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Flexible Silicone Rubber Cables
Short Description:
Silicone Rubber Cables use silicone rubber as the insulating or sheathing material. Due to the inherent properties of silicone rubber—such as high-temperature resistance, low-temperature flexibility, softness, wear resistance, and corrosion resistance—these cables maintain stable electrical performance in high-temperature environments, exhibit excellent aging resistance, and have a long service life. They are suitable for fixed installation power transmission lines or flexible connection cables
Product Introduction
Selection Guidelines
Classification standard
Installation and Maintenance Precautions
| Dimension | Detailed Description |
|---|---|
| Product Definition | A special type of industrial cable that uses silicone rubber series polymer materials such as methyl vinyl silicone rubber (MVQ), phenyl silicone rubber, and fluorosilicone rubber (FVMQ) as the core insulation/sheath material. It is the core category of special industrial cables with high temperature resistance, high flexibility, and harsh environment resistance, which can adapt to extreme working conditions that conventional cables cannot cover. |
| Core Materials | The core insulation layer is made of silicone rubber series materials; the conductor is oxygen-free copper/tinned copper/silver-plated copper conductor (multi-strand ultra-fine flexible conductor is preferred for high flexibility scenarios); the sheath can be matched with silicone rubber, low smoke zero halogen flame retardant polyolefin, chloroprene rubber and other materials. Composite structures such as armouring, shielding, and composite insulation can be customized according to application scenarios. |
| Core Characteristics | 1. Excellent temperature resistance: long-term operating temperature ranges from -60℃ to 180℃, and special modified silicone rubber can reach -90℃ to 200℃. Its high and low temperature cycle resistance is far superior to ordinary PVC/XLPE/rubber cables;2. Excellent flexibility: silicone rubber material has low elastic modulus and high softness, can be laid with an extremely small bending radius, and has excellent bending resistance and fatigue fracture resistance, which is suitable for dynamic scenarios requiring frequent movement and repeated bending;3. Strong weather resistance and aging resistance: UV resistance, ozone resistance, heat and humidity resistance, salt spray resistance, and the service life of long-term outdoor laying can reach more than 10 years, far exceeding that of ordinary rubber cables;4. Stable electrical performance: high insulation resistance, low dielectric constant, small dielectric loss, excellent high-frequency signal transmission performance, strong anti-electromagnetic interference capability, and almost no attenuation of electrical performance in a wide temperature range;5. Outstanding flame retardant and safety performance: pure silicone rubber material itself has self-extinguishing properties, no dripping, low smoke and non-toxic, can meet the highest flame retardant grade requirements, and releases no corrosive toxic gases during combustion, which is suitable for high safety requirement scenarios;6. Oil and chemical corrosion resistance: modified silicone rubber can withstand corrosive media such as mineral oil, synthetic oil, acid and alkali solutions, and organic solvents, which is suitable for complex corrosive environments such as chemical industry, ships, and oil fields. |
| National Implementation Standards | Basic standard: GB/T 5013 Series Standards for Rubber Insulated Cables for Rated Voltages up to and Including 450/750V;Power cable standard: GB/T 12706 Series Standards for Extruded Insulated Power Cables and Accessories for Rated Voltages from 1 kV to 35 kV;Special performance standards: GB/T 19666 General Rules for Flame Retardant and Fire Resistant Wires and Cables, GB/T 2951 General Test Methods for Cable Insulation and Sheath Materials;Material standard: GB/T 14831 Insulating and Sheathing Compounds for Power Cables for Rated Voltages up to and Including 35 kV. |
| Core Application Scenarios | 1. Extreme high and low temperature environments: long-term high/low temperature operation scenarios such as metallurgy, electric power, boilers, low temperature cold storages, and aerospace;2. High flexibility dynamic scenarios: scenarios requiring frequent movement and repeated bending such as industrial robots, drag chain systems, automation equipment, mobile machinery, and elevators;3. Outdoor harsh environments: scenarios with high weather resistance and aging resistance requirements such as photovoltaics, wind power, offshore platforms, port machinery, and outdoor lighting for long-term outdoor laying;4. High safety flame retardant scenarios: scenarios with extremely high requirements for low smoke non-toxicity and flame retardant and fire resistance such as rail transit, aviation, ships, high-rise buildings, mines, and fire emergency;5. Precision signal transmission scenarios: high-precision and high-frequency signal transmission scenarios such as communications, radar, medical equipment, and industrial automation;6. Oil and corrosion resistance scenarios: scenarios with oil stain, acid and alkali, and organic solvent corrosion such as chemical industry, pharmacy, oil fields, ships, and sewage treatment. |
