Tuesday, June 19, 2018
Publication Date: 09/1/2012
Archive >  September 2012 Issue >  New Products > 

Helukabel Intros Flex Aluminum Power Cable
Finely stranded aluminum cable offers high flex and bending.
Elgin, IL — Aluminum power cable technology for wind turbines took a giant leap forward with the introduction of Helukabel®'s Heluwind® WK Powerline ALU. This diesel locomotive (DLO)-like power cable is made of finely-stranded aluminum and is highly flexible, offering customers the performance capabilities of a standard copper cable, but at a fraction of the cost.

Since the Powerline ALU is made of aluminum its weight is reduced by nearly 50 percent, it is quicker and easier to install, as well as being less expensive than comparable copper power cables.

Conventional aluminum power cables produced today are stiff and cannot be bent, which prevents the installation of a single cable length. Wind turbine installers are forced to interrupt the cable by splicing it up to 80 times in four tower sections to connect the stiff aluminum cable across the length of the down tower. Once the base is reached, an additional interruption in the cable is needed to make the flex connection to the inverter. This installation process takes two to three days.

The installation advantage of the flexible Powerline ALU is that one length of cable can run from behind the drip loop in the down tower area directly to the inverter in the tower base. It requires only one splice, between the copper loop cable and the power line, and a crimp cable lug to connect the power line to the inverter. This enhanced installation procedure takes only four to six hours. In addition, reducing the splice count to one improves the safety and protection of the turbine's power cable, since most technical failures are caused by bad splices.

Constructed using a finely-stranded aluminum core and wrapped with specially-formulated, heat-resistant insulation and outer jacket, the Powerline ALU is not only highly flexible, but extremely durable with resistance to UV-light, oil and fire.

Additional characteristics include: broad operating temperature range — -20°C (flexing) and -40°C (fixed) to +105°C (both fixed and flexing); tight bending radius — 10x cable diameter (flexing), 4x cable diameter (fixed); recyclable (RoHS); halogen-free (LSZH).

The Powerline ALU comes in two standard types, 0.6/1kV and 1.8/3kV, and can be ordered in bulk or pre-assembled (includes tube connector and crimped cable lug). Both cable types are available as robust versions, which have an abrasion-resistant and cut-resistant outer jacket.

Currently, the Powerline ALU is CE compliant and can have UL/CSA approval upon request.

Contact: Helukabel USA, 1355 Bowes Rd., Unit C, Elgin, IL 60123 847-930-5118 fax: 847-622-8766 sales@helukabel.com Web:

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