4ABLES %XPLANATIONS
4ECHNICAL$ATA
4YPE TRADEMARK
4YPE DESIGNATION
!PPROVALSSTANDARDS
!PPLICATION
%LECTRICAL PARAMETERS
4HERMAL PARAMETERS
-ECHANICAL PARAMETERS
#HEMICAL PARAMETERS
$ESIGN &EATURES
#ONDUCTORS
#OMPOUNDS INSULATION INNER AND OUTER SHEATH
3HIELD
&IELD CONTROL
#ORE ARRANGEMENT
3UPPORT ELEMENTS
!NTITORSION BRAID
-ARKING
4YPETRADEMARK
4RADEMARKS FOR FLEXIBLE
ELECTRIC CABLES FOR CRANES AND
MATERIAL HANDLING EQUIPMENT
&LEXIBLE CABLES
#/2$!&,%8š
4OUGH RUBBERSHEATHED REELING
CABLE
.3(4¾5
0,!./&,%8š
&LAT RUBBERSHEATHED FESTOON CABLE
.'&,'¾5
2/.$/&,%8š
2OUND RUBBERSHEATHED FESTOON
CABLE ALSO SUITABLE FOR SIMPLE REELING
.'2$'¾5
302%!$%2&,%8š
3PECIAL CABLE FOR GRAVITYFED COLLECTOR
BASKET OPERATION 93,4¾
/04/&,%8š
2UBBERSHEATHED FLEXIBLE FIBREOPTIC
CABLE
02/4/,/.š
(6 REELING CABLES
.43#'%7¾5
3PECIAL COMPOUNDS
02/4/$52š
68
)NSULATING COMPOUND 06# USED IN LIFT
CONTROL CABLES AND 302%!$%2&,%8
02/4/&)2-š
3HEATHING COMPOUND 0#0 USED IN
#/2$!&,%8 02/4/,/.
#OMPOUND WITH SPECIAL RESISTANCE TO ABRA
SION AND TEARING '- QUALITY
02/4/,/.š
)NSULATING COMPOUND %02 USED IN
#/2$!&,%8 02/4/,/.
2UBBER COMPOUND WITH EXCELLENT ELECTRICAL
PROPERTIES RESISTANT TO HEAT AND WEATHER
3ELECTION AND $IMENSIONING #RITERIA
4YPETYPE DESIGNATION
4HE TYPE DESIGNATES A GROUP OF FLEXIBLE ELECTRIC CABLES WHICH HAVE
THE SAME DESIGN FEATURES AND WHICH ARE INTENDED FOR A SPECIFIC RANGE
OF TECHNICAL APPLICATIONS
4HE TYPE DESIGNATION IS A LETTER COMBINATION ACCORDING TO $). 6$%
WHICH DESCRIBES THE TYPE IN CODED FORM
&OR DETAILS OF THE DESIGN FEATURES PLEASE REFER TO TABLE PAGE &OR DETAILS OF THE APPLICATION PLEASE REFER TO THE APPLICATION AND
INSTALLATION GUIDELINES TABLE PAGES AND -
3UFFIX TO THE TRADEMARK EG /04/&,%8 - FOR
-INING
-3
-EDIUMVOLTAGE -6
.
$ESIGN ACCORDING TO THE CORRESPONDING
STANDARD
.
"ASED ON A STANDARD
,93,4+
,IGHTWEIGHT LIFT CONTROL CABLE UP TO M
SUSPENSION LENGTH
/
!DDITIONAL INFORMATION ABOUT THE TYPE WITHOUT
GREENYELLOW MARKED CORE
.'&,'¾5
&LAT RUBBERSHEATHED FLEXIBLE FESTOON CABLE
0,!./&,%8
¾
/ILRESISTANT OUTER SHEATH ACCORDING TO
$). 6$% 0ART 0ARA /%
.'2$'¾5
2OUND RUBBERSHEATHED FLEXIBLE FESTOON CABLE
ALSO SUITABLE FOR SIMPLE REELING
2/.$/&,%8
2$
2OUND CABLE
3(4
K6 REELING CABLE
3,
#ONTROL CABLE
3-
&LEXIBLE CABLES FOR EXTREMELY HIGH MECHANICAL
STRESS PREVIOUSLY USED AS SUPPLEMENT TO THE
TRADEMARKS #/2$!&,%83- AND
02/4/,/.3- PREVIOUSLY DERIVED FROM
3IEMENS MACHINE CABLE
.3(4¾5
4OUGH RUBBERSHEATHED FLEXIBLE REELING CABLE
#/2$!&,%8
.43#'%7¾5 (6 REELING CABLES 02/4/,/. TO K6
93,4+
,IFT CONTROL CABLE UP TO M SUSPENSION LENGTH
93,4¾
3PECIAL CABLE FOR GRAVITYFED COLLECTOR BASKET
OPERATION 302%!$%2&,%8
3-+
93,9#9+
,IFT CONTROL CABLE UP TO M SUSPENSION
LENGTH
.EW CABLE GENERATION COMBINING THE HIGH RE
QUIREMENT PROFILES OF 3- AND +
3-2
h2v FOR REDUCED IE SAME DIAMETER AS
02/4/,/. STANDARD CABLE OTHERWISE
ADVANCED 02/4/,/.3- DESIGN
34
#ONTROL CORES WITHIN THE CABLE
4
3UPPORT ELEMENT
43
2EELING CABLE
5
&LAMERETARDANT OUTER SHEATH ACCORDING TO
$). 6$% 0ART hNONINFLAMMABLEh
Ä,
-ONITORING CONDUCTOR WITHIN THE CABLE 5%,
7
7EATHER RESISTANT
9
06# COMPOUND
#ONDUCTING NONMETAL CASING OVER THE STRANDED
CORES OR BETWEEN THE INNER AND OUTER SHEATH
SHIELD
:
0RINTED NUMBERS
0ROTECTIVEEARTH CONDUCTOR UNIFORMLY DISTRIBUTED
IN THE THREE INTERSTICES
#'%
#ONDUCTING NONMETAL CASING OVER THE INSULA
TION OF THE OUTER CONDUCTORS
%
0ROTECTIVEEARTH CONDUCTOR UNIFORMLY DISTRIBUTED
OVER THE INSULATION OF THE OUTER CONDUCTOR
&,
&LAT CABLE
&&/
4ELECOMMUNICATION LINES WITHIN THE CABLE
&IBREOPTIC 'ERMAN ,7,
'
(3
2UBBER COMPOUND
(IGHVOLTAGE (6
*
!DDITIONAL INFORMATION ABOUT THE TYPE WITH
GREENYELLOW MARKED CORE
+
2UBBER CROSS IN THE CENTRE OF THE CABLE OR
LOWTEMPERATURE RESISTANT IN THE CASE OF LIFT CON
TROL CABLES AND + AS A SUPPLEMENT TO THE TRADE
MARK EG #/2$!&,%8+
+/.
#ONCENTRIC PROTECTIVE CONDUCTOR BETWEEN THE
INNER AND OUTER SHEATH OR CONCENTRIC CON
TROLMONITORING CONDUCTOR
,
,IGHTWEIGHT CABLE DESIGN
,7,
&IBREOPTIC &/
4HE TYPE DESIGNATION CAN BE DECIPHERED AS FOLLOWS
#
#
#%
#'
#ONDUCTING METAL CASING OVER THE STRANDED
CORES OR BETWEEN THE INNER AND OUTER SHEATH
SHIELD
!DDITIONAL INFORMATION ABOUT THE SHIELD FOR THE
CONDUCTOR CROSSSECTIONS EG X #
WHICH MEANS MM§ INDIVIDUALLY SHIELDED OR
X X # WHICH MEANS X MM§ TWISTED
AND SHIELDED PAIRS
#ONDUCTING METAL CASING OVER THE INSULATION OF
THE OUTER CONDUCTORS
4HE 'ERMAN CHARACTERS h¾v AND hÄv ARE TRANSFORMED INTO THE INTERNATIONAL
h/%v AND h5%v RESPECTIVELY
69
!PPROVALSSTANDARDS
&LEXIBLE ELECTRIC CABLES FOR CRANES AND MATERIAL HANDLING EQUIPMENT
HAVE TO BE ABLE TO COPE WITH THE EXPECTED OPERATION AND INSTALLATION
CONDITIONS $ETAILS ARE GIVEN IN THE APPLICATION AND INSTALLATION GUIDE
LINES )N ADDITION FLEXIBLE ELECTRIC CABLES FOR CRANES AND MATERIAL HAN
DLING EQUIPMENT ARE DESCRIBED WITH REGARD TO DESIGN AND TESTS AS
LAID DOWN IN NATIONAL AND INTERNATIONAL STANDARDS DESIGN REGULATIONS
$ESIGN REGULATIONS
4HE SUMMARY IN TABLE PAGE SHOWS ALL THE DESIGN REGULA
TIONSSTANDARDS ACCORDING TO WHICH THE FLEXIBLE ELECTRIC CABLES FOR
CRANES AND MATERIAL HANDLING EQUIPMENT ARE DESIGNED AND
MANUFACTURED 4HE FOLLOWING DISTINCTIONS ARE MADE BETWEEN NA
TIONAL AND INTERNATIONAL REGULATIONS
!PPLICATION AND INSTALLATION GUIDELINES
$). 6$% 0ART !PPLICATION OF CABLES AND FLEXIBLE CORDS IN
POWER INSTALLATIONS
'ENERAL INFORMATION ON CABLES
$). 6$% 0ART !PPLICATION OF CABLES AND FLEXIBLE CORDS IN
POWER INSTALLATIONS
2ECOMMENDED VALUES FOR
CURRENTCARRYING CAPACITY OF CABLES
$). 6$% 0ART %RECTION OF POWER INSTALLATIONS WITH RATED
VOLTAGES UP TO 6
#RANES
$). 6$% %RECTION OF POWER INSTALLATIONS WITH RATED
VOLTAGES ABOVE K6
$). 6$% 3PECIFICATION FOR THE ERECTION OF ELECTRICAL
INSTALLATIONS IN UNDERGROUND MINES
$). 6$% 3PECIFICATION FOR THE ERECTION OF ELECTRICAL
INSTALLATIONS IN OPENCAST MINES QUARRIES
AND SIMILAR WORKS
%. 0ART 3AFETY REGULATIONS FOR THE CONSTRUCTION AND
INSTALLATION OF PASSENGER LIFTS GOODS LIFTS AND
SERVICE LIFTS
.ATIONAL STANDARD
$). 6$% $). 'ERMAN 3TANDARDS )NSTITUTE 6$% !SSOCIATION
OF 'ERMAN %LECTRICAL %NGINEERS
'ERMANY IS THE ONLY COUNTRY WHICH HAS ISSUED SPECIAL DESIGN
REGULATIONS FOR FLEXIBLE ELECTRIC CABLES FOR CRANES AND MATERIAL HAN
DLING EQUIPMENT 4HE TOUGHRUBBER SHEATHED FLEXIBLE REELING CA
BLES #/2$!&,%8 .3(4¾5 THE (6 REELING CABLES
02/4/,/. .437¾5 AND THE FLAT RUBBERSHEATHED FLEXIBLE CA
BLES 0,!./&,%8 .'&,'¾5 ARE DESCRIBED AND STANDARDIZED IN
$). 6$% 4HIS SET OF STANDARDS HAS FOUND RECOGNITION IN
%UROPE AND IN MANY COUNTRIES OUTSIDE %UROPE AND IS ACCEPTED
AS OR SPECIFIED AS hSTATE OF THE ARTh
4HE NEW GENERATION OF REELING CABLES DESCRIBED IN THIS CATALOG
GENERALLY CONFORMS TO THESE STANDARDS HOWEVER THEY DEVIATE IN
A NUMBER OF POINTS WHERE IT IS NECESSARY TO ACHIEVE AN
ENHANCED FEATURE PROFILE %FFORTS ARE BEING MADE TO HAVE THESE
MODIFICATIONS INCORPORATED IN THE RELEVANT STANDARDS
.O SUCH DESIGN REGULATIONS EXIST FOR 2/.$/&,%8
302%!$%2&,%8 /04/&,%8 AND LIFT CONTROL CABLES 4HESE ARE
0IRELLI SPECIAL CABLES THE DESIGN OF WHICH IS BASED ON EXISTING DE
SIGN REGULATIONS OR GENERAL REGULATIONS OF $). 6$%
)NTERNATIONAL STANDARD
)NTERNATIONAL STANDARDS HAVE BEEN TAKEN INTO ACCOUNT FOR ALL OUR
CABLES WHERE THIS WAS POSSIBLE
&OR USE AT AN INTERNATIONAL LEVEL SOME DESIGN FEATURES OF FLEXIBLE
ELECTRIC CABLES FOR CRANES AND MATERIAL HANDLING EQUIPMENT COV
ERED BY $). 6$% ARE ALSO LISTED OR CERTIFIED IN LINE WITH 5, OR
-3(!
5NDERWRITERS ,ABORATORIES )NC
5, IS AN APPROVAL AND STANDARDIZATION INSTITUTE IN THE 53!