| Model Selection Module | Core Points | Detailed Description and Red Line Requirements |
|---|---|---|
| Core Red Line Principles for Model Selection | Compliance First | 1. All model selection must comply with the current national cable standards. For special scenarios such as fire protection/emergency/mine/rail transit, compliant products with corresponding flame retardant/fire resistant/MA/3C mandatory certification must be selected;2. Non-standard products without test reports and certification are strictly prohibited, especially in high-risk scenarios;3. The rated voltage, temperature resistance grade, flame retardant grade, and bending radius must be higher than the maximum requirements of the actual application scenario. Low-specification models are strictly prohibited from being used beyond their applicable scenarios. |
| Scenario Matching | 1. Fully adapt to the ambient temperature, corrosion grade, mechanical external force, laying method, operating status, and signal transmission requirements of the application scenario;2. High/low temperature scenarios must be matched with silicone rubber materials of corresponding temperature resistance grade, dynamic bending scenarios must select high tear resistant and high flexibility models, and strong corrosion scenarios must select oil and corrosion resistant modified silicone rubber models;3. Scenarios with mechanical external force risks must select armoured structure, mobile scenarios must select multi-strand flexible conductor structure, high drop scenarios must select steel wire armoured structure, and high frequency signal scenarios must select special shielding structure. | |
| Performance Adaptation | 1. The electrical performance, transmission performance, mechanical performance, and environmental resistance must fully meet the actual application requirements, with a 10%~20% redundancy reserved;2. Operation beyond the rated voltage, long-term operating temperature, minimum bending radius, and current carrying capacity is strictly prohibited;3. Take into account the economy and convenience of operation and maintenance, give priority to general-purpose models, and avoid excessive customization that leads to difficulties in later operation and maintenance. | |
| Core Material and Specification Selection | Insulation Material Selection | 1. Conventional high temperature/high flexibility scenarios (-60℃~180℃): priority is given to ordinary methyl vinyl silicone rubber material, with moderate cost and strong versatility;2. High fire risk/low smoke non-toxic requirement scenarios: priority is given to flame retardant modified silicone rubber material, and the corresponding flame retardant grade is matched according to the risk level;3. Fire emergency/fire resistance requirement scenarios: fire resistant mica tape + silicone rubber composite insulation structure must be selected, and the corresponding fire resistance grade is matched;4. Drag chain/robot/frequent bending dynamic scenarios: priority is given to high tear resistant modified silicone rubber material, with excellent tear resistance, wear resistance, and fatigue fracture resistance;5. Oil and corrosion resistance/chemical industry/ship scenarios: priority is given to fluorosilicone rubber/oil resistant modified silicone rubber material, which can withstand corrosive media;6. Red line requirement: The long-term allowable operating temperature of the insulation material must be higher than the maximum temperature of the actual working environment + conductor operating temperature rise, with a safety redundancy of more than 20℃ reserved. |
| Conductor Specification Selection | 1. Conductor material: oxygen-free copper conductor is selected for conventional scenarios, tinned copper/silver-plated copper conductor is selected for high temperature/high frequency/high humidity scenarios to reduce high frequency loss and improve oxidation resistance;2. Conductor cross section: determined according to current carrying capacity, voltage drop, and short circuit current verification, with a current carrying capacity redundancy of more than 10% reserved. Operation beyond the current carrying capacity is strictly prohibited;3. Conductor structure: single strand/7 strand hard conductor is selected for fixed laying, multi-strand ultra-fine flexible conductor is selected for mobile/flexible scenarios, single solid conductor is selected for high frequency scenarios to reduce skin effect, and high flexibility stranded flexible conductor must be selected for drag chain scenarios. | |
