
Feichun CU/XLPE/CTS/PVC/AWA/PVC 6.35/11 kV — Single-Core XLPE Copper Cable with Aluminium Wire Armour
A full-English engineering guide to the fixed-installation medium-voltage construction: copper conductor, semiconducting conductor screen, XLPE insulation, semiconducting insulation screen, crape-paper semiconducting tape, copper tape metallic screen, PVC separation sheath, single-layer aluminium wire armour and PVC outer sheath. The article separates the supplied 8/4/26 source record, official current product pages and an secondary catalogue revision revision.
Contents
- Engineering position
- Designation and construction logic
- Standards and evidence
- Complete source specification
- Technical matrix
- Derived installation checks
- Electrical, thermal and fault design
- Layer-by-layer cross-section
- Single-core screen and armour system
- Fire and PVC boundary
- Fixed-route applications
- Handling and termination
- Selection comparison
- Failure-mode controls
- Feichun certification scope
- Source and revision audit
1. Engineering position: a screened and aluminium-wire-armoured single-core MV cable
The conductor screen, XLPE insulation and insulation screen form the radial dielectric system. The copper tape is the metallic electric-field boundary and an earth-fault path that requires continuity and bonding design.
The single aluminium-wire armour layer is mechanically distinct from the copper tape screen. Armour continuity, bonding, corrosion environment, cleats and entry protection must be designed for the installation.
Single-core geometry changes induced-current behaviour, screen bonding, armour bonding, cleat selection, magnetic effects and formation calculations. Three-core assumptions must not be copied into this design.
The supplied/current record gives -20 … 90 °C. This article keeps the 8/4/26 record separate from any unprovided revision.
2. Designation and construction logic
| Designation / field | Engineering reading | Design consequence | Evidence status |
|---|---|---|---|
| CU | Copper phase conductor. | Use the exact cross-section row for DCR, ampacity, voltage drop and short-circuit screening. | Supplied construction |
| XLPE | Cross-linked polyethylene insulation around the screened conductor. | Coordinate insulation, semiconducting screens, terminations, joints and test levels with the 6.35/11 kV system. | Supplied construction |
| CTS | Copper tape metallic screen. | Control screen continuity, bonding, touch voltage, induced effects and earth-fault I²t. | Supplied construction / official product records |
| PVC / AWA / PVC | PVC separation sheath, single-layer aluminium wire armour and PVC outer sheath. | Keep electrical screen duties separate from mechanical armour duties; verify PVC fire and environmental evidence for the project. | Supplied construction / official product records |
| 6.35/11 kV | Rated voltage Uo/U (Um). | Confirm system earthing, switching, withstand, accessory class and protection coordination. | Supplied characteristic field |
Copper conductor → semiconducting conductor screen → XLPE insulation → semiconducting insulation screen → crape-paper semiconducting tape → copper tape metallic screen → PVC separation sheath → single-layer aluminium wire armour → PVC outer sheath.
The copper tape is an electrical screen. The AWA layer is a mechanical armour. Their continuity, bonding, thermal duty and accessory interfaces must be verified independently.
PVC is explicitly supplied for the separation and outer sheath. Do not market this construction as LSZH or halogen-free without a matching declaration and test report.
The source publishes a 15 (xD) laying factor and fixed-installation applications, but no continuous-flex rating. This does not qualify the cable for reeling, festoon or energy-chain service.
