3.1 B

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Compounds for Nexans handling cables

1. GeneralitiesThe selection of the correct compound assume thedetailed analysis of the application where the cableis used.

In the case of flexible, movable applications such asin cranes the compounds for insulation, semi-conductive layer, outer and inner sheaths arechosen by Nexans for several factors as highmechanical properties, chemical resistance andthermal requirements.

Nexans is familiar with the high performancerequirements in flexible applications combined withhigh mechanical stress. Due to this, Nexansespecially uses in our RHEYFIRM®(RTS) only high-grade rubber insulation such as RHEYCLEAN®®-HV.

This special compound, manufactured in severalversions allows to reduce wall-thickness for thedifferent voltage rates from 6 to 30 kV.We generally use compounds that exceed requiredstandards like VDE.

In our product range RHEYFIRM®(RTS) andRHEYCORD®(RTS) we only use the compound5GM5 instead of 5GM3. This high gradecompound has a much higher tensile strength, tearresistance and abrasion resistance than the morecommonly used compound 5GM3.

Additional advantages of this special outer sheathcompound are high flame retardancy properties,ozone, weather and ageing resistance. Furthermoreit has excellent elastic behaviour even in lowtemperatures.

NEXANS distinguish compounds betweenThermoplastics and Elastomerics.

Both compounds are used for insulation, inner andouter sheaths. The graph and table on the followingpages give a short introduction to compound andexplain the typical and most important characteristicsfrom several materials used in Nexans handlingcables.

Sheath

CR/PCP

InsulationEPRXLPE

Elastomerics Thermoplastics

InsulationPVCTPE-E

SheathPURPVC

Compounds

Cross-linked polymermaterials, which do notflow viscous on highertemperature, but theyreact rubber elastic at atemperature range.

Not cross-linked macro-molecular connections.It is possible to re-use itagain and again withwarm up into plasticcondition.

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TERM

S

PUR

THER

MA

L PR

OPE

RTIE

SCH

EMIC

AL

PRO

PERT

IES

MEC

HA

NIC

AL

PRO

PERT

IES

Abr

evia

tion

VDE

Desi

gnat

ion

Chem

ical

Desi

gnat

ion

Wea

ther

Resi

stan

t

COMPOUNDS

Flam

e Re

tard

ant

Beha

viou

rin

cas

e of

fire

Chem

ical

Re

sist

ance

(oil,

gre

ase,

fuel

, sol

vent

)

Hal

ogen

Free

Wat

erA

bsor

ptio

n(%

)Fl

exib

ility

Abr

asio

nTe

nsile

Stre

ngth

(N/m

m2 )

Elon

gatio

nat

bre

ak(%

)

Shor

e(A

)

ELASTOMERICS

TPE-

E

PVC

11Y

13Y Y

Poly

uret

hane

Poly

este

r

Poly

viny

lch

lorid

e

Am

bien

tTe

mpe

ratu

re(m

obile

op

erat

ion)

(°C)

CR/

PCP

EPR

EVA

5G 3G 4G

Poly

chlo

ropr

ene

Ethy

lene

-Pr

opyl

ene

Rubb

er

Ethy

lene

-vi

nyla

ceta

te

-55

+80

-100

+13

0

-25

+70

-40

+100

-30

+90

-30

+125

+++

used

onl

y fo

rin

sula

tion

++ +++

used

onl

y fo

rin

sula

tion

- - ++ +++

+ -

flam

mab

le

flam

mab

le

flam

mab

le

self

extin

guis

h

self

extin

guis

h

+++

++ ++ +++ +

Yes

Yes

No

No

0.5

Yes

0.5

0.4

1.0

0.1

++ ++ +++

+++

+++

+++

35-5

055

0-65

085

+ -

++

12.5

-25

19

130-

150

550-

750

70-9

5

70

Basic

RAW

Mat

eria

ls us

ed in

Nex

ans H

andli

ng C

ablesTHERMOPLASTICS

XLPE

cros

s-lin

ked

poly

ethy

lene

-50

+90

used

onl

y fo

rin

sula

tion

-fla

mm

able

+Ye

s0.

7+

-+

15-1

830

0-45

0+

used

onl

y fo

r in

sula

tion

used

onl

y fo

r in

sula

tion

used

onl

y fo

r se

mi-c

ondu

ctiv

e la

yer

+++

exce

llent

++ v

ery

good

+ go

od+

- m

edim

- l

ow

PUR

FRPo

lyur

etha

ne-5

5 +8

0++

++

++Ye

s0.

5++

+++

35-4

555

0-65

080

self

extin

guis

h

Strength members in flexible cables could be placed indifferent arrangements:

• outside the cable

• elements (e.g. braid) between inner and outer sheaths

• in flat cables besides the cores

• in the center of cable.

The effects of a strength member are:

• to take over a part of the pulling force to reduce themechanical stress from the copper conductor.

It ensures compliance with VDE 0298 standard part 3of 15 N/mm2 (referring to the copper cross-section ofthe main cores).

• to reduce the risk of a corkscrew-effect. That wouldbe caused by turning off the stranding from the coresand simultaneus turning on in an other part of the cable length.