| Structure Selection | 1. No mechanical external force, indoor/equipment laying: priority is given to non-armoured structure, with low cost, convenient laying, and the best flexibility;2. Direct burial, pipe laying, outdoor, with mechanical impact: priority is given to steel tape armoured structure, with high protection level, compression and impact resistance;3. High drop, vertical laying, with large tensile force: priority is given to steel wire armoured structure, with excellent tensile and anti-falling performance;4. High frequency signal, automatic control, with electromagnetic interference: shielded structure must be selected. For high frequency/high precision control scenarios, priority is given to overall shield + pair shield double layer shielding, with shielding coverage ≥85%;5. Drag chain/robot/frequent bending scenarios: high tear resistant silicone rubber insulation + wear-resistant sheath + ultra-fine flexible conductor composite structure must be selected, which matches the bending life requirements;6. Fire protection/emergency/high risk scenarios: fire resistant + high flame retardant composite structure must be selected to ensure power supply stability in fire scenarios. | |
| Voltage Grade Selection | 1. Control signal/equipment supporting: priority is given to 450/750V rated voltage, with strong versatility and complete accessory matching;2. Low voltage power supply: priority is given to 0.6/1kV rated voltage, which is suitable for most industrial low voltage power supply scenarios;3. Medium voltage power supply/grid connection transmission: 6kV, 10kV, 35kV rated voltage is selected according to the system voltage, and special cable accessories of corresponding voltage grade must be matched;4. High frequency/RF signal transmission: special high frequency silicone rubber cables with corresponding characteristic impedance (50Ω/75Ω) must be selected, and ordinary power/control cables are strictly prohibited from being replaced;5. Red line requirement: The rated voltage of the cable must be higher than the maximum operating voltage of the system, and operation beyond the rated voltage is strictly prohibited. | |
| Scenario Adaptation Selection Verification | Environmental Parameter Verification | 1. Temperature verification: confirm that the long-term allowable operating temperature of the cable ≥ the maximum ambient temperature + conductor operating temperature rise, and sufficient temperature resistance redundancy must be reserved for high/low temperature scenarios;2. Corrosion verification: confirm that the corrosion resistance of the cable insulation/sheath material fully matches the corrosive media such as oil stain, acid and alkali, and organic solvent in the environment. Ordinary silicone rubber materials are strictly prohibited in strong corrosion scenarios;3. Weather resistance verification: for long-term outdoor laying, silicone rubber materials with UV resistance, ozone resistance, and heat and humidity resistance must be selected, and ordinary indoor cables are strictly prohibited from being replaced;4. Flame retardant verification: select cables of corresponding flame retardant/fire resistance grade according to the fire risk level of the scenario, and Class A high flame retardant or fire resistant cables must be selected for high risk scenarios. |
| Laying Parameter Verification | 1. Bending radius verification: confirm that the minimum allowable bending radius of the cable ≤ the actual laying bending radius. The minimum bending radius for fixed laying is ≥10 times the cable outer diameter, for mobile laying is ≥15 times the cable outer diameter, and for drag chain scenarios is ≥5 times the cable outer diameter. Laying with excessive small bending radius is strictly prohibited;2. Laying method verification: confirm that the cable structure fully matches the laying method. Direct burial must select armoured + rodent and ant proof structure, drag chain must select high flexibility and bending resistance structure, and vertical laying must select anti-slip steel wire armoured structure;3. Laying space verification: confirm that the outer diameter, weight, and structure of the cable fully match the laying pipeline, cable tray, drag chain, and installation space to avoid installation failure. | |
| Electrical Performance Verification | 1. Current carrying capacity verification: according to the laying method, ambient temperature, and number of parallel cables, verify that the allowable current carrying capacity of the cable ≥ the actual maximum operating current, with a redundancy of more than 10% reserved;2. Voltage drop verification: verify that the line voltage drop of the cable ≤ the maximum allowable voltage drop of the system. For long-distance transmission, the conductor cross section must be increased or low loss materials must be selected;3. Short circuit current verification: verify that the short circuit thermal stable current of the cable ≥ the maximum short circuit current of the system to ensure that the cable will not be broken down in short circuit scenarios;4. High frequency performance verification: for high frequency signal scenarios, the characteristic impedance, attenuation, standing wave ratio, transmission delay and other parameters of the cable must be verified to fully match the signal transmission requirements. | |
| Compliance and Supporting Selection | Certification and Test Confirmation | 1. It must be confirmed that the target product has a complete factory test report, and the test items cover core indicators such as electrical performance, mechanical performance, flame retardant performance, temperature resistance performance, and bending life;2. For special scenarios such as fire protection/emergency/mine/rail transit, it must be confirmed that the product has corresponding mandatory certifications such as flame retardant/fire resistant/MA/3C, the certification is within the validity period, and the certification scope covers the selected specifications;3. Non-standard products without certification and test reports are strictly prohibited. |
