4

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Tables/Explanations

Selection and Dimensioning Criteria, Hints on Application

Type/trademark 4/2Type, type designation 4/3

Approvals/standards 4/4Colour coding of fibre-optics 4/5

ApplicationInstallation of reeling cablesCentre feeding pointTransport of mining-type cables intounderground minesLaying instructions for OPTOFLEX(M)Stripping semiconductive layers fromPROTOLON trailing cables

Determination of the sag on mast mounting

4/64/84/94/10

4/11

4/124/13

Electrical parameters 4/14Thermal parameters 4/18

Mechanical parameters 4/20Chemical parameters 4/28

Design Features

Conductors 4/29Compounds 4/31

Shield 4/35Electrical field control with cables / hybrid sealing ends 4/36

Core arrangement 4/37

Support elements 4/39

Anti-torsion braid 4/39

Marking 4/40

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Trademarks usedfor flexible electric cablesfor mining applications

Flexible cables

Special compounds

Type/trademark

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CORDAFLEX®

OPTOFLEX®

PROTOLON®

PROTOMONT®

SUPROMONT®

LHD cable for scoop operations1 kV tough rubber-sheathed reeling cable(N)SHTÖU

Heavy tough rubber-sheathed flexiblecables (N)SHÖU, NSSHÖU,2YSLGCGÖU, NSSHCGEÖU

Medium-voltage mining-type cablesfor fixed installationNYHSSYCY, N3GHSSYCY

PROTODUR®

PROTOFIRM®

PROTOLON® Insulating compound EPR used inCORDAFLEX, PROTOLON, PROTOMONT.Rubber compound with excellent electricalproperties, resistant to heat and weather

Sheathing compound PCP used inCORDAFLEX, PROTOLON, PROTOMONT,compound with special resistance toabrasion and tearing, 5GM5 quality

Insulating compound PVCused in SUPROMONT cables

Rubber-sheathedflexible fibre-optic cable

Medium-voltage reeling cable, trailingcables, Medium-voltage flexible cables,R-(N)TSCGEWÖU F-(N)TSCGEWÖU,NTSCGEWÖU, NTMCGCWÖU

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Selection and Dimensioning Criteria

The type designates a group of flexible cables which have thesame design features and which are intended for a specific rangeof technical applications.The type designation is a letter combination in conformity withDIN VDE, which describes the type in coded form1).For details of the application, please refer to the applicationguidelines, table 4/3, page 4/6.

…K... Rubber cradle separator in the centre of thecable

KON Concentric protective conductor between theinner and outer sheath or concentric control/monitoring conductor

L... Lightweight cable design

LWL Fibre-optic (FO)

(M) Appendix to trademark, “M = Mining“

N Design according to the correspondingstandard

(N) Based on a standard

-O Additional information about the type - withoutgreen/yellow marked core

Ö1) Oil-resistant outer sheath (according toDIN VDE 0473, Part -2-1, Para. 10) (OE)

R- Definition of application: Reeling, as appendixto the type designation

(SB) Appendix to trademark:Trailing operation

..SH.. Heavy tough rubber-sheathed flexible min-ing-type cable (Rough handling)

..SHT... 1 kV reeling cable

..SL.. Control cable

ST Control cores within the cable

(ST) Appendix to trademark to denote watercompatibility (submersible pump units)

..T.. Support element

..TM.. Trailing cable for medium mechanical stresses

..TS.. Trailing cable

U Flame-retardant outer sheath (according toDIN VDE 0472, Part 804) “non-inflammable“

ÜL1) Monitoring conductor within the cable (UEL)

(V) Appendix to trademark for coal cutter cables(V = reinforced)

..W.. Weather resistant

Y PVC compound

(Z) Appendix to trademark for coal cutter cables(Z = tensile strength optimized)

2Y... Definition of the insulation material (2Y = PE)

/3 Protective-earth conductor uniformly distrib-uted in the three interstices

/3E Protective-earth conductor uniformly distrib-uted over the insulation of the outer conductor

