Cable and Wire Application
Up to a maximum of 1000 N, the
operational tensile strain for all cables and wires is calculated as 15 N
of tensile load for each mm² of cross-sectional copper area. It is
irrelevant whether the cables or wires employed have a solid or flexible
conductor, or whether they are intended for fixed or flexible use.
During laying or installing of solid conductor core cables, such as NYY
for fixed installations, a factor of 50 N/mm² can be used. Example
calculation of maximum tensile load for an ÖLFLEX® CLASSIC 100 5 G 10
mm² (stranded flexible conductor) in operation: Total copper
cross-section: 5 cores x 10 mm² = 50 mm² Tensile load in Newton: 50 mm² x
15 N = 750 N Tensile load in kilograms: 750 N : 10 = 75 kg Calculation
of the resulting max. vertical cable suspension length: Cable weight,
version 5 G 10 mm²: 792 kg = 1000 m Cable length, version 5 G 10 mm²: 75
kg = ??? m Max. suspension length: (75 x 1000) : 792 = 94.7 m If a
cable features a separate support element, the maximum tensile load
specified on the relevant catalogue page applies. Support elements are
also required if a lamp, device or control console is to be affixed to a
free-hanging cable. In this case, it must be ensured that the combined
weights of the cable and the lamp or device do not exceed the maximum
recommended tensile strain! The mechanical tensile strain or force is
measured in Newton (N).
In most cases, customers simply ask
whether our cables and wires are free of silicone. What is actually
being queried is whether the cables are free of "PWIS" (paint-wetting
impairment substances), as silicone is not the only substance that can
impede paint-coating. The main PWIS are silicones, paraffin, oils and
greases. Cables and wires that contain such substances should not come
into contact with any parts to be painted. The storage of such products
in paint shops can also be problematic, even if there is no direct
contact with unpainted work pieces; this is because substances like
silicone in particular emit a lot of gas, which can settle on unpainted
parts or even contaminate entire priming paint baths. The undesired
consequence is that the paint fails to bond with the PWIS-contaminated
sections of the work piece, resulting in the dreaded circular "craters"
or "pinpricks" on the painted surface. Therefore, products containing
silicone are strictly prohibited in such applications. In most cases,
this restriction not only applies to cables and wires, but also to cable
glands, connectors, protective conduits and other accessories. Lapp
Kabel can confirm that especially the ÖLFLEX® and UNITRONIC® cables
which were tested in our own laboratory are free of PWIS. However, this
confirmation only applies to the materials used during product
manufacture. It does not cover the potential risk of subsequent
contamination with paint-impeding substances when the products are
handled during transport, storage and further processing. Additional
information, a list of all PWIS-inspected Lapp cable products and a
pre-defined confirmation letter can be found at the following link:
LABS-PWIS
It goes without saying that all
products in our ÖLFLEX® FD and UNITRONIC® FD ranges designated as
suitable for drag chain use have been thoroughly tested in our drag
chain centre during development. However, due to the wide range of cable
dimensions as well as the limited test chain capacity and the
relatively long test duration, it is not possible to perform separate
tests for each individual product article. In many cases, conducting
drag chain tests until such time that the cable is damaged or destroyed
is neither possible nor expedient, since a large number of cables would
require several million bending cycles and would thus spend many years
in the test center before they eventually fail. We subject our FD cables
to at least five million bending cycles under the strictest test
conditions. This means that cables listed in the catalogue and data
sheet with a flexible bending radius of, for example, 7.5 x cable
diameter have actually only been tested with a test chain radius of 5 x
cable diameter. Our extensive experience in this area has shown that
cables reaching five million cycles can easily accomplish significantly
higher cycle numbers without encountering problems. In some cases,
cables have been removed from the test chain without significant damage
after 11 million bending cycles, simply to make room for new test
cables. Depending on individual travel and speeds, our test chains
complete between 5000 and 20,000 cycles per day. Even if test logs
detailing the exact number of bending cycles exist for the inspected
cable dimension, these cannot be made available to customers or third
parties. If a customer contacts you to obtain confirmation on bending
cycle numbers for a specific product, you can request a customer letter
from the product manager responsible for ÖLFLEX® FD and UNITRONIC® FD
cables. This letter provides general information on the suitability of
all ÖLFLEX® FD and UNITRONIC® FD cables for at least five million
bending cycles as well as details on test conditions and parameters.