• to reduce the risk of torsion in a cable by a reductionof the tensile force of the stranding conductor.

The most common strength members are:

• Steel rope

• Polyamid/ polyester ropes

• Aramid/ kevlar yarns

• Natural fiber e.g. sash line

• Coated E-glass

Depending on the detailed application of the flexiblehandling cable, physical characteristics like elongation[%], elastic stability (N/mm2), breaking load (kN),laying types and reversed bending properties of thedifferent strength members must be analysed.

Other integrated elements like reinforcement braidsused as strength member, relieve the conductor afterstress application. The strength members used byNexans relieve the conductor instantaneously with stressapplication.

3.1 C

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Strength Member

Stress-strain curves

4000

3000

2000

1000

0 5 10 15 20

Steel

Aramid/Kevlar

PolyesterNylon

Elongation (%)

Tens

ile s

treng

th (N

/mm

2 )

3.1 D

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Anti-Torsion Braid

Torsional stresses is caused by different conditions:

In most flexible handling cables, we use an anti-torsion braid. The anti-torsion braid consist of synthetic threads witha very high tensile strength. It is embedded between inner and outer sheath to prevent twisting, loops, push off theouter sheath and “corkscrew-effects”.

• Changes of direction into different planes

• Non aligned guide pulley

• Sloping cable guide into the deflection pulley

• High dynamic stress

• High tensile load of the cable

Anti-torsion braid in a RHEYFIRM®(RTS)

Criterias to build up a heavy duty reinforcement:

• A good chemical bonding between synthetic threadsand sheath compound

• Braid angle

• Braid coverage percentage

• Material of reinforcement

• Shear resistance of the reinforcement element

Cork screw-effect

20 x

d

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Bending Radius

up to

8 m

m3

x d

3 x

d4

x d

9 - 1

2 m

m4

x d

4 x

d4

x d

13 -

20 m

m5

x d

5 x

d5

x d

abov

e 20

mm

5 x

d5

x d

5 x

d6

x d

Cabl

e Ty

peca

ble

oute

rdi

amet

er(m

m)

entr

y be

llfe

stoo

nap

plic

atio

ne-

chai

nre

elin

gop

erat

ion

cabl

e te

nder

Dive

rtin

g un

itw

ith te

nsio

nco

ntro

l

s-sh

ape

defle

ctio

n

RHEY

CORD

(BS)

RHEY

CORD

RHEY

CORD

(RTS

)RH

EYFE

STO

ON

RHEY

FIRM

(RTS

)RH

EYFI

RM (S

I)

BUFL

EX X

’PRE

M L

V

BUFL

EX X

’PRE

M M

VBU

FLEX

SC

7.5

x d

7.5

x d

5 x

d

20 x

d

20 x

d

15 x

d15

x d

12 x

d10

x d

10 x

d10

x d

8 x

d8

x d

8 x

d8

x d

6 x

d

15 x

d15

x d

10 x

d10

x d

10 x

t

10

to 1

2* x

tH

07VV

H6-

FPV

C-Fl

at

RHEY

FLAT

-N

RHEY

CORD

-OFE

R

RHEY

CORD

-OFE

SR

RHEY

CORD

-OFE

M

14 -

16 m

m

17 -

19 m

m

9 - 1

1 m

m

200

mm

125

mm

125

mm

200

mm

125

mm

125

mm

125

mm

125

mm

125

mm

125

mm

200

mm

200

mm

200

mm

200

mm

500

mm

500

mm

APP

LICA

TIO

NS

3.1 E

d = outer diameter t = thickness * = according to the cable width

To ensure a long life term for flexible cables in handling applications it is important to considerate the followingtable which is based on the VDE standard and our additional experience. If the bending radius is reduced,simultaneus stresses on all components of the cable increase and damages could appear.

H harmonized typeN N standard type according to VDE

(N) (N) (N) (N) in line with VDES S tough flexible cableH H heavy duty cable

07 nominal voltage 450/750 VG G 3G 3G rubber (EPR) insulation

V V PVC insulation and PVC sheathRD RD flexible round cable

FL FL flexible flat cableH6 harmonized flat cable-F conductor class, fine stranded class 5

T T anti-torsion elementC metallic screen over cores

G G G rubber sheathC screen between inner and outer sheath5G 5G outer sheath, rubber type 5GM5 according to DIN VDE 0207 part 21

OE OE OE OE oil resistantU U U U flame-retardant-J -J -J -J with green/yellow core

-O -O without green/yellow core(RTS) Reduced Torsion Special

RHEYFESTOON®(N)3GRD5G Flexible Round Festoon CablesRHEYFESTOON®(N)3GRDGC5G Flexible Screened Round Festoon CablesRHEYFLAT®-N (N)GFLCGOEU-J Screened Rubber Flat CablesRHEYFLAT®-N NGFLFOEU-J Rubber Flat CablesRHEYCORD®(RTS) (N)SHTOEU-J Extra Heavy Duty Reeling CablesRHEYCORD® NSHTOEU-J Reeling CablesH07VVH6-F PVC Flat Cables

