LED UV Irradiation Crosslinking Low Smoke Halogen Free Flame Retardant Cable Manufacturing Equipment

• Customization: Available
• Application: Industrial
• Material Shape: Round Wire
• Sheath Material: Crosslinking
• Insulating Material: XLPE
• Conductor Type: Stranded
• Certification: CE
• Wire Core Material: Red Copper Wire
• Total Power: 22kw
• Control System: Delta or Siemens
• Apply Color: Red/Yellow/Green/Blue
• Cable Material: Add Special Optical Initiators
• Irradiation Form: UV Lamp
• Transport Package: Plywood
• Trademark: Hapro
• Origin: China
• HS Code: 84794000
• Production Capacity: 100/Year

Product Description

Hapro has developed the UVI,UVII type radiation system based on traditional transformers and capacitors driven mercury lamp , UVE-I,UVE-II type electronic radiation system driven mercury lamp and  UVL-I type  radiation system based on UV LED  light source.
UV LED device is the most advanced UV radiation source, it has higher energy efficiency (about 30%), narrow wave length band width (5nm half power band width)and long life expectancy (40000 hours),It use the special distribution of lamp beads from 300~450nm bands to match the most spectral absorption range of the photoinitiator.
Newly developed distributed network power source was used to power LED devices. Power sources was arranged along the LED distribution and mounted back to back with LED devices and make the interconnection as short as possible. 3 wire connection of every device made it possible to switch on and off and adjust the power.

The LED light sources were mounted in a tunnel structure. The light radiated the center of the tunnel where the manufactured wire and cable go through. The radiation power can be set from 0 to 100% smoothly.Optical lens adopts imported ultraviolet fused quartz and vacuum coating technology, which greatly improves the utilization rate of ultraviolet energy.  The advantages of UV-LED system over traditional UV lamp system and electron beam radiation and crosslinking:
vLow energy consumption :UV-LED system is only consume 1/4 energy comparing that of traditional UV lamp system at same production,1/30 energy comparing that of electron accelerator.
vFast production:Compare to crosslinking, and consigned electron beam processing, the crosslinking processing is finished simultaneously with the extrusion.
Low production cost:No intermediate movement and storage of the product, save the human power and additional cost. Low cost of UV radiation compound.
vLong life expectancy of the system :Life expectancy of the LED device is 4000 hours,no bead loss in normal working environment, and the perfect output power stability, See the life comparison table.
Environment friendly:The wave length is only 5nm band width, no short wave length UV energy induced Oz emission, no infrared and heat radiation, no strong visible light pollution. Ozone discharge is included into Emission standards for odor pollutants,US stipulate 0.1ppm, China stipulate 0.15ppm,UVL-I equipment won't products ozone.A water cooling system and a 2kW air blower are needed for extracting small molecule emission from the material during extrusion to keep the tunnel clean.
vSmall in size, easy to installation: The system can be inserted in traditional plastic insulating extruding production line, 1.8-2.0m in length and 2.5-3.0m in width in between extruding die and water trouph, water cooling system can be arranged properly.
Easy to operation :Pneumatic turn open and close the tunnel structure, make the conveying of the wire and clean the lens easy and ordinary operator can do it.
Low cost of maintenance:No lamp should be change, and no reflector should be replaced. The daily maintenance is only the clean of the lens surface by soft paper. For electronic beam system, maintenance is a heavy task.

Equipment performance parameters:

1,Total power consumption : 22kW ;
Radiation box : 14kW ;
Chiller : 5kW ;
Smoke purifier: 3kW
2,Irradiation diameter:30 mm
3,Irradiation length :1000 mm
4,Lamp life :Under normal rated power usage, the life of the LED lamp has decreased to about 70%, which is over 30000 ~40000 hours.
5,Dimensions:1500*1300*1615mm(LxWxH)


 

	crosslinking	Electron accelerator  irradiated crosslinking		UVLED irradiation  crosslinking
Equipment investment	Low(steam room  or warm pool)	High		Medium
Energy consumption	High(Long heating)	High(>600kW)		Low(<22kW)
Production cost	High	High		Low
Production cycle	Long (Secondary processing)	Long (Secondary processing)		Short (Online crosslinking)
Heat shrinkable	large	large		small<2%
	Medium pressure  lamp			Electrodeless lamp			UVLED irradiation crosslinking
Equipment investment	Low	High		Medium
Energy consumption	70 kW		80kW		22kW
Maintenance cost	High		High		Low
Production speed	Low		Low		Fast (Online crosslingking)
Lamp life	500 hours		8000 hours		40000 hours
Consumables	Lamp tube, reflector plate		Lamp tube, reflector plate,magnetron		No
Stability of production speed	Bad		Bad		Good
Environmental	Ozone		Ozone		No Ozone
Operation	Complex		Complex		Simple
Floor space	Large		Large			Small

• Technical parameters:

Item	Name	Specification
1	Power supply	3 phase 380V+N+PE ,50Hz
2	Power consumption	Total power consumption : 22kW ; Radiation box : 14kW ; Chiller : 5kW ; exhaust fan: 3kW
3	Irradiation diameter	0~30mm
4	Dimensions	Radiation box :1500*1300*1615mm(L x W x H)/  Chiller:1500*800*1800mm(L x W x H)
5	Light source	The self-developed UV LED light source adopts the proprietary chip from the world's top manufacturers.It has high energy output and the unique design of the optical system by using hybrid wavelength technology, adopts imported special material of glass processing into special lens. It has lower energy loss by coating the lens surface , It adopts the liquid cooling system to get longer LED life.
6	LED CPS	The self-developed power module adopts the Japanese imported chip and adopts the vacuum irrigation technology to protect it.It has overload, short circuit, circuit breaker, over-current, over-voltage and over-temperature protection.Multi - channel redundant distribution,network control.
7	Power output	Output optical power 0~ 100% (Real limit to 20%~100%)
8	Lamp life	Under normal rated power usage, the life of the LED lamp has decreased to about 70%, which is over 30000 ~40000 hours.
9	Production speed	Please refer to the actual production speed table
10	Characteristic	Low energy consumption,Online cross-linking ,Low production cost,Long life,One key to start & Easy operation,Low maintenance costs, Environment friendly, No Ozone
11	Cooling way	Liquid cooling
12	Safe guarding	Current monitor, Temperature monitor, Scram button,Extinction alarm, Chiller alarm; Constant temperature control from air conditioner
13	Exhaust smoke	Smoke purifier or High pressure exhaust fan