4HE 5, STANDARD IS REQUESTED IN .ORTH !MERICA AND ALSO TO
SOME EXTENT IN THE &AR %AST
-3(! -INE 3AFETY AND (EALTH !DMINISTRATION
4HE -3(! LISTING WAS SPECIALLY ISSUED FOR THE CORRESPONDING
ELECTRIC CABLES BY THE h$EEP -INE 3AFETYh OFFICE AT (ARRISBURG
53! 4HE FLAMERETARDANT BEHAVIOUR OF THE CABLES WAS TESTED
70
3ELECTION AND $IMENSIONING #RITERIA
!PPOVALSSTANDARDS
&LEXIBLE CABLES
4YPE
'ERMAN STANDARD $). 6$%
#/2$!&,%83-+6
.3(4¾5
$). 6$% 0ART '/342{
0,!./&,%8
.'&,'¾5
$). 6$% 0ART &ILE 2 '/342{
2/.$/&,%8
.'2$'¾5
"ASED ON $). 6$% 0ART 6$% 2EG .O '/342{
302%!$%2&,%8
93,4¾
"ASED ON $). 6$% '/342{
/04/&,%8
)NTERNATIONAL STANDARDS
"ASED ON $). 6$% "ASED ON $). 6$% "ASED ON &$$) )3/
)%# 0ART -3(! 3# 02/4/,/.3-+
.43#'%7¾5
$). 6$% 0ART -3(! 0
'/342{
02/4/,/.3-+ ,7,
.43+#'%7¾5
$). 6$% 0ART -3(! 0
'/342{
,IFT CONTROL CABLE
,93,4+ 93,4+
93,9#9+
"ASED ON $). 6$% 6$% 2EG .O 3%-+/ 33 4ABLE
71
!PPLICATION
&LEXIBLE ELECTRIC CABLES FOR CRANES AND MATERIAL
HANDLING EQUIPMENT ARE TO BE SELECTED IN AC
CORDANCE WITH THE APPLICATION FOR WHICH THEY
ARE INTENDED CABLE GUIDANCE SYSTEM AND IN
ACCORDANCE WITH THE EXPECTED OPERATION AND
INSTALLATION CONDITIONS
)F NECESSARY THE CABLES ARE TO BE PROTECTED
AGAINST MECHANICAL THERMAL OR CHEMICAL INFLU
ENCES AND ALSO AGAINST THE PENETRATION OF
MOISTURE FROM THE ENDS OF THE CABLES
&LEXIBLE ELECTRIC CABLES FOR CRANES AND MATERIAL
HANDLING EQUIPMENT MUST NOT BE INSTALLED IN
THE GROUND $UCTS THROUGH FIRE BARRIERS IN THE
FORM OF SAND ETC OR TEMPORARY COVERING WITH
SOIL SAND OR SIMILAR MATERIAL EG ON CONSTRUC
TION SITES DO NOT COUNT AS BEING IN THE GROUND
)N GENERAL FIXING MATERIALS MUST NOT DAMAGE
THE FLEXIBLE CABLES
&LEXIBLE ELECTRIC CABLES FOR CRANES AND MATERIAL
HANDLING EQUIPMENT HAVE TO BE RELIEVED OF TEN
SION WHEN THEY ARE CONNECTED TO MOBILE
EQUIPMENT CRANES MATERIAL HANDLING EQUIP
MENT AND MUST BE SECURED TO PREVENT THEM
FROM TWISTING SHARP BENDING AND AXIAL COM
PRESSION 4HE SHEATHS OF THE FLEXIBLE ELECTRIC
CABLES MUST NOT BE DAMAGED AT THE ENTRIES OR
BY THE STRESSRELIEF DEVICES
4ABLE SHOWS THE MECHANICAL STRESSABILITY
AND THE NORMAL APPLICATIONS OF FLEXIBLE ELECTRIC
CABLES FOR CRANES AND MATERIAL HANDLING EQUIP
MENT
&LEXIBLE CABLES!PPLICATION
#/2$!&,%83-+ 6 .3(4¾5
&LEXIBLE REELING CABLE FOR HIGH AND VERY HIGH MECHANICAL STRESSES ON MO
BILE EQUIPMENT MOBILE CABLE TENDER SYSTEMS FESTOON SYSTEMS AND FOR
VERTICAL REELING OPERATION !LSO FOR APPLICATIONS TO WHICH $). 6$% AND APPLY /PENCAST AND UNDERGROUND MINING
0,!./&,%8 .'&,'¾5
&LEXIBLE POWER AND CONTROL CABLE FOR USE ON FESTOON SYSTEMS AND FOR
CONNECTING MOVABLE PARTS OF MACHINE TOOLS MATERIAL HANDLING EQUIP
MENT ETC ASSOCIATED WITH HIGH MECHANICAL STRESSES AND FREQUENT
BENDING DURING OPERATION AND FOR BENDING IN ONE PLANE ONLY
2/.$/&,%8 .'2$'¾5
&LEXIBLE POWER AND CONTROL CABLE FOR USE ON FESTOON SYSTEMS AND FOR
CONNECTING MOVABLE PARTS OF MACHINE TOOLS MATERIAL HANDLING EQUIP
MENT ETC ASSOCIATED WITH HIGH MECHANICAL STRESSES AND FREQUENT
BENDING DURING OPERATION 3UITABLE FOR SIMPLE REELING
2/.$/&,%8#&#.'2$'#'¾5
&OR USE ON FESTOON SYSTEMS EG ON GANTRY CRANES HALL GANTRY CRANES
RACK MATERIAL HANDLING EQUIPMENT TRANSPORTATION SYSTEMS OR MACHINE
TOOLS )N PARTICULAR FOR APPLICATIONS WHERE THERE IS A DANGER OF INTERFER
ENCE TO DATA TRANSMISSION SYSTEMS FROM POWER CABLES 4HE CABLES ARE
USED FOR HIGH MECHANICAL STRESSES AND FREQUENT BENDING !LSO SUITABLE
FOR USE AS A FLEXIBLE MOTOR POWER SUPPLY CABLE
302%!$%2&,%8 93,4¾
&EEDER CABLE FOR LOADLIFTING EQUIPMENT EG SPREADER WITH HIGH MECHANI
CAL STRESS IN GRAVITYFED COLLECTOR BASKET OPERATION
/04/&,%8
&OR OPTICAL SIGNAL AND DATA TRANSMISSION ON CRANES AND MATERIAL HANDLING
EQUIPMENT SUITABLE FOR FORCED GUIDANCE EG REELS FESTOON SYSTEMS CA
BLE TENDERS AT HIGH DATA RATES LARGE BANDWIDTH AND ABSOLUTE IMMUNITY
TO ELECTROMAGNETIC INTERFERENCE
02/4/,/.3-+ .43#'%7¾5
&LEXIBLE (6 REELING CABLE ALSO SUITABLE FOR FESTOON SYSTEMS WITH HIGH
TO EXTREME MECHANICAL STRESSES EG HIGH TRAVEL SPEEDS DYNAMIC TENSILE
LOADS MULTIPLE CHANGES OF DIRECTION INTO DIFFERENT PLANES CHURNING ON
RUNNING OVER ROLLERS AND TORSIONAL STRESSES -AINLY FOR MOBILE EQUIPMENT
EG FASTMOVING CONTAINER CRANES CRANES LARGE MOBILE EQUIPMENT AND
EXCAVATORS !LSO FOR APPLICATIONS TO WHICH $). 6$% AND APPLY /PENCAST AND UNDERGROUND MINING
02/4/,/.3-+ ,7, .43+#'%7¾5
&LEXIBLE (6 REELING CABLE ALSO SUITABLE FOR FESTOON SYSTEMS FOR COM
BINED POWER AND DATA TRANSMISSION WITH HIGH TO EXTREME MECHANICAL
STRESSES EG HIGH TRAVEL SPEEDS DYNAMIC TENSILE LOADS MULTIPLE
CHANGES OF DIRECTION INTO DIFFERENT PLANES CHURNING ON RUNNING OVER
ROLLERS AND TORSIONAL STRESSES -AINLY FOR MOBILE EQUIPMENT EG
FASTMOVING CONTAINER CRANES CRANES LARGE MOBILE EQUIPMENT AND EX
CAVATORS !LSO FOR APPLICATIONS TO WHICH $). 6$% AND APPLY
/PENCAST AND UNDERGROUND MINING
,IFT CONTROL CABLE
&OR CONNECTING LIFTS AND SIMILAR TRANSPORT AND MATERIAL HANDLING EQUIP
MENT WITH MEDIUM MECHANICAL STRESSES WITH SUSPENSION LENGTHS UP TO
M M AND M IN DRY DAMP AND WET LOCATIONS
4ABLE 72
3ELECTION AND $IMENSIONING #RITERIA
-ECHANICAL STRESS
-EDIUM
(IGH
&ORCED GUIDANCE
6ERY
HIGH
EXTREME
!PPLICATION
/UTDOORS
(AZARD
OUS
AREAS
#ONSTRUC
TION
SITES
)NDOORS
)NDUSTR
PLANT MACHIN
ERY
OPEN
CAST
-INING
UNDER
GROUND
9ES
9ES
"ENDING IN ONE
PLANE ALLOWED NO
REELING
9ES
&OR FESTOON OPERA
TION AND SIMPLE REEL
ING
9ES
&OR FESTOON OPERA
TION
9ES
&OR GRAVITYFED COL
LECTOR BASKET OPERA
TION
9ES
2ANDOM CYLINDRICAL
REELING NOT ALLOWED
9ES
9ES
9ES
)N LIFT SYSTEMS
.ORMAL APPLICATION
73
)NSTALLATION OF REELING CABLES
4O ENSURE PROPER AND FAULTFREE OPERATION
OF FLEXIBLE ELECTRIC REELING CABLES FOR MINING
APPLICATIONS SUCH AS 02/4/,/. AND
#/2$!&,%8 IT IS NECESSARY TO OBSERVE
CERTAIN RULES FOR CABLE ATTACHMENT INSTALLA
TION ON THE OPERATING DRUM
4HE CABLE CAN BE DIRECTLY WOUND FROM THE
SUPPLY DRUM TO THE OPERATING DRUM 0ULLING
OFF THE DRUM AND LAYING STRETCHED ON THE
GROUND OR hDEKINKINGh PRIOR TO TAKING UP
THE CABLE ON THE OPERATING DRUM SHOULD
NOT BE CARRIED OUT
)NCORRECT
#ORRECT
3UPPLY DRUM
3UPPLY DRUM
3UPPLY DRUM
3UPPLY DRUM
&IG 4HE DIRECTION OF LAY EMPLOYED IN MANUFAC
TURE OF POWER CABLES IS ALWAYS LEFTHAND
3TYPE )T IS THEREFORE RECOMMENDED THAT
THE START OF THE WINDING OF REELING POWER
CABLES ON CYLINDRICAL REELS SHOULD ALWAYS
BE AT THE LEFT SIDE
4HIS MEASURE ENSURES A CLEAN AND CORRECT
WINDING PATTERN EVEN WHEN NO GUIDANCE
HELICAL SLOT HAS BEEN PROVIDED ON THE REEL
BODY
4HE DIRECTION OF LAY EMPLOYED IN MANUFAC
TURE OF CONTROL CABLES IS ALWAYS
RIGHTHAND FOR WHICH REASON SUCH CABLES
SHOULD BE OPERATED WITH THE START OF THE
WINDING AT THE RIGHT SIDE
)NCORRECT
&IG 3TART OF WINDING FOR POWER CABLES
74
#ORRECT
3ELECTIONAND$IMENSIONING#RITERIA
#ENTRE FEEDING POINT
"5)3?TIF
)N MANY INSTALLATIONS EG BUNK
ERING EQUIPMENT THE POWER
INFEED POINT IS LOCATED AT THE
CENTRE OF THE GUIDEWAY 4HE
FLEXIBLE ELECTRIC REELING CABLES
SUCH AS #/2$!&,%8 AND
02/4/,/. -2 ARE NORMALLY
CONNECTED THROUGH UNDERFLOOR
INFEEDS &IG )N ORDER TO ACHIEVE EFFECTIVE
STRAIN RELIEF IN CONJUNCTION WITH
CABLEWEAR MINIMIZING DEFLEC
TION FROM THE INFEED POINT WE
RECOMMEND THE USE OF UN
DERFLOOR INFEEDS &IG )T IS
IMPORTANT THAT THE SPECIFIED
BENDING RADIUS BE MAINTAINED
AND THAT THE CABLE BE FASTENED
AT THE COMPENSATION CYLINDER BY
MEANS OF A CLIP WHICH HOW
EVER SHOULD BE ATTACHED ONLY
AFTER THE ND WINDING
&IG &LEXIBLE ELECTRIC REELING CABLE
%NTRY BELL FOR INFEED
#ABLE TRAY
#ABLE STRAIGHTTHROUGH JOINT
"URIED CABLE
#OMPENSATION CYLINDER
#ABLE CLIP LARGE AREA DESIGN
D
-AX CABLE DIAMETER
2MIN
"ENDING RADIUS OF ENTRY BELL AND
BENDING RADIUS OF COMPENSATION
CYLINDER
&IG -IN PERMISSIBLE BENDING RADIUS AS A FUNCTION OF THE CABLE DIAMETER
&LEXIBLE CABLES
#/2$!&,%8
2ATED VOLTAGE 55
5P TO K6
02/4/,/.
D IN MM
5P TO !BOVE TO !BOVE TO !BOVE 2MIN
XD
XD
XD
!BOVE K6
XD
X D
4ABLE 75
%LECTRICAL PARAMETERS
6OLTAGES
&OR THE RATED OPERATING AND TEST VOLTAGES OF CABLES THE DEFINI
TIONS GIVEN IN $). 6$% 0ART APPLY 3OME OF THESE ARE
MENTIONED IN TABLE BELOW
#ABLES WITH A RATED VOLTAGE 55 UP TO K6
4HESE CABLES ARE SUITABLE FOR USE IN THREEPHASE !# SIN
GLEPHASE !# AND $# INSTALLATIONS THE MAXIMUM CONTINUOUSLY
PERMISSIBLE OPERATING VOLTAGE OF WHICH DOES NOT EXCEED THE RATED
VOLTAGE OF THE CABLES BY MORE THAN FOR CABLES WITH A RATED
VOLTAGE 55 UP TO AND INCLUDING 6
FOR CABLES WITH A RATED VOLTAGE 55 K6
!# ALTERNATING CURRENT
$# DIRECT CURRENT
2ATED VOLTAGE
4HE RATED VOLTAGE OF AN INSULATED ELECTRIC CABLE IS THE VOLTAGE
WHICH IS USED AS THE BASIS FOR THE DESIGN AND THE TESTING OF THE
CABLE WITH REGARD TO ITS ELECTRICAL CHARACTERISTICS
4HE RATED VOLTAGE IS EXPRESSED BY THE TWO VALUES OF POWER FRE
QUENCY VOLTAGE 55 IN 6
5 RMS VALUE BETWEEN ONE CONDUCTOR AND hEARTHh
5 RMS VALUE BETWEEN TWO CONDUCTORS OF A MULTICORE CABLE
OR OF A SYSTEM OF SINGLECORE CABLES
)N A SYSTEM WITH !# VOLTAGE THE RATED VOLTAGE OF A CABLE MUST BE
AT LEAST EQUAL TO THE RATED VOLTAGE OF THE SYSTEM FOR WHICH IT IS
USED 4HIS REQUIREMENT APPLIES BOTH TO THE VALUE 5 AND THE
VALUE 5
)N A SYSTEM WITH $# VOLTAGE ITS RATED VOLTAGE MUST NOT BE MORE
THAN TIMES THE VALUE OF THE RATED VOLTAGE OF THE CABLE
/PERATING VOLTAGE
4HE OPERATING VOLTAGE IS THE VOLTAGE APPLIED BETWEEN THE CON
DUCTORS AND EARTH OF A POWER INSTALLATION WITH RESPECT TO TIME AND
PLACE WITH TROUBLEFREE OPERATION
&LEXIBLE CABLES
#ABLES IN $# INSTALLATIONS
)F THE CABLES ARE USED IN $# INSTALLATIONS THE CONTINUOUSLY PER
MISSIBLE $# OPERATING VOLTAGE BETWEEN THE CONDUCTORS MUST NOT
EXCEED TIMES THE VALUE OF THE PERMISSIBLE !# OPERATING VOLT
AGE )N SINGLEPHASE EARTHED $# INSTALLATIONS THIS VALUE SHOULD
BE MULTIPLIED BY A FACTOR OF 4EST VOLTAGE
2EGARDING THE TEST VOLTAGE OF FLEXIBLE CABLES THE VALUES GIVEN IN
THE CORRESPONDING PARTS OF $). 6$% APPLY )F THE RELEVANT
SHIELD IS MISSING AS FOR EXAMPLE WITH #/2$!&,%8 AND
0,!./&,%8 CABLESvCORE AGAINST COREv IS TESTED IN APPROPRIATE
COMBINATIONS 4HE VALUES ARE TO BE REGARDED AS !# TEST VOLTAGES
UNLESS STATED OTHERWISE FOR SINGLEPHASE TESTING IE THE !# TEST
VOLTAGE IS APPLIED BETWEEN THE CORE AND THE CORRESPONDING
SHIELDING EG SEMICONDUCTIVE LAYER EARTH CONDUCTOR SHIELD
4ELECOMMUNICATION CORES PAIRS AND OTHER SHIELDED PAIRS EG
X# ARE TESTED hCORE AGAINST COREh AND hCORE AGAINST SHIELDh
WHEREBY THE TEST VOLTAGES ARE CORRESPONDINGLY DIFFERENT
7ITH SINGLECORE CABLES WITHOUT SHIELDING THE CORRESPONDING
OPPOSITE POLE IS A WATER BATH
2ATED
-AX PERMISSIBLE OPERATING VOLTAGE
VOLTAGE
IN
!# SYSTEMS
IN $# SYSTEMS
UNEARTHED
55
55
5
K6
6
6
0,!./&,%8
302%!$%2&,%8
#ABLES WITH A RATED VOLTAGE 55 GREATER THAN K6
4HESE CABLES ARE SUITABLE FOR USE IN THREEPHASE AND SIN
GLEPHASE !# INSTALLATIONS THE MAXIMUM OPERATING VOLTAGE OF
WHICH DOES NOT EXCEED THE RATED VOLTAGE OF THE CABLE BY MORE
THAN K6
6
4EST VOLTAGE APPLIED TO THE COMPLETE CABLE
SINGLEPHASE 0OWER
EARTHED
CORES
5
K6
K6
#ONTROL
CORES
0ILOT
CORES
K6
K6
4ELE
COMM
CORES
K6
6
6
6
K6
K6
K6
K6
K6
K6
K6
K6
K6
K6
K6
K6
K6
K6
K6
K6
K6
K6
K6
K6
,IFT CONTROL CABLE
#/2$!&,%8
2/.$/&,%8
02/4/,/.
