336.4 MCM MERLIN ACSR Conductor Cable
The ACSR CAA 336.4 KCM 18/1F MERLIN is a robust and efficient aluminium conductor steel reinforced cable, designed for high-performance in overhead power transmission and distribution lines. This conductor consists of 18 strands of hard-drawn 1350-H19 aluminium helically stranded around a single galvanized steel core wire, delivering an ideal combination of electrical conductivity and mechanical strength.
Compliant with ASTM B232, this ACSR configuration is widely adopted in South American and international power systems. The steel core, galvanized to Class A or B, offers protection against corrosion, ensuring long service life in harsh environmental conditions. Meanwhile, the aluminium strands provide excellent current-carrying capacity and conductivity.
The MERLIN design is particularly suitable for medium-voltage transmission lines and long-span installations where mechanical tension and conductor sag need to be controlled without compromising electrical performance.
Construction
Technical Specifications
Quality Control
Application
Construction
336.4 MCM MERLIN ACSR Conductor Cable Construction
Standard
Product ASTM B232
Due to its excellent electrical conductivity, aluminum is commonly used for electrical conductors. However, aluminum conductors in transmission and distribution lines often require additional mechanical strength, usually provided by galvanized steel wires in the cores of ACSR cables.
Due to its excellent electrical conductivity, aluminum is commonly used for electrical conductors. However, aluminum conductors in transmission and distribution lines often require additional mechanical strength, usually provided by galvanized steel wires in the cores of ACSR cables.
Construction
Featuring a concentric stranded structure, ACSR has hard-drawn 1350-H19 aluminum wire layers twisted onto a galvanized steel wire core—single or stranded, depending on size. The steel wire includes Class A or B galvanization for corrosion defense. ACSR is engineered to meet transmission and distribution lines’ electrical and mechanical strength requirements, offering optimal designs through precise combinations of aluminum and galvanized steel wires.
Applications
Predominantly employed as bare cable for overhead electrical transmission lines, with additional use as primary and secondary bare cable in distribution systems.
Conditions for Ampacity Calculation
Conductor temperature = 75 °C;
Room temperature = 25 °C
Room temperature = 25 °C
Technical Specifications
336.4 MCM MERLIN ACSR Conductor Cable
336.4 MCM MERLIN ACSR Conductor Cable
| Construction characteristics | |
| Type of cable | Merlin |
| Type of conductor | Circular, stranded |
| Conductor material | aluminum / Steel Core |
| Conductor flexibility | Class AA |
| Conductor shape | Circular non compacted |
| Dimensional characteristics | |
| Conductor cross-section | 336.4 kcmil |
| Aluminium cross-section | 170.22 mm² |
| Conductor cross-section | 179.68 mm² |
| Number of aluminium wires | 18 |
| Diameter of aluminium wires | 3.47 mm |
| Number of steel wires | 1 |
| Diameter of steel wires | 3.47 mm |
| Diameter of steel core | 3.47 mm |
| Conductor diameter | 17.35 mm |
| Average geometric radius | 0.00674 m |
| Aluminium content | 471.6 kg/km |
| Steel content | 73.6 kg/km |
| Approximate weight | 545.2 kg/km |
| Nominal outer diameter | 17.35 mm |
| Number of cores | 1 |
| Number of round wires | 19 |
| Electrical characteristics | |
| Max. DC resistance of the conductor at 20°C | 0.1694 Ohm/km |
| Max. electric resistance AC 60Hz 75°C | 0.205 Ohm/km |
| Inductive reactance | 0.377 Ohm/km |
| Capacitive reactance | 0.2266 MOhm.km |
| Ampacity | 520.0 A |
| Mechanical characteristics | |
| Rated breaking load (Class A) | 4015 kgf |
| Rated breaking load (Class B) | 3950 kgf |
| Hardness type | 1350-H19 |
| Usage characteristics | |
| Length | 2500 m |
| Reel net weight | 1360 kg |
| Packaging | Reel 125/100 |
Quality Control
336.4 MCM MERLIN ACSR Conductor Cable
Raw Material Test
Raw material testing for the Merlin ACSR Conductor Cable follows ASTM B230 and B498. Aluminum ingots are analyzed for chemical purity (Si<0.1%, Fe<0.2%) and hardness using spectrometers. Steel wires undergo carbon content (0.5-0.8%), galvanization thickness (259g/m² min), and torsion cycles (min 16). Joint compounds are checked for compatibility. The structured process: vendor documentation review, sample extraction, lab testing (hardness Rockwell B80 max), mechanical verification (aluminum tensile 145 MPa), corrosion chamber exposure, and pass/fail determination. This secures high-grade materials for the Merlin ACSR Conductor Cable's balanced properties and overhead resilience.