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Letter CodeLow voltage: Flexible Cable Types

(N) (N) (N) in line with VDET T T trailingS S heavy duty

M single sheath typeFL flexible flat cable

CGE conducting non metallic screenCGC CGC conducting metallic screen

W W W heat-resistant EPR insulationT anti-torsion elementOE OE OE oil resistantU U U flame-retardantS S S rubber outer sheath type 5GM5 according to DIN VDE 0207 part 21OFE OFE Optical Fiber Element(RTS) Reduced Torsion Special(RS) Reduced Special

RHEYFIRM® (N)TSFLCGCWOEUS Flexible Flat Reeling CablesRHEYFIRM® (N)TMCGCWOEUS Flexible Screened Single Core CablesRHEYFIRM® (N)TSCGEWTOEUS Reeling Cables

High voltage: Flexible Cable Types

3.1 F

3.1 G

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Units of Measurement

Equivalence between metric size and AWG-kcmil

The US American standardization extracts several standardized sections from 0.324 to 253 mm2.Sections are designed by a gauge-number AWG or a section in MCM (Mil Circular Mil).AWG numbers are identical with the British Brown and Sharpe (B&S) numbers.1 Mil = 0.0254 mm = 1/100 inch1 MCM = 0.5067 mm2

18 0.823 7 10.55 250 12717 1.04 6 13.3 300 15216 1.31 5 16.77 350 17715 1.65 4 21.15 400 20314 2.08 3 26.67 450 22813 2.63 2 33.62 500 25312 3.31 1 42.41 550 27911 4.17 1/0 53.49 600 30410 5.261 2/0 67.439 6.631 3/0 85.018 8.361 4/0 107.2

AWG/kcmil AWG/kcmilmm2 mm2 MCM mm2

1 mils 1 0.001 0.0000833 0.0000278 0.00254 0.0000254

1 inch 1,000 1 0.0833 0.02278 2.54 0.0254

1 foot 12,000 12 1 0.3333 30.48 0.3048

1 yard 36,000 36 3 1 91.44 0.9144

1 cm 393.7 0.3937 0.0328 0.01094 1 0.01

1 m 39,370 39.37 3,281 1,094 100 1

Unit mils inch foot m

Conversion from non-metric systems - Measures of length

cmyard

3.2 A

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For alternative current system having a nominal voltage above 1 kV and less than 35 kV (3 phases)

Voltage Definition

Definition

Nominal Voltage: voltage between phases for which the system is designated.

Operating Voltage: electrical potentiel difference between 2 conductors in normal conditions.

For alternative current system having a nominal voltage between 100 V and 1000 V

230/400 V 277/480 V 300/500 V(+ or - 10%)

400/630 V 480 V 450/750 V(+ or - 10%)

1000 V 600 V 0.6/1 kV

Operating Nominal Voltage

50 Hz 60 HzCable Voltage

The cable voltage (Uo/U) is designed by 2 values:- Uo is voltage between phase and neutral- U is voltage between phases

3.6 kV 3 kV or 3.3 kV 1.8/3 (3.6) kV7.2 kV 6 kV or 6.6 kV 3.6/6 (7.2) kV12 kV 10 kV or 11 kV 6/10 (12) kV

17.5 kV 15 kV 8.7/15 (17.5) kV24 kV 20 kV or 22 kV 12/20 (24) kV36 kV 33 kV 18/30 (36) kV

4.4 kV 4.16 kV 3.6/6 (7.2) kV14.5 kV 13.8 kV 8.7/15 (17.5) kV26.4 kV 24.94 kV 18/30 (36) kV

50 Hz

Highest voltage of equipment Operating Nominal VoltageCable Voltage

60 Hz

Highest voltage of equipment Operating Nominal VoltageCable Voltage

3.2 B

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XLPE or EPRMulti-cores cable

three loaded coreson ground in acc. withIEC 60 364-5-52-12

(A)

Nominal cross sectionof conductor

(mm2)

Current Carrying CapacityCorrection factors

Short-circuit capacity1. Current Carrying Capacity

1.5 29 19 23 222.5 38 25 32 304 53 34 42 406 69 43 54 51

10 98 60 75 7116 127 80 100 9525 173 101 127 12135 219 126 158 15050 276 153 192 18270 345 196 246 23495 414 238 298 283

120 489 276 346 329150 564 318 399 375185 644 362 456 428240 776 424 538 511

XLPE or EPRSingle-core cable

free in air in acc. withEN 50 355

(A)

PVCMulti-cores cable threeloaded cores free in air

type E in acc. withIEC 60 364-5-52-12

(A)

XLPE or EPRMulti-cores cable

three loaded coresfree in air in acc. withIEC 60 364-5-52-12

(A)

XLPE or EPR Conductor temperature: 90 °C/ Reference ambient temperature of 30 °CPVC Conductor temperature: 70 °C/ Reference ambient temperature of 30 °C

Ambient Temperature

(°C)