3. Standards and evidence review
| Reference | Role | Engineering interpretation | Boundary |
|---|---|---|---|
| BS 6622 | Product standard listed by the supplied source. | BSI describes the standard as covering armoured thermosetting-insulated cables for fixed network or industrial installations across the relevant voltage range, including copper or aluminium conductors, metallic screens and aluminium or galvanised-steel armour options. | Confirm adopted edition and exact Feichun conformity file. |
| IEC 60332-1-2 | Flame-retardant reference listed by the source. | The official IEC procedure concerns vertical flame propagation for a single insulated wire or cable using a 1 kW pre-mixed flame. | Test-method reference; not a grouped-cable fire declaration or CPR class by itself. |
| IEC 60502-2 | Related international MV cable reference. | It is included for engineering cross-reference to extruded-insulation MV fixed-installation cable practice. | Not listed as the product standard in the supplied record; verify project adoption separately. |
| PVC sheath system | Separation and outer sheath material. | Evaluate fire, smoke, corrosive gas, chemical, UV, water, impact, enclosure and penetration requirements for the actual route. | No CPR class, LSZH declaration or halogen-free claim is supplied. |
| Source hierarchy | User record versus official additions. | Supplied values are primary; official pages add independently labelled construction and product-list context; derived radii are arithmetic checks. | Feichun project dossier controls procurement release. |
4. Complete source specification
| Specification field | Reference value | Engineering interpretation | Evidence status |
|---|---|---|---|
| Product designation | CU/XLPE/CTS/PVC/AWA/PVC 6.35/11 kV | Single-core XLPE-insulated copper-conductor MV cable with copper-tape screen, PVC separation sheath, single-layer aluminium wire armour and PVC outer sheath. | Supplied source |
| Product description | 6.35/11 kV XLPE insulated aluminium wire armoured, single core cables with copper conductor | Fixed-installation MV construction for energy networks, residential or industrial areas, underground or ducts where mechanical stresses are expected. | Supplied source |
| Product standard | BS 6622 | Confirm the project-adopted edition and exact Feichun conformity route. | Supplied source |
| Application | These are cables with low dielectric losses used in energy networks with sudden load changes where mechanical stresses expected. Laid in residential or industrial areas, underground or in ducts. | The supplied application wording is preserved; final suitability also depends on voltage, thermal, mechanical, fire, screen, armour and accessory studies. | Supplied source |
| Conductor | Copper | Phase conductor material stated by the source. | Supplied construction |
| Conductor flexibility | Not stated | The source does not assign a flexibility class. The 15 (xD) value is a laying factor, not a continuous-flex or reeling qualification. | Not supplied |
| Number of cores | 1 | Single-core geometry governs screen bonding, armour bonding, induced effects, cleats and formation calculations. | Supplied characteristics |
| Published cross-sections | 70, 95, 120, 150, 185, 240, 300, 400, 500 and 630 mm² | All ten source rows are reproduced in the complete matrix. | Supplied matrix |
| Rated Voltage Uo/U (Um) | 6.35 / 11 kV | The source does not add an Um value in parentheses; match system earthing and accessories to the project voltage. | Supplied source |
| Mechanical resistance to impacts | Good | Qualitative impact resistance does not replace route protection and controlled handling. | Supplied source |
| Operating temperature, range | -20 … 90 °C | Apply actual ambient, soil, duct, grouping and accessory limits. | Supplied source |
| Short-circuit max. conductor temperature | 250 °C | Use with conductor and screen I²t, protection clearing time, joints and terminations. | Supplied source |
| Bending factor when laying | 15 (xD) | Calculate the minimum laying-radius screening value from the ordered outside diameter. | Supplied source |
| Max. conductor temperature in service | 90 °C | Continuous conductor service limit stated by the source. | Supplied source |
| Flame retardant | IEC 60332-1-2 | Single-cable vertical flame-propagation test reference; not a complete CPR class. | Supplied source |
| Conductor screen | Semi-conducting compound(XLPE) | Controls the electric-field transition between copper and XLPE. | Supplied construction |
| Insulation | XLPE | Primary extruded solid dielectric. | Supplied construction |
| Insulation screen | Semi-conducting compound(XLPE) | Controls the outer electric-field interface. | Supplied construction |
| Semi-conducting tape | Crape paper | Source wording retained exactly; confirm the released material specification. | Supplied construction |
| Metallic screen | Copper tape | Electrical screen and earth-fault path; dimensions and bonding must match the ordered size. | Supplied construction |
| Separation sheath | PVC | Separates copper screen from aluminium wire armour. | Supplied construction |
| Wire armour | Single layer aluminium wire | Mechanical armour distinct from the copper tape screen; bonding and corrosion design remain required. | Supplied construction |
| Outer sheath | PVC | External environmental and mechanical interface; no LSZH claim is added. | Supplied construction |
| Generated / source record | Generated 8/4/26 — www.nexans.com.tr — Page 1 / 2 | Preserved from the supplied reference. | Supplied metadata |
| Source continuation | CU/XLPE/CTS/PVC/AWA/PVC 6.35/11 kV — Page 2 / 2 | Preserved from the supplied reference. | Supplied metadata |
| Source disclaimer | All drawings, designs, specifications, plans and particulars of weights, size and dimensions contained in the technical or commercial documentation of Nexans is indicative only and shall not be binding on Nexans or be treated as constituting a representation on the part of Nexans. | Use the released Feichun document and project-approved calculations for procurement and installation. | Supplied metadata |
5. Complete technical matrix — CU/XLPE/CTS/PVC/AWA/PVC 6.35/11 kV
The following matrix preserves all ten supplied rows and every supplied field. Air ratings are stated at 30 °C; buried ratings are stated at 20 °C. Flat and trefoil formation values must not be interchanged.