The bending radii of cables are
defined according to their installation type. In the case of fixed or
static installation, a smaller bending radius can be chosen than would
be required for flexible applications since the cable is only bent once
in the former case. In the cable industry, we generally distinguish
between three installation types: Fixed installation: The cables are
installed statically, in cable ducts for instance, where they are fixed
and immovable. In this case, there should be no movement or vibrations
during operation. The cables can therefore be bent more sharply and
usually subjected to somewhat higher or lower ambient temperatures than
in the case of flexible applications. Highly flexible application (e.g.
permanent bending in drag chain): The bending radii specified for
ÖLFLEX® and UNITRONIC® FD cables are always based on continuous flexible
use in the energy supply chain. Even though all drag chains vary and
have different parameters, it is possible to use the relevant bending
radius, acceleration and travel to make an educated assessment as to a
cable's suitability for the intended application. These specifications
provide a relatively clear impression of the exact application planned
by the customer. Flexible application (occasional flexing):
Unfortunately, no exact definitions exist for this installation type,
unlike for the fixed and highly flexible options. How often and how
sharply a cable is bent in the customer's application varies from case
to case. In order to reflect as many applications as possible, a
relatively high bending radius is specified for this installation type.
It is then largely irrelevant whether the cable is bent just once per
day or moved more often, e.g. in the case of a connecting cable for a
portable device that is unplugged/plugged in multiple times over the
course of a day. However, to avoid situations where cables that are not
designed for highly flexible drag chain use are subjected to permanent
bending outside the energy supply chain, the property "occasional
flexing" is used on many of our catalogue pages. This reduces the danger
of cables being used in continuous flexible applications for which they
are not intended.
Many operators and users are unaware
that special factors have to be considered when installing cables in
areas with raised ambient temperatures. This not only includes the
self-heating resulting from the current load, but also the
material-specific behavior of the core and sheath insulation in high
ambient temperatures. Non-electricians in particular are mostly not
familiar with the fact that the ampacity of a cable is reduced as the
temperature increases. For example, an ÖLFLEX® CLASSIC 100 3 G 1.5 mm²
can carry 18 A (100%) at an ambient temperature of +30°C. If the
temperature rises to +60°C, the ampacity is reduced to 9 A (50%) –
calculated on the basis of VDE 0298-4 / catalogue appendix table T12-1
or T12-2. Due to a complex chemical conversion process (formation of
orthosilicic acid), insulation materials like silicone, which are
regularly used in ambient temperatures up to +180°C, can harden and
embrittle prematurely as of +100°C in the absence of adequate
ventilation. If the max. permissible ampacity and associated
self-heating of the cable is also exceeded, the ageing process
accelerates accordingly. To counteract this effect, adequate volumes of
air or oxygen must be supplied to such cables and wires when operated in
high ambient temperatures. If closed ducts, tubes or pipes are packed
full of cables, this can often result in premature damage as a result of
disintegrated insulation and cable sheaths or even corrosion of the
copper conductor.
To be used underground without
additional protection, cables must meet the relevant standards (as in
the case of NYY cables) or at least fulfill specific constructional
design requirements for this installation. The outer jacket of cables
that is laid underground without extra protection must be reinforced and
of a sufficient strength and resistant to both mechanical impact and
hydrolysis. The minimum outer sheath thickness for direct burial depends
on the cable dimension, but should not be less than 1.8 mm. As far as
possible; cables that meet these requirements should still be embedded
in sand or covered by a protective covering to offer mechanical
protection from rubble and stones. Generally speaking, all cables are
suitable for direct burial, provided that they are enclosed in suitable
protective tubes and pipes and are adequately resistant to hydrolysis.
Even though some customers have
successfully employed standard ÖLFLEX® cables in drag chain
applications, despite their not being developed for permanent flexible
use in energy supply chains, we are unable to recommend such practices
as no corresponding experience or test data exists. In our test centers,
we only assess the suitability of ÖLFLEX® and UNITRONIC® cables with
the designation "FD", which were developed specifically for such highly
flexible applications. It is entirely at the customer's discretion to
employ cables for unintended purposes, e g. as drag chain cables.
