XHHW-2 Cable Extrusion Line

XHHW-2 Cable Extrusion Line

XHHW-2 is a cable model that complies with North American standards (UL 44, NEC NFPA 70). Its full name is 90 ° C cross-linked polyethylene insulated cable for humid environments.
The meanings of Letters and Numbers:
X: The representative insulation material is XLPE Insulation. This is the core of its high performance.
HH: The maximum allowable working temperature for the cable is 90 ° C.
W: The representative cable can be used in water resistant environments.
-2: This is a key suffix representing the rated operating temperature of the cable at 90 ° C, which can be used in humid environments; At the same time, its rated temperature in dry places is higher, at 90 ° C. (Unlike XHHW, which typically has a temperature of 75 ° C in dry places and 90 ° C in humid places).
Implementation standard: UL 44 (Standard for Thermoset Insulated Wires and Cables).
Rated voltage: commonly 600 V, there are also 1000 V levels.
Conductor:
Material: Usually copper or aluminum.
Structure: Single core solid or multi stranded.
Insulation material: cross-linked polyethylene (XLPE).
Working Temperature:
Long term allowable working temperature: ≤ 90 ° C (whether in dry or humid environments)
Maximum temperature during short circuit: ≤ 250 ° C
Main Features:
Core advantages:
Good heat resistance: XLPE insulation allows it to operate for a long time at 90 ° C, with a current carrying capacity higher than PVC insulation (such as THHN/THWN-2, although both are at 90 ° C, XHHW is usually thicker).
Moisture resistance: Designed for use in humid environments, it can be directly buried in wet cement or used in damp places.
Durable: XLPE insulation has excellent anti-aging, abrasion resistance and chemical corrosion resistance.
Lead free and halogen-free: Modern XHHW-2 cables typically meet lead-free requirements, and XLPE itself is halogen-free.
Disadvantages:
Higher hardness: Compared to THHN and other cables, their insulation layer is usually thicker, resulting in harder cables and slightly greater difficulty in bending.
High cost: higher cost than standard PVC insulated cables (such as THW).

XHHW-2 Cable Extrusion Line

The XHHW-2 low-voltage cable extrusion production line is a complete set of equipment specifically designed for manufacturing insulated cores and protective sheaths of power cables rated at 0.6/1 kV and below. Its core process involves melting solid plastics (such as PVC or XLPE) through heating and pressurization, then continuously and uniformly coating conductors (copper/aluminum wires) or assembled cable cores. After cooling and solidification, a smooth, dense, and uniformly thick insulating layer or protective sheath is formed.

Core Components

The XHHW-2 cable extrusion production line is a highly coordinated automated system, primarily consisting of the following major components:
Pay-off Unit:
Supports and releases the conductor or cable core, providing stable and controllable tension to prevent thinning or twisting of the conductor.
Preheater:
Heats the conductor before it enters the die head to remove moisture, reduce internal stress, and improve adhesion between the plastic and the conductor.
Extruder:
Screw: Conveys, compacts, melts, and homogenizes the plastic.
Barrel: Heats and cools the plastic.
Drive Motor: Provides power to the screw.
Die Head: Connects the extruder to the die.
Die (Tip and Die): Determines the thickness, concentricity, and shape of the extruded layer.
Cooling Trough:
Rapidly cools and solidifies the high-temperature cable. Typically features segmented temperature control to ensure material stability and avoid internal stress.
Haul-off Unit:
Provides the driving force for the production line. Its speed must be extremely stable, as it is critical for ensuring uniform extrusion thickness.
Spark Tester:
An online quality inspection device that applies high voltage to the insulating layer to detect defects such as pinholes or impurities, triggering alarms and marking the locations.
Take-up Unit:
Winds the finished cable neatly onto a reel, maintaining constant tension and synchronizing with the haul-off speed.
Control System:
Uses a PLC / industrial computer to centrally control all parameters (temperature, speed, tension, etc.), ensuring stable and reproducible production.

XHHW-2 Cable Extrusion Line Datasheet

Model	70	80	90	100	120
Screw Diameter (mm)	φ70	φ80	φ90	φ100	φ120
Screw L/D Ratio	26:1	26:1	26:1	25:1	25:1
Extrusion Amount (kg/hr)	140	200	250	320	450
Outlet Wire (mm)	2-15	3-25	5-35	8-60	10-80
Total Power (KW)	40	55	63	120	165
Production Speed(Max., m/min)	300	200	200	100	80
Take-up Spool	500/800	800/1250	800/1600	1000/2000	2000/2500
Storage Length	240 m	200 m	180 m	0	0

XHHW-2 Cable Extrusion Line Application

Thanks to its durability and moisture resistance, XHHW-2 has a wide range of applications:
Internal power distribution in buildings: as feeders and branch circuits in commercial and industrial buildings, laid in pipelines and trunking.
Damp environment: directly used in damp places, such as sewage treatment plants, food processing plants, basements, etc. It can also be directly buried in wet cement.
Industrial facilities: power and equipment supply for factories and workshops.
Service entrance line: used as an entry service cable from the power grid to the building.
Applicable laying method: mainly used for laying in pipelines and conduits, and can also be installed in other approved methods such as cable trays.

XHHW-2 Cable Extrusion Line

The XHHW-2 low-voltage cable extrusion production line is a complete set of equipment specifically designed for producing XHHW-2 cables & other insulation cores and sheaths of power cables with rated voltage of 0.6/1kV and below. The details are as follows:
Conductor Insulation
Function: Extrudes insulating material onto copper or aluminum conductors to form the primary insulation layer.
Common Materials: Cross-linked polyethylene (XLPE), polyethylene (PE), polyvinyl chloride (PVC), etc.
Requirements: Uniform thickness, high concentricity, absence of impurities, and no microvoids. The insulation extrusion process for high-voltage cables demands the highest technical precision.

Sheathing Extrusion

Function: Extrudes a protective sheath over the assembled cable core.
Purpose: Provides mechanical protection, corrosion resistance, moisture resistance, UV resistance, flame retardancy, etc.
Common Materials: Polyvinyl chloride (PVC), polyethylene (PE), polyolefins, etc.