YJVR Class 5 Flexible Copper XLPE Power Cable Vibration-Prone Industrial

YJVR is a low-voltage flexible power cable designed for fixed installations requiring superior bending performance; it is suitable for AC power transmission and distribution systems with a rated voltage of 0.6/1 kV. The "R" in the model designation denotes flexibility (soft construction). Its primary distinction from rigid YJV cables lies in the use of Class 5 stranded, fine-filament annealed copper conductors—compliant with IEC 60228 and GB/T 3956 standards—complemented by cross-linked polyethylene (XLPE) insulation and a durable PVC outer sheath.

Unlike YJV cables, which utilize solid or semi-rigid Class 1 or 2 conductors, the YJVR features conductors formed by tightly stranding dozens of ultra-fine annealed copper wires, resulting in exceptional resistance to bending fatigue. This design facilitates easier routing through curved conduits and terminal connections within cramped cabinets, while also offering better adaptability to environments subject to slight vibrations. Although its current-carrying capacity is only 3%–5% lower than that of a YJV cable with the same cross-sectional area, it significantly reduces on-site installation difficulty, shortens labor time, and substantially improves the success rate of terminal crimping.

This product series covers configurations ranging from 1 to 5 cores with cross-sections from 1.5 mm² to 630 mm². Widely adopted by electrical design institutes, installers, and system integrators worldwide, it serves as the preferred flexible wiring solution for projects involving complex layouts, indoor cabinet wiring, machinery and equipment integration, and secondary building power distribution.

• GB/T 12706.1-2020: National standard for extruded insulation power cables with rated voltages of 0.6/1 kV
• IEC 60502-1: International standard for low-voltage extruded insulation power cables
• IEC 60228: Standard for conductor classification (Class 5 flexible conductors)
• GB/T 3956: Standard for cable conductors
• GB/T 19666: Standard for flame-retardant grades (customizable ZA/ZB/ZC grades)

Standard Factory Acceptance Tests: Conductor DC resistance test, 3.5 kV/5 min power-frequency withstand voltage test, and insulation resistance test

Comprehensive Certification System: ISO9001 Quality Management System certification, CE certification, third-party type test reports, and raw material inspection documentation; fully compliant with requirements for international tendering, technical reviews, and project completion acceptance.

Constructed from multiple ultra-fine annealed copper strands twisted with precise pitch control to form a compact, circular conductor, meeting Class 5 flexibility requirements. Its low internal stress eliminates the risk of wire breakage during repeated bending and pulling operations. High-purity annealed copper ensures stable DC resistance and minimal heat generation during long-term load operation, effectively preventing localized overheating at terminals. The conductor’s uniform, circular profile ensures consistent crimping results with cable terminals, effectively reducing the risk of poor contact.

Features extruded XLPE insulation of uniform thickness, with real-time monitoring of concentricity during production. XLPE withstands continuous high temperatures of 90°C, offering thermal stability far superior to standard PVC insulation. It provides higher insulation resistance and exhibits excellent resistance to moisture, chemical corrosion, and insulation aging, effectively preventing leakage and short-circuit faults in confined, damp wiring spaces.

Fills the interstices between insulated cores to maintain the cable's overall circularity; cushions against internal compression and friction during bending and pulling, preventing scratches on the insulation surface; blocks moisture ingress; stabilizes the cable's structural roundness, facilitating installation in conduits.

Extruded black PVC sheath with uniform thickness; resistant to mild oil, acids, alkalis, and UV aging, as well as mechanical abrasion during installation. Balanced hardness provides a combination of overall flexibility and external mechanical protection; suitable for installation in indoor cable trays, conduits, cabinets, and enclosed trenches.

U₀/U: 0.6/1kV (AC 50Hz); maximum system operating voltage Um = 1.2kV; designed for general low-voltage power transmission and distribution.