| Supporting Accessory Selection | 1. Special cable accessories that fully match the voltage grade, specification, and material of the cable must be selected simultaneously, including terminals, intermediate joints, wiring terminals, connectors, and fixing parts;2. For medium voltage cables, special cold shrink/heat shrink accessories of corresponding voltage grade must be selected, and low voltage accessories are strictly prohibited from being replaced;3. For high flame retardant/fire resistant scenarios, supporting accessories of corresponding flame retardant/fire resistant grade must be selected to ensure the safety performance matching of the whole link;4. For drag chain/mobile scenarios, suitable flexible fixing parts and guide devices must be selected to avoid damage to the cable during laying. | |
| Operation and Maintenance Supporting Confirmation | 1. Priority is given to models with large market holdings and strong versatility to ensure convenient later accessory supply and operation and maintenance replacement;2. Excessively customized non-standard models are avoided to prevent excessive later operation and maintenance costs and replacement difficulties;3. It is confirmed that the manufacturer has complete after-sales technical support and on-site installation guidance services to ensure the correct installation and use of the cable. |
| Classification Dimension | Sub-category | Core Definition and Characteristics | Typical Model Examples |
|---|---|---|---|
| By Core Insulation Material (Core Classification) | Ordinary Silicone Rubber Insulated Cable | Uses methyl vinyl silicone rubber as the core insulation material, with a long-term operating temperature of -60℃~180℃. It is a general-purpose high temperature resistant and high flexibility silicone rubber cable with moderate cost, which is suitable for most conventional high temperature and flexible scenarios. | YG, YGC, KGG, YGV |
| Flame Retardant Silicone Rubber Insulated Cable | Uses modified silicone rubber with flame retardant added as the insulation/sheath material, with a flame retardant grade up to Class A of GB 31247. It has low smoke zero halogen, no dripping, and strong self-extinguishing property, which is suitable for high fire risk scenarios. | ZR-YG, ZR-YGC, ZB-KGG, ZA-YGV | |
| Fire Resistant Silicone Rubber Insulated Cable | Adopts a composite structure of fire resistant mica tape + silicone rubber insulation, which can maintain normal power supply for more than 3 hours in 950℃~1000℃ flame, and also has high temperature resistance and high flexibility characteristics. It is suitable for fire emergency and high safety requirement scenarios. | NH-YG, NH-YGC, NH-KGG, N-YGV | |
| High Tear Resistant Silicone Rubber Insulated Cable | Uses modified high tear resistant silicone rubber as the insulation/sheath material. Its tear strength and wear resistance are far superior to ordinary silicone rubber, while retaining high flexibility and high temperature resistance characteristics. It is suitable for dynamic scenarios with frequent bending and wear such as drag chains and robots. | YGG, YGC-F, KGG-F, YGV-H | |
| Oil and Corrosion Resistant Silicone Rubber Insulated Cable | Uses fluorosilicone rubber and oil-resistant modified silicone rubber as the insulation/sheath material, which can withstand corrosive media such as mineral oil, synthetic oil, acid and alkali solutions, and organic solvents, with a long-term operating temperature of -60℃~200℃. It is suitable for corrosive environments such as chemical industry, oil fields, and ships. | YG-F, YGC-FS, KGG-FY, YGV-F | |
| By Structural Characteristics | Non-armoured Silicone Rubber Cable | No metal armouring layer, simple structure, convenient laying, low cost, and excellent flexibility. It is suitable for indoor/equipment fixed/mobile laying without mechanical external impact. | YG, YGC, KGG, YGV |
| Armoured Silicone Rubber Cable | Added steel tape/steel wire/aluminum-plastic composite tape armouring layer, with excellent mechanical impact, compression and tensile resistance, high protection level, while retaining the high temperature resistance and high flexibility characteristics of silicone rubber. It is suitable for direct burial, pipe laying, outdoor scenarios with mechanical external force risks. | YGV22, YGC22, KGG22, YG32 (steel wire armoured) | |
| Shielded Silicone Rubber Cable | Added copper mesh/aluminum foil/tinned copper tape shielding layer, with extremely strong anti-electromagnetic interference and anti-radio frequency interference capability, high signal transmission stability, while retaining high flexibility and high temperature resistance characteristics. It is suitable for high-frequency signal, automatic control, and precision instrument supporting scenarios. | KGG, YGP, YGCP, KGG22P (overall shield + pair shield) | |