!S A RESULT OF ITS EXCELLENT
INSULATION CHARACTERISTICS
0,!./&,%8 IS APPROVED FOR
APPLICATIONS AT THE
K6 LEVEL
76
4ABLE 3ELECTION AND $IMENSIONING #RITERIA
%LECTRICAL PARAMETERS
#URRENTCARRYING CAPACITY
)F AFTER ALL SELECTION CRITERIA HAVE BEEN TAKEN INTO ACCOUNT THE TYPE OF
FLEXIBLE ELECTRIC CABLE TO BE USED FOR CRANES AND MATERIAL HANDLING
EQUIPMENT HAS BEEN DECIDED ON THE NECESSARY CROSSSECTION OF THE
CONDUCTOR CAN BE DETERMINED EITHER FROM THE CURRENT TO BE TRANSMIT
TED OR FROM THE POWER
)NSTALLATION CONDITIONS STRETCHED LAYING SUSPENDED FREELY IN THE
AIR REELED VARIATIONS IN AMBIENT TEMPERATURE GROUPING TYPE OF
OPERATION CONTINUOUS DUTY INTERMITTENT PERIODIC DUTY AND THE
USE OF MULTICORE CABLES ARE TO BE TAKEN INTO ACCOUNT
4ABLE IS VALID FOR CONTINUOUS DUTY AT ª# AMBIENT TEMPERA
TURE AND THREE LOADED CORES RUBBERINSULATED OR 06#INSULATED
CABLES
2UBBERINSULATED
#/2$!&,%8
02/4/,/. (6 REELING CABLES UP TO K6
0,!./&,%8
2/.$/&,%8
#ROSSSECTION
MM
3TRETCHED
3USPENDED
2EELED IN
LAYING
!
&ACTOR FREELY IN AIR
!
LAYER
!
LAYERS
!
LAYERS
!
LAYERS
!
LAYERS
!
LAYERS
!
LAYERS
!
02/4/,/. (6 REELING CABLES ABOVE K6
4HE REDUCTION FACTOR IS ALSO VALID FOR FLAT
REELING CABLES SPIRALLY
06#INSULATED
,IFT CONTROL CABLE
302%!$%2&,%8
4ABLE #URRENTCARRYING CAPACITY OF FLEXIBLE CABLES FOR CRANES AND
MATERIAL HANDLING EQUIPMENT
77
Electrical parameters
De-rating factors
The de-rating factors take into account the installation and operating conditions, such as temperature, grouping, intermittent
periodic duty and the number of simultaneously loaded cores.
They are to be used for determining the current-carrying capacity in accordance with table 4/4 (page 4/9).
De-rating factors for varying ambient temperatures
Flexible cables
Ambient temperature °C
10
15
20
25
30
35
40
45
50
55
60
65
70
CORDAFLEX
1.15
1.12
1.08
1.04
1.00
0.96
0.91
0.87
0.82
0.76
0.71
0.65
0.58
PLANOFLEX
1.15
1.12
1.08
1.04
1.00
0.96
0.91
0.87
0.82
0.76
0.71
0.65
0.58
RONDOFLEX
1.15
1.12
1.08
1.04
1.00
0.96
0.91
0.87
0.82
0.76
0.71
0.65
0.58
PROTOLON
1.15
1.12
1.08
1.04
1.00
0.96
0.91
0.87
0.82
0.76
0.71
0.65
0.58
SPREADERFLEX
1.22
1.17
1.12
1.06
1.00
0.94
0.87
0.79
0.71
0.61
0.50
Lift control cable
1.22
1.17
1.12
1.06
1.00
0.94
0.87
0.79
0.71
0.61
0.50
Table 4/5
De-rating factors for grouping
Arrangement
Number of multi-core cables or number of single or three-phase circuits made
up of single-core cables (2 or 3 loaded conductors)
1
2
3
4
5
6
7
8
9
10 12 14 16 18 20
Bunched directly at the
wall, the floor, in conduit
or ducting, on or in the
wall
1.0 0.8 0.7 0.65 0.6 0.57 0.54 0.52 0.5 0.48 0.45 0.43 0.41 0.39 0.38
Single layer on the wall
or floor, touching
1.0 0.85 0.79 0.75 0.73 0.72 0.72 0.72 0.71 0.70
Single layer on the wall or
= =
floor, spaced with a
clearance of 1 x cable
diameter between adjacent cables
1.0 0.94 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9
Single layer under ceiling,
touching
0.95 0.81 0.72 0.68 0.66 0.64 0.63 0.62 0.61
Single layer under ceiling,
spaced with a clearance
= =
of 1 x cable diameter
between adjacent cables
0.95 0.85 0.85 0.85 0.85 0.85 0.85 0.85 0.85 0.85 0.85 0.85 0.85 0.85 0.85
Table 4/6
78
=
=
3ELECTION AND $IMENSIONING #RITERIA
%LECTRICAL PARAMETERS
$ERATING FACTORS FOR INTERMITTENT PERIODIC DUTY
!MBIENT
TEMPERATURE
$UTY CYCLE
ª#
.OMINAL
CROSSSECTION
$UTY FACTOR %$ MM
MIN
4ABLE
$ERATING FACTORS FOR MULTICORE CABLES WITH CONDUCTOR CROSSSECTIONS UP TO MM
.UMBER OF
LOADED
CORES
$ERATING
FACTOR
$ERATING
FACTORS
.UMBER OF SIMULTANEOUSLY LOADED CORES
4ABLE
0ERMISSIBLE SHORTCIRCUIT CURRENT AT MAX PERMISSIBLE SHORTCIRCUIT TEMPERATURES OF THE CONDUCTOR SURFACE AND FOR A FAULT DURATION TKR S
#ROSSSECTION MM
#/2$!&,%8
3HORTCIRCUIT CURRENT K!
2/.$/&,%8
02/4/,/.
4ABLE
4HE SHORTCIRCUIT CURRENTCARRYING CAPACITY ItHZ FOR A SHORTCIRCUIT DURATION TK DEVIATING FROM TKR S IS ITHZ ITHR –
TKR
TK
79
%LECTRICAL PARAMETERS
%LECTROMAGNETIC COMPATIBILITY
%LECTROMAGNETIC COMPATIBILITY IS THE CAPABILITY OF AN ELECTRICAL OR
ELECTRONIC DEVICE TO FUNCTION CORRECTLY IN ITS ELECTROMAGNETIC ENVI
RONMENT AND NOT TO CAUSE INTERFERENCE TO THE ENVIRONMENT TO AN
IMPERMISSIBLE DEGREE
4HIS MATTER IS OF IMMEDIATE CONCERN FOR ALL THOSE ENGAGED IN PLAN
NING AND MANUFACTURING ELECTRICAL EQUIPMENT AND INSTALLATIONS
/N THE ONE HAND THE %-# LEGISLATION INTRODUCED IN 'ERMANY
FROM AND ON THE OTHER HAND THE HIGH PROCESSING
SPEED AND TRANSMISSION RATES OF MODERN ELECTRONICS NECESSITATE
INCREASED ATTENTION BEING PAID TO THE QUESTION OF THE INFLUENCE OF
TRANSMITTED AND RECEIVED INTERFERENCE .ONOBSERVANCE OF THE
CURRENTLY VALID %-# STANDARDS CAN LEAD TO IMPOSITION OF FINES
3TANDARDS
3TANDARDS WHICH DIRECTLY ADDRESS THE QUESTION OF CABLE CON
STRUCTION OR CABLE CHARACTERISTICS DO NOT EXIST 7HETHER A CABLE
CAUSES INTERFERENCE OR NOT IS SOLELY DEPENDENT ON THE MANNER IN
WHICH IT IS USED &ROM THE POINT OF VIEW OF THE USER THOSE STAND
ARDS WHICH SPECIFY LIMIT VALUES FOR PERMISSIBLE LEVELS OF INTERFER
ENCE ARE RELEVANT 4HESE REFER TO EQUIPMENT PLANTS OR OTHER
ELECTRICAL INSTALLATIONS AND THUS REFER INDIRECTLY TO THE CABLES
4HOSE RESPONSIBLE FOR ERECTION OR MANUFACTURE THEREOF MUST CON
FIRM OR PROVE THAT THEIR EQUIPMENT MEETS THE %-# REQUIREMENTS
4HE CURRENTLY VALID STANDARDS AND REGULATIONS WHICH ARE IMPOR
TANT FOR USE OF INSULATED CABLES ARE LISTED IN &IG #RITERIA FOR %-# CABLE SELECTION
3ELECTION OF THE MOST SUITABLE CABLE AND APPLICATIONCONNECTION
AT SITE FROM THE POINT OF VIEW OF %-# CAN BE CARRIED OUT EMPLOY
ING THE CRITERIA LISTED BELOW
5SE OF A CABLE SHIELD WITH LOW TRANSFER IMPEDANCE
3YMMETRICAL DESIGN AND OPERATION OF THE CABLE
#HOICE OF SUITABLE MATERIALS BY REASON OF THE HIGHER VOLTAGE
STRESS OF THE INSULATION BY REFLECTIONS AT FREQUENCIES ABOVE
-(Z LOW LOSS FIGURE
-OREOVER THE 2/.$/&,%8# CABLE DESIGN HELPS MANUFACTURERS
AND OPERATORS OF ELECTRICAL INSTALLATIONS TO MAINTAIN THE LIMIT VALUES
SPECIFIED IN THE %-# LEGISLATION 02/4/,/. (6 REELING CABLES
AND #/2$!&,%8 FROM MM§ CONDUCTOR CROSSSECTION ARE
ALSO EMINENTLY SUITABLE AS %-# CABLES AS A RESULT OF THEIR PRECISE
AND SYMMETRICAL THREECORE DESIGN
#ONTROL CABLES DATA TRANSMISSION AND BUS CABLES
EG 02/&)"53
)NTERFERENCEFREE DATA TRANSMISSION CAN ONLY BE ACHIEVED ESPE
CIALLY WHEN POWER AND DATA TRANSMISSION CABLES LIE CLOSE TO
GETHER BY IMPLEMENTATION OF SPECIAL MEASURES
#ABLE DESIGNS WITH TWISTED AND SHIELDED PAIRS HAVE PROVEN THEIR
SUITABILITY FOR SUCH APPLICATIONS IN PARTICULAR AS BUS CABLES 4HE
LAIDUP LENGTH AND THE SHIELD ARE MATCHED SO THAT THE TRANSFER IM
PEDANCE AND THE SHIELD ATTENUATION ARE OPTIMIZED AT -(Z
4HE FOLLOWING CABLE DESIGNS ARE EMINENTLY SUITABLE FOR USE AS DATA
AND BUS CABLES
#/2$!&,%8 3-+ WITH OR TWISTED AND SHIELDED PAIRS
#/2$!&,%8 3-+ WITH COMBINED PAIRS SINGLE CORES
0,!./&,%8 WITH OR TWISTED AND SHIELDED PAIRS
2/.$/&,%8 WITH OR TWISTED AND SHIELDED PAIRS
4ABLE SHOWS THE SPECIFIC CHARACTERISTICS OF CRANE CABLES
WITH TWISTED AND SHIELDED PAIRS XX# AS A FUNCTION OF THE FRE
QUENCY
#ABLES WITH FIBREOPTICS
4HE OPTIMUM SOLUTION AS REGARDS %-# IS THE USE OF GLASS FI
BREOPTICS )N ADDITION TO THE WELLKNOWN DESIGN /04/&,%8 WE
ARE IN A POSITION TO OFFER ALL THE TYPES OF CABLES MANUFACTURED BY
US AS COMBINED COPPER FIBREOPTIC CABLES TO SPECIAL ORDER
0RICES AND DELIVERY TIMES ARE AVAILABLE ON REQUEST )N MOST CASES
THE OVERALL DIAMETER OF THE COMBINED CABLES IS IDENTICAL TO THAT OF
PURE COPPER CABLES !TTENTION IS DRAWN HERE IN PARTICULAR TO THE
02/4/,/. DESIGN WITH INTEGRATED FIBREOPTICS WHICH HAS
FORMED PART OF OUR STANDARD DELIVERY PROGRAM SINCE ,ARGE CLEARANCE BETWEEN THE INTERFERENCE SOURCE AND THE INTER
FERENCE SINK POWER CABLES LAYED SPATIALLY SEPARATED FROM THE
DATA CABLES
Standards and regulations relevant to
EMC of cables
%ARTHING AT BOTH ENDS AND COAXIAL CONNECTION OF THE SHIELD
5SE OF FILTERS
,AYING ON EARTHED SURFACES
4HE DESIGN OF A CABLE IS OF DECISIVE IMPORTANCE FOR THE EVALUATION
OF %-# 4HE MOST COMMONLY EMPLOYED CONSTRUCTIONAL DESIGNS
OF POWER AND CONTROL CABLES REGARDING THEIR %-# CHARACTERISTICS
ARE LISTED IN &IG 3ELECTION OF %-# CABLES FOR APPLICATIONS ON CRANES AND
MATERIAL HANDLING EQUIPMENT
0OWER CABLES
)N RECENT YEARS A NEW GENERATION OF HIGHSPEED SWITCHING TRAN
SISTORS )'"4 HAS BEEN EMPLOYED FOR CONVERTERS FOR VARI
ABLESPEED MOTORS 5SE OF SUCH CONVERTERS RESULTS IN HIGH RATES
OF VOLTAGE RISE AND HIGHFREQUENCY HARMONICS &OR THIS REASON
CONSEQUENT INTERFERENCE MUST BE TAKEN INTO ACCOUNT )N ORDER TO
COUNTERACT THIS INTERFERENCE SPECIAL MEASURES ARE REQUIRED FOR
THE POWER CABLES 7E RECOMMEND THE USE OF 2/.$/&,%8#
SHIELDED %-# CABLES !S A RESULT OF AN OPTIMIZED DESIGN
REGARDING SHIELD MATERIALS AND GEOMETRY THIS CABLE TYPE FULFILLS ALL
THE REQUIREMENTS WITH RESPECT TO MECHANICAL CHARACTERISTICS FOR
FLEXIBLE CABLES FOR FESTOON SYSTEM AND CABLE TENDER OPERATION AND
IS ALSO DISTINGUISHED BY SUPERIOR SHIELD CHARACTERISTICS #ONSE
QUENTLY INTERFERENCE EMISSION IS REDUCED TO AN ACCEPTABLE DEGREE
OR EVEN COMPLETELY SUPPRESSED
80
This standard defines electromagnetic compatibility for instrumentation and control equipment for industrial process
applications. It describes methods for evaluation of the susceptibility to electromagnetic interference. It further describes tests, by means of which the influence of
electromagnetic interference from external sources on the
operational behaviour of cables and their maximum
achievable transmission rates can be determined.