Process inspection
Process inspection in Merlin ACSR Conductor Cable production ensures ASTM B232 adherence. Wire preparation ensures clean surfaces. The stranding machine calibrates for an 18/1 configuration with die compression. Tension control prevents loosening. Lubrication application prevents galling. Reeling checks for even winding. Key steps: input material check, machine calibration (tension 500N), in-line diameter measurement, sample pull testing, flaw detection with ultrasonics, and rework for inconsistencies. This ensures the Merlin ACSR Conductor Cable's tight stranding, even galvanization, and structural integrity for overhead use.
Finished Product
Finished Merlin ACSR Conductor Cable testing confirms ASTM B232 compliance. Key tests: rated tensile strength (8,680 lbs), conductivity, and weight verification. The process steps: end preparation, machine calibration, incremental tension to rupture, strain gauge recording, post-failure examination, and data logging. Corrosion tests: 500-hour salt spray. Additional: vibration (Aeolian) for endurance. Passing affirms the Merlin ACSR Conductor Cable's low expansion coefficient, high fatigue life, and suitability for overhead transmission in dynamic conditions. Additional verifications include zinc coating uniformity, lay length (300-400mm), and weather simulation (UV/ice loading).
Application
Ideal for overhead medium-voltage lines in rural utilities, wind farms, and grid extensions. Used for medium spans in moderate climates, connecting overhead transformers to consumers for efficient, low-cost electricity delivery in suburban and industrial areas.
Technical Advantages
● 30+ years of manufacturing experience
● ISO and UL certified production
● Customized cable and transformer solutions
Product Packaging
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What are the advantages of power cables and overhead lines?(1) Reliable operation, because it is installed in a hidden place such as underground, it is less damaged by external forces, has less chance of failure, and the power supply is safe, and it will not cause harm to people; (2) The maintenance workload is small and frequent inspections are not required; (3) No need to erect towers; (4) Help improve power factor.
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Which aspects should be considered when choosing the cross section of a power cable?(1) The long-term allowable working current of the cable; (2) Thermal stability once short circuited; (3) The voltage drop on the line cannot exceed the allowable working range.
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What are the measures for cable fire prevention?(1) Use flame-retardant cables; (2) Use fireproof cable tray; (3) Use fireproof paint; (4) Fire partition walls and fire baffles are installed at cable tunnels, mezzanine exits, etc.; (5) Overhead cables should avoid oil pipelines and explosion-proof doors, otherwise local pipes or heat insulation and fire prevention measures should be taken.
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What should be paid attention to during the transportation and handling of cables?(1) During transportation, loading and unloading, cables and cable reels should not be damaged. It is strictly forbidden to push the cable reels directly from the vehicle. Generally, cables should not be transported and stored flat. (2) Before transporting or rolling the cable reel, ensure that the cable reel is firm, the cable is wound tightly, the oil pipe between the oil-filled cable and the pressure oil tank should be fixed without damage, the pressure oil tank should be firm, and the pressure indication should meet the requirements.
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What inspections should be carried out for the acceptance of cable lines?(1) The cable specifications should meet the regulations, the arrangement should be neat, no damage, and the signs should be complete, correct and clear; (2) The fixed bending radius of the cable, the related distance and the wiring of the metal sheath of the single-core power cable should meet the requirements; (3) The cable terminal and the middle head should not leak oil, and the installation should be firm. The oil pressure of the oil-filled cable and the meter setting should meet the requirements; (4) Good grounding; (5) The color of the cable terminal is correct, and the metal parts such as the bracket are completely painted; (6) There should be no debris in the cable trench, tunnel, and bridge, and the cover should be complete.
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