Top 5 Mistakes to Avoid When Buying Medium Voltage Cables

By JianYunCable -

 

Medium voltage (MV) power cables, rated from 6 kV to 35 kV per IEC 60038, are essential for power distribution in industrial, utility, and infrastructure projects. Purchasing the wrong cables can lead to safety risks, system failures, or regulatory non-compliance. Based on industry insights and standards like IEC 60502-2, this guide outlines the top 5 mistakes to avoid when buying MV cables, with preventive tips to ensure reliable performance and a lifespan of 25–30 years. 


Table of Contents

1. Focusing Solely on Price Without Considering Performance

Many buyers prioritize low costs, overlooking cable quality, which can result in inferior materials (e.g., substandard XLPE insulation) leading to overheating or breakdown.

  • Consequences: Reduced current capacity (e.g., <200 A for 50 mm² at 11 kV), higher voltage drop (>1.5%), and premature failure.
  • How to Avoid: Evaluate total lifecycle costs, including durability and efficiency. Compare performance specs like insulation resistance (>1000 MÎİ/km) and partial discharge (<10 pC). Partner with certified manufacturers like Henan Province Jianyun Cable Co., Ltd., offering TUV-compliant MV cables with proven performance.

2. Ignoring Load Requirements and Current-Carrying Capacity

Selecting cables without calculating load current (I = P / (√3 × V × cosφ)) or ampacity often leads to undersized conductors (e.g., 25 mm² instead of 50 mm² for 200 A).

  • Consequences: Overheating (exceeding 90°C for XLPE), insulation degradation, and short circuits.
  • How to Avoid: Use IEC 60364 sizing charts to determine cross-section based on current, length, and derating (e.g., 0.91 at 40°C). Ensure cables meet IEC 60228 conductor classes. Jianyun Cable provides sizing tools for accurate selection.

3. Overlooking Environmental Factors

Failing to consider ambient conditions (e.g., high temperatures >40°C, moisture, or chemicals) results in unsuitable insulation or sheathing (e.g., PVC instead of XLPE for harsh environments).

  • Consequences: Moisture ingress causing water treeing or corrosion, reducing lifespan by 50%.
  • How to Avoid: Select XLPE or EPR insulation for high temperatures (90°C) and LSZH sheathing for fire safety. Apply derating for soil (e.g., 0.85 underground). Jianyun Cable’s PUR-sheathed MV cables offer chemical resistance.

4. Not Verifying Certifications and Standards Compliance

Purchasing without confirming certifications (e.g., TUV, UL) or standards (e.g., IEC 60502-2) leads to counterfeit or non-compliant cables.

  • Consequences: Customs rejections, regulatory penalties, or safety failures (e.g., flame propagation per IEC 60332-3).
  • How to Avoid: Request certificates from accredited bodies and verify via databases (e.g., TUV Certipedia). Ensure RoHS/REACH compliance. Jianyun Cable provides TUV-certified MV cables with batch test reports.

5. Choosing the Wrong Conductor Material or Insulation Type

Selecting aluminum over copper without accounting for higher resistance (<0.028 Îİ/km vs. <0.017 Îİ/km for 50 mm²) or PVC over XLPE for high-stress applications.

  • Consequences: Increased voltage drop or thermal overload, requiring larger sizes and raising costs.
  • How to Avoid: Use copper for high-conductivity needs; aluminum for cost-sensitive long runs. Select XLPE for 90°C operation. Jianyun Cable offers both copper and aluminum MV cables with XLPE insulation.

6. Summary Table

MistakeConsequencesPrevention
Price Focus OnlyOverheating, failureEvaluate lifecycle costs, select certified cables
Ignoring LoadShort circuitsUse IEC 60364, apply derating
Overlooking EnvironmentDegradationSelect XLPE/LSZH, apply derating
Not Verifying CertificationsRejectionsRequest TUV/UL reports, verify databases
Wrong MaterialVoltage dropMatch copper/XLPE for high performance

7. Conclusion

Avoiding common mistakes when buying medium voltage cables—such as price fixation, ignoring load requirements, overlooking environmental factors, not verifying certifications, and choosing the wrong material—ensures safe and efficient projects. By prioritizing performance, compliance, and proper sizing, buyers can mitigate risks like overheating or system failures. Henan Province Jianyun Cable Co., Ltd. exemplifies a trusted supplier, offering TUV-certified MV cables with robust quality control and competitive pricing. Through diligent evaluation and partnership with reliable manufacturers, buyers can secure cables that support long-term efficiency and safety for 25–30 years.

Source: JianYunCable.

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