2.1 Correction factors for ambient air temperature

10 1.22 1.1515 1.17 1.1220 1.12 1.0825 1.06 1.0430 1.00 1.0035 0.94 0.9640 0.87 0.9145 0.79 0.8750 0.71 0.8255 0.61 0.7660 0.50 0.7165 0.6570 0.5875 0.5080 0.41

PVC Insulation

Temperature: 70 °C

XLPE or EPR Insulation

Temperature: 90 °C

For other short-circuit times (lower than 5 seconds), the short-circuit current density has to be calculated with thefollowing formula:

dt = d x 1/√t

2.2 Correction factors for reeling cablesBasis in free air (in line with EN 60204-11)

0.85 0.65 0.45 0.35 0.85 0.75 0.65

1

Multilayer Reel

432

Monospiral Reel

round cableventilated

round cablenon-ventilated

flat cableventilated

Number oflayers

2.3 Reduction factors for groups of several circuits or several multicores cables

1.00 0.80 0.65 0.55 0.50 0.45 0.40 0.40

Number of 3 cores circuits

Arrangement 20

3 Short-circuit current density in A/mm2 for 1 second

70 °C 150 °C 109 117 124 131 138

90 °C 200 °C 122 128 135 141 147 153 159

90 °C 250 °C 143 149 154 159 165 170 176

90 °C 250 °C 143 149 154 159 165 170 176

90 °C 250 °C 143 149 154 159 165 170 176

plain copper conductor+ PVC

Number of 3 cores circuits

Insulating material Permissible operatingtemperature 90 °CPermissible short-circuit

temperature 80 °C 70 °C 60 °C 50 °C 40 °C 30 °C

tinned copper conductor+ EPR

plain copper conductor+ TPE

plain copper conductor+ XLPE

plain copper conductor+ EPR

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161296421

Bunched in air, on a surface, embedded or enclosed

3.2 C

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Voltage Drop

Voltage drops are determined by using the following formula:

Δu = b x l x iB ( R cos ϕϕ + λλ sinϕϕ )

With:

ΔΔu voltage drop (in Volts)b coefficient equal to √3 for three-phases circuits, or 2 for single-phase circuits

R electrical resistance of conductors in normal service (in �/km)l straight length of the wiring systems (in km)cos ϕ power factor, if no precise details, the power factor is taken equal to 0.8

(sin ϕ= 0.6)

λ reactance per unit length of conductors (in �/km)iB current value (in Ampere)

For the application of the formula it is necessary toknow the exact cable specification.

For a fast calculation of the section it is recommendedto use the following tables which give the value of the voltage drop, available for most of the low voltagecables and for different values of cos ϕ.

Voltage drops are calculated for a three-phasescircuit:

• 3 or 4 copper cores cables• 3 single cores cables

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1.5 25.10 22.70 20.20 15.302.5 15.20 13.70 12.30 9.304 9.50 8.60 7.80 5.805 6.40 5.80 5.30 4.00

10 3.80 3.50 3.20 2.4016 2.40 2.20 2.00 1.6025 1.50 1.40 1.30 1.0435 1.10 1.06 0.97 0.8050 0.80 0.80 0.74 0.6270 0.56 0.57 0.55 0.4695 0.40 0.43 0.42 0.37

120 0.33 0.37 0.36 0.32150 0.26 0.30 0.30 0.28185 0.21 0.26 0.27 0.25240 0.17 0.22 0.23 0.22300 0.13 0.19 0.20 0.21

Cross-section area(mm2)

Voltage drop (V/ A x km)

cos ϕ = 0.6cos ϕ = 0.8cos ϕ = 0.9cos ϕ =1

Low voltage cables with PVC insulation (max. temperature: 70 °C) 3 or 4 copper cores

1.5 26.00 24.20 21.50 16.202.5 15.50 14.40 12.80 9.604 10.00 9.00 8.00 6.105 6.60 6.10 5.40 4.20

10 3.90 3.60 3.20 2.5016 2.50 2.30 2.10 1.5025 1.60 1.50 1.35 1.1035 1.15 1.10 1.00 0.8550 0.85 0.80 0.75 0.6570 0.57 0.60 0.55 0.5095 0.42 0.45 0.42 0.40

120 0.35 0.35 0.36 0.34150 0.28 0.30 0.32 0.31185 0.23 0.25 0.28 0.24240 0.18 0.21 0.26 0.23300 0.14 0.18 0.24 0.21

Cross-section area (mm2)

Voltage drop(V/ A x km)

cos ϕ = 0.6cos ϕ = 0.8cos ϕ = 0.9cos ϕ = 1

Low voltage cables with EPR or XLPE insulation (max. temperature: 90 °C) 3 or 4 copper cores

Biggestdimensions StandardizationHighest

BPSeMaximal number

of participants

CAN BUS 1 Mbit/s to 40 m 1 km at 50 Kbit/s 64(128) ISO 11898

ProfiBUS 500 Kbit/s to 200 m 1200 m at 93 Kbit/s 256 ISO 19245

InterBUS 500 Kbit/ s to 40 m 12,8 km at 400 m Segments 256 ISO 19258

3.3 A

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BUS SystemData transmission

BUS Systems are used as a communication mediumfor sectored actuators, sensors and steering in theautomation industry and where electronic modules

have to be connected easily. Only one cableconnects all components.