| High Flexibility Drag Chain Special Silicone Rubber Cable | Adopts a composite structure of multi-strand ultra-fine flexible conductor + high tear resistant silicone rubber insulation + wear-resistant sheath, which can achieve more than 10 million times of repeated bending without fracture, and the minimum bending radius can reach 5 times the cable outer diameter. It is suitable for high-frequency dynamic scenarios such as drag chains, robots, and automation equipment. | YG-TR, YGC-TR, KGG-TR, YGV-TR | |
| Flat Silicone Rubber Cable | Adopts a flat structure design, with multi-core wires arranged in parallel, thin thickness, high flexibility, and can be laid against the wall. It is suitable for scenarios with limited installation space such as elevators, traveling cranes, and mobile equipment. | YGB, YGCB, KGGB, YGVB | |
| By Rated Voltage Grade | Low Voltage Control Silicone Rubber Cable | Rated voltage 450/750V, number of cores ranges from 2 to 61. It is suitable for industrial control, signal transmission, and equipment supporting, and is the most widely used general-purpose category. | KGG, KGV, YG, YGV |
| Low Voltage Power Silicone Rubber Cable | Rated voltage 0.6/1kV, 1.8/3kV, number of cores ranges from 1 to 5, conductor cross section 1.5mm²~400mm². It is suitable for industrial low voltage power supply and equipment power supporting, and its high temperature resistance is far superior to ordinary power cables. | YGC, YGV, YGC22, YGV22 | |
| Medium Voltage Silicone Rubber Cable | Rated voltage 6kV, 10kV, 35kV. It is suitable for industrial medium voltage power supply, photovoltaic/wind power grid connection, and underground mine medium voltage transmission. Special medium voltage cable accessories must be matched, and it also has high temperature resistance and high flexibility characteristics. | YGC-6kV, YGV22-10kV, YG-35kV | |
| High Frequency/RF Silicone Rubber Cable | Rated voltage 50Ω/75Ω characteristic impedance, adopts a solid silver-plated copper conductor + low density silicone rubber insulation structure, with excellent high-frequency transmission performance, low attenuation and small standing wave ratio. It is suitable for RF signal, high frequency communication, radar, medical equipment and other scenarios. | SGR, SGR-50, SGR-75, YG-RF | |
| By Laying Method | Fixed Laying Silicone Rubber Cable | Conductor is single strand/7 strand hard conductor, stable structure, high mechanical strength, while retaining the high temperature resistance and weather resistance characteristics of silicone rubber. It is suitable for long-term fixed laying scenarios such as indoor, tunnel, pipeline, and direct burial. | YG, YGC, YGV22, YGC22 |
| Mobile Laying Silicone Rubber Cable | Conductor is multi-strand ultra-fine flexible conductor, excellent flexibility, fatigue fracture resistance, can be bent repeatedly. It is suitable for dynamic scenarios such as equipment movement, drag chain, robot, and frequent bending, and is the core advantage category of silicone rubber cables. | YGG, YGC-TR, KGG-TR, YGV-R | |
| High Drop/Vertical Laying Silicone Rubber Cable | Matched with steel wire armouring + anti-slip structure, excellent tensile and anti-falling performance, while retaining the high temperature resistance and weather resistance characteristics of silicone rubber. It is suitable for high drop vertical laying scenarios in mines and tunnels, and can withstand large axial tensile force. | YG32, YGC32, YGV32 | |
| Outdoor Direct Burial Laying Silicone Rubber Cable | Matched with steel tape armouring + rodent and ant proof + waterproof sheath composite structure, with a protection level up to IP68, UV resistance, heat and humidity resistance, salt spray resistance. It is suitable for long-term outdoor direct burial laying scenarios. | YGV22, YGC22, YG22-FS | |
| By Flame Retardant and Fire Resistant Grade | Ordinary Flame Retardant Silicone Rubber Cable | Flame retardant grade ≥ Class C of GB 31247, no dripping, low smoke. It is suitable for general industrial scenario flame retardant requirements. | YG, YGC, KGG |
| High Flame Retardant Silicone Rubber Cable | Flame retardant grade ≥ Class B of GB 31247, low smoke and non-toxic, no dripping, strong self-extinguishing property. It is suitable for medium and high risk scenarios such as rail transit, high-rise buildings, and mines. | ZB-YG, ZB-YGC, ZB-KGG | |
| Ultra High Flame Retardant Silicone Rubber Cable | Flame retardant grade ≥ Class A of GB 31247, completely non-combustible, no dripping, extremely low smoke density. It is suitable for the highest safety requirement scenarios such as aviation, ships, fire protection, and high gas mines. | ZA-YG, ZA-YGC, ZA-KGG | |
| Fire Resistant Silicone Rubber Cable | Fire resistant grade ≥ Class N of GB 19666, which can maintain normal power supply for more than 90 minutes in 950℃ flame, and also has high flame retardant and high temperature resistance characteristics. It is suitable for fire emergency, mines, rail transit and other scenarios. | NH-YG, NH-YGC, NH-KGG |
| Maintenance Level | Maintenance Items | Execution Cycle | Operation Standard | Abnormal Handling Method |
|---|---|---|---|---|