Tests based on this standard reveal the maximum loading
IEC 801-4
limits of LAN cables as a result of uniform, random and
periodic interference.
In this standard the limit values and measuring procedures
EN 55011
(DIN VDE
for radio frequency interference caused by industrial, sci0875, Part 11) entific and medical high-frequency equipment (ISM devices) are defined.
This standard corresponds to DIN VDE 0878, Part 3: Limit
EN 55022
values and measuring procedures for radio frequency interference caused by information processing equipment (ITE).
The radiated energy of a cable can be measured in simulated operation. In addition, the limit value classes A and B
for radio frequency interference voltages are defined.
This regulation of the German Federal Ministry for Post
Official
Journal
and Telecommunication deals with radio frequency interRegulation
ference and interference voltage emission.
243/1991
Information on this subject is also to be found in FTZ TL-6145-3000 issued by the Research and Technology Centre of the German Post Office.
IEC 801-3
&IG 3ELECTION AND $IMENSIONING #RITERIA
%LECTRICAL PARAMETERS
#ONSTRUCTION
3HIELD
%-# EVALUATION
3YMMETRICAL
#U BRAID
POSSIBLY WITH #U
FLEECE
/PTIMUM
3YMMETRICAL
CORE
#U BRAID
SINGLE CORE
'OOD
5NSYMMETRICAL
CORE
#U BRAID
POSSIBLY WITH #U
FLEECE
'OOD
3YMMETRICAL
n
3ATISFACTORY
5NSYMMETRICAL
CORE
n
-EDIOCRE
5NSYMMETRICAL
PARALLEL CORES OR
FLAT CABLE
#U BRAID
-EDIOCRE
5NSYMMETRICAL
PARALLEL CORES OR
FLAT CABLE
n
0OOR
3YMMETRICAL
CORE
#U BRAID
POSSIBLY WITH #U
FLEECE
/PTIMUM
3YMMETRICAL
CORE
n
6ERY GOOD
3YMMETRICAL
CORE
n
'OOD WITH
SYMMETRICAL
OPERATION
5NSYMMETRICAL
CONCENTRICALLY
STRANDED
#U BRAID
OVERALL SHIELD
/FTEN ADEQUATE
WITH ADJACENT CORES
5NSYMMETRICAL
CONCENTRICALLY
STRANDED
#U BRAID
INDIVIDUALLY SHIELDED
CORES
/FTEN ADEQUATE
WITH ADJACENT CORES
5NSYMMETRICAL
CONCENTRICALLY
STRANDED
n
0OOR
%-# POWER CABLES
%-# CONTROL CABLES
&IG #ABLE
CHARACTERISTICS
AND FREQUENCY
DEPENDENCY
5NIT
&REQUENCY IN K(Z
2ESISTANCE
2
7KM
)NDUCTANCE
,
M(KM
,EAKANCE
'
M3KM
#APACITANCE
#
N&KM
#HARACTERISTIC
IMPEDANCE
:
7
!TTENUATION
A
D"KM
#ABLE CHARACTERISTICS
OF CRANE CABLES WITH TWISTED AND
SHIELDED PAIRS X X #
4WISTED AND SHIELDED PAIRS X# CAN BE
EMPLOYED WITHOUT MODIFICATION IN THE CABLE
DESIGNS #/2$!&,%8 2/.$/&,%8
0,!./&,%8 302%!$%2&,%8
02/4/,/. AND LIFT CONTROL CABLES
4ABLE 81
4HERMAL PARAMETERS
4HE DIFFERENT TEMPERATURE LIMITS OF THE INDIVIDUAL FLEXIBLE ELECTRIC
CABLES FOR CRANES AND MATERIAL HANDLING EQUIPMENT ARE SUMMA
RIZED IN TABLE 5NDER NO CIRCUMSTANCES MAY THE VALUES SHOWN BE EXCEEDED
DUE TO INTERACTION OF INTERNAL *OULE HEAT AND THE AMBIENT TEM
PERATURE
)F CABLES ARE EXPOSED TO RADIATION EG SUNLIGHT THE TEMPERATURE
OF THE OUTER SHEATH OF THE FLEXIBLE ELECTRIC CABLE CAN RISE TO A LEVEL
WHICH IS SIGNIFICANTLY HIGHER THAN THE AMBIENT TEMPERATURE 4HIS
SITUATION MUST BE COMPENSATED FOR BY CORRESPONDING REDUCTION
OF THE CURRENTCARRYING CAPACITY
4HE TEMPERATURES ON THE SURFACE OF THE CABLE ARE LIMITS FOR THE
AMBIENT TEMPERATURE
!LL INSULATING AND SHEATHING COMPOUNDS OF THE FLEXIBLE ELECTRIC CA
BLES BECOME STIFFER AS THE TEMPERATURE DROPS )F THE TEMPERATURE
FALLS BELOW THE SPECIFIED LIMIT A POINT CAN BE REACHED BELOW WHICH
THE COMPOUNDS USED BECOME BRITTLE
)N ADDITION TO THIS MORE FORCE SOMETIMES CONSIDERABLY MORE IS
NEEDED FOR BENDING A FLEXIBLE ELECTRIC CABLE DUE TO THE INCREASE OF
STIFFNESS OF THE INSULATING AND SHEATHING COMPOUNDS AT LOWER
TEMPERATURES 4HIS CAN CREATE PROBLEMS IN THE USE OF FLEXIBLE ELEC
TRIC CABLES FOR CRANES AND MATERIAL HANDLING EQUIPMENT EG WITH
THE REEL DRIVE
4EMPERATURE LIMITS
&LEXIBLE CABLES
4YPE
OF THE CONDUCTOR
DURING OPERATION
OF THE CONDUCTOR
DURING SHORTCIRCUIT
ON THE SURFACE OF
THE CABLE
FIXED INSTALLATION
ON THE SURFACE OF
THE CABLE FULLY
FLEXIBLE OPERATION
#/2$!&,%83-+
.3(4¾5
n TO n TO 0,!./&,%8
.'&,'¾5
n TO n TO 2/.$/&,%8
.'2$'¾5
n TO n TO 302%!$%2&,%8
93,4¾
n TO n TO n
n
n TO n TO n TO n TO n TO n TO n TO n TO n TO n TO /04/&,%8
02/4/,/.&,,7,
.43&,#'%7¾5
02/4/,/.3-+ ,7, .43+#'%7¾5
,IFT CONTROL CABLE
4ABLE
82
4EMPERATURE LIMIT DURING OPERATION STORAGE INSTALLATION AND TRANSPORT ª#
&OR SUSPENSION
LENGTHS UP TO M &OR SUSPENSION
LENGTHS UP TO M 3ELECTION AND $IMENSIONING #RITERIA
4HERMAL PARAMETERS
4HE RELATIONSHIP BETWEEN THE BENDING STIFFNESS OF FLEXIBLE ELECTRIC
CABLES FOR CRANES AND MATERIAL HANDLING EQUIPMENT AND THE TEM
PERATURE IS SHOWN IN &IG 4HE RATIO OF THE BENDING FORCE IS GIVEN AS
&& WITH & & Ž#
! COMPARISON OF THE LOWTEMPERATURE FLEXIBILITY OF OUR CABLES
USING THE OLD AND NEW DESIGNS 02/4/,/. AND #/2$!&,%8
IS SHOWN IN &IG 2ATIO
OF BENDING
FORCE
"END
ING
FORCE
0REVIOUSLY
.EW GENERATION
4EMPERATURE ª#
4EMPERATURE ª#
&IG &IG 4HE TEMPERATURE LIMITS ON THE SURFACE OF THE CABLE ARE SPECIFIED
TO ENSURE PROBLEMFREE AND HEALTHY OPERATION DURING FORCED GUID
ANCE OF FLEXIBLE ELECTRIC CABLES FOR CRANES AND MATERIAL HANDLING
EQUIPMENT ESPECIALLY WHILE RUNNING OVER SHEAVES AND DURING
REELING OPERATION
(IGHER TEMPERATURES INFLUENCE THE HARDNESS ABRASION RESISTANCE
TO TEAR PROPAGATION AND THE TRANSVERSE PRESSURE STABILITY OF THE
INSULATING AND SHEATHING COMPOUNDS AND CAN THUS LEAD TO A RE
DUCTION OF THEIR SERVICE LIFE
&LEXIBLE ELECTRIC CABLES SHOULD BE SELECTED INSTALLED AND OPER
ATED SO THAT THE EXPECTED DISSIPATION OF *OULE HEAT IS NOT HIN
DERED IN ANY WAY AND THEREFORE NO RISK OF FIRE IS INCURRED
83
-ECHANICAL PARAMETERS
4ENSILE LOADS
4HE TENSILE LOADS OF COPPER CONDUCTORS IN FLEXIBLE ELECTRIC CABLES FOR CRANES AND MATERIAL HANDLING
EQUIPMENT AS SPECIFIED BY $). 6$% 0ART SHOULD NOT EXCEED .MM§ (OWEVER HIGHER
VALUES ARE ALLOWED FOR SOME CABLES AS SHOWN IN TABLE 4HESE VALUES REFER TO TENSILE LOAD ONLY
4HESE MAXIMUM PERMISSIBLE LIMITS OF TENSILE LOAD ARE TO BE REGARDED AS THE SUM OF THE STATIC AND
DYNAMIC LOADS
7HEN THE PERMISSIBLE TENSILE FORCE IS BEING CALCULATED SHIELDS CONCENTRIC CONDUCTORS AND SPLIT
PROTECTIVEEARTH CONDUCTORS AS WELL AS INTEGRATED CONTROL CORES AND MONITORING CORES OF POWER CA
BLES MUST NOT BE INCLUDED IN THE CALCULATION
&OR HIGHER TENSILE LOADS APPROPRIATE STEPS HAVE TO BE TAKEN SUCH AS INCREASING THE BENDING RADII
OR USING SPECIAL CABLE DESIGNS WITH STRESS RELIEVING SUPPORT ELEMENTS )N SOME CASES A SHORTER
SERVICE LIFE CAN BE EXPECTED )N THIS CASE THE CABLE MANUFACTURER SHOULD BE CONSULTED
4HE MAXIMUM PERMISSIBLE TENSILE LOAD FOR INSTALLING FIXED LAYING FLEXIBLE CABLES IS .MM§ RE
FERRED TO THE CROSSSECTION OF THE CONDUCTOR
&LEXIBLE CABLES
4YPE
$). 6$%
.MM
0RYSMIAN
.MM
#/2$!&,%83-+
.3(4¾5
0,!./&,%8
.'&,'¾5
2/.$/&,%8
.'2$'¾5
302%!$%2&,%8
93,4¾
REFER ALSO TO DESIGN
FEATURES PAGE n
. FOR THE COMPLETE CABLE
/04/&,%8
02/4/,/.&,,7,
.43&,#'%7¾
02/4/,/.3-+ ,7,
.43+#'%7¾5
REFER ALSO TO DESIGN
FEATURES PAGE ,IFT CONTROL CABLE
-AXIMUM TENSILE LOAD DURING
INSTALLATION AND OPERATION OF
FLEXIBLE ELECTRIC CABLES FOR
CRANES AND MATERIAL HANDLING
EQUIPMENT
4ABLE 4ORSIONAL STRESSES
&LEXIBLE ELECTRIC CABLES FOR CRANES AND MATERIAL HANDLING EQUIPMENT ARE GENERALLY NOT DESIGNED FOR
TORSIONAL STRESSES 4HE LATTER CAN HOWEVER NOT BE AVOIDED DURING OPERATION
4HE MAXIMUM PERMISSIBLE TORSIONAL STRESSES WHICH OCCUR DURING OPERATION AT ENTRIES SLEWING
GEARS WINDMILLS ETC ARE SUMMARIZED IN TABLE )F THE LIMITS ARE EXCEEDED THIS CAN LEAD TO A REDUCTION IN SERVICE LIFE )N CRITICAL CASES THE CABLE
MANUFACTURER SHOULD BE CONSULTED
4ORSIONAL STRESSES CREATED BY THE SYSTEMS INVOLVED EG DUE TO MISALIGNMENT OF CABLE GUIDANCE
SYSTEMS OBLIQUE CABLE PAY OUT SHOULD BE AVOIDED AND ARE NOT INCLUDED HERE
&LEXIBLE CABLES
4YPE
A ªM
#/2$!&,%83-+
.3(4¾5
p 0,!./&,%8
.'&,'¾5
.OT PERMISSIBLE
2/.$/&,%8
.'2$'¾5
p ª
302%!$%2&,%8
93,4¾
#ORRESPONDING TO APPLICATION
DESIGNED FOR BEST TORSIONAL PROPERTIES
p /04/&,%8
02/4/,/.&,,7,
.43&,#'%7¾5
NA
02/4/,/.3-+ ,7,
.43+#'%7¾5
p 4ABLE 84
-AXIMUM TORSIONAL STRESSES
DURING OPERATION OF FLEXIBLE
ELECTRIC CABLES FOR CRANES AND
MATERIAL HANDLING EQUIPMENT
3ELECTION AND $IMENSIONING #RITERIA
-ECHANICAL PARAMETERS
-INIMUM BENDING RADII
)F THE BENDING RADII ARE SMALLER THAN THOSE PERMITTED A REDUCED
SERVICE LIFE CAN BE EXPECTED DEPENDING ON THE STRESS CONDITIONS
4HE VALUES GIVEN IN TABLE SHOULD BE TAKEN AS A BASIS
4HE MINIMUM BENDING RADII ARE SHOWN AS THE PRODUCT OF THE
OVERALL DIAMETER OF THE CABLE AND A FACTOR WHICH IS DEPENDENT ON
THE DIAMETER OF THE CABLE EG X D
4HE MINIMUM PERMISSIBLE BENDING RADII ARE VALID WITHIN THE SPECI
FIED AMBIENT TEMPERATURE RANGE SEE THERMAL PARAMETERS PAGE
SUBJECT TO THE PROVISION THAT THE PERMISSIBLE TENSILE LOADS ARE
NOT EXCEEDED SEE MECHANICAL PARAMETERS PAGE )N CRITICAL CASES THE CABLE MANUFACTURER SHOULD BE CONSULTED
-INIMUM PERMISSIBLE BENDING RADII 2
&LEXIBLE CABLES
#/2$!&,%8 0,!./&,%8
2/.$/&,%8 302%!$%2&,%8 02/4/,/.
,IFT CONTROL CABLE
02/4/,/.