Field bus is the generic name for all bus systems which are used for the metrology, steering and controllingengineering. These are:

• CAN• ProfiBUS• InterBUS• ASI BUS

According to DIN (German Institute forStandardization) standard a field bus in generalshould transmit a small volume of data in fast timeseries on a digital compare between sensors,actuators and steering. as the requirements to the bussystem depends on the level of automation, there is

no field bus which can solve all tasks optimaltogether.Following table shows a short overview of the mostimportant features of the three most popularBUS systems:

Automation for Factory Process

General Purposes Automation Automation

PROFIBUS-FMS PROFIBUS-DP PROFIBUS-PA

Universal Fast Application oriented

• Large variety of applications • Plug and Play • Powering over the BUS

• Multi-Master communication • Efficient and cost effective • Instrinsic Safety

Profi-BUS Familly

Dev

ice

prof

iles

App

licat

ion

prof

iles

EN 50170 Volume 2 and DIN 19245 Part 1 to 4

BUS systems

3.3 B

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Optical Fibers

General OverviewOptical fibers are mainly used to transmit informationover long distances and with high bit rates. Theirbenefits are numerous: the signal transmitted on thefiber is not disturbed by any electromagnetic wavecreated by power cables or electric machines. It alsoprovides more security, as these cables can be fullydielectric. Besides, they provide a weight and spacesaving due to their small diameter, only 250 μm.

Different fiber types are available:

• Multimode fibers are used for Local Area Networks(LAN) where the network links can be up to 2,000meters. Two standard sizes of core are offered: 62.5 μm and 50 μm (with better performances).Multimode fibers have a graded index profile toreduce the dispersion of the signal during thetransmission. The high size of the core is interestingfor easy connection and does not require high costtest equipment.

• Singlemode fibers are able to transmit over longerdistances. The installation is more delicate as theyhave a smaller core of 9 μm. This implies moreprecise connectors and test equipment.

Coating

Cladding

Core

An optical fiber is made up of three main parts: thecore, the cladding and the coating.In the center, the “core” is made of doped silica andis surrounded by the “cladding”, made of naturalsilica.The light signal propagates along the core and thesignal is reflected on the surface between the coreand the cladding.An acrylic “coating”, generally made of two layers,is protecting the sillica part against abrasion duringinstallation.

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Multimodes fibers

125 μm

62.5 μm 50 μm 9 μm

62.5/125

Singlemode fiber

50/125 9/125

Optical fibers are used at specific wavelength.Multimodes fibers are mainly used at 850 nm and1,300 nm and Singlemode are used at 1,310 nmand 1,550 nm. The attenuation performances arebetter at the higher bandwidth with consequentlyimproved transmission performances.Optical fiber can be provided with differentcharacteristics. Indeed the performance need forfiber in patch cord or fiber over one kilometer linkare obviously different. The fiber choice is based onoptical parameters such as attenuation, bandwidthperformances and chromatic dispersion.Different international standards are available todescribe the optical fiber characteristics: ITU G652for Singlemode fiber and IEC 60793-2-10 forMultimode fibers are worldwide references.

On a global network point of view, although the costof multimode fiber is more important than thesinglemode’s, the complete system is more economic.Indeed Multimode fibers are used with cheaptransmission components LED(1) or VCSEL(2) whilstSinglemode fiber operates with more expensiveLASER.

(1) LED: Light Emitting Diode(2) VCSEL: Vertical Cavity Surface Emitting Laser

125 μm125 μm

{ {

Nexans are able to preassemble optical fibers withplugs, we can provide this service in our factory or on site. A fiber optic connector is a non permanentjoin between two fibers.

In the optic connector systems gives a plurality toconnector, they are not compatible among onanother. It is recommendable to use ST connector orE2000 connector for reel and flexible cables withintegrated fiber optics.

A high quality connetor is required to achieve the bestpossible transfer of light signal between fibers.

An E2000 connector is a special connector with highlevel attenuation coefficient. This connector is suitablefor multimode fiber and singlemode fiber.Due to the code system, this connector is very userfriendly and can also be fit as a single connector orduplex connector The built-in filler cap protects the ferrule againstcontamination. The filler cap open/close during theconnector plug in/out.

E2000 Connector

Optical fiber connectors

This type of connector is suitable for both multimodefiber and singlemode fiber. The ST connector and thebajonet-holder is the most popular used connectorworldwide.