..3G.. Definition of the insulating material (3G = EPR)

Type/type designation

NSHTÖU LHD cable for scoop operations:Tough rubber-sheathed 1kV flexible reelingcable CORDAFLEX (S)

R-(N)TSCGEWÖU Medium-voltage reeling cable, 6 to 30 kVPROTOLON (M)

F-(N)TSCGEWÖU Medium-voltage flexible cable, 6 to 30 kVPROTOLON (M)

NTSCGEWÖU Trailing cables PROTOLON, 3 to 35 kV

(N)SHÖU Heavy tough rubbers-sheathed flexible cable,1kV, for applications in open-cast mining,PROTOMONT (M)

NSSHÖU Heavy tough rubber-sheathed flexible cable,1kV, for applications in underground mining,PROTOMONT

NSSHCGEÖU Coal cutter cables for underground miningapplicationsPROTOMONT(Z) and PROTOMONT(V)

NTMTWÖU Heavy tough rubber-sheathed flexible cablefor lifts, user-operated winders in undergroundmining applications

NTMCGCWÖU Trailing cables of single-sheath design formedium mechanical stresses

NYHSSYCY PVC-insulated medium-voltage cables forfixed installation, SUPROMONT

N3GHSSYCY EPR-insulated medium-voltage cables forfixed installation, SUPROMONT

2YSLGCGÖU Data, signal and control cable for mininginstallations PROTOMONT MSR Mining

The type designation can be deciphered as follows:

..C.. Conducting metal casing over the strandedcores or between the inner and outer sheath(shield)

(C) Additional information about the shield for theconductor cross-sections, e.g. 12 x 1 (C)which means 1 mm² individually shielded or6 x (2 x 1)C which means 2 x 1 mm² twistedand shielded pairs

..CE.. Conducting metal casing over the insulation ofthe outer conductors

..CG.. Conducting non-metal casing over thestranded cores or between the inner andouter sheath (shield)

..CGE.. Conducting non-metal casing over the insula-tion of the outer conductors

F- Definition of the application: Fixed Installation,as supplement to the type designation

FM Telecommunication lines within the cable

G Rubber compound

HS High-voltage (H.V.)

-J Additional information about the type:with green/yellow marked core

1) The German characters “Ö” and “Ü” are transformedinto the international “OE” and “UE”, respectively

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Flexible electric cables for mining applications have to be able tocope with the expected operation and installation conditions.Details are given in the application and installation guidelines. In ad-dition, flexible electric cables for mining applications are describedwith regard to design and tests as laid down in national and inter-national standards (design regulations).

Application and installation guidelinesDIN VDE 0298, Part 3 Application of cables and flexible cords

in power installationsl General information on cables

DIN VDE 0298, Part 4 Application of cables and flexible cordsin power installationsl Recommended values for

current-carrying capacity of cablesDIN VDE 0101 Erection of power installations with rated

voltages above 1 kV

DIN VDE 0118 Specification for the erection of electricalinstallations in underground mines

DIN VDE 0168 Specification for the erection of electricalinstallations in open-cast mines, quarriesand similar works

IEC 621 Electrical installations for outdoor sitesunder heavy conditions (incl. open-castmines and quarries)