2ATED VOLTAGE 5 5
5P TO K6
!BOVE K6
-AXIMUM OVERALL DIAMETER OF THE CABLE OR
MAXIMUM THICKNESS OF THE FLAT CABLE MM
5P TO !BOVE TO !BOVE TO !BOVE &IXED INSTALLATION
XD
XD
XD
XD
XD
&ULLY FLEXIBLE OPERATION
XD
XD
XD
XD
X D
&OR THE ENTRY EG AT A
CENTRE FEED POINT
XD
XD
XD
XD
X D
&OR FORCED GUIDANCE WITH
REELING OPERATION
XD
XD
XD
XD
X D
&OR FORCED GUIDANCE WITH
FESTOON OPERATION
XD
XD
XD
XD
X D
&OR FORCED GUIDANCE WITH
POWER TRACKS
XD
XD
XD
XD
X D
&OR FORCED GUIDANCE WITH
SHEAVES
X D
X D
X D
X D
X D
&OR FORCED GUIDANCE WITH
CABLE TENDERS
X D
X D
X D
X D
X D
-INIMUM DISTANCE WITH
DOUBLE OR 3TYPE DIRECTIONAL
CHANGES
X D
X D
X D
X D
X D
X D
/04/&,%8
MINIMUM
PERMISSIBLE
BENDING
RADIUS
MM
4ABLE
85
-ECHANICAL PARAMETERS
4RAVEL SPEEDS
&LEXIBLE ELECTRIC CABLES FOR CRANES AND MATERIAL HANDLING EQUIP
MENT ARE INTENDED FOR USE ON MOBILE EQUIPMENT AND ARE DE
SIGNED TO COPE WITH THE TECHNICAL REQUIREMENTS OF THE APPLICATION
)N ORDER TO COLLECT PAY OUT AND MOVE FLEXIBLE ELECTRIC CABLES THERE
ARE DIFFERENT CABLE GUIDANCE SYSTEMS SUCH AS REELS FESTOONS
TENDERS POWER TRACKS BASKETS SHEAVE GUIDED CABLE STORAGE
SYSTEMS AND LIFTS AS WELL AS SHEAVES AND MULTIROLLER GUIDES
4HE CRANES AND MATERIAL HANDLING EQUIPMENT AND CONSEQUENTLY
ALSO THE CABLE GUIDANCE SYSTEMS ARE OPERATED AT DIFFERENT TRAVEL
SPEEDS AND ARE THEREFORE SUBJECTED TO STRESS WHICH CAN VARY
FROM LOW TO VERY HIGH
$URING OPERATION OF THE MOBILE EQUIPMENT THE FLEXIBLE ELECTRIC CA
BLES ARE SUBJECTED TO STRESS SUCH AS TENSION TRANSVERSE PRES
SURE TORSION AND BENDING 4HUS THE TRAVEL SPEED AND THE
ACCELERATION ARE TO BE CONSIDERED AS INDIRECT CRITERIA FOR THE
STRESSES APPLIED TO THE FLEXIBLE ELECTRIC CABLES
4HE MAXIMUM PERMISSIBLE TRAVEL SPEEDS FOR THE INDIVIDUAL FLEXIBLE
ELECTRIC CABLES ARE SUMMARIZED IN TABLE )N THE CASE OF GANTRY CRANE DRIVES THE TRAVEL SPEED OF THE ACTUAL
MOBILE EQUIPMENT IS IMPLIED 5SUALLY CYLINDRICAL OR MONOSPIRAL
REELS ARE EMPLOYED
4HE TROLLEY DRIVE CARRIES OUT HORIZONTAL MOVEMENT OF THE HOISTING
GEAR AND THE DRIVERS CABIN &ESTOONS TENDERS AND POWER TRACKS
OR SHEAVE GUIDED CABLE STORAGE SYSTEMS ARE USED HERE AS CABLE
GUIDANCE SYSTEMS
)N THE CASE OF THE HOISTING GEAR THE SPEED OF THE LOADLIFTING DE
VICE SUCH AS THE SPREADER OR GRAB IS IMPLIED
.ORMALLY EITHER REELS LOCATED IN THE TROLLEY OR BASKETS ON THE
LOADLIFTING DEVICE ARE USED FOR THE CABLE GUIDANCE SYSTEM
)F THE TRAVELSPEED LIMITS ARE EXCEEDED A REDUCTION IN SERVICE LIFE
CANNOT BE EXCLUDED 4HE CABLE MANUFACTURER SHOULD BE CON
SULTED
-AXIMUM TRAVEL SPEED OF FLEXIBLE ELECTRIC CABLES FOR
CRANES AND MATERIAL HANDLING EQUIPMENT
&LEXIBLE CABLES
'ANTRY CRANE DRIVE
REELING
(OIST DRIVE
VERTICAL RUN
REELING OR BASKET
MMIN
MMIN
MMIN
#/2$!&,%83-+6
.3(4¾5
.O RESTRICTION
&OR SPEEDS OVER MMIN
CONSULT THE CABLE MANUFAC
TURER
0,!./&,%8
.'&,'¾5
.O APPLICATION
&OR SPEEDS OVER MMIN
CONSULT THE CABLE MANUFAC
TURER
.O APPLICATION
2/.$/&,%8
.'2$'¾5
&OR SPEEDS OVER MMIN
CONSULT THE CABLE MANUFAC
TURER
.O APPLICATION
302%!$%2&,%8
93,4¾
.O APPLICATION
.O APPLICATION
.O RANDOM
WOUND REEL
.O APPLICATION
/04/&,%8
02/4/,/.&,,7,
.43&,#'%7¾5
.O APPLICATION
.O APPLICATION
02/4/,/.3-+ ,7,
.43+#'%7¾5
.O RESTRICTION
&OR SPEEDS OVER MMIN
CONSULT THE CABLE MANUFAC
TURER
.O APPLICATION
,IFT CONTROL CABLE
&OR SUSPENSION
LENGTHS UP TO M
&OR SUSPENSION
LENGTHS UP TO M
.O APPLICATION
.O APPLICATION
4ABLE
86
4ROLLEY DRIVE
FESTOONS AND TENDERS
3ELECTION AND $IMENSIONING #RITERIA
-ECHANICAL PARAMETERS
!DDITIONAL TESTS
!DEQUATE TESTING OF THE GOOD OPERATING
CHARACTERISTICS NEEDED FOR FLEXIBLE ELECTRIC
CABLES FOR CRANES AND MATERIAL HANDLING
EQUIPMENT IS NOT POSSIBLE WITH THE TESTS
SPECIFIED BY $). 6$% 0RYSMIANFLEXIBLEELECTRIC
CABLES FOR CRANES AND MATERIAL HANDLING
EQUIPMENT ARE THEREFORE SUBJECTED TO ADDI
TIONAL AND CONTINUOUS MECHANICAL TESTS AT
THE MANUFACTURERS WORKS +ABEL UND
,EITUNGSWERK AT .EUSTADT NEAR #OBURG
4HESE ADDITIONAL TESTS FACILITATE
TIMECOMPRESSED EXAMINATION OF THE RUN
NING AND SERVICE CHARACTERISTICS UNDER DIF
FERENT KINDS OF MECHANICAL STRESS SUCH AS
REVERSED BENDING STRENGTH RUNNING OVER
SHEAVES FLEXING WORK AND REELING OPERATION
IN RELATION TO TENSILE LOAD AND BENDING RADII
4HE ADDITIONAL TESTS CAN BE SEEN
IN TABLE 3CHEMATIC REPRESENTATION OF THE ADDITIONAL TESTS
2EVERSED BENDING TEST
"ASED ON $). 6$% 0ART 4ESTING OF FLEXIBLE ELECTRIC CABLES FOR CRANES
AND MATERIAL HANDLING EQUIPMENT UNDER IN
CREASED LOADS
#ABLE DIAMETER UP TO MM
MAXIMUM TENSILE LOAD .
%ACH MOVEMENT FROM ONE EXTREME POSITION
TO ANOTHER ª IS COUNTED AS A CYCLE
2OLLER BENDING TEST TYPE !
4ESTING THE ROLLER BENDING CHARACTERISTICS OF
FLEXIBLE ELECTRIC CABLES FOR CRANES AND MATE
RIAL HANDLING EQUIPMENT BASED ON $). 6$%
0ART #ABLE DIAMETER UP TO MM
%ACH MOVEMENT BETWEEN THE EXTREME POSI
TIONS IS COUNTED AS A CYCLE
2OLLER BENDING TEST TYPE "
4ENDER TEST
0RACTICEORIENTED TESTING OF FLEXIBLE ELECTRIC
CABLES FOR CRANES AND MATERIAL HANDLING
EQUIPMENT WITH REFERENCE TO RUNNING AND
SERVICE CHARACTERISTICS
#ABLE DIAMETER FROM UP TO MM
%ACH MOVEMENT BETWEEN THE EXTREME POSI
TIONS IS COUNTED AS A CYCLE
2OLLER BENDING TEST TYPE #
&LEXING TEST
4ESTING THE RUNNING CHARACTERISTICS FLEXING
OF FLEXIBLE ELECTRIC CABLES FOR CRANES AND MA
TERIAL HANDLING EQUIPMENT FOR EVALUATION OF
THE MECHANICAL SERVICE CHARACTERISTICS
#ABLE DIAMETER FROM UP TO MM
%ACH MOVEMENT BETWEEN THE EXTREME POSI
TIONS IS COUNTED AS A CYCLE
-OVING DISTANCE M
4RAVEL DISTANCE M
-OVING
DISTANCE
2EELING TEST
0RACTICEORIENTED TESTING OF FLEXIBLE ELECTRIC
CABLES FOR CRANES AND MATERIAL HANDLING
EQUIPMENT WITH REFERENCE TO RUNNING AND
SERVICE CHARACTERISTICS
#ABLE DIAMETER UP TO MM
%ACH REELING OR UNREELING OPERATION IS
COUNTED AS A CYCLE
4HE REELED LENGTH IS M
4ORSIONAL STRESS TEST
4HE CABLE IS ALTERNATELY TWISTED LEFT AND RIGHT
THROUGH AN ANGLE A BY APPLICATION OF THE
TENSILE FORCE &
4ORSIONAL ANGLE ¢ ª
4ORSIONAL TORQUE .M
4ENSILE FORCE
.
4ABLE 87
-ECHANICAL PARAMETERS
4ABLE SHOWS THE TEST CONDITIONS FOR THE INDIVIDUAL FLEXIBLE
ELECTRIC CABLES FOR CRANES AND MATERIAL HANDLING EQUIPMENT 4HE
TENSILE LOADS AND THE BENDING AND SHEAVE RADII ARE SPECIFIED AND
THE MINIMUM NUMBER OF CYCLES WHICH MUST BE ACHIEVED
4HE DECISIVE CRITERION FOR PASSING A TEST IS THE NUMBER OF BROKEN
INDIVIDUAL WIRES IN THE COPPER CONDUCTOR ANDOR THE BREAKING OF
THE ELECTRICAL CONDUCTOR
)N THE ROLLER BENDING TESTS TYPE ! AND " THE DEGREE OF DEFORMA
TION CORKSCREWING EFFECT IS TESTED ADDITIONALLY
4EST CONDITIONS FOR THE ADDITIONAL MECHANICAL TESTS
!DDITIONAL TEST
&LEXIBLE CABLE
#/2$!&,%83-+
02/4/,/.3-+
0,!./&,%8
#ONTROL
CABLE
2EVERSED BENDING TEST
2OLLER BENDING TEST
TYPE !
$ MM
2OLLER BENDING TEST
TYPE "
MM $ MM
4ENDER TEST
2OLLER BENDING TEST
TYPE #
MM $ MM
FLEXING TEST
4ENSILE LOAD
.MM
"ENDING DIAMETER
X $
MM
SHIELDED
0OWER
CABLE
.MM
.MM
$). 6$% 0 4AB .UMBER OF CYCLES
4ENSILE LOAD
.MM
"ENDING DIAMETER
X $
.UMBER OF CYCLES
4ENSILE LOAD
.MM
"ENDING DIAMETER
MM
.UMBER OF CYCLES
4ENSILE LOAD
.MM
.MM
"ENDING DIAMETER
X $
X $
.UMBER OF CYCLES
X $
4ABLE
!DDITIONAL TEST
&LEXIBLE CABLE
2/.$/&,%8
#ONTROL
CABLE
/04/&,%8
0OWER
CABLE
,IFT CONTROL CABLE
UP TO
M
UP TO
M
UP TO
M
3USPENSION LENGTH
2EVERSED BENDING TEST
2OLLER BENDING TEST
TYPE !
$ MM
4ENSILE LOAD
.MM
.
"ENDING DIAMETER
$). 6$% 0 4AB MM
.UMBER OF CYCLES
4ENSILE LOAD
.
.MM
.MM
.MM
"ENDING DIAMETER
MM
X $
X $
X $
.UMBER OF CYCLES
.MM
.MM
.