Number of cores: 1, 2, 3, 4, 5

Nominal cross-sectional area range: 1.5mm², 2.5mm², 4mm², 6mm², 10mm², 16mm², 25mm², 35mm², 50mm², 70mm², 95mm², 120mm², 150mm², 185mm², 240mm², 300mm², 400mm², 500mm², 630mm²

Conductor standard: IEC 60228 Class 5 flexible stranded copper conductor

Maximum long-term continuous operating temperature of conductor: 90°C

Maximum short-circuit withstand temperature of conductor (duration ≤ 5 seconds): 250°C

Minimum ambient installation temperature: 0°C; pre-heating is required for installation below 0°C

Rated design service life under standard installation and normal operating conditions: ≥ 30 years

Minimum bending radius for multi-core YJVR: ≥ 12 × cable outer diameter (D)

Minimum bending radius for single-core YJVR: ≥ 15 × cable outer diameter (D)

Structural characteristics note: YJVR is an unarmored flexible cable and is not suitable for direct burial where it would be subjected to soil pressure; if underground installation is required, it must be installed within protective conduit, placed in a cable tray, or laid in an enclosed cable trench.

Continuous current-carrying capacity meets standard low-voltage power distribution design requirements. Although the capacity is slightly lower (3%–5%) than that of YJV cables of the same specification, the gains in installation efficiency and long-term wiring reliability more than compensate for this difference. It is particularly well-suited for routing along complex, curved paths, navigating narrow spaces, and connecting power to equipment subject to vibration.

• Flexible conductor structure (Class 5) resolves installation bottlenecks associated with rigid cables in complex layouts.

The minimum bending radius is significantly smaller than that of rigid YJV cables, facilitating routing through conduits with multiple bends, narrow cabinet partitions, and compact equipment terminal compartments. This eliminates the risk of insulation cracking caused by forced bending of rigid YJV cables, reduces post-installation hazards, and enhances the feasibility of designs involving high-density wiring.

• Bending fatigue resistance suits operating environments with slight vibration.

The multi-strand fine copper wire structure disperses bending stress, preventing individual wire breakage caused by prolonged micro-vibrations from fans, motors, and automation equipment. It ensures more stable long-term contact performance at terminals, thereby reducing the risks of overheating and intermittent power supply failures.

• A comprehensive standardization system simplifies engineering selection and drawing design.

This series covers a full range of core and cross-section specifications, featuring verified ampacity tables, standardized bending radius parameters, and compatible terminal accessories; it is widely recognized by design institutes. Engineers are spared the need for custom solution validation, thereby accelerating drawing reviews, technical clarifications during tendering, and project approvals, while reducing the risk of calculation and selection errors.

• XLPE high-temperature insulation enhances circuit overload tolerance.

With a long-term operating temperature of 90°C, the cable supports higher load currents than standard PVC-insulated flexible cables. It is suitable for power distribution circuits prone to occasional overloads, thereby increasing the safety margin of electrical systems in commercial, industrial, and building applications.

• Customizable flame-retardant ratings meet fire safety code requirements for public and industrial sectors.

The entire product range offers flame-retardant versions (ZA, ZB, and ZC grades) that comply with fire safety acceptance standards for terminal power distribution in high-rise buildings, auxiliary cabling in underground utility tunnels, wiring across fire compartments in industrial plants, and electrical infrastructure projects.

• Standardized, mass-produced models eliminate the price premiums often associated with custom-engineered products.

YJVR cables in mainstream cross-sectional sizes are produced in continuous runs; unlike non-standard, specialized flexible cables, they offer stable unit pricing and predictable lead times. Procurement teams can lock in precise budget quotes during the tendering phase, effectively mitigating the impact of raw material price fluctuations.

• Simplified on-site installation reduces total labor and installation costs.

These cables navigate curved conduits more easily, and the stripping and crimping of terminals are faster. Compared to standard YJV cables, on-site installation efficiency improves by over 30%, shortening project timelines and lowering overall labor costs for electrical installation contractors.

• Low O&M costs offset the slight premium in raw material prices.

Although raw material costs are marginally higher than those of YJV cables with equivalent cross-sections, the product's lower line failure rate, reduced incidence of terminal overheating, and minimized troubleshooting requirements lower long-term inspection, repair, and replacement expenses. This delivers exceptional comprehensive value over the entire lifecycle for fixed power distribution projects.

• In-stock availability of mainstream specifications to shorten delivery lead times

Finished stock is maintained for common small-to-medium cross-section specifications (2.5mm², 4mm², 6mm², 10mm²; 3-core and 4-core configurations). This enables us to meet needs ranging from small-batch trial orders and urgent project restocking to rapid bulk shipments, thereby preventing project delays caused by lengthy production cycles.

