YJLV-0.6-1kV
YJLV Cable — Aluminium Conductor XLPE Insulated 0.6/1 kV Power Cable
All-aluminium conductor in the same XLPE build as YJV — around 55 % lighter per metre, for long runs where cost per amp decides.
Replace the letter combination and one substitution happens: YJLV uses aluminium-alloy conductor wire instead of copper, then the same XLPE insulation and PVC oversheath the standard YJV build uses. The result is a cable that weighs roughly half as much per kilometre, which changes installation economics as much as it changes the invoice — longer drum lengths per lift, fewer drum changes on a long route, and less load on tray supports and cable hangers.
Two engineering points follow and they must be handled rather than glossed over. Aluminium conducts about 61 % as well as copper, so the equal-ampacity substitution is typically one or two standard sizes up: 50 mm² copper becomes 70 mm² aluminium, 120 mm² becomes 150 mm². And aluminium creeps under bolt pressure and oxidises within minutes of exposure, so terminations need bimetallic lugs, jointing compound and a defined torque. Voltcore supplies both with the quotation and can pre-crimp lugs at the factory.
Specification
| Item | Value |
|---|---|
| Rated voltage U0/U (Um) | 0.6/1 (1.2) kV |
| Conductor | Class 2 stranded aluminium or aluminium alloy 8030, IEC 60228 |
| Core count | 1, 2, 3, 4, 5, 3+1, 3+2, 4+1 |
| Cross-section range | 10 - 630 mm² |
| Insulation | Cross-linked polyethylene (XLPE) |
| Oversheath | PVC type ST1/ST2, black |
| Max conductor temperature, continuous | 90 °C |
| Max conductor temperature, short circuit (5 s) | 250 °C |
| Conductor conductivity | Minimum 61 % IACS for alloy 8030 annealed wire |
| Minimum bending radius, multi-core | 15 × overall diameter |
| Minimum installation temperature | 0 °C |
| Test voltage at 50 Hz | 3.5 kV, 5 min |
| Approximate weight versus YJV, equal section | 55 - 60 % lower net weight for sections above 25 mm² |
| Termination requirement | Bimetallic lug with joint compound, torque to manufacturer table |
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. ConductorAluminium or aluminium-alloy 8030 wires stranded to IEC 60228 Class 2 and compacted, with greater wire count per section than copper to hold flexibility
- 2. InsulationExtruded XLPE applied directly over the conductor in one pass and cross-linked under steam pressure; thickness identical to the copper YJV schedule
- 3. Laying-up and fillerCores cabled with polypropylene fillers and closed by a binder tape; filler volume may rise where the compacted aluminium diameter exceeds the copper equivalent
- 4. OversheathExtruded PVC type ST1/ST2 black with UV-stabilised carbon black, or LSZH compound where specified
Reference dimensions and weights
| Nominal cross-section (mm²) | Conductor structure (no./mm) | Insulation thickness (mm) | Approx. overall diameter (mm) | Approx. net weight (kg/km) |
|---|---|---|---|---|
| 4×10 | 7/1.35 | 0.7 | 19.6 | 420 |
| 4×16 | 7/1.70 | 0.7 | 22.1 | 540 |
| 4×25 | 7/2.14 | 0.9 | 25.4 | 720 |
| 4×35 | 7/2.52 | 0.9 | 27.8 | 890 |
| 4×50 | 19/1.78 | 1.0 | 31.0 | 1110 |
| 4×70 | 19/2.14 | 1.1 | 35.4 | 1400 |
| 4×95 | 19/2.52 | 1.1 | 40.2 | 1750 |
| 4×120 | 37/2.03 | 1.2 | 44.0 | 2080 |
| 4×150 | 37/2.25 | 1.4 | 48.4 | 2450 |
| 4×185 | 37/2.52 | 1.6 | 53.6 | 2890 |
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
- Net weight typically 55-60 % below the copper YJV section-equivalent, allowing longer drum lengths and fewer supports per route.
- Aluminium alloy 8030 annealed wire holds above 61 % IACS conductivity and resists the creep that caused failure in older pure-aluminium conductors.
- Same 90 °C continuous and 250 °C / 5 s short-circuit insulation rating as copper YJV, once the larger conductor section is selected.
- Deep-compression bimetallic lugs, factory crimped when specified, remove the most common cause of aluminium termination overheating.
- Lower material cost volatility: aluminium pricing moves in a different cycle to copper, which stabilises multi-month project budgets.
- Volcore also supplies the aluminium version with shaped compact conductors at 70 mm² and above, reducing finished diameter by up to 8 %.
Typical applications
- Long low-voltage feeders between remote substations and plant buildings
- Rural and peri-urban distribution networks where cost per amp governs the tender
- Solar farm and wind farm collector feeders routed across open ground
- Underground-to-overhead transitions and pole-mounted distribution links
- Campus and industrial park ring mains designed at 400 V with spare capacity
- Temporary supply where handling weight limits drum change frequency on site
Ordering options
- Aluminium alloy 8030 or grades to ASTM B800 / B801 depending on project practice
- Factory-crimped bimetallic lugs supplied fitted and capped per drum quantity
- Shaped (sector) conductors above 70 mm² to reduce finished diameter
- LSZH oversheath for tunnel and station routes where aluminium is specified for weight
- Joint compound and torque specification pack issued with every shipment
Standards manufactured to
- IEC 60502-1
- GB/T 12706.1
- IEC 60228 (conductor, Class 2)
- IEC 60889 (hard-drawn aluminium wire for stranding)
- ASTM B800 and B801 for alloy 8030 wire where specified
- IEC 61238-1 (compression and mechanical connectors, tested combinations)
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 YJLV Aluminium Conductor XLPE Power 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
YJLV Aluminium Conductor XLPE Power Cable — frequently asked questions
Which aluminium size replaces a given copper section?
Work upward one or two steps: 25 mm² copper becomes 35 mm² aluminium, 50 becomes 70, 95 becomes 120, 150 becomes 185, 240 becomes 300. Voltcore includes this mapping and the resulting voltage drop and ampacity figures with every aluminium quotation so the engineer can compare options directly.
How much lighter is YJLV than the equivalent YJV?
For sections above 25 mm² the finished net weight typically runs 55-60 % lower, because the conductor is the dominant mass. A 4-core 185 mm² YJV weighs about 8,520 kg/km; the same size in YJLV is around 2,890 kg/km. That allows roughly twice the drum length per lift and fewer joints per kilometre.
Do I need special lugs for YJLV?
Yes. Use friction-welded bimetallic lugs or tin-plated aluminium barrel lugs with jointing compound, torqued to the connector manufacturer's figure. Aluminium creeps and oxidises, so a copper lug crimped directly onto aluminium will loosen. Voltcore supplies tested lug combinations to IEC 61238-1 and can pre-crimp them.
Does YJLV carry the same current as YJV at the same size?
No. At equal cross-section an aluminium conductor carries roughly 75-78 % of the copper rating, so the larger aluminium size is selected to match. Once the substitution is made the ampacity is equivalent, the 90 °C insulation rating is unchanged, but expect about 1.5x jointing labour and verify the larger lug barrel fits the gland.
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