MM
MM
2OLLER BENDING TEST
TYPE "
MM $ MM
4ENDER TEST
4ENSILE LOAD
"ENDING DIAMETER
.UMBER OF CYCLES
2OLLER BENDING TEST
TYPE #
MM $ MM
FLEXING TEST
4ENSILE LOAD
2EELING TEST
"ENDING DIAMETER
MONOSPIRAL REELING
.UMBER OF CYCLES
2EEL DIA MM
.UMBER OF CYCLES
4ABLE
88
3ELECTION AND $IMENSIONING #RITERIA
#HEMICAL PARAMETERS
2ESISTANCE TO CHEMICALS
4HE INDIVIDUAL BASIC TYPES OF MATERIALS USED FOR FLEXIBLE ELECTRIC
CABLES FOR CRANES AND MATERIAL HANDLING EQUIPMENT SUCH AS 0#0
OR %02 CAN BE VERY DIFFERENT FROM EACH OTHER IN THEIR RESISTANCE TO
CHEMICALS DEPENDING ON THE REQUIRED PROPERTIES &URTHERMORE
THE PROPERTIES OF THE MATERIALS CAN VARY GREATLY FROM MANUFACTURER
TO MANUFACTURER
#HEMICAL
-ATERIAL
%02
06#
/THER FACTORS WHICH INFLUENCE FLEXIBLE ELECTRIC CABLES FOR CRANES
AND MATERIAL HANDLING EQUIPMENT SUCH AS THE CONCENTRATION AND
DEGREE OF WETTING OF THE CHEMICALS THEIR TEMPERATURE AND THE
PENETRATION TIME HAVE DIFFERENT EFFECTS ON THE RESISTANCE TO
CHEMICALS AND HAVE TO BE INVESTIGATED FROM CASE TO CASE
4HE CHEMICAL INDUSTRY HAS DRAWN UP A TABLE WHICH SHOWS A
ROUGH SUMMARY OF THE RESISTANCE TO CHEMICALS OF VARIOUS BASIC
TYPES OF MATERIAL THE OVERVIEW IN TABLE IS NOT TO BE DEEMED
A SUBSTITUTE FOR A DETAILED EXAMINATION
#HEMICAL
#3-
0#0
05
-ATERIAL
%02
!CETON
+EROSINE
!CETIC ACID ,ACTIC ACID
!LUMINIUM CHLORIDE SOLUTION
,INSEED OIL
!LUMINIUM SULFATE SOLUTION
,UBRICATING OILS
!MMONIA ANALHYDROUS
-AGNESIUM CHLORIDE SOLUTION
!MMONIUM CHLORIDE SOLUTION
-ETHANOL
!MMONIUM HYDROXIDE SOLUTION
-ETHYL CHLORIDE
!MMONIUM SULFATE SOLUTION
-ETHYL ETHYL KETONE
!MYL ACETATE
-ETHYL ALCOHOL
!NILINE
-INERAL OIL
!SPHALT
.APHTA
"ENZINE
.APHTALENE
"ENZOLE
.ITRIC ACID "ORAX SOLUTION
0ERCHLOR ETHYLENE
"ORIC ACID SOLUTION
0ETROLEUM
"UTYL ACETATE
0HENOL
#ALCIUM BISULPHITE SOLUTION
0HOSPHORIC ACID
#ALCIUM CHLORIDE SOLUTION
0ICRIC ACID
#ALCIUM HYDROXIDE SOLUTION
0OTASSIUM CHLORIDE
#ARBON DISULPHIDE
0YRIDINE
#ARBON TETRACHLORIDE
3OAP SOLUTION
#HLOROBENZENE
3ODIUM HYDROXIDE #HLOROACETIC ACID
3ODIUM HYPOCHLORIDE
#HLORINE GAS WET
3OYA BEAN OIL
#HLORINE GAS DRY
3ULPHUR
#HLOROFORM
3ULPHUROUS ACID
#OPPER CHLORIDE SOLUTION
3ULPHURIC ACID #OPPER SULPHATE SOLUTION
3TEARIC ACID
#YCLOHEXANE
4OLUENE
$IBUTYLTPHTALATE
4RANSFORMER OIL
$IESEL OILS
4RIBUTYL PHOSPHATE
%THYL ACETATE
4RICHLORETHYLENE
%THYL ALCOHOL
4RIETHANOLAMINE
%THYLENE GLYCOL
4URPENTINE
%THYLEN OXIDE
6EGETABLE OILS AND GREASE
&ORMALDEHYDE 7ATER
&UEL OIL
8YLENE
'LYCERINE
:INC CHLORIDE SOLUTION
06#
#3-
0#0
05
(YDAULIC OILS
(YDROCHLORIC ACID (YDROGEN SULPHIDE
4ABLE 2ESISTANT
,IMITED RESISTANCE
.ONRESISTANT
.OT TESTED
89
#ONDUCTORS
#ONDUCTORS FOR FLEXIBLE ELECTRIC CABLES ARE DESIGNED
ACCORDING TO $). 6$% .OWADAYS THE CON
DUCTORS ARE MADE OF COPPER #U !LUMINIUM AND
OTHER MATERIALS HAVE NOT FOUND GENERAL ACCEPTANCE
!N OVERVIEW OF THE COMMON KINDS OF CONDUCTORS IS
SHOWN IN TABLE #OMMON TYPES OF CONDUCTORS
!BBREVIATION
$ESIGNATION
3PECIFICATIONREGULATION
2% CONDUCTOR
#IRCULAR SOLID
$). 6$% #LASS 2- CONDUCTOR
#IRCULAR STRANDED
$). 6$% #LASS 2-6 CONDUCTOR
#IRCULAR STRANDED COMPACTED
$). 6$% #LASS & CONDUCTOR
&INELY STRANDED
$). 6$% #LASS &3 CONDUCTOR
6ERY FINELY STRANDED
0IRELLI SPECIFICATION
&& CONDUCTOR
%XTREMELY FINELY STRANDED
$). 6$% #LASS -AX DIAMETER OF THE SINGLE
WIRES
MM
2ESISTANCE OF THE
CONDUCTOR AT ª#
7KM
&
CONDUCTOR
#LASS &3
CONDUCTOR
0IRELLI
&&
CONDUCTOR
#LASS "ARE SINGLE
WIRES
4INNED
SINGLE WIRES
4ABLE )N MANY COUNTRIES THE DESIGN OF THE CONDUCTORS AC
CORDING TO $). 6$% IS ACCEPTED 4HE REGULA
TION CORRESPONDS TO #%.%,%# ($ 3 AND
)%# 4HE CONDUCTOR CLASSES & &3 AND && ARE EMPLOYED
FOR FLEXIBLE ELECTRIC CABLES FOR CRANES AND MATERIAL
HANDLING EQUIPMENT 4HE CONDUCTOR CLASSES ARE DI
VIDED INTO NOMINAL CROSSSECTIONS 4HE INDIVIDUAL
CONDUCTOR CLASSES & &3 AND && AND THE NOMINAL
CROSSSECTIONS ARE DEFINED BY SPECIFICATION OF THE
MAXIMUM DIAMETER OF THE SINGLE WIRES AND BY THE
MAXIMUM RESISTANCE OF THE CONDUCTOR AT ª#
SEE ALSO TABLE 4HESE FLEXIBLE CONDUCTORS ARE MADE OF BARE OR
TINNED ANNEALED COPPER 4HE CONDUCTORS ARE CON
STRUCTED OF MANY SINGLE WIRES ALL OF WHICH MUST
HAVE THE SAME DIAMETER
4HE CONDUCTORS USED IN FLEXIBLE ELECTRIC CABLES FOR
CRANES AND MATERIAL HANDLING EQUIPMENT ARE SUM
MARIZED IN TABLE 4HE CONDUCTOR FOR
FLEXIBLE ELECTRIC CABLES &LEXIBLE CABLE
IS DESIGNED ACCORDING
TO $). 6$% AS #/2$!&,%83-+
DESCRIBED IN THE ADJA
CENT TABLE AND ESPE
CIALLY IN TABLE 0,!./&,%8
4HE CONSTRUCTION OF
THE CONDUCTOR ITSELF
AND ITS DESIGN FEATURES 2/.$/&,%8
ARE OPEN TO VARIATION
302%!$%2&,%8
.OMINAL
CROSSSECTION
MM
4ABLE 4YPE
#ONDUCTOR USED
.3(4¾5
%LECTROLYTIC COPPER TINNED VERY FINELY STRANDED
#LASS h&3v
.'&,'¾5
%LECTROLYTIC COPPER NOT TINNED
UP TO MM EXTREMELY FINELY STRANDED #LASS FROM MM FINELY STRANDED #LASS .'2$'¾5
%LECTROLYTIC COPPER TINNED
FINELY STRANDED #LASS 93,4¾
%LECTROLYTIC COPPER NOT TINNED
VERY FINELY STRANDED #LASS h&3v
/04/&,%8
02/4/,/.3-+
.43#'%7¾5
02/4/,/.3-+ ,7,
.43+#'%7¾5
,IFT CONTROL CABLE
,93,4+
93,4+
93,9#9
4ABLE 90
&IBREOPTICS NO COPPER CONDUCTORS
%LECTROLYTIC COPPER TINNED
VERY FINELY STRANDED #LASS h&3h
PROTECTIVEEARTH CONDUCTOR LIKEWISE
%LECTROLYTIC COPPER NOT TINNED
MM§ EXTREMELY FINELY STRANDED #LASS OTHERWISE FINELY STRANDED #LASS $ESIGN&EATURES
#ONDUCTORS
&IG SHOWS THE DESIGN ELEMENTS OF A CONDUCTOR FOR FLEXIBLE
ELECTRIC CABLES FOR CRANES AND MATERIAL HANDLING EQUIPMENT $E
PENDING ON THE CROSSSECTION OF THE CONDUCTOR A FLEXIBLE CON
DUCTOR CONSISTS OF ONE OR MORE STRANDS WHICH ARE LAID UP AROUND
A CENTRAL STRAND IN SEVERAL LAYERS )N THE DIAGRAM SIX INDIVIDUAL
STRANDS SECOND LAYER ARE LAID UP AROUND A CENTRAL STRAND FIRST
LAYER ! THIRD LAYER WOULD THEN BE MADE FROM INDIVID
UAL STRANDS ARRANGED AROUND THE SECOND LAYER
3
$,
D,
D%$
3TRAND
,ENGTH OF LAY
$IAMETER OF CONDUCTOR
$IAMETER OF STRANDS
$IAMETER OF SINGLE WIRES
3INGLE WIRE D%$
#ENTRE
&IRST LAYER
3ECOND
LAYER
&IG #ONDUCTOR DESIGN
4HE STRANDS OF THE FLEXIBLE CONDUCTORS CONSIST OF MANY SINGLE
WIRES BUNCHED TOGETHER 4HE SINGLE WIRES CAN BE LAID UP
BUNCHED TO THE RIGHT OR LEFT THUS DETERMINING THE DIRECTION OF
LAY 4HIS IS SHOWN IN &IG AS THE : DIRECTION OF LAY RIGHT OR THE
3 DIRECTION OF LAY LEFT
4HIS ALSO APPLIES TO A CONDUCTOR WHICH IS LAID UP OF SINGLE
STRANDS
,EFT
3 DIRECTION
2IGHT
: DIRECTION
&IG $IRECTION OF LAY
4HE CONDUCTOR DESIGN AND THE NOMINAL CROSSSECTION OF THE FLEX
IBLE & &3 AND && CONDUCTORS FOR FLEXIBLE ELECTRIC CABLE ARE USUALLY
AS SHOWN IN TABLE #ONDUCTOR
DESIGN
"UNCHED
3TRANDED
& CONDUCTOR
UP TO MM
FROM MM
&3 CONDUCTOR
UP TO MM
FROM MM
&& CONDUCTOR
UP TO MM
FROM MM
4ABLE
$EPENDING ON THE COMBINATION OF THE INDIVIDUAL DESIGN ELEMENTS
OF A CONDUCTOR THERE ARE THREE BASIC TYPES OF CONDUCTORS SEE
TABLE 4HE MAIN ADVANTAGE OF THE UNIFORMLAY CONDUCTOR IS ITS HIGH
FLEXIBILITY !S A RESULT OF ITS DESIGN THE CONDUCTOR ALSO HAS A
SMALLER DIAMETER THAN OTHER TYPES OF CONDUCTORS $ISADVANTAGES
ARE ITS SUSCEPTIBILITY TO TORSIONAL LOADS UNSTABLE AND ITS POOR RE
SISTANCE TO AXIAL COMPRESSION AND SHARP BENDING
4HE ALTERNATINGLAY CONDUCTOR IS VERY STABLE WITH RESPECT TO
TORSIONAL LOADS AND IS NOT SENSITIVE TO AXIAL COMPRESSION AND
SHARP BENDING ! DISADVANTAGE IS ITS RELATIVELY LOW FLEXIBILITY !S A
RESULT OF ITS DESIGN THE MANY CROSSING POINTS OF THE SINGLE WIRES
CAUSE A LOT OF FRICTION WHICH CAN LEAD TO EARLY BREAKING OF THE
CONDUCTOR AS COMPARED TO THE OTHER TWO TYPES OF CONDUCTORS
4HE ALTERNATINGLAY CONDUCTOR HAS THE LARGEST DIAMETER COM
PARED TO THE OTHER TWO TYPES OF CONDUCTORS
4HE DESIGN OF THE OPPOSITELAY CONDUCTOR BEST MEETS THE
REQUIREMENTS OF FLEXIBLE ELECTRIC CABLES FOR CRANES AND MATERIAL
HANDLING EQUIPMENT )T COMBINES THE ADVANTAGES OF BOTH THE
UNIFORMLAY CONDUCTOR AND THE ALTERNATINGLAY CONDUCTOR WITHOUT
ANY OF THEIR DISADVANTAGES 4HIS CONDUCTOR IS HIGHLY FLEXIBLE
REMAINS STABLE WITH RESPECT TO TORSIONAL LOADS AND EXHIBITS HIGH
AXIAL COMPESSION AND SHARP BENDING STRENGTH )T HAS PROVEN ITS
EXCELLENT CHARACTERISTICS IN MANY YEARS OF PRACTICE 4HE OPPO
SITELAY CONDUCTOR IS USED FOR #/2$!&,%8 0,!./&,%8
2/.$/&,%8 302%!$%2&,%8 02/4/,/. AND LIFT CONTROL
CABLES
4YPES OF CONDUCTORS
5NIFORMLAY
CONDUCTOR
$ESIGN
3TRAND
#ENTRE
:
ND
!LTERNATINGLAY
CONDUCTOR
/PPOSITELAY
CONDUCTOR
LAYER
:
:
RD LAYER
:
:
$ESIGN
3TRAND
,AYER
#ENTRE
:
ND LAYER
3
:
RD LAYER
:
3
$ESIGN
3TRAND
,AYER
#ENTRE
3
ND
4ABLE
,AYER
LAYER
3
:
RD LAYER
3
:
91
#OMPOUNDS
)NSULATING AND SHEATHING COMPOUNDS
4ABLE GIVES AN OVERVIEW OF ALL COMMON COMPOUNDS USED FOR FLEXIBLE ELEC
TRIC CABLES
! BASIC DISTINCTION IS MADE BETWEEN THERMOPLASTICS AND ELASTOMERS
4HERMOPLASTICS GENERALLY KNOWN AS PLASTIC ARE USUALLY NOT CROSSLINKED
%LASTOMERS GENERALLY KNOWN AS RUBBER ARE ALWAYS CROSSLINKED
3ERIAL
-ATERIAL
!BBREVIATION
.O
4YPE DESIGNATION
6$%
(ARM
4HERMOPLASTICS
0OLYVINYL CHLORIDE
06#
9
6
#ROSSLINKED POLYVINYL CHLORIDE
06#
8
6
0OLYETHYLENE
0%
9
%
#ROSSLINKED POLYETHYLENE
8
8
,OWPRESSURE POLYETHYLENE
0%
9N
%
&OAM POLYETHYLENE
0%
9
0OLYSTYRENE
03
9
1
0OLYAMIDE
0!
9
1
0OLYTETRAFLUOR ETHYLENE
04&%
9
%
0ERFLUOR ETHYLENE PROPYLENE
0%0
9
%
%THYLENE TETRAFLUOR ETHYLENE
%4&%
9
%
0OLYIMIDE
0)
9
1
0OLYPROPYLENE
00
9
%
0OLYVINYLDENE FLUORIDE
06$&
9
1
0OLYURETHANE
40505
9
1
0OLYTEREPHTHALIC ACID ESTER
0%40
9
1
0OLYESTER THERMOPLASTIC
0ERFLUOR ETHYLENE OXYALKANE
0&!
9
0OLYCHLOROTRIFLUOR ETHYLENE
%#4&%
9
9
%LASTOMERS
.ATURAL RUBBER
.2
'
2
3YNTHETIC RUBBER
32
'
2
3TYRENEBUTADIENE RUBBER
3"2
'
2
3ILICON RUBBER
3)2
'
3
LSOBUTHYLENEISOPRENE RUBBER
))2
'
"
%THYLENEPROPYLENE RUBBER
%02%0$-
'
"
%THYLENE VINYLACETATE
%6!
'
'
#HLOROPRENE RUBBER
#20#0
'
.
#HLOROSULFONATED POLYETHYLENE
#3-
'
.
(YPALON
&LUOR ELASTOMERS
.ITRILE BUTADIENE RUBBER
."2
#HLORATED POLYETHYLENE
#-#0%
'
'
.