• Universal compatibility with standard low-voltage accessories to reduce procurement management overhead

Compatible with standard low-voltage crimp terminals, cable connectors, junction boxes, and wiring accessories—eliminating the need for custom-made terminals. This simplifies tasks for project procurement teams, including Bill of Materials (BOM) management, incoming quality inspections, and on-site warehouse management.

• Power wiring within low-voltage distribution cabinets, PLC control cabinets, VFD cabinets, switchgear compartments, and compact electrical equipment assemblies
• Power distribution wiring in commercial buildings, high-rise residences, shopping malls, and municipal public facilities—particularly where installations involve multiple conduit bends, dense cable tray routing, and complex layouts
• Power connections for equipment subject to continuous, slight vibration during operation, such as automated production lines, machine tools, fans, pumps, and compressors
• Internal wiring for modular equipment, containerized power stations, and skid-mounted units, facilitating equipment disassembly, relocation, and wiring adjustments
• Locations where installing rigid YJV cables is difficult, such as enclosed indoor cable trenches, vertical cable shafts, concealed ceiling installations, and secondary distribution branch circuits
• Internal wiring for distributed photovoltaic combiner boxes and auxiliary power connections for energy storage cabinets, accommodating frequent module replacements and ongoing maintenance needs

Project Requirements: Replacement of aging rigid cables within 120 low-voltage power distribution cabinets; modification of concealed branch circuits routed through conduits with multiple bends in tight ceiling spaces; extremely high demands on installation feasibility; requirement to pass local electrical inspections and ensure long-term, stable power supply operation.

Solution Implemented: Bulk procurement of YJVR-type flexible cables (specifications: 3×4mm², 4×6mm², 5×10mm²), with a total supply length of 28.6 kilometers.

Project Outcomes: The flexible cable structure allowed for smooth routing through conduits with multiple bends, eliminating insulation risks associated with the forced bending of the original rigid YJV cables; the terminal crimping pass rate improved from 87% to 99.5%; on-site construction time was reduced by 28%; the project successfully passed the electrical completion inspection; and the general contractor designated YJVR as the standard flexible wiring model for subsequent commercial renovation sub-projects.

Project Requirements: Installation of new power lines for 78 units of automated stamping, welding, and assembly equipment. Operating conditions involved persistent, low-level vibration and confined terminal connection spaces. Requirements included preventing wire breakage and terminal overheating caused by long-term operation to ensure the production line's stable and continuous performance.

Solution Implemented: Flexible cables (specifications: YJVR 3×16mm² and 4×25mm²) were selected, with a total supply length of 16.2 km; flame-retardant cables (ZRC-YJVR) were used in designated workshop fire zones.

Project Outcomes: The use of Class 5 flexible conductors effectively withstood long-term vibration fatigue, with no instances of wire breakage or overheating over three years of operation. The setup facilitated future equipment relocation and line modifications, thereby reducing annual maintenance downtime. The system consistently passed the plant's annual electrical safety audits, achieving the goal of reliable, long-term power supply.

Project Requirements: Involved internal electrical connections for 420 PV combiner boxes; required accommodation of compact internal spaces; necessitated support for frequent component maintenance, replacement, and wiring adjustments; and demanded high wiring flexibility alongside a robust thermal safety margin.

Solution Implemented: YJVR-type flexible cables with small cross-sections (2×2.5 mm² and 3×4 mm²); total supply length of 9.7 km.

Project Outcomes: The cables' small bending radius facilitated neat routing within the confined spaces of the combiner boxes; the 90°C-rated XLPE insulation effectively withstood temperature fluctuations during outdoor operation; components were easily disconnected and rewired during maintenance; and no insulation degradation or short-circuit faults occurred over two years of operation, fully meeting the grid-connection acceptance standards for distributed PV projects.

• Electrical Parameter Calculations Must Be Completed Before Specifying the Cable

  Before selecting YJVR cables, calculations regarding load-carrying capacity and voltage drop, as well as an assessment of the installation route's curvature, must be performed based on the actual installation length, number of bends, and operating environment. Our technical team offers free, customized selection comparison reports to help you mitigate risks associated with insufficient current-carrying capacity or avoid procurement waste caused by over-specification.