In principle, most materials used in
the cable industry are resistant to salt or sea water. Even though some
plastics absorb more or less water than others, it is largely
irrelevant whether the cables are made of PVC, PUR, chloroprene rubber,
PTFE or even silicone. However, caution is advised in the case of some
halogen-free and highly flame-retardant cables made of special, highly
filled polymers. The flame-retarding additives can be strongly
hygroscopic and are thus easily saturated with water. Even if the cable
sheath compound displays no negative effects when exposed to sea water,
not every cable is suitable for maritime use. At high sea in particular,
cables are subjected to high levels of UV radiation and must be
sheathed accordingly. Another factor to be considered is whether the
cable only makes occasional contact with sea water or is used underwater
on a permanent basis. As the water depth increases, so does the
pressure on the cable. This is referred to as the water column. The
pressure for a 1 meter water column is 0.10 bar. Therefore, at a depth
of 100 meters, the pressure is already 11 bar (100 m x 0.1 bar = 10 bar +
1 bar air pressure at sea level). At this pressure, cables with many
air cavities in the core stranding can become compressed, or the water
may gradually diffuse through the cable jacket and insulation and reach
the conductor. In many cases, cables intended for such applications are
chosen indiscriminately due to a distinct lack of alternatives which
have been thoroughly tested and approved for underwater use – ÖLFLEX®
AQUA RN8 being one example. At relatively low water depths, this is
generally without problems. However, deep-sea applications definitely
necessitate special cables, which are designed to cope with the
conditions and water pressures prevalent at such depths. Within the Lapp
Group, LAPP Muller in France is one company that has specialized in the
development of cables for underwater use.
Vacuum technology is particularly
prevalent in the coating industry, where it is used for a large number
of products. Vacuums enable the application of very thin layers to the
relevant product, while preventing oxidation and contamination. Today,
products such as compact discs, eyeglass lenses, precision optical
components, mobile telephones, tools, semiconductors and even flat
screens are coated under vacuum conditions. In vacuum coating systems,
it is often necessary to pass cables through the vacuum, e.g. to contact
light sensors. In many cases, the evaporation produced in the negative
vacuum pressure results in increased ambient temperatures, which further
limits the potential cable selection. The size of the occurring
negative pressure is also relevant. Many insulation and outer jacket
materials already emit substances, such as plasticizers, at normal
atmospheric conditions and this process is both facilitated and
accelerated by the negative pressure in a vacuum. As a result, cables
can harden and brittle prematurely, while the emitted substances can
contaminate the entire vacuum. Due to their relatively high gas
emission, plastics such as PVC, chloroprene rubber and silicone in
particular are less suitable for vacuum applications. Although we have
limited experience and test data with regard to vacuum applications, we
would recommend the use of fluoropolymer cables made of PTFE, such as
the ÖLFLEX® HEAT 260, due to their wide temperature range and very low
gas emission. Plastics such as PEEK (polyetheretherketone), PI
(polyimide) and PA (polyamide) are also well suited to vacuum
applications, but these materials are very stiff and quite expensive,
making them unsuitable for use for standard cables.
- ÖLFLEX® Fortis
- ÖLFLEX® Tray II
- ÖLFLEX® Control TM
ÖLFLEX® Tray II
- Harmonized Cables
- ÖLFLEX® CLASSIC 100
- ÖLFLEX® CLASSIC 100 CY
- ÖLFLEX® PUR S
- ÖLFLEX® H07RN-F
- ÖLFLEX® HEAT 180 SiHF
- ÖLFLEX® HEAT 180 GLS
- ÖLFLEX® HEAT 180
- H05SS-F EWKF
- UNITRONIC® FD CY
- UNITRONIC® FD CP
- UNITRONIC® FD 890
- UNITRONIC® LIYY
- UNITRONIC® LIYCY
ÖLFLEX® 190
- ÖLFLEX® Fortis
- ÖLFLEX® Tray II
- ÖLFLEX® Control TM
- ÖLFLEX® TC 600
- ÖLFLEX® VFD Slim
- ÖLFLEX® VFD Symmetrical
- ÖLFLEX® VFD with Brake
- ÖLFLEX® SDP ÖLFLEX® Auto I
- ÖLFLEX® Auto X
- ÖLFLEX® Tray II
- ÖLFLEX® Control TM
Up to a maximum of 1000 N, the operational tensile strain for all cables
and wires is calculated as 15 N of tensile load for each mm² of
cross-sectional copper area. It is irrelevant whether the cables or
wires employed have a solid or flexible conductor, or whether they are
intended for fixed or flexible use. During laying or installing of solid conductor core cables, such as NYY for fixed installations, a factor of 50 N/mm² can be used.
