | 880 | 1.15 |
Reference figures for preliminary sizing and drum planning. Overall diameter and weight vary with strand construction and sheath thickness tolerance; certified drawings are issued with each quotation.
Engineering characteristics
- XLPE insulation rated 90 °C continuous, 30 K above PVC/A control cable
- Short-circuit conductor limit of 250 °C for 5 s against 160 °C for PVC
- Lower insulation density than PVC, so roughly 4 % less mass at the same construction
- 450/750 V rating with 3.5 kV rms for 5 min test voltage
- Insulation resistance above 3 000 MΩ·km at 90 °C, measured per production length
- Cross-linking verified by hot-set elongation, maximum 175 % under load at 200 °C
- Available as KYJVP with braid screen and KYJV22 with steel tape armour
Typical applications
- Control and interlock circuits in steel, cement and glass plants with high ambient temperature
- Substations and switchrooms where fault levels push toward the PVC short-circuit limit
- Outdoor cable racks in Gulf, African and South-East Asian climates
- Long runs where voltage drop forces a larger section and heat build-up follows
- Transformer and generator auxiliary control wiring near hot equipment
Ordering options
- KYJVP: copper wire braid screen for screened heat-resistant control circuits
- KYJV22: steel tape armoured, minimum bending radius 12 × overall diameter
- WDZ-KYJV: low-smoke zero-halogen sheath to IEC 60754-1 and IEC 61034-2
- 0.6/1 kV rating where the circuit is fed from a 1 kV system
- Tinned copper conductor for coastal and marine installations
Standards manufactured to
- GB/T 9330
- IEC 60228 (conductor)
- IEC 60502-1 (insulation thickness and test practice where applicable)
- GB/T 19666 (flame-retardant grades)
- IEC 60332-1-2 (flame propagation)
Manufactured to other standards on request. Send the standard number with your RFQ and we will quote against it rather than against a near-equivalent.
Price and availability for KYJV XLPE Insulated Control Cable
Include cross-section, core count, voltage grade, route length and installation method — those five determine price more than anything else on the page.
- Engineer-reviewed before pricing
- Reference drawings issued with the quotation
- Free sample up to free sample up to 5 m
KYJV XLPE Insulated Control Cable — frequently asked questions
Does the PVC sheath limit the 90 °C rating of KYJV?
The conductor may run at 90 °C, but the sheath surface is still governed by its own compound, so the current rating follows the PVC sheath limit rather than the XLPE limit in most installation methods. The benefit appears during overloads and faults, not in steady-state ampacity.
Is KYJV halogen free?
The XLPE insulation contains no halogen, but the standard ST1 PVC sheath does. Where the specification calls for low smoke zero halogen, order WDZ-KYJV with an LSZH sheath and confirm the IEC 60754-1 and IEC 61034-2 test reports with the order.
Can KYJV replace KVV on an existing drawing?
Dimensionally the two are close, generally within 0.2 mm on overall diameter, so gland and tray fill are usually unaffected. Confirm the insulation thickness and the resistance figures against the reference table before substituting, and check that the termination ferrules suit the same conductor structure.
What is the minimum bending radius for KYJV?
15 × overall diameter for the unarmoured cable and 12 × for the KYJV22 armoured version, both at the minimum installation temperature of 0 °C. Below 0 °C, warm the cable before pulling rather than bending it cold.
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