| Daily Per Shift Inspection (Fixed Laying) / Pre-use Inspection (Mobile/Drag Chain Laying) | Appearance Integrity Inspection | Per shift / before each use | 1. Check the cable outer sheath for damage, cracking, bulging, deformation, aging and discoloration, and no exposed insulation layer;2. Check the cable surface for oil stain, dust, corrosive medium adhesion, and no sharp object scratches, rolling or wear marks;3. Check the cable laying path for looseness, falling, excessive bending, twisting, dragging, and no risk of being rolled by equipment or vehicles;4. Check the cable joints, terminals, and connectors for heating, sparking, leakage, deformation, the seal is intact without damage, and the wiring is firm without looseness. | 1. If slight damage, aging or wear of the sheath is found, mark it immediately and arrange for professional personnel to repair it;2. If exposed insulation layer, joint heating and sparking, or serious cable deformation/twisting are found, cut off the power and stop the machine immediately, continue to use is strictly prohibited, and arrange for professional personnel to test and replace the cable;3. If the cable is rolled, excessively bent or dragged, cut off the power immediately, test the insulation performance and conductor integrity of the cable, and replace it immediately if it is unqualified. |
| Laying Status Inspection | Per shift / before each use | 1. Check whether the bending radius of the cable meets the requirements, and no excessive small radius bending, twisting or winding;2. Check whether the cable fixing, suspension and guide devices are firm, and no looseness, falling off, or anti-slip failure. For drag chain cables, check whether the drag chain runs smoothly without jamming;3. Check the cable tray, pipeline, and direct burial path for collapse, blockage, water ingress, and rodent and ant gnawing marks;4. For mobile cables, check whether there is friction or collision with surrounding equipment and structural parts, and the protective measures are intact. | 1. If the bending radius exceeds the standard, twisting or winding is found, cut off the power and stop the machine immediately, re-lay the cable in a standardized manner, and test the insulation performance;2. If the fixing/guide device is loose, falls off or jams, stop the machine and repair and reinforce it immediately. For high drop vertical laying, the power must be cut off immediately for treatment;3. If rodent and ant gnawing marks are found, test the cable sheath and insulation performance immediately, replace it immediately if the damage is serious, and take rodent and ant prevention measures simultaneously. | |
| Operating Environment Inspection | Per shift / before each use | 1. Check whether the operating environment temperature of the cable is within the allowable range, no over temperature operation, and keep away from open flames and high temperature heat sources;2. Check whether there are flammable and explosive media, acid/alkali/organic solvent leakage around the cable, and no corrosion or fire safety hazards;3. For outdoor cables, check whether there is the influence of heavy rain, flood, UV exposure, ice and snow coverage, and the protective measures are intact;4. For drag chain/mobile cables, check that there are no obstacles or sharp objects in the running track to avoid damage to the cable during operation. | 1. If the ambient temperature exceeds the standard or the cable is close to a high temperature heat source, stop the machine and cool down immediately, check the cause of over temperature, and replace the cable with a higher temperature resistance grade if necessary;2. If corrosive medium leakage or flammable and explosive media are found, clean and isolate them immediately, check the cable corrosion condition, replace it immediately if the damage is serious, and take protective measures simultaneously;3. If the protective measures for outdoor cables are found to be invalid, stop the machine and repair them immediately, and take waterproof, sun protection, anti-freezing and anti-mechanical damage protection measures. | |
| Monthly Regular Test | Insulation Resistance Test | Once a month | 1. In the power-off state, use a 500V/1000V megohmmeter to test the insulation resistance between the cable cores and between the cable core and the earth;2. The insulation resistance of control cables is ≥10MΩ·km, low voltage power cables is ≥10MΩ·km, medium voltage cables is ≥100MΩ·km, and high frequency cables is ≥1000MΩ·km;3. The test environment temperature is 20℃±5℃, the relative humidity is ≤80%, and the cable must be fully discharged before the test to ensure the accuracy of the test data. | 1. If the insulation resistance is lower than the standard value, check the cause immediately, and test whether there is moisture, damage, aging, or water ingress;2. If the insulation resistance drops by more than 30%, arrange for professional personnel to conduct a comprehensive test immediately, and replace the cable if necessary;3. If the insulation resistance is found to be 0, cut off the power immediately, continue to use is strictly prohibited, check the short circuit point and replace the cable. |