Example calculation of maximum tensile load for an ÖLFLEX® CLASSIC 100 5 G 10 mm² (stranded flexible conductor) in operation:
Total copper cross-section: 5 cores x 10 mm² = 50 mm²
Tensile load in Newton: 50 mm² x 15 N = 750 N
Tensile load in kilograms: 750 N : 10 = 75 kg
Calculation of the resulting max. vertical cable suspension length:
Cable weight, version 5 G 10 mm²: 792 kg = 1000 m
Cable length, version 5 G 10 mm²: 75 kg = ??? m
Max. suspension length: (75 x 1000) : 792 = 94.7 m
If a cable features a separate support element, the maximum tensile load specified on the relevant catalogue page applies. Support elements are also required if a lamp, device or control console is to be affixed to a free-hanging cable. In this case, it must be ensured that the combined weights of the cable and the lamp or device do not exceed the maximum recommended tensile strain!
The mechanical tensile strain or force is measured in Newton (N).
Example calculation of maximum tensile load for an ÖLFLEX® CLASSIC 100 5 G 10 mm² (stranded flexible conductor) in operation:
Total copper cross-section: 5 cores x 10 mm² = 50 mm²
Tensile load in Newton: 50 mm² x 15 N = 750 N
Tensile load in kilograms: 750 N : 10 = 75 kg
Calculation of the resulting max. vertical cable suspension length:
Cable weight, version 5 G 10 mm²: 792 kg = 1000 m
Cable length, version 5 G 10 mm²: 75 kg = ??? m
Max. suspension length: (75 x 1000) : 792 = 94.7 m
If a cable features a separate support element, the maximum tensile load specified on the relevant catalogue page applies. Support elements are also required if a lamp, device or control console is to be affixed to a free-hanging cable. In this case, it must be ensured that the combined weights of the cable and the lamp or device do not exceed the maximum recommended tensile strain!
The mechanical tensile strain or force is measured in Newton (N).
No, extension or compensating can´t be used in combination with a Pt 100/Pt 1000 temperature probe.
There are two very different ways of performing temperature measurements:
Temperature measurement with a "Pt100/Pt1000 temperature probe or resistance thermometer":
The measurement of temperatures using resistance thermometers is based on the fact that all conductors and semiconductors alter their electrical resistance in line with the current temperature. The Pt100 and Pt1000 sensors are widely used temperature probes that measure changes in resistance of a platinum element at different temperatures. Highly accurate measurements between -200 ℃ and +850°C are often based on the change in electrical resistance of a platinum wire or layer. Unlike with sheathed thermocouples, no so-called extension or compensating cables are used to connect resistance thermometers. Ordinary copper conductors are used instead.
Temperature measurement with a "thermocouple or sheathed thermocouple":
A thermocouple comprises two electrical conductors made of different metals, which are connected at one end (measuring point). The two open ends form the comparison point. In the case of sheathed thermocouples, the two conductors are enclosed in a protective tube, usually made of steel. Thermocouples can measure somewhat higher temperatures (> 1600°C) than resistance thermometers and offer faster response times. Extension and compensating cables are effectively used to extend the thermocouple. The cables are usually connected to a display device, e.g. a galvanometer or an electronic measuring instrument, via a temperature comparison point.
There are two very different ways of performing temperature measurements:
Temperature measurement with a "Pt100/Pt1000 temperature probe or resistance thermometer":
The measurement of temperatures using resistance thermometers is based on the fact that all conductors and semiconductors alter their electrical resistance in line with the current temperature. The Pt100 and Pt1000 sensors are widely used temperature probes that measure changes in resistance of a platinum element at different temperatures. Highly accurate measurements between -200 ℃ and +850°C are often based on the change in electrical resistance of a platinum wire or layer. Unlike with sheathed thermocouples, no so-called extension or compensating cables are used to connect resistance thermometers. Ordinary copper conductors are used instead.
Temperature measurement with a "thermocouple or sheathed thermocouple":
A thermocouple comprises two electrical conductors made of different metals, which are connected at one end (measuring point). The two open ends form the comparison point. In the case of sheathed thermocouples, the two conductors are enclosed in a protective tube, usually made of steel. Thermocouples can measure somewhat higher temperatures (> 1600°C) than resistance thermometers and offer faster response times. Extension and compensating cables are effectively used to extend the thermocouple. The cables are usually connected to a display device, e.g. a galvanometer or an electronic measuring instrument, via a temperature comparison point.