600/1000V, XLPE Insulated and Lead Sheathed Cables according to IEC 60502-1
Application
These cables are used for electricity supply in low voltage installation system, They are suitable for installation in indoors and outdoors, in cable ducts, under ground, in power and switching stations, local energy distributions, industrial plants, where there is no risk of mechanical damage. The lead sheath brings an enhanced resistance to aromatic hydrocarbons.
Construction
Conductors
The conductors shall be either of Class 1 or Class 2 of plain or metal-coated annealed copper or of plain aluminium or aluminium alloy, or of Class 5 of plain or metal-coated copper in accordance with IEC 60228.
Insulation
XLPE material and thickness shall be as per IEC 60502-1, rated for 90°C continuous operation.
Colour Code
Colour Code (1)
1 Core | Red or Black |
2 Cores | Red, Black |
3 Cores | Red, Yellow, Blue |
4 Cores | Red, Yellow, Blue, Black |
5 Cores | Red, Yellow, Blue, Black, Green |
Above 5 Cores | Black Cores with White numerals |
Colour Code (2)
1 Core | Brown or Blue |
2 Cores | Brown, Blue |
3 Cores | Brown, Black, Grey |
4 Cores | Blue, Brown, Black, Grey |
5 Cores | Green/Yellow, Blue, Brown, Black, Grey |
Above 5 Cores | Black Cores with White numerals |
Other colours can be manufactured upon request.
Assembly / Inner Covering
The inner coverings may be extruded or lapped. For cables with circular cores, except cables with more than five cores, a lapped inner covering shall be permitted only if the interstices between the cores are substantially filled. A suitable binder is permitted before application of an extruded inner covering. The material is compatible with the insulating material,The materials used for inner coverings and fillers shall be suitable for the operating temperature of the cable and compatible with the insulating material.For halogen free cables, the inner covering and fillers shall also be halogen free compound.
Lead Sheath
lead or lead alloy and shall be applied as a reasonably tight-fitting seamless tube.
Seperation Sheath
The seperation sheath shall be of extruded PVC Type ST2 as per IEC 60502-1, or other material refer to outer sheath material.
Armour
Aluminum/galvanized steel/steel wires applied helically over the Inner Covering as per IEC 60502-1, or double aluminum/steel tapes and copper/tinned copper wire can also be manufactured upon request.
Outer Sheath
Outer sheath shall be of extruded PVC Type ST1/ST2 as per IEC 60502-1, Polyethylene type ST3/ST7, Halogen free compound ST8, Polychloroprene, chlorosulfonated polyethylene or similar polymers, type SE1 are also available on request.
Applications and Suitability
The primary application of 600/1000V XLPE insulated and lead sheathed cables lies in low-voltage electricity supply systems. These cables are engineered for installation in both indoor and outdoor settings, including cable ducts, underground burials, power stations, switching stations, local energy distribution networks, and industrial facilities. A key stipulation is that they should be deployed in environments where there is no significant risk of mechanical damage, unless armoured variants are selected.
One of the standout features is the lead sheath, which provides superior resistance to aromatic hydrocarbons—chemical compounds commonly found in petroleum products, solvents, and industrial effluents. This makes these cables particularly suitable for petrochemical plants, refineries, and areas prone to soil contamination, such as mining operations in South Africa. For instance, in the Witwatersrand region, where historical gold mining has led to hydrocarbon-laden soils, these cables ensure longevity and prevent insulation degradation.
In contrast to unarmoured types, armoured versions incorporate aluminium or galvanised steel wires, enhancing mechanical protection for direct burial or exposed installations. This adaptability allows for use in harsh conditions without compromising electrical integrity. Furthermore, the cables' compatibility with halogen-free compounds in certain configurations aligns with environmental regulations, reducing fire hazards in densely populated industrial zones.
The 90°C continuous operating temperature rating of the XLPE insulation enables higher current-carrying capacities compared to PVC-insulated alternatives, optimising energy efficiency in power distribution. In South African contexts, where load shedding and grid stability are concerns, such cables contribute to resilient infrastructure by minimising downtime and maintenance needs.
Advantages and Performance Analysis
The integration of XLPE insulation with lead sheathing confers several advantages. Thermally, the 90°C rating permits up to 20-30% higher current capacity than PVC cables, reducing conductor sizes and costs. Chemically, the lead barrier resists hydrocarbons, extending life in polluted soils—vital in South Africa's industrial heartlands like Gauteng.
Mechanically, armoured types withstand impacts per IEC tests, while the seamless lead tube prevents water treeing in XLPE. Electrically, low dielectric losses ensure efficiency, and colour coding minimises faults.
Compared to non-lead sheathed cables, these offer superior environmental resistance but at higher weight and cost, necessitating careful selection. In halogen-free versions, they meet fire safety norms like SANS 10142-1.
600/1000V XLPE insulated and lead sheathed cables, as per IEC 60502-1, exemplify engineering precision for low-voltage power transmission. Their multifaceted construction—from conductors to outer sheaths—ensures reliability across applications, particularly in chemically aggressive environments. By understanding these specifications, professionals can optimise designs for safety and efficiency, contributing to sustainable electrical infrastructure.
In South Africa, adopting such standards bolsters grid resilience amid growing energy demands. Future innovations may include eco-friendly lead alternatives, but for now, these cables remain a cornerstone of electrical engineering.