4ABLE
92
.OTES
9 4YPE DESIGNATION FOR A THERMOPLASTIC MATERIAL
' 4YPE DESIGNATION FOR AN ELASTOMERIC MATERIAL
8 4YPE DESIGNATION FOR A CROSSLINKED THERMOPLASTIC MATERIALTHE LETTER h8h
REPLACES THEh9hINh8h FOR CROSSLINKED POLYETHYLENE
!DDITIONAL DESIGNATION FOR FOAM MATERIALS
THE ZERO IS PLACED INFRONTOFTHERELEVANTTYPE DESIGNATIONEGh9h FOR FOAMED 0%
$ESIGN&EATURES
#OMPOUNDS
)N TABLE THE COMPOUNDS NORMALLY USED FOR FLEXIBLE ELECTRIC
CABLES FOR CRANES AND MATERIAL HANDLING EQUIPMENT ARE COMPARED
TO THE COMPOUNDS SPECIFIED FOR THESE CABLES BY $). 6$% STAND
ARDS )N MANY CASES A COMPOUND OF A HIGHER QUALITY IS USED THAN
THAT SPECIFIED BY $). 6$% STANDARDS
.OWADAYS THE INSULATING AND SHEATHING COMPOUNDS OF FLEXIBLE
ELECTRIC CABLES ARE MADE ALMOST EXCLUSIVELY OF ELASTOMERIC MATERI
ALS 4HERMOPLASTIC MATERIALS HAVE NOT BEEN WIDELY ACCEPTED 4HE
GREAT ADVANTAGE OF ELASTOMERS UNDER HEAVYDUTY OPERATING CON
DITIONS LIES IN THEIR VERY GOOD MECHANICAL PROPERTIES SUCH AS RE
VERSIBLE ELASTIC FORCEELONGATION CHARACTERISTIC AND THEIR HIGH
RESISTANCE TO ABRASION AND TEAR PROPAGATION )N ADDITION THESE
COMPOUNDS ARE EXCELLENTLY SUITED FOR UNRESTRICTED USE OUTDOORS
4HEY ARE CHARACTERIZED BY THEIR GOOD RESISTANCE TO THE WEATHER
TEMPERATURE VARIATIONS CHEMICALS AND THEIR FLAME RETARDANCE
&URTHERMORE ELASTOMERIC MATERIALS CAN BE ADAPTED TO MATCH
THEIR TECHNICAL PROPERTIES FOR PARTICULAR APPLICATIONS 4HE ELASTO
MER %02 %0$- WITH ITS HIGH RESISTANCE TO OZONE AND 56 AND
ITS SUPERIOR FLEXIBILITY UNDER COLD CONDITIONS COMBINED WITH EXCEL
LENT ELECTRICAL CHARACTERISTICS IS WORTHY OF SPECIAL MENTION AS AN
INSULATING MATERIAL #/2$!&,%8 02/4/,/. 0,!./&,%8 AND
2/.$/&,%8 EMPLOY THIS INSULATION MATERIAL
4HE TOUGH FLAMERETARDANT AND WEATHERRESISTANT 0#0 IS A
TRIEDANDTESTED SHEATHING COMPOUND FOR FLEXIBLE ELECTRIC CABLES
4HIS SHEATHING COMPOUND IS USED IN '- AND '- QUALITY FOR
#/2$!&,%8 02/4/,/. 0,!./&,%8 2/.$/&,%8 AND
/04/&,%8 CABLES
%XCEPTIONS ARE LIFT CONTROL CABLES 302%!$%2&,%8 AND PARTLY
/04/&,%8 CABLES (ERE COMPOUNDS SUCH AS 06# %4&% AND
05 ARE USED WHICH ON ACCOUNT OF THEIR TECHNICAL PROPERTIES HAVE
BEEN SELECTED FOR THESE FLEXIBLE CABLES FOR PARTICULAR APPLICATIONS
ND AND RD SHEATH
ST SHEATH
)NSULATION
)NTERSTICES
.ORMALLY
6$% CERTIFICATE
4YPE OF CABLE
#ONDUCTOR
#OMPOUNDS TO 6$%
0RYSMIANCOMPOUNDS
&LEXIBLE CABLES
)NSULATION )NTERSTI
CES
)NNER
SHEATH
/UTER
SHEATH
)NSULATION )NTERSTI
CES
ST
SHEATH
ND RD
SHEATHS
&LEXIBLE REELING CABLES
.3(4¾5
')
'-B
'-
32
#2
')
%02
'-
0#0
'-
0#0
#/2$!&,%83-+
.232
&LAT RUBBERSHEATHED
CABLES .'&,'¾5
')
'-
#2
'-
#2
')
'-
'-
'-
0,!./&,%8
%02
0#0
0#0
0#0
'-
.232
#2
'-
0#0
2OUND RUBBERSHEATHED
CABLES .'2$'¾5
')
'-B
'-B
'-
%02
%02
%02
0#0
3PECIAL FLEXIBLE CABLE
FOR GRAVITYFED COLLECTOR
BASKET OPERATION 93,4¾
9)
,EAD BALL CORDS
9-
06#
4EXTILE THREADS
05
2UBBERSHEATHED FLEXIBLE
FIBREOPTIC CABLES
9)
'-
'-
%4&%
0#0
0#0
(6 REELING CABLES
.43#'%7¾5
,IFT CONTROL CABLES
93,4+
')
%02
'-B
32
'-
#2
')
'-
'-
'-
%02
%02
%02
0#0
9)
9-
9-
06#
06#
06#
2/.$/&,%8
302%!$%2&,%8
/04/&,%8
02/4/,/.3-+
,IFT CONTROL CABLES
4ABLE 93
#OMPOUNDS
4HE SPECIFIC REQUIREMENTS FOR THE INSULATING AND SHEATHING COM
POUNDS USED IN FLEXIBLE ELECTRIC CABLES FOR CRANES AND MATERIAL
HANDLING EQUIPMENT ARE SHOWN IN TABLE 4HE CHARACTERISTICS
ARE SPECIFIED IN $). 6$% AND ALLOW A PRELIMINARY ESTIMATION
OF THE PROPERTIES OF THESE COMPOUNDS 3PECIAL COMPOUNDS HAVE
BEEN DEVELOPED FOR THE NEW GENERATION OF (6 REELING CABLES
2EQUIREMENTS
5NIT
4HE CHARACTERISTICS OF THIS NEW GENERATION ARE SPECIFIED UNDER
#/2$!&,%83-+ AND 02/4/,/.3-+ IN TABLE 2ECENTLY TESTS WERE ADDED RELATING TO ABRASION RESISTANCE TO
TEAR AND TEAR PROPAGATION SHORE HARDNESS AND RESISTANCE TO
OZONE AND ELECTRICAL VALUES SUCH AS LOSS FACTOR AND DIELECTRIC
CONSTANT
#OMPOUND
02/4/,/.3-+
#/2$!&,%83-+
)NSULATION 3HEATH 3HEATH 3HEATH )NSULATION ST
SHEATH
ND RD
SHEATH
)NSULATION ST
SHEATH
ND RD
SHEATH
%02
32
0#0
0#0
%02
%02
0#0
%02
%02
0#0
')
'-B
'-
'-
')
'-
'-
')
'-
'-
-AX PERMISSIBLE OPERATING TEMPERA
TURE OF THE CONDUCTOR
MAX ª#
4ENSILE STRENGTH BEFORE AGEING
MIN
.MM§ 5LTIMATE ELONGATION BEFORE AGEING
MIN
AT
ª#
p
p p p p
p
p
p
p
p
OVER
D
.MM§ p
p
p
¢
p
!GEING
4ENSILE STRENGTH AFTER AGEING
MIN
#HANGE IN TENSILE STRENGTH AFTER AGEING MAX ¢
p
p
5LTIMATE ELONGATION AFTER AGEING
MIN
#HANGE IN ULTIMATE ELONGATION AFTER
AGEING
MAX ¢
p
p
p
¢
p
p
¢
p
!BRASION
MAX MM¨
4EAR RESISTANCE
MIN
.MM
2ESISTANCE TO TEAR PROPAGATION
MIN
.MM
3HORE HARDNESS !
MIN
4HERMAL EXPANSION
AT
ª#
p
p p p
p
p
p
p
p
OVER
MIN
WITH
.CM§
p
LOADED
MAX
RELIEVED
MAX 2ESISTANCE TO OIL
AT
ª#
p
p p p
p
OVER
H
WITH
BAR
p
p
p
p
#HANGE IN TENSILE STRENGTH AFTER
STORING IN OIL
¢
p
p
¢
p
p
#HANGE IN ULTIMATE ELONGATION AFTER
STORING IN OIL
¢
p
p
¢
p
p
AT
ª#
OVER
H
2ESISTANCE TO OZONE
/ZONE CONCENTRATION
PPHM
2ELATIVE HUMIDITY
&LOW VELOCITY
MMS
.O
TEARING
.O
TEARING
.O
TEARING
.O
TEARING
2EQUIREMENTS
3URFACE RESISTANCE AT ª#
MIN
7
6OLUME RESISTANCE AT ª#
MIN
7 X CM 6OLUME RESISTANCE AT ª#
MIN
7 X CM X
$IELECTRIC CONSTANT AT ª#
MIN
ER
TAN D
,OSS FACTOR AT ª#
4ABLE 94
$ESIGN&EATURES
3HIELD
&IELD CONTROL
4HE SHIELD IS A hBARRIERv AGAINST ELECTROMAGNETIC FIELDS AND PRO
TECTS ELECTRIC SIGNALS AGAINST EXTERNAL SIGNALS 4HE AIM IS TO
WEAKEN OR STOP UNWANTED SIGNALS TO SUCH AN EXTENT THAT THE
WANTED DATA SIGNALS CAN BE TRANSMITTED WITHOUT INTERFERENCE IN
THE ENDANGERED SIGNALLING CONDUCTOR 4HERE ARE THREE BASIC TYPES
OF SHIELD STRUCTURE
/VERALL SHIELD OVER SEVERAL CORES
3HIELDED PAIRS
)NDIVIDUALLY SHIELDED CORES
4HE OVERALL SHIELD OVER SEVERAL CORES USUALLY PLACED BETWEEN THE
INNER AND OUTER SHEATHS NECESSITATES USE OF A SPECIAL DESIGN FOR
FLEXIBLE ELECTRIC CABLES FOR CRANES AND MATERIAL HANDLING EQUIP
MENT IN ORDER TO PREVENT DESTRUCTION OF THE SHIELD BY TENSILE FORCES
AND COMPRESSIVE PRESSURES OCCURRING WITH FREQUENT MOVEMENT
4HIS HAS BEEN TAKEN INTO ACCOUNT IN DESIGN OF 2/.$/&,%8#
FLEXIBLE CABLES FOR FESTOON SYSTEMS
3HIELDED PAIRS AND INDIVIDUALLY SHIELDED CORES ON THE OTHER HAND
HAVE PROVEN THEMSELVES IN PRACTICE AND ARE SUCCESSFULLY USED IN
#/2$!&,%8 0,!./&,%8 2/.$/&,%8 302%!$%2&,%8
AND LIFT CONTROL CABLES
"RAIDED SCREENS ARE CHARACTERIZED BY THEIR TRANSFER IMPEDANCE
WHICH IS DEFINED AS THE RATIO OF THE VOLTAGE DROP ALONG THE SHIELD
ON THE INTERFERED SIDE TO THE PARASITIC CURRENT ON THE OTHER SIDE
4HE TRANSFER IMPEDANCE 2+ $). IS GIVEN FOR A SPECIFIC FRE
QUENCY IN M7M AND IS USUALLY PLOTTED WITH RESPECT TO FREQUENCY
4HE LOWER THE TRANSFER IMPEDANCE OF A SHIELD THE BETTER THE
SCREENING EFFECT 4HE TRANSFER IMPEDANCE OF THE BRAIDED SCREENS
USUALLY USED FOR FLEXIBLE ELECTRIC CABLES FOR CRANES AND MATERIAL
HANDLING EQUIPMENT IS OPTIMIZED AT -(Z AND IS THEREFORE FO
CUSSED ON DATAPROCESSING QUALITY
! TYPICAL TRANSFER IMPEDANCE CHARACTERISTIC IS SHOWN IN THE DIA
GRAM IN &IG 4HE CORES OF 02/4/,/. (6 REELING CABLES OF VOLTAGE LEVEL K6
AND ABOVE ARE ALWAYS EQUIPPED WITH INNER AND OUTER
SEMICONDUCTIVE LAYERS MADE OF SEMICONDUCTIVE RUBBER
4HE INNER AND OUTER SEMICONDUCTIVE LAYERS ARE EXTRUDED WITH THE
INSULATION IN A SINGLEPASS OPERATION 3ECURE BONDING TO THE INSULA
TION IS OBTAINED AS A RESULT OF THIS METHOD OF EXTRUSION
4HE INNER SEMICONDUCTIVE LAYER PREVENTS BUILDUP OF EXCESSIVE
ELECTRICAL FIELD STRENGTH AT THE INDIVIDUAL WIRES OF THE FLEXIBLE CON
DUCTOR AND PARTIAL DISCHARGES BETWEEN THE CONDUCTOR AND THE IN
SULATION
4HE OUTER SEMICONDUCTIVE LAYER SERVES AS A CORE SHIELD AND PER
FORMS THE FOLLOWING TASKS
0ROTECTION AGAINST ELECTRIC SHOCK
!VOIDANCE OF PARTIAL DISCHARGES IN THE CONDUCTOR ASSEMBLY
'ENERATION OF THE RADIAL ELECTRICAL FIELD IN THE INSULATION
$ISCHARGE OF CURRENT IN THE EVENT OF A FAULT
4HE CORE SHIELD IS THUS AN INTEGRAL COMPONENT OF THE PROTEC
TIVEEARTH CONDUCTOR
4HE RESISTANCE BETWEEN THE PROTECTIVEEARTH CONDUCTOR AND ANY
POINT ON THE OUTER SEMICONDUCTIVE LAYER MUST NOT EXCEED 7
4HE PROTECTIVEEARTH CONDUCTOR WHICH TOUCHES THE CORE SHIELD IS
COVERED WITH SEMICONDUCTIVE RUBBER AND ENSURES LONGITUDINAL CON
DUCTIVITY OF THE SYSTEM &IG SHOWS THE CROSSSECTION OF A
02/4/,/. (6 REELING CABLE WITH INNER AND OUTER
SEMICONDUCTIVE LAYERS
)N ADDITION TO THE ELECTRICAL REQUIREMENTS THE CORE SHIELD IN FLEXIBLE
ELECTRIC CABLES FOR CRANES AND MATERIAL HANDLING EQUIPMENT MUST
ALSO BE ABLE TO COPE WITH THE HIGH SOMETIMES VERY HIGH MECHANI
CAL STRESSES
-ETAL SHIELDS ARE MORE LIABLE TO BECOME DEFECTIVE WHEN USED IN
FLEXIBLE ELECTRIC CABLES FOR CRANES AND MATERIAL HANDLING EQUIPMENT
AND ARE INFERIOR TO SHIELDS MADE OF SEMICONDUCTIVE RUBBER MATERIAL
2+ M7M
ND RD SHEATH
0OWER CONDUCTOR
ST SHEATH
0ROTECTIVEEARTH CONDUCTOR
WITH SEMICONDUCTIVE RUBBER
COVERING
3EMICONDUCTIVE RUBBER COV