ST Connector (standard)

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Core diameter 9.0 ± 0,5 µm 50 ± 3 µm 62.5 ± 3 µm

Core non-circularity ≤ 5.0 %

Cladding diameter 125 ± 2 µm

Cladding non-circularity ≤ 2 %

Coating diameter 245 ± 10 µm

Numeral aperture 0.200 ± 0.015 0.275 ± 0.015

Attenuation coefficient at:

850 nm ≤ 2.8 dB/km ≤ 3.4 dB/km

1300 nm ≤ 1.0 dB/km ≤ 1.1 dB/km

1550 nm ≤ 0.6 dB/km

(>1000 m cable length)

Brandwidth at:

850 nm - ≥ 600MHz * km ≥ 200MHz * km

1300 nm - ≥ 1200MHz * km ≥ 600MHz * km

Dispersion at:

1310 nm < 3.5 ps/nm*km

1550 nm < 18 ps/nm*km

Index of reflaction (IOR) at:

850 nm 1.482 1.496

1300 nm 1.477 1.491

1310 nm 1.4677

1550 nm 1.4682

Strip force (peak) 1.3 ≤ Fpeak strip ≤ 8.9 N

Proof TEST 690 N/mm2

Test elongation for 1s 1.0 %C

opyr

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Geometrical characteristics

... E9/125 ... G50/125

Technical fibers properties

... G62.5/125

Fiber types

Optical characteristics

Mechanical characteristics

3.3 C

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Sealing Ends

GeneralitiesBesides cables, Nexans group manufactures sealing ends and plugs for high voltage cables up to 30 kV. We are able to offer preassemblies of outdoor and indoor sealing ends.We can provide this service in our factory or on site.

Indoor Sealing EndsUsed for high voltage cables from6 up to 30 kV for transformers,substations, terminal boxes and motorconnections boxes.

Outdoor Sealing EndsUsed for high voltage cables from6 up to 30 kV for connections tooverhead lines, in dirty environmentsand emergency power supplies.

High Voltage PlugsInner or outer cone plugs andthree-phases open pit plugs.

3.3 D

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Splicing

GeneralitiesFrom an economical point of view it only makessense to repair or splice handling cables having alarge conductor size. For implementation of spliceswell-founded knowledge of the fitter is needed.Furthermore for a bunched conductor splice avulcanizing machine for the vulcanisation ofelastomeric compounds is required.

The fundamental principle of splicing is to build anexact reproduction of the handling cable design(including the outer diameter) and the flexibility.

Pictured below, for a HV reeling cable, a shortintroduction shows the different phases of a repair.

First step is to strip-off the outer and inner sheaths.Further the bunched conductor has to be weldedstrand by strand, and layer by layer.

After applying and vulcanization of the inner sheaththe reinforcement will be wrapped.

Vulcanizing machine

By using different material tapes, we rebuild thetriple extrusion:• semi-conducting inner layer• insulation• semi conducting outer layer

Finally the outer sheath will be taped till the equaldiameter of the original cable.

3.3 E

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Mechanical tests for flexible handling cables:“Handling Application Center”

GeneralitiesIn Nexans factories, strict quality control is one of themost important tasks to ensure a long-life term of ourproducts.Due to the high mechanical, torsion and tensilestresses appeared in handling applications, Nexanscarry out extreme mechanical type tests before a newproduct range is introduced into the market. The testconditions are much more harder then the reality inthe application.

Climate-tests, continous-tests for artificial ageing,mechanical and chemical compound properties (e.g.tensile strength, elongation, density, tear resistanceand abrasion, oil, ozone, UV resistance) serve toincrease the operating period of our products. Allthese tests are the basis for Nexans to improve thehigh quality level and cable performance.

Torsional resistance test / Anti twisting test

The torsional resistance test is carried out to evaluatethe mechanical behaviour of cable with respect to,it’s twisting properties at simultaneus tensile load,different torsional angle and twisting speed.

Operating conditions:

• Cable outer diameter from 8 to 50 mm• Cable test length from 3 to 5 m• Pulling force: F max= 7000 N• Torsion torque up to 700 N.m• Checking of electrical continuity

The anti twisting test is carried out to evaluate theresistance of the cable regarding of twisting force.

Reeling test

The objective of the reversed bending test is thebehaviour to reeling stress on cables :- tensile load- torsion on pulley- friction on sheath

Operations conditions• cable outer diameter from 17 to 50 mm• pulling force 6 000 N max• deviation of 2.5 ° max• linear speed: 80, 110, 150 m/min• acceleration up to 0.5 m/s2

• checking of electrical continuity

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Roller Bending Test

The bending test is used to behaviour to rollerbending stress on cables with tensile load. Cablesconstruction and material choice.

Operations conditions• round cable with outer diameter up to 25 mm• flat cable with thickness up to 10 mm• pulling force up to 100 N• linear speed: 0.33 m/s• cable test length: 5 m• dielectric checking during the test

(cable under voltage)

Alternating/Reversed Bending Test

In line with the DIN VDE 0472-603, HD 21.2 S3, HD 22.2 S3. To show the operating conditions underenhanced bending stress. This test permits us todevelop better conductor design.

Operating conditions:

• cycle movement: max 180°• tensile load: max 3,000 N

(depending on cross-section)

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Stiffness Test

The objective of the siftness test is the studyconstruction of flexible cables and materials choice

Operations conditions• cable outer diameter from 17 to 70 mm

• bending angle � up to 90 °C

Drag Chain Test

This test facility permits the combination of smallbending radius, with high acceleration and highspeed movement.