| Cross section [mm²] | Nom. outer diam. [mm] | Approx. weight [kg/km] | Max. DC Resist. Cond. 20 °C [Ohm/km] | Perm. current in air 30 °C — flat [A] | Perm. current in air 30 °C — trefoil [A] | Perm. current buried 20 °C — flat [A] | Perm. current buried 20 °C — trefoil [A] | Approx. inductance — trefoil [mH/km] | Approx. inductance — flat [mH/km] | Nom. phase capacitance [µF/km] | Short-circuit conductor 1 s [kA] | Short-circuit screen 1 s [kA] | Nexans Ref. |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| 70 | 28.0 | 1500 | 0.268 | 356 | 296 | 246 | 239 | 0.4 | 0.58 | 0.27 | 10 | .77 | 10536094 |
| 95 | 30.0 | 1800 | 0.193 | 434 | 361 | 293 | 285 | 0.38 | 0.57 | 0.31 | 13.6 | .58 | 10536178 |
| 120 | 33.0 | 2250 | 0.153 | 500 | 417 | 332 | 323 | 0.37 | 0.56 | 0.34 | 17.2 | .77 | 10535896 |
| 150 | 34.0 | 2500 | 0.124 | 559 | 473 | 366 | 361 | 0.36 | 0.55 | 0.36 | 21.4 | .77 | 10535916 |
| 185 | 36.0 | 2750 | 0.099 | 637 | 543 | 410 | 406 | 0.35 | 0.54 | 0.4 | 26.5 | 1.03 | 10535973 |
| 240 | 38.0 | 3500 | 0.075 | 745 | 641 | 470 | 469 | 0.33 | 0.52 | 0.45 | 34.3 | 1.03 | 10535993 |
| 300 | 41.0 | 4250 | 0.06 | 846 | 735 | 524 | 526 | 0.33 | 0.51 | 0.49 | 42.9 | 1.29 | 10536011 |
| 400 | 45.0 | 5250 | 0.047 | 938 | 845 | 572 | 590 | 0.32 | 0.51 | 0.54 | 57.2 | .96 | 10536030 |
| 500 | 48.0 | 6250 | 0.037 | – | 1000 | – | 688 | 0.31 | 0.49 | 0.61 | 71.5 | 1.54 | 10536053 |
| 630 | 53.0 | 7750 | 0.028 | – | 1150 | – | 774 | 0.3 | 0.49 | 0.69 | 90.1 | 1.16 | 10536077 |
Dashes are preserved exactly as supplied. Final Feichun release documents must govern the ordered cross-section, dimensions, screen, armour, accessories and route rating.
6. Derived installation checks
Only two arithmetic conversions are made: r = 15 × D and approximate mass per 100 m = kg/km ÷ 10. These are derived checks, not additional manufacturer values.
| Cross section | Source outer diameter | Laying factor | Derived minimum laying radius | Approx. mass per 100 m |
|---|---|---|---|---|
| 70 mm² | 28.0 mm | 15 × D | 420.0 mm | 150.0 kg/100 m |
| 95 mm² | 30.0 mm | 15 × D | 450.0 mm | 180.0 kg/100 m |
| 120 mm² | 28.0 mm | 15 × D | 420.0 mm | 225.0 kg/100 m |
| 150 mm² | 34.0 mm | 15 × D | 510.0 mm | 250.0 kg/100 m |
| 185 mm² | 36.0 mm | 15 × D | 540.0 mm | 275.0 kg/100 m |
| 240 mm² | 38.0 mm | 15 × D | 570.0 mm | 350.0 kg/100 m |
| 300 mm² | 41.0 mm | 15 × D | 615.0 mm | 425.0 kg/100 m |
| 400 mm² | 45.0 mm | 15 × D | 675.0 mm | 525.0 kg/100 m |
| 500 mm² | 48.0 mm | 15 × D | 720.0 mm | 625.0 kg/100 m |
| 630 mm² | 53.0 mm | 15 × D | 795.0 mm | 775.0 kg/100 m |
7. Electrical, thermal and short-circuit design
Every published size has its own diameter, mass, DCR, inductance, capacitance, ampacity and conductor short-circuit value. Select the exact Nexans reference and cross-section before calculating voltage drop or thermal margin.
Air values are stated at 30 °C and buried values at 20 °C. Correct for ambient, soil thermal resistivity, duct, spacing, grouping, formation, screen losses, armour effects and accessories.
The copper tape is the metallic screen; the AWA is a separate armour layer. Verify bonding, parallel paths, induced current, touch voltage, armour continuity and earth-fault duty together.