ERING AS A CORE SHIELD
)NNER LIMITATION OF THE ELECTRIC
FIELD SEMICONDUCTIVE RUBBER
COVERING
)NSULATION
&REQUENCY K(Z
&IG &IG 95
#ORE ARRANGEMENT
4HE BASIC CRITERIA OF THE CORE ARRANGEMENT
FOR FLEXIBLE ELECTRIC CABLES FOR CRANES AND
MATERIAL HANDLING EQUIPMENT ARE SUMMA
RIZED IN THE ADJACENT TABLE
)N ROUND FLEXIBLE ELECTRIC CABLES THE INDIVID
UAL CORES ARE ARRANGED BY LAYING THEM UP
5P TO THREE CORES ARE LAID UP WITHOUT A CEN
TRAL ELEMENT &OUR CORES AND ABOVE ARE LAID
UP AROUND A CENTRE WHICH CAN ALSO CONSIST
OF THREECORE STRANDED ELEMENTS
! STRETCHED CORE IN THE CENTRE OF THE FLEXIBLE
CABLE AS THE ACTUAL CENTRE OR PLACED IN THE
CENTRE IS NOT PERMITTED ACCORDING TO THE
$). 6$% STANDARDS ! STRETCHED CORE AT THE
CENTRE OF THE FLEXIBLE CABLE WOULD QUICKLY RE
SULT IN PREMATURE FAILURE OF THE CONDUCTOR
DUE TO BREAKAGE ESPECIALLY IN FLEXIBLE ELEC
TRIC CABLES FOR CRANES AND MATERIAL HANDLING
EQUIPMENT
! MAXIMUM OF THREE CORE LAYERS IS BEST FOR
THE CONDUCTOR ASSEMBLY )NVESTIGATIONS
HAVE SHOWN THAT IF THERE ARE MORE THAN
THREE LAYERS THE INTERNAL STABILITY OF THE FLEXI
BLE CABLE AND IN CONSEQUENCE THE SERVICE
LIFE IS REDUCED AS A RESULT OF INCREASING SEC
ONDARY AND RELATIVE FORCES BETWEEN THE
CORES
4HE LENGTH OF LAY 3 IS A DESIGN FEATURE USED
FOR LAYING UP THE CONDUCTOR ASSEMBLY SEE
TABLE AND INFLUENCES THE BENDING FLEXI
BILITY AND THE BENDING STABILITY 4HE LENGTH OF
LAY IS AN IMPORTANT FACTOR FOR THE SERVICE LIFE
OF FLEXIBLE ELECTRIC CABLES FOR CRANES AND MA
TERIAL HANDLING EQUIPMENT
)N THE CASE OF FLAT FLEXIBLE CABLES LAYING UP IS
NOT USUALLY NECESSARY AS THE CORES ARE AR
RANGED PARALLEL TO EACH OTHER &LAT FLEXIBLE
CABLES WITH LAID UP BUNDLES REPRESENT AN
EXCEPTION TO THIS RULE 4HIS SPECIAL FORM OF
CORE ARRANGEMENT IS SELECTED FOR LARGE NUM
BERS OF CORES IN ORDER TO ENSURE THE RE
QUIRED STABILITY OF THE FLAT CABLES
2OUND FLEXIBLE CABLES
,AYING UP OF TWO TO THREE CORES WITHOUT A
CENTRE
#ORES
,AYING UP OF FOUR OR MORE CORES WITH CENTRE
3PECIAL DESIGN THE CENTRE COMPRISES
THREE CORES
#ENTRE
-AXIMUM THREELAYER DESIGN
STANDARD UP TO CORES
#ENTRE
#ORES
3TRETCHED CORE
! STRETCHED CORE IN THE CENTRE OF A FLEXIBLE
CABLE IS NOT PERMITTED
4HE LENGTH OF LAY 3 IS THE LENGTH MEAS
URED IN THE DIRECTION OF THE LAY OVER WHICH
A CORE CIRCUMSCRIBES ª AROUND THE
LAYING AXIS
)T IS GIVEN AS A MULTIPLE OF THE DIAMETER $
OVER THE CONDUCTOR ASSEMBLY EG
3 X $
&LAT FLEXIBLE CABLES
0ARALLEL ARRANGED CORES
#ORES LAID UP IN BUNDLES
REFER TO ROUND FLEXIBLE CABLES
PARALLEL ARRANGED BUNDLES
4ABLE #OLOUR DESIGNATION OF THE FIBREOPTICS
-ONOMODE DESIGN % MM
'RADEDINDEX FIBRE DESIGN ' MM
'RADEDINDEX FIBRE DESIGN ' MM
NF NATURAL COLOURING
"OLDFACED COLOUR DESIGNATIONS ARE INDICES
RELATIVE TO THE FIBRE TYPE
96
.O OF FIBRES
&IBRE COLOUR
(OLLOW CORE COLOURS
X %
/' ". 7( 2$ "+ 9%
X NF
X %
/'0+ ".0+ 7(0+ 2$0+
"+0+ 9%0+
X NF
X %
"5 /' '.
9% "+ NF NF NF NF
X '
/' '. ". 7( 2$ "+
X NF
X '
/'0+ '.0+ ".0+ 7(0+
2$0+ "+0+
X NF
X '
"5 /' '.
'. "+ NF NF NF NF
X '
"5 /' ". 7( 2$ "+
X NF
X '
"50+ /'0+ ".0+ 7(0+
2$0+ "+0+
X NF
X '
"5 /' '.
"5 "+ NF NF NF NF
$ESIGN&EATURES
#ORE ARRANGEMENT
4ABLE SHOWS THE NORMAL LENGTHS OF LAY IN FLEXIBLE ELECTRIC CABLES FOR CRANES AND MATERIAL HANDLING EQUIPMENT
,ENGTH OF LAY 3
4YPE OF CABLE
,ENGTH OF LAY OF CORES FOR 0IRELLI FLEXIBLE ELECTRIC CABLES FOR USE ON
CRANES AND MATERIAL HANDLING EQUIPMENT
&LEXIBLE REELING CABLES
.3(4¾5
&LAT RUBBERSHEATHED FLEXIBLE
CABLES .'&,'¾5
X$
3PECIAL FLEXIBLE CABLES FOR
GRAVITYFED COLLECTOR BASKET
OPERATION 93,4¾
)NDIVIDUAL CORES LAID UP IN BUNDLES
"UNDLES LAID UP AROUND THE CENTRE
2UBBERSHEATHED FLEXIBLE
FIBREOPTIC CABLES
%SPECIALLY LAID UP AROUND A '&+ SUPPORT ELEMENT
(6 REELING CABLES
.43#'%7¾5
,IFT CONTROL CABLES
93,4+
M SUSPENSION LENGTH
M SUSPENSION LENGTH
M SUSPENSION LENGTH
)NDIVIDUAL CORES
"UNDLES
#/2$!&,%83-+
0,!./&,%8
0ARALLEL ARRANGED CORES OR BUNDLES
2OUND RUBBERSHEATHED
FLEXIBLE CABLES .'2$'¾5
&LEXIBLE CABLES
X $
2/.$/&,%8
X $
X $
302%!$%2&,%8
/04/&,%8
X$
02/4/,/.3-+
02/4/,/.3-+ ,7,
X $
X $
X$
X$
,IFT CONTROL CABLES
4ABLE
97
3UPPORT ELEMENTS – !NTITORSION BRAID
3UPPORT ELEMENTS
&LEXIBLE ELECTRIC CABLES FOR CRANES AND MATERIAL HANDLING EQUIP
MENT SHOULD NOT BE STRESSED ABOVE THE LIMITS SET OUT IN
TABLE PAGE FOR THE PERMISSIBLE TENSILE FORCES )F HIGHER
TENSILE FORCES ARE TO BE EXPECTED SUPPORT ELEMENTS HAVE TO BE
PROVIDED AS PART OF THE STRUCTURE OF THE CABLE 4HERE ARE SEVERAL
POSSIBILITIES FOR INTEGRATION OF SUPPORT ELEMENTS IN CABLES
4WO VARIANTS ARE NORMALLY USED
! SUPPORT ELEMENT LOCATED IN THE CENTRE OF THE CABLE
OR
! BRAID BETWEEN THE INNER AND OUTER SHEATH
4HE FORCEELONGATION DIAGRAM IN &IG SHOWS THE CHARACTERISTIC
OF THESE CABLES WITH DIFFERENT ARRANGEMENTS OF SUPPORT ELEMENTS
AS COMPARED TO A CABLE WITHOUT A SUPPORT ELEMENT
!FTER A COMPACTING PHASE IN WHICH THE INDIVIDUAL CABLE ELEMENTS
ARE INITIALLY PULLED TOGETHER UNTIL THE COPPER CONDUCTOR BEGINS TO
BEAR THE TENSILE FORCE THE CABLE WITHOUT A SUPPORT ELEMENT RE
MAINS LINEAR IN THE FIRST SECTION OF THE CURVE CURVE # )N THE NEXT
PHASE ELONGATION INCREASES CONSIDERABLY ON A SLIGHT INCREASE OF
FORCE
#ABLES WITH A BRAID AS A SUPPORT ELEMENT BETWEEN THE INNER AND
OUTER SHEATH BEHAVE IN THE FIRST SECTION OF THE CURVE CURVE " IN A
SIMILAR MANNER TO CABLES WITHOUT A SUPPORT ELEMENT 4HE BRAID
BECOMES EFFECTIVE AS A SUPPORT ELEMENT AND BEARS THE APPLIED
FORCE ONLY AFTER THE FORCE AND THE CONSEQUENT ELONGATION HAVE IN
CREASED OVER A CERTAIN PERIOD OF TIME 4HE TENSILE FORCE WHICH IS
BORNE INCREASES WITH LESS ELONGATION THAN THAT OF THE CABLE WITH
OUT A SUPPORT ELEMENT 4HE BRAID AS A SUPPORT ELEMENT CAN PRE
VENT THE CABLE EG FROM TEARING
#ABLES WITH A CENTRAL SUPPORT ELEMENT BEHAVE DIFFERENTLY PROVIDED
THAT THE SUPPORT ELEMENT WAS CORRECTLY DIMENSIONED 4HE SUP
PORT ELEMENT BEARS THE TENSILE FORCES FROM THE VERY BEGINNING AND
THUS RELIEVES THE COPPER CONDUCTOR CURVE !
4HE FORCEELONGATION CHARACTERISTICS OF THE SUPPORT ELEMENTS AND
OF THE COPPER CONDUCTORS ARE DECISIVE FOR CORRECT DESIGN OF THE
SUPPORT ELEMENT AND DIMENSIONING OF THE FLEXIBLE CABLES 4HE AC
TUAL DESIGN SHOULD BE WORKED OUT IN CLOSE COOPERATION WITH THE
CABLE MANUFACTURER
!NTITORSION BRAID
&LEXIBLE ELECTRIC CABLES FOR CRANES AND MATERIAL HANDLING EQUIP
MENT ARE OFTEN FITTED WITH AN ANTITORSION BRAID BETWEEN THE INNER
AND OUTER SHEATH IN ORDER TO MINIMIZE TWISTING UNDER TORSIONAL
LOADS
4HIS APPLIES TO #/2$!&,%83-+ 02/4/,/.3-+ AND LIFT
CONTROL CABLES
!N ANTITORSION BRAID IS NOT USED FOR 0,!./&,%8 NOT POSSIBLE FOR
THIS PARTICULAR TYPE OF CABLE 2/.$/&,%8 NOT NECESSARY FOR THE
APPLICATION INVOLVED AND 302%!$%2&,%8 FULLY DESIGNED FOR BEST
TORSIONAL PROPERTIES
4ENSILE FORCE &
#ENTRAL SUPPORT
ELEMENT
"RAID
%LONGATION E
#OMPACTING PHASE
&IG 4ORSIONAL MOMENT
7ITHOUT BRAID
4HE EFFECT OF AN ANTITORSION BRAID ON THE ANGLE OF TORSION A WITH
INCREASING TORSIONAL MOMENT FOR COMPARABLE CABLES WITH AND
WITHOUT AN ANTITORSION BRAID IS SHOWN IN &IG 4HE FLEXIBLE CABLE WITH ANTITORSION BRAID TENDS TO TWIST LESS THAN
THE FLEXIBLE CABLE WITHOUT A BRAID FOR THE SAME TORSIONAL MOMENT
7ITH BRAID
!NGLE OF TORSION A
&IG 98
7ITHOUT SUPPORT
ELEMENT
$ESIGN&EATURES
-ARKING
0RYSMIANFLEXIBLE ELECTRIC CABLES FOR CRANES AND
MATERIAL HANDLING EQUIPMENT ARE MARKED ON
THE OUTER SHEATH AS SHOWN IN TABLE )N ADDITION SOME FLEXIBLE CABLES CONTAIN
COMPANY IDENTIFICATION THREADS ANDOR
6$% IDENTIFICATION THREADS
&LEXIBLE CABLES
4YPE
-ARKING ON OUTER SHEATH
#OMPANY
IDENTIFICATION
THREAD
6$%
IDENTIFICATION
THREAD
#/2$!&,%83-+6
.3(4¾5
#/2$!&,%83-+6
.3(4¾5*/ NUMBER OF CORES X CROSSSECTION
)N THE CORE
ASSEMBLY
)N THE CORE
ASSEMBLY
0,!./&,%8
.'&,'¾5
6$% 0,!./&,%8 .'&,'¾5*/ NUMBER OF CORES X
CROSSSECTION 6 ª# 5, 0,!./&,%8 !7'
.O!7'NUMBER OF CORES CORE TYPE /54$//2
2/.$/&,%8
.'$'¾5
2/.$/&,%8 .'2$'¾5*/ NUMBER OF CORES X
CROSSSECTION K6 6$% 2EG .O
5NDER THE
SHEATH OR
INSULATION
.O
302%!$%2&,%8
93,4¾
302%!$%2&,%8 93,4¾* NUMBER OF CORES X
CROSSSECTION
)N THE
CORE
ASSEMBLY
.O
9EAR OF MANUFACTURE /04/&,%8 ' OR MICRON 'ERMANY 0-3(!3# .O
.O
.43#'%7¾5 6$% 02/4/,/.3-+
.43 xNUMBER OF CORES X CROSSSECTION RATED VOLTAGE
.43+#'%7¾5 9EAR OF MANUFACTURE SERIAL NUMBER
.O
.O
,93,4+
93,4+
93,94+*:
AND
93,9#94+*
)N THE
CORE
ASSEMBLY
.O
/04/&,%8
02/4/,/.3-+
02/4/,/.3-+ ,7,
,IFT CONTROL CABLE
,93,4+ M
93,4+ M
)N CORE OR IN THE
GREENYELLOW CORE
4ABLE
99
#ABLE$RUM/VERVIEW
$RUM3IZE
7EIGHT
KG
#OMPARISON
$IMENSIONS
ΠX WIDTH
CM
6OLUME
M
X X X X X X X X X X X X X X X X #ROSS3ECTION
METRICAL
MM
!7'3IZES
MM
-#-
-#-
-#-
-#-
-#-
-#-
-#-
!7' !MERICAN 7IRE 'AGE
100
+ABEL UND 3YSTEME 'MB(
!NWENDUNGSTECHNIK UND %XPORT
!USTRA”E $ .EUSTADT BEI #OBURG
/RDER .O %+!!
0RINTED IN 'ERMANY