Design regulationsThe summary in table 4/1 (page 4/5) shows all the design regu-lations/standards, according to which the flexible electric cablesfor mining applications are designed and manufactured. Thefollowing distinctions are made between national and interna-tional regulations:National standardDIN VDE (DIN = German Standards Institute; VDE = Associa-tion of German Electrical Engineers)Germany is the only country which has issued special designregulations for flexible electric cables for mining applications.The 1 kV tough rubber-sheathed flexible reeling cablesCORDAFLEX NSHTÖU, the trailing cables PROTOLONNTS..WÖU and the rubber-sheathed flexible cables NSSHÖUare described and standardized in DIN VDE 0250. This set ofstandards has found recognition in Europe and in manycountries outside Europe and is accepted as or specified as“state of the art“.No such design regulations exist for the MSR Mining andOPTOPLEX cables. These are Pirelli special cables, the designof which is based on existing design regulations or general reg-ulations of DIN VDE.International standardFor use on an international level, some design features of flexi-ble electric cables for mining applications covered by DIN VDEare also listed or certified in line with MSHA.MSHA = Mine Safety and Health AdministrationThe MSHA listing was specially issued for the correspondingflexible electric cables by the “Deep Mine Safety“ office atHarrisburg, USA. The flame-retardant behaviour of the cableswas tested.WUG = Approval of the Polish Mining Inspectorate, necessaryfor use of cables in Polish mines.

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Approvals/standards

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Selection and Dimensioning Criteria

Flexible cables Type German standard DIN VDE International standards

Table 4/1

Appovals/standards

CORDAFLEX (S)

OPTOFLEX (M)

PROTOLON (M)

PROTOLON (SB)

PROTOLON (ST)

PROTOMONT

PROTOMONT MSR Mining

PROTOMONT (Z)

PROTOMONT (V)

PROTOMONT (V)

NSHTÖU DIN VDE 0250, Part 814 MSHA P 189-3

Based on DIN VDE 0888 Based on FDDI, ISO/and DIN VDE 0168 IEC 9314, MSHA SC 189-1

(N)TSCGEWÖU Based on DIN VDE 0250, Part 813 MSHA P 189-4

NTSCGEWÖU DIN VDE 0250, Part 813 MSHA P 189-4WUG-GE 83/98

NTSCGEWÖU DIN VDE 0250, Part 813 MSHA P 189-4

NSSHÖU DIN VDE 0250, Part 812 MSHA P 189-3WUG-GE-104/97

2YSLGCGÖU Based on DIN VDE 0282, Part 4 WUG-GE 1/99

NSSHCGEÖU DIN VDE 0250, Part 812 MSHA P 189-3WUG-GE-68/97

NSSHCGEÖU DIN VDE 0250, Part 812 MSHA P 189-3WUG-GE-69/97

NTSKCGECWÖU DIN VDE 0250, Part 813 MSHA P 189-4WUG-GE-73/98

No. of fibres Fibre colours Buffering tube colours

6 x 1E9/125 OG/ BN / WH / RD / BK / YE 6 x nf

6 x 2E9/125 OG-PK / BN-PK / WH-PK / RD-PK /BK-PK / YE-PK

6 x nf

6 x 3E9/125 BU / OG / GN YE / BK/ / nf / nf / nf / nf

6 x 1G50/125 OG / GN / BN / WH / RD / BK 6 x nf

6 x 2G50/125 OG-PK / GN-PK / BN-PK / WH-PK /RD-PK / BK-PK

6 x nf

6 x 3G50/125 BU / OG / GN GN / BK / nf / nf / nf / nf

6 x 1G62.5/125 BU / OG / BN / WH / RD / BK 6 x nf

6 x 2G62.5/125 BU-PK / OG-PK / BN-PK / WH-PK /RD-PK / BK-PK

6 x nf

6 x 3G62.5/125 BU / OG / GN BU / BK / nf / nf / nf / nf

Table 4/2

nf = natural colouringBold-faced colour codings areindices relative to the fibre type

Monomode design E9/125 µm

Graded-index fibre design G50/125 µm

Graded-index fibre design G62.5/125µm

Colour coding of fibre-optics

PROTOMONT (M) (N)SHÖU Based on DIN VDE 0250, Part 812 MSHA P 189-3

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Flexible cables/application

Flexible reeling cable suitable for very high mechanical stresses inconjunction with mono spiral reels and cylindrical reels

CORDAFLEX (S)

For optical transmission of signals and data for material handling equip-ment and alongside belt conveyors

OPTOFLEX (M)