• Standardized Procedures for Cable End Stripping and Crimping Must Be Followed

  Specialized wire-stripping tools must be used to remove insulation, ensuring the conductor core remains undamaged. Before crimping terminals, loose fine copper strands must be twisted tightly together to prevent overheating caused by detached individual strands. Crimping bare conductor cores directly without using terminals is strictly prohibited to ensure long-term electrical contact reliability.

• Strict Control of Bending Radius During Pulling and Installation

  Minimum bending radius limits must be observed throughout the installation process; sharp bends and excessive pulling force are strictly prohibited. Chamfered protective sleeves should be installed at conduit entry and exit points to prevent scratching the outer sheath or damaging the insulation layer during cable pulling.

• Clarification of Installation Environment and Application Limitations

  YJVR unarmored flexible cables are not suitable for direct burial where they would be subjected to soil compression loads; if direct burial is required, PVC or HDPE protective conduits must be used. These cables are not suitable for applications involving frequent, long-term reciprocating motion (specialized flexible drag-chain cables should be used for such applications).

• Ambient Temperature Requirements for Installation

  The ambient temperature during installation must not be lower than 0°C. If installation must be performed in temperatures below freezing, the cable should be pre-heated to prevent the outer sheath from becoming brittle and cracking during bending.

• Standardized Storage and Transport Management for Cable Reels

  Cable reels should be stored on a flat, solid surface within a dry, well-ventilated warehouse, avoiding prolonged exposure to rain or direct sunlight. During loading, unloading, and transportation, precautions must be taken to prevent severe impacts, crushing, or tipping, as these could cause defects—such as damage to the outer sheath or disarray of the internal conductor stranding—that would compromise electrical performance.

• Comprehensive Certification Packages Tailored to Tender Requirements for the YJVR Flexible Cable Series

  All products are manufactured in strict accordance with GB/T 12706 and IEC 60502 international standards. We provide a complete suite of documentation—including factory qualification credentials, comprehensive type test reports, routine records of withstand voltage and resistance tests, third-party inspection certificates, and editable technical data sheets—fully satisfying global tender requirements regarding document review, submission, and electrical engineering acceptance.

• Rigorous Raw Material Selection and End-to-End Quality Control in Flexible Cable Production

  We utilize high-purity oxygen-free annealed copper rods and specialized medium-density XLPE materials designed for flexible cables. Key processes—such as stranding, insulation extrusion, cabling, and sheathing—are equipped with real-time online monitoring systems for outer diameter and concentricity. This ensures consistent conductor resistance, uniform insulation thickness, and stable flex-fatigue performance across production batches, thereby minimizing the risk of rejection during on-site inspections for large-scale tender orders.

• Flexible, Personalized Customization for Specialized Project Requirements

  We provide customized services for YJVR cables across various specifications (core counts and cross-sectional areas) based on client drawings and specific project technical requirements. Options include flame-retardant modifications (ZA/ZB/ZC grades), cut-to-length services, custom core color coding, and specialized packaging (wooden reels or export-grade steel reels).

• Factory-Direct Sales with Stable Pricing and Flexible Order Quantities

  Operating our own cable manufacturing facilities eliminates intermediary markups. We support small-batch sample trials to meet initial project qualification needs and prioritize production scheduling for large-volume orders. Ample stock is maintained for mainstream small-to-medium cross-section YJVR specifications to ensure rapid delivery and meet urgent timelines for power engineering projects.

• Comprehensive, Professional Technical Support for Low-Voltage Electrical Engineering

  Our team of professional cable design engineers provides free current-carrying capacity calculations, comparative analysis of YJVR vs. YJV lifecycle costs, consultation on optimizing cable laying plans, remote and on-site installation guidance, and systematic post-sales quality tracking. These services are backed by a formal, long-term product warranty policy, fully alleviating technical and quality concerns for procurement and engineering teams after orders are placed.

• Extensive cross-border export experience in low-voltage power distribution projects

  We offer mature export packaging solutions, comprehensive customs documentation support, and highly efficient global logistics channels. We have a proven track record of reliable supply for projects across Southeast Asia, Central Asia, Africa, the Middle East, and Latin America—spanning commercial building renovations, factory automation upgrades, distributed PV system installations, and municipal power infrastructure. Furthermore, we are well-versed in the inspection, acceptance, and compliance filing regulations for YJVR flexible cables across various overseas markets.