The source states a 250 °C maximum conductor temperature and publishes one-second conductor and screen values by size. Verify protection I²t, screen and armour paths, joints and terminations together.
8. Layer-by-layer cross-section
The diagram follows the supplied nine-layer construction and makes the electrical copper-tape screen visually distinct from the mechanical aluminium-wire armour. It intentionally does not invent layer thicknesses, screen section, armour wire diameter or manufacturing tolerances.
9. Single-core electrical and screen-armour system
Semiconducting screens and the copper tape must be continuous through joints and terminations to prevent local field concentration and uncontrolled screen potential.
Choose bonding from system voltage, route length, induced voltage, circulating-current limits, earth-fault duty and local earthing rules.
Armour bonding and continuity must be coordinated with gland, cleat, entry, earthing and corrosion-control details. Armour is not a replacement for the copper screen.
Screen preparation, XLPE diameter, PVC layers, AWA termination detail, stripping lengths and conductor size must match the ordered accessory system.
10. Fire and PVC performance boundary
The supplied record lists IEC 60332-1-2. The IEC publication describes a single-cable vertical flame-propagation procedure using a 1 kW pre-mixed flame.
No Eca, Cca, B2ca or s/d/a classification is stated in the current user record. Do not infer one from IEC 60332-1-2.
Confirm smoke, corrosive gas, halogen, fire stopping, penetrations, ventilation, water and local construction requirements from the actual project.
The supplied current record and official 70 mm² page both state -20 … 90 °C; the governing revision must be identified in procurement.
11. Fixed-route applications
Use in energy-network feeders with sudden load changes after conductor, screen, armour, voltage-drop and protection studies are complete.
Check soil thermal resistivity, water exposure, drainage, route spacing, screen bonding, armour bonding, joint access and impact protection.
Check duct fill, pulling tension, sidewall pressure, entry radius, cable arrangement, heat dissipation, water management and armour scraping.
Evaluate fixed substations, plant feeders and shore-side MV routes for corrosion, flooding, impact, fire, maintenance and earthing.
The source establishes fixed-route service and a laying factor, not continuous flexing. Use a qualified dynamic cable family for reeling, festoon or drag-chain motion.
12. Handling and termination
- Confirm the exact controlled product reference from 10536094 through 10536077, including cross-section, outer diameter, mass, DCR, screen and armour details.
- Apply the 15×D laying factor to the ordered diameter. The supplied matrix gives a derived screening range of 420.0 mm at 28.0 mm OD to 795.0 mm at 53.0 mm OD.
- Keep the drum aligned with the pay-off direction. Prevent reverse winding, uncontrolled twist, flange impact and local PVC sheath or AWA damage.
- Use rollers and supports that control bending, sidewall pressure and armour loading. Do not pull against a sharp duct entry or force the copper screen around a local obstruction.
- Prepare the conductor screen, XLPE insulation, semiconducting screen, copper tape, PVC separation sheath, AWA and PVC outer sheath using the approved termination or joint kit method.
- Record screen continuity, armour continuity and bonding, phase identification, conductor resistance, insulation and sheath tests, torque and accessory inspection before energisation.
- Complete MV withstand or partial-discharge tests where specified by the project, and retain product reference, batch, test results and as-built route records.