PROTOLON (M) R-(N)TSCGEWÖU

Flexible reeling cable suitable for high mechanical stresses, e.g. for ex-cavators, hoisting equipment and large mobile equipment

PROTOLON (ST)

Flexible medium-voltage cable for trailing operation for power supply tolarge mobile equipment in open-cast mines, in particular where the outersheath is subjected to extreme abrasion and chaffing stresses

PROTOLON (M) F-(N)TSCGEWÖU

Flexible medium-voltage cable, e.g. for laying alongside belt conveyorsand on material handling equipment

PROTOLON single-core cables

Medium-voltage cable for flexible applications, e.g. for connection ofswitchgear cubicles and for connection of transformers

Data, signal and control cables for mining installations for applicationswith high mechanical stresses in open-cast mines, e.g. for laying along-side conveyor belts and on material handling equipment

PROTOMONT (M) MSR data, signal and control cables

Flexible rubber-sheathed cable for very high mechanical stresses, e.g. forpower supply of fixed installation equipment such as machines, motors,distribution boards and equipment in underground mines

PROTOLON (SB)

Flexible medium-voltage cable for continuous use in water, e.g.for power supply to dredgers or pumps

PROTOMONT

Coal cutter trailing cable for free trailing in underground mines for powersupply of coal cutters

PROTOMONT (V)

Coal cutter cable for use in the cable protection chain for power supplyto coal cutters in underground mines

PROTOMONT (Z)

SUPROMONT

Flexible medium-voltage cable for fixed installation in underground minesand tunnel construction applications

PROTOMONT mine hoist cables

Flexible special control and signalling cable for connection ofuser-operated hoists (user-operated winders) in underground mines forfree suspension lengths of up to 200 m

Medium-voltage reeling cable with overall concentric monitoring shieldaccording to DIN VDE 0118 for power supply of tunnel driving machines

PROTOMONT tunnel driving machine cables

Application

PROTOMONT (M)

Flexible rubber-sheathed cable for very high mechanical stresses, e.g.for laying alongside belt conveyors and on material handling equipmentin open-cast mines

l Normal applicationTable 4/3

Flexible electric cables for underground andopen-cast mining applications are to be se-lected in accordance with the application forwhich they are intended (cable guidance sys-tem) and in accordance with the expectedoperation and installation conditions.If necessary, the cables are to be protectedagainst mechanical, thermal or chemical influ-ences and also against the penetration ofmoisture from the ends of the cables.Flexible electric cables for mining applicationsmust not be installed in the ground. Ductsthrough fire barriers in the form of sand, etc,or temporary covering with soil, sand or simi-lar material, e.g. on construction sites and inopen-cast mines, do not count as being inthe ground.In general, fixing materials must not damagethe flexible electric cables.Flexible electric cables have to be relieved oftension when they are connected to mobileequipment and must be secured to preventthem from twisting, sharp bending and axialcompression. The sheaths of the flexible elec-tric cables must not be damaged at the en-tries or by the stress-relief devices.Table 4/3 shows the mechanical stressabilityand the normal applications of flexible electriccables for mining applications.

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Yes

Yesfor trailing operation

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Yes

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Yesfor chain operation

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Yesfor trailing operation

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Selection and Dimensioning Criteria

Mechanical stress Forced guidance Application

Medium High Veryhigh(extreme)

Outdoors Hazard-ousareas

Construc-tionsites

Indoors Mobileequip-ment &machinery

Open-cast

Under-ground

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The direction of lay employed in manufac-ture of power cables is always left-hand(S-type). It is therefore recommended thatthe start of the winding of reeling powercables on cylindrical reels should alwaysbe at the left side.This measure ensures a clean and correctwinding pattern, even when no guidancehelical slot has been provided on the reelbody.The direction of lay employed in manufac-ture of control cables is alwaysright-hand, for which reason such cablesshould be operated with the start of thewinding at the right side.

