397.5 MCM IBIS ACSR Conductor Cable
The ACSR CAA 397.5 MCM 26/7F IBIS conductor is a high-strength aluminium conductor steel reinforced (ACSR) cable, engineered for use in overhead transmission and distribution systems where both mechanical durability and electrical performance are critical.
Manufactured in accordance with ASTM B232, this conductor is constructed with 26 strands of hard-drawn 1350-H19 aluminium helically laid over 7 galvanized steel strands, offering an optimal balance between conductivity, corrosion resistance, and tensile strength.
The steel core, galvanized to Class A or B standards, provides structural support and resistance to environmental corrosion, while the outer aluminium layers ensure efficient current-carrying capacity. This concentric-lay stranded design makes the IBIS conductor a reliable and widely used solution in medium- and high-voltage power networks, particularly for long-span overhead lines.
Construction
Technical Specifications
Quality Control
Application
Construction
397.5 MCM IBIS ACSR Conductor Cable Construction
Standard
Product ASTM B232
Aluminum is extensively used in electrical conductors due to its excellent electrical properties. Nevertheless, aluminum conductors in transmission and distribution lines usually require extra mechanical reinforcement, which is often supplied by the galvanized steel wires in ACSR cores.
Aluminum is extensively used in electrical conductors due to its excellent electrical properties. Nevertheless, aluminum conductors in transmission and distribution lines usually require extra mechanical reinforcement, which is often supplied by the galvanized steel wires in ACSR cores.
Construction
ACSR is defined as a concentrically stranded conductor, with hard-drawn 1350-H19 aluminum wires layered around a galvanized steel core—either single-wire or stranded, sized appropriately. Its steel wire features Class A or B galvanization for corrosion resistance. To meet the electrical and mechanical strength requirements of transmission and distribution lines, ACSR provides suitable designs through balanced ratios of aluminum and galvanized steel wires.
Applications
Commonly used as bare cable in overhead power transmission, and further serves as primary and secondary bare cable for distribution circuits.
Conditions for Ampacity Calculation
Conductor temperature = 75 °C;
Room temperature = 25 °C
Room temperature = 25 °C
Technical Specifications
397.5 MCM IBIS ACSR Conductor Cable
397.5 MCM IBIS ACSR Conductor Cable
| Construction characteristics | |
| Type of cable | Ibis |
| Type of conductor | Circular, stranded |
| Conductor material | aluminum / Steel Core |
| Conductor flexibility | Class A |
| Conductor shape | Circular non compacted |
| Dimensional characteristics | |
| Conductor cross-section | 397.5 kcmil |
| Aluminium cross-section | 201.34 mm² |
| Conductor cross-section | 234.07 mm² |
| Number of aluminium wires | 26 |
| Diameter of aluminium wires | 3.14 mm |
| Number of steel wires | 7 |
| Diameter of steel wires | 2.44 mm |
| Diameter of steel core | 7.32 mm |
| Conductor diameter | 19.88 mm |
| Average geometric radius | 0.00807 m |
| Aluminium content | 559.3 kg/km |
| Steel content | 255.7 kg/km |
| Approximate weight | 815 kg/km |
| Nominal outer diameter | 19.88 mm |
| Number of cores | 1 |
| Number of round wires | - |
| Electrical characteristics | |
| Max. DC resistance of the conductor at 20°C | 0.1439 Ohm/km |
| Max. electric resistance AC 60Hz 75°C | 0.172 Ohm/km |
| Inductive reactance | 0.3635 Ohm/km |
| Capacitive reactance | 0.2201 MOhm.km |
| Ampacity | 590.0 A |
| Mechanical characteristics | |
| Rated breaking load (Class A) | 7386 kgf |
| Rated breaking load (Class B) | 7163 kgf |
| Hardness type | 1350-H19 |
| Usage characteristics | |
| Length | 1670 m |
| Reel net weight | 1360 kg |
| Packaging | Reel 125/100 |
Quality Control
397.5 MCM IBIS ACSR Conductor Cable
Raw Material Test
Raw material testing for the Merlin ACSR Conductor Cable ensures compliance with ASTM B230 and B232 standards. Aluminum wires (1350-H19) are inspected for purity (>99.5%), conductivity (>61.5% IACS), and elongation (>1.5%) using spectrometry and tensile machines. Steel core wires (Class A galvanized) undergo zinc coating mass (min 259g/m²), tensile strength (1300-1450 MPa), and ductility checks via wrap and torsion tests. Samples are subjected to corrosion simulation in salt spray chambers and impurity analysis via microscopy. Only approved raw materials advance to stranding, guaranteeing the Merlin ACSR Conductor Cable's balanced aluminum-steel ratio, corrosion resistance, high tensile strength, and reliable overhead performance under varying loads.
Process inspection
During the manufacturing of the Merlin ACSR Conductor Cable, process inspection adheres to ASTM B232. Aluminum drawing ensures wire diameter tolerance (±0.025mm) and surface smoothness with micrometers. Steel core galvanizing controls zinc thickness (80-100µm) and adhesion via stripping tests. Stranding line monitors 18/1 lay ratio, compactness, and tension balance using optical sensors. Real-time checks for ovality and strand continuity occur at multiple points. Final lubrication and spooling verify coil integrity. Key steps: pre-stranding material dryness confirmation, parameter logging (speed, tension), intermediate sampling for microscopy, defect rejection (breaks/cracks), and post-stranding dimensional verification. This multi-point oversight ensures the Merlin ACSR Conductor Cable achieves uniform stranding and optimal steel-aluminum bonding.
Finished Product
The finished Merlin ACSR Conductor Cable undergoes comprehensive testing to ASTM B232 standards. Routine tests include overall diameter (0.684 inches), weight per length (315 lbs/1000ft), and DC resistance (0.0510 Ω/1000ft at 20°C). Mechanical tests cover ultimate tensile strength (8,680 lbs) and elongation using universal machines. Electrical withstand and partial discharge checks confirm integrity. The process steps: reel sampling, preparation with grips, gradual load application to break point, timed hold for creep, post-test fracture analysis, and documentation. Additional verifications include zinc coating uniformity, lay length (300-400mm), and weather simulation (UV/ice loading).
Application
Merlin ACSR Conductor Cable is ideal for overhead transmission and distribution lines in utility networks, rural electrification, and industrial power grids. Commonly used for spans up to 300m in moderate wind/ice areas, connecting substations to transformers for efficient 69-138kV service.
Technical Advantages
● 30+ years of manufacturing experience
● ISO and UL certified production
● Customized cable and transformer solutions
Product Packaging
Wires and Cables packaging (1)
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