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3.3 F

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Installation and Laying Instructions

Long-life terms of flexible reeling cables in cranes andother handling systems depend on cables installationand laying in a professional way. To ensure that, you have to respect the followingrules:

The most professional and safety way to avoid torsionstress is to lay the complete cable length from thesupply drum over support rollers on the ground withunfixed ends. If this is not possible, in case of lessspace, lay up the cable like in the below mentionedways.

WRONG RIGHT

Changes in directions must be avoided.

To traverse a Nexans flexible cablelength (left hand laid) on a cylindricalreel, you must start on the left side of thereel for winding up as shown on thepicture.

Feeding / Anchoring Systemsfor reeling cables

GeneralitiesTo ensure an optimum result regarding the service life of reeling cables, some important instructions must benoticed in the various methods of feeding/anchoring systems.

Center feedingIn many installations the anchoring device is located at thecenter of the guideway. Flexible reeling cables are normallyconnected over the entry bell through the underground centerpoint. To guaranty an effective strain-bearing, the flexiblehandling cable must be turned at least 2 1/2 times around thestress-bearing drum.

The advantage of the two-way center point anchoring is theshort cable length in comparison to an end anchoring device.Critical points in center feeding system are the dynamic loadpeaks due to the change of direction.

End anchoring deviceIn opposite to the center feeding system, the completeinstallation including e.g. guideway, device and powersupply is appropriate overground. To avoid dynamic stress due to tensile load in the cable.Nexans recommends to use:• stress bearing drums, • and / or• cables with integrated strength member

Anchoring vertical drum spreader cableIn the case of anchoring vertical spreader cable, the stressbearing drum is placed on the top of the spreader. Nexansrecommends in this application, stress bearing drums insteadof cable grips or other cable anchoring system. For a perfectoperation it is important to turn the cable at least 2 1/2 timesaround the stress bearing drum.

3.3 G

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3.3 H

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Repair and Emergency Service

Flexible cables used in cranes and other handlingsystems are exposed to extreme mechanicalconditions during their operations. Due to this, it isn´tpossible to prevent damages.

In order to avoid high cost during stand still of thecrane and high detention charges of the vessel, it isnecessary to carry out immediate, professional andreliable repairs in case of damage of the powercable.

There for, Nexans provides an extensive repair andemergency service including:

Repairs of• insulation • inner and outer sheath • splicing of cables without increasing diameter• splicing/ repair of optical fiber elements

Worldwide 24h emergency call:+49 (0)2166 27 2176

3.3 I

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Drum Dimensions

Export Drums (one-way)

E45 504 450 150 300 353 130 14 0.081

E60 664 610 300 330 383 175 25 0.163

E70 754 700 250 385 438 200 27 0.249

E75 804 750 350 385 444 300 33 0.287

E90 954 900 450 475 550 600 72 0.501

E95 A 1054 950 350 475 550 550 72 0.583

E105 A 1,104 1,050 500 500 583 600 75 0.711

E115 1,204 1,150 600 650 734 800 110 1.064

E120 1,254 1,200 600 670 754 950 120 1.186

E130 1,354 1,300 700 650 734 1,100 140 1.346

E153 1,584 1,530 800 650 754 1,700 180 1.892

E165 A 1,730 1,650 900 820 951 2,200 310 2.846

E165 B 1,730 1,650 750 1,000 1,147 2,100 370 3.431

E190 1,980 1,900 1,000 1,000 1,147 2,700 490 4.497

E210 2,180 2,100 1,100 1,000 1,187 4,500 700 5.510

E245 2,530 2,450 1,300 1,000 1,187 4,800 930 7.598

E260 2,680 2,600 1,600 1,000 1,187 6,700 1,100 8.526

Drum Type

Lagging-diameter

D1(mm)

Flange-diameter

D2(mm)

Barreldiameter

D3(mm)

Winding width

L1(mm)

Overallwidth

L2(mm)

Maximumcarryingcapacity

(kg)

Drumweight

(kg)

Drumvolume

(D1)2 x L2 (m3)

D2D1

L1

L2

D3

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KTG Plastic drums

050/7 500 150 456 404 100 4

070 710 355 510 400 250 11

080 800 400 510 400 350 16

090 900 450 680 560 400 23

050/7 1000 500 704 560 500 32

Drum Type

Flange-diameter

D1(mm)

Barrel-diameter

D2(mm)

Overallwidth

L1(mm)

Winding widthL2

(mm)

Maximumcarryingcapacity

(kg)

Drumweight

(kg)

KTG Standard wooden/ Steel-tyred wooden drums

071 710 355 520 400 250 25 28

081 800 400 520 400 400 31 35

091 900 450 690 560 750 47 51

101 1000 500 710 560 900 71 78

121 1250 630 890 670 1700 144 165

141 1400 710 890 670 2000 175 199

161 1600 800 1100 850 3000 280 309

181 1800 1000 1100 840 4000 380 413

201 2000 1250 1350 1045 5000 550 600

221 2240 1400 1450 1140 6000 710 753

250 2500 1400 1450 1140 7500 875 923

251 2500 1600 1450 1130 7500 900 925

281 2800 1800 1635 1280 10000 1175 1240

Drum Type

Flange-diameter

D1(mm)