| Earthing Continuity Test | Once a month | 1. In the power-off state, use an earth resistance tester to test the earthing continuity of the cable shielding layer, armouring layer, and earthing terminal;2. The earth resistance value is ≤4Ω, and the conduction resistance between the shielding layer and the earthing terminal is ≤0.5Ω;3. Check the earthing line for looseness, breakage, corrosion, and the earthing electrode is intact without damage, and the connection is firm. | 1. If the earth resistance exceeds the standard, check the earthing line immediately, repair the loose, broken and corroded parts, and test again;2. If the shielding layer earthing is found to be invalid, cut off the power and repair it immediately to ensure the earthing continuity and avoid the failure of anti-electromagnetic interference and electrostatic accumulation;3. If the earthing electrode is damaged, replace the earthing electrode immediately to ensure the reliability of the earthing system. | |
| Special Inspection of Joints and Terminals | Once a month | 1. In the power-off state, check the sealing performance of the cable joints, terminals and connectors, and no leakage, cracking, deformation or aging;2. Use an infrared thermometer to test the surface temperature of the joints, terminals and wiring terminals, and no abnormal heating, the temperature difference with the cable body is ≤5℃;3. Check the wiring terminals for looseness, oxidation, burning, the tightening torque meets the standard, and no discharge or sparking trace. | 1. If the joint seal is invalid, leakage or cracking is found, cut off the power and stop the machine immediately, re-seal it, and test the insulation performance;2. If abnormal heating or excessive temperature difference of the joint is found, check the cause immediately, test whether there is virtual connection, oxidation or overload, and re-make the joint or replace the connector if necessary;3. If the wiring terminal is loose or burnt, cut off the power and tighten it immediately, replace the damaged terminal, and ensure the reliable connection. | |
| Quarterly Special Test | Current Carrying Capacity and Temperature Monitoring | Once a quarter | 1. When the cable is running at full load, use an infrared thermometer to test the surface temperature of the cable conductor and outer sheath, arrange test points evenly along the full length of the cable, and focus on testing the joints, turns, and densely laid parts;2. The outer sheath temperature of the cable is ≤ the long-term allowable operating temperature of the insulation material, and no local over temperature point or abnormal temperature rise;3. Test the influence of the ambient temperature, laying method, and number of parallel cables on the current carrying capacity, and verify whether the actual operating current of the cable is within the allowable current carrying capacity range. | 1. If local over temperature or abnormal temperature rise of the cable is found, check the cause immediately, and test whether there is overload, local short circuit, insulation aging, or poor contact;2. If the operating current exceeds the allowable current carrying capacity, reduce the load immediately, check the cause of overload, and replace the cable with a larger cross section if necessary;3. If the overall temperature of the cable is generally over temperature, stop the machine immediately, check the influence of the ambient temperature, laying method and heat dissipation conditions, and optimize the laying and heat dissipation scheme. |
| Withstand Voltage Test | Once a quarter (important scenarios) / once every six months (conventional scenarios) | 1. In the power-off state, conduct power frequency withstand voltage test on the cable according to the national standard requirements. The test voltage for 450/750V control cables is 2kV, lasting for 5 minutes; for 0.6/1kV power cables, the test voltage is 2.5U0, lasting for 5 minutes; for medium voltage cables, it is implemented according to the corresponding voltage grade standard;2. No breakdown, no flashover, no obvious heating during the test, and no obvious drop in insulation resistance after the test;3. The cable must be fully discharged before the test, the test environment meets the standard requirements, safety protection measures are taken, and live test is strictly prohibited. | 1. If breakdown or flashover occurs during the test, stop the test immediately, check the fault point, and replace the faulty cable;2. If the insulation resistance drops obviously after the test, check whether the cable is damp, aged, locally damaged, or has water ingress, and replace the cable if necessary;3. If the cable in important scenarios fails the test, it is strictly prohibited to continue to be put into use, and replace it immediately. | |
| Special Inspection of Mechanical Performance | Once a quarter | 1. Check the flexibility and bending resistance of the cable, and no cracking, core breaking or sheath damage after repeated bending test for mobile/drag chain cables;2. Check the armouring layer and shielding layer for corrosion, breakage, deformation, falling off, and the protective performance is intact;3. Check the mechanical strength of the cable suspension, fixing and guide devices, and no looseness, deformation, or fatigue fracture;4. Check the weather resistance of outdoor cables, and no aging, cracking, powdering, or discoloration. | 1. If the armouring layer or shielding layer is corroded, broken or deformed, repair it immediately, and replace the cable if the damage is serious;2. If the flexibility of the mobile/drag chain cable decreases, cracks or serious wear are found, replace it immediately to avoid sudden faults caused by core breaking;3. If aging, powdering or cracking of outdoor cables is found, test the insulation performance immediately, and replace it if it is unqualified. | |