13. Selection comparison for engineers
Source-based selection comparison
| Requirement | Source reference | What must be verified | Engineering decision |
|---|---|---|---|
| 6.35/11 kV fixed feeder | Cu / XLPE / copper tape / PVC / AWA / PVC | Confirm system earthing, formation, screen and armour bonding, accessories and protection. | Candidate after exact-size release. |
| 70 mm² | 28.0 mm OD; 1500 kg/km; 356 A air flat; 239 A buried trefoil; Ref 10536094 | Check voltage drop, thermal corrections, fault duty, pulling and termination. | Use the 70 mm² row. |
| 240 mm² | 38.0 mm OD; 3500 kg/km; 745 A air flat; 469 A buried trefoil; Ref 10535993 | Check route correction, screen/armour duty, voltage drop and accessories. | Use the 240 mm² row. |
| 630 mm² | 53.0 mm OD; 7750 kg/km; 1150 A air trefoil; 774 A buried trefoil; Ref 10536077 | Large-cable pulling, cleats, duct, termination, fault and thermal checks. | Use the 630 mm² row. |
| PVC fixed route | PVC separation and outer sheath; IEC 60332-1-2; no CPR class supplied | Confirm current fire dossier, smoke strategy, penetrations and local rules. | Do not assume LSZH or CPR class. |
| Reeling / festoon / drag chain | 15×D laying factor only; fixed-route application | Cycles, torsion, speed, acceleration and dynamic bend radius require another design. | Select a dedicated dynamic cable. |
14. Failure-mode controls
| Failure mode | Mechanism | Control action | Release evidence |
|---|---|---|---|
| Wrong product row | One size’s diameter, ampacity or reference is mixed with another row. | Use the exact Nexans reference and cross-section on every schedule, drum and test record. | Product code, matrix row and released drawing. |
| Radius violation | 15×D is applied to a different diameter or ignored at duct entries. | Calculate the ordered-size radius and control rollers, entry geometry and support spacing. | Method statement and installation inspection. |
| Screen-armour confusion | Copper tape screen is treated as armour, or AWA is treated as the complete earth-fault path. | Verify screen continuity, armour continuity, bonding, parallel paths, clearing time and joint or termination capability. | Earthing, armour and short-circuit study. |
| Revision mixing | Current -20 … 90 °C data is silently merged with an unprovided revision. | Identify the governing revision in the purchase specification and technical submittal. | Controlled datasheet and revision register. |
| Fire-class upgrade | IEC 60332-1-2 is marketed as LSZH, Cca, B2ca, Eca or grouped-cable fire performance. | Use the exact product declaration and project fire strategy; make no unprovided claim. | Product-specific fire dossier. |
| Dynamic misuse | Fixed-route PVC/AWA cable is installed on a reel, festoon or energy chain. | Select a qualified dynamic cable with mechanical cycle and torsion evidence. | Dedicated dynamic-cable data required. |
15. Feichun Cable certification and project assurance
Certification and market documentation apply to the exact conductor size, screen construction, sheath compound, AWA construction, accessory system, destination market and shipment batch.
Confirm conductor resistance, outer diameter, mass, copper-screen and armour details, thermal ratings, short-circuit duty, sheath tests, fire declaration and accessory compatibility for the ordered construction.
Feichun can develop a technically controlled alternative to major international or European cable brands when the complete construction, standards, drawings, test reports, accessories and project conditions are compared.
ATEX, IECEx, VDE, CE, UKCA, EAC and Russian Fire Safety documentation must be matched to the applicable product scope. Certification capability does not make every size or every cable construction automatically certified.
16. Source and revision audit
| Source | Reference / use | Status and limitation |
|---|---|---|
| Nexans family page | https://www.nexans.com.tr/en/products/xlpe-insulated-medium-voltage/copper-conductor/CU-XLPE-CT-64397.html | Current 6.35/11 kV family page: BS 6622, application, construction, ten size references and current characteristics. |
| Nexans family PDF | https://www.nexans.com.tr/.rest/catalog/v1/family/pdf/64397/CU-XLPE-CTS-PVC-AWA-PVC-6-35-11-kV | Official family PDF link for the same 6.35/11 kV construction; use the controlled revision supplied for procurement. |
| Nexans 70 mm² page / PDF | https://www.nexans.com.tr/en/products/xlpe-insulated-medium-voltage/copper-conductor/CU-XLPE-CT-64397/product~10536094~.html / https://www.nexans.com.tr/.rest/catalog/v1/product/pdf/10536094 | Size-specific cross-check: 28.0 mm OD, 1500 kg/km, 6.35/11 kV, PVC/AWA/PVC and 15×D. |
| Nexans 630 mm² page / PDF | https://www.nexans.com.tr/en/products/xlpe-insulated-medium-voltage/copper-conductor/CU-XLPE-CT-64397/product~10536077~.html / https://www.nexans.com.tr/.rest/catalog/v1/product/pdf/10536077 | Size-specific cross-check: 53.0 mm OD, 7750 kg/km, 1150 A air trefoil and 774 A buried trefoil. |
| BS 6622 scope | https://knowledge.bsigroup.com/products/electric-cables-armoured-cables-with-thermosetting-insulation-for-rated-voltages-from-3-8-6-6-kv-to-19-33-kv-requirements-and-test-methods | Independent standard-scope context; confirm the project-adopted edition and conformity route. |
| IEC 60502-2 | https://webstore.iec.ch/en/publication/95394 | International fixed-installation MV context; not silently substituted for the supplied BS 6622 product standard. |
| IEC 60332-1-2 | https://webstore.iec.ch/en/publication/80873 | Single-cable flame-propagation test context; not a complete CPR declaration. |
| User-supplied 8/4/26 record | Primary source | All supplied values, matrix rows, construction, page labels and disclaimer are preserved. |