Barrel-diameter

D2(mm)

Overallwidth

L1(mm)

Windingwidth

L2(mm)

Maximumcarryingcapacity

(kg)

Steel-tyredwooden drum

weight(kg)

Standardwooden drum

weight (kg)

D2D1

L2

L1

Drum size and drum type

121

approx. drum barrel Ø ≤ 40 x D approx. drum barrel Ø ≤ 25 x D approx. drum barrel Ø ≤ 15 x D

approx. drum barrel Ø ≤ 15 x D approx. drum barrel Ø ≤ 50 x D

141 161 181 201 221 250 251 281101091081071061051

cablediameter

mm

Drum capacity and cable lengths (only KTG drums for round cables)

cablediameter

mm

6 1130 1110 2024 2755 67 815 840 1480 2340 78 630 640 1064 1463 2730 89 460 470 890 1152 2202 2866 910 390 388 680 980 1768 2349 1011 320 315 564 760 1404 1910 1112 260 254 470 643 1206 1540 1213 220 238 385 542 1032 1339 2727 1314 190 190 360 454 880 1159 2265 2967 1415 170 180 300 430 749 1000 1990 2480 1516 150 140 239 358 632 860 1756 2205 1617 130 134 228 294 603 736 1545 1960 1718 110 102 218 280 505 705 1355 1737 1819 105 96 172 228 485 599 1184 1535 2722 1920 100 92 165 220 402 576 1139 1352 2435 2830 2021 80 90 159 210 387 485 990 1304 2172 2527 2122 65 122 167 315 468 856 1145 1930 2248 2223 62 117 160 304 389 827 999 1870 2172 2954 2324 60 113 156 294 377 709 967 1657 1927 2608 2425 58 110 150 285 365 688 839 1608 1867 2522 2526 56 80 116 226 299 668 814 1420 1650 2218 2627 78 113 220 290 567 700 1244 1450 2150 2860 2728 76 109 215 282 550 680 1210 1410 1880 2777 2829 73 106 209 226 462 663 1180 1370 1826 2450 2976 2930 70 103 165 220 450 564 1028 1200 1583 2383 2893 3031 76 157 214 438 550 1003 1166 1540 2089 2558 3132 74 153 209 428 537 866 1009 1500 2035 2978 2490 3233 72 150 204 352 450 846 985 1289 1984 2908 2428 3334 146 158 344 440 828 962 1257 1726 2605 2134 3435 108 154 336 430 710 824 1227 1685 2547 2083 2890 3536 105 150 329 422 692 806 1040 1646 2270 2035 2820 3637 103 148 265 348 678 788 1017 1418 223 1174 2760 3738 144 259 340 664 772 994 1386 1969 1735 2432 3839 110 254 334 560 653 972 1356 1930 1697 2380 3940 105 249 327 549 640 812 1328 1892 1486 2330 4041 102 244 264 539 627 795 1130 1664 1435 2036 4142 100 190 259 529 615 779 1107 1633 1406 1995 4243 187 254 437 510 763 1085 1603 1199 1956 4344 183 249 430 502 750 1065 1574 1175 1692 4445 180 245 422 492 610 890 1373 1153 1660 4546 177 240 415 484 600 874 1349 1130 1630 4647 174 187 408 475 589 858 1326 1110 1600 4748 130 184 330 386 578 842 1144 930 1366 4849 127 180 325 380 568 828 1125 914 1342 4950 125 178 319 373 558 878 1107 898 1320 5051 123 175 314 367 442 666 1089 883 1298 5152 120 172 310 360 435 655 1072 869 1276 5253 170 305 356 428 644 912 715 1072 5354 126 230 280 420 634 898 700 1056 5455 124 235 276 414 624 885 690 1040 5556 122 232 270 408 614 872 680 1022 5657 121 228 267 400 488 860 668 1006 5758 119 225 263 304 480 720 658 990 5859 117 222 260 300 473 710 649 815 5960 220 256 295 466 700 640 803 6061 216 252 290 460 690 610 790 6162 160 190 287 453 680 500 780 6263 158 187 282 448 670 494 770 6364 156 184 280 440 662 487 760 6465 154 182 275 335 640 480 748 6566 152 180 270 330 534 474 738 6667 150 178 266 326 528 468 588 6768 174 264 320 520 462 580 6869 172 186 317 515 456 574 6970 170 184 313 510 450 566 7071 168 182 310 502 342 558 7172 166 180 305 498 338 552 7273 164 177 300 190 334 545 7374 162 175 297 486 330 540 7475 160 173 294 480 326 532 7576 112 170 291 380 322 526 7677 110 168 287 375 318 520 7778 109 166 284 370 314 514 7879 108 164 281 367 310 508 7980 107 163 278 363 306 502 80

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This catalogue shows a general description of products which characteristics are not contratual in any case. Nexans reserves the right to change specifications without prior notice. All total or partial reproduction, donewithout Nexans’s authorization is unlawful.