| Annual Comprehensive Test and Long-term Operation and Maintenance | Comprehensive Electrical Performance Test | Once a year | 1. Complete the full set of electrical performance tests of the cable according to the national standard requirements, including core indicators such as insulation resistance, withstand voltage, conductor resistance, capacitance, dielectric loss, high frequency performance, and earth resistance;2. All test indicators must meet the national standard and product technical requirements, and no unqualified items;3. Compare the test data over the years, analyze the change trend of cable performance, predict the aging condition, and formulate operation and maintenance and replacement plans. | 1. If the test indicators are unqualified, check the cause immediately, and replace the cable if necessary;2. If the cable performance continues to decline and the aging trend is obvious, formulate a replacement plan in advance to avoid sudden faults;3. If the transmission performance of the high frequency/control cable decreases, check it immediately and replace the unqualified cable. |
| Full Life Cycle Ledger Update | Once a year / after each maintenance and replacement | 1. Establish a full life cycle operation and maintenance ledger for the cable, recording the cable model specification, laying date, laying position, test records, maintenance records, replacement records, and scrap records;2. Update the ledger in time after each test, maintenance, and replacement to ensure the ledger information is complete and traceable;3. After the annual test is completed, fully update the ledger, analyze the operating status of the cable, and formulate the operation and maintenance, test, and replacement plan for the next year. | 1. If the ledger information is missing or incomplete, complete it immediately to ensure the operation and maintenance information of all cables is traceable;2. If the cable operating life is close to the design service life, formulate a replacement plan in advance to avoid extended use;3. Cables that have been repaired many times and have continuous performance decline shall be included in key monitoring, and scrapped and replaced in advance if necessary. | |
| Scrap and Replacement Management | Implemented according to actual test results | 1. The cable must be scrapped and replaced immediately if any of the following conditions occurs:① The insulation resistance and withstand voltage test are unqualified and cannot be repaired;② The outer sheath and insulation layer are seriously damaged, aged and cracked and cannot be repaired;③ The conductor core is broken or short circuited and cannot be repaired;④ The operating life exceeds the product design service life, and the performance is seriously reduced;⑤ Accidents such as short circuit, overload, fire, mechanical rolling have occurred, and the cable performance is damaged;⑥ The bending life expires, and serious wear and cracking occur;2. Scrap cables must be marked, strictly prohibited from being reused, and disposed of according to environmental protection regulations;3. The replacement cable must be a compliant product of the same specification and model to ensure performance matching, and can be put into use only after passing the test after installation. | 1. If the cable meets the scrap conditions, cut off the power and stop the machine immediately, continue to use is strictly prohibited, and arrange for professional personnel to replace it;2. The replacement cable must be laid, installed and tested in strict accordance with the specifications, and can be put into use only after passing the test;3. Scrap cables shall be disposed of in accordance with environmental protection requirements, and random discarding, secondary sales and non-standard reuse are strictly prohibited. | |
| Operation and Maintenance Personnel Training and Specification Update | Once a year | 1. Conduct training on cable professional knowledge, operation specifications, and safety procedures for operation and maintenance personnel, who can only take up their posts after passing the assessment;2. Update the latest national/industry standards and specifications in a timely manner, and synchronously update the operation and maintenance management system and operation standards;3. Summarize the annual operation and maintenance experience, analyze the causes of high-frequency faults, optimize the operation and maintenance plan, and improve the operation and maintenance management level. | 1. Operation and maintenance personnel who fail the training assessment are strictly prohibited from taking up their posts to operate;2. If the operation and maintenance system is not updated in a timely manner after the standards and specifications are updated, rectify it immediately;3. For high-frequency faults occurring in the annual operation and maintenance, formulate a special rectification plan to avoid repeated occurrence. |