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Installation of reeling cables

Incorrect Correct

Supply drum Supply drum

Supply drum Supply drum

Incorrect Correct

Fig. 4/1

Fig. 4/2 Start of winding for power cables

To ensure proper and fault-free operationof flexible electric reeling cables for miningapplications such as PROTOLON andCORDAFLEX, it is necessary to observecertain rules for cable attachment (installa-tion on the operating drum).The cable can be directly wound from thesupply drum to the operating drum. Pullingoff the drum and laying stretched on theground or “dekinking“ prior to taking upthe cable on the operating drum shouldnot be carried out.

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In many installations, e.g. bunk-ering equipment, the powerinfeed point is located at thecentre of the guideway. Theflexible electric reeling cablessuch as CORDAFLEX andPROTOLON (M)-R are normallyconnected through underfloorinfeeds (Fig. 4/3).In order to achieve effectivestrain relief in conjunction withcable-wear minimizing deflec-tion from the infeed point, werecommend the use of un-derfloor infeeds (Fig. 4/4). It isimportant that the specifiedbending radius be maintainedand that the cable be fastenedat the compensation cylinder bymeans of a clip, which, how-ever, should be attached onlyafter the 2nd winding.

Min. permissible bending radius as a function of the cable diameter

Flexible cables CORDAFLEX PROTOLON

Rated voltage U0/U Up to 0.6/1 kV Above 0.6/1 kV

d in mm Up to 8 Above 8 to 12 Above 12 to 20 Above 20

Rmin 3 x d 4 x d 5 x d 5 x d 10 x d

Table 4/4

Fig. 4/3

1 Flexible electric reeling cable

2 Entry bell for infeed

3 Cable tray

4 Cable straight-through joint

5 Buried cable

6 Compensation cylinder

7 Cable clip (large area design)

d Max. cable diameter

Rmin Bending radius of entry bell andbending radius of compensationcylinder

Selection and Dimensioning Criteria

Centre feeding point

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Fig. 4/4

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In view of the tight and narrow conditions which exist in undergroundmines, transport of mining-type cables into such underground minesrequires special handling. In cases where, due to the large diameter,the cable cannot be transported on the supply drum to the vicinity ofthe longwall, transport must be effected using transport containers.For this purpose the cable is laid into the transport container in “8"shaped loops (Fig. 4/5).In the case of PROTOMONT (Z) and PROTOMONT (V) coal cutter ca-bles in particular, no torsional stress may be applied to the cable whenpulling it out, since thiswould have a negativeeffect on the operatingperformance and ser-vice life of the cable. Forthis reason the cablemust be pulled out be-ginning at the insertionend and care must betaken to ensure that noloops are formed, whichon further pulling of thecable could lead totwisting of the cable.In addition care must betaken to ensure that thebending radius ismaintained and that thepermissible tensileforces are not exceededon transportation to thelongwall. The bestmethod for stress-minimizing is to carrythe cable by hand, al-though this is the mostcumbersome method.

Fig. 4/5

Transport of mining-type cables into underground mines

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Selection and Dimensioning Criteria 4

11

Laying instructions for OPTOFLEX (M) cables

OPTOFLEX (M) fibre-optic cables are designed for the severeoperating conditions prevailing in mining applications.However, maintenance of the desired transmission characteristicsis also dependent on a number of factors, which must be takeninto account for laying and installation.

The permissible tensile load of2000 N may not be exceededduring laying. Special care mustbe taken in this regard, where thecable is supplied in long supplylengths and is pulled off axiallyfrom the supply drum. Thethereby occurring accelerationforces of the drum must under nocircumstances be transmittedthrough the cable.

Laying of the cable must be car-ried out in such a manner that theminimum bending radius of50 mm is maintained under all cir-cumstances. In particular, on en-try into equipment and switchgearcubicles care must be taken toensure that kinking of the cabledoes not occur.

Care must be taken to ensurethat, when the cable is fastenedby means of cable clips, cablebinding bands, etc, the permissi-ble transverse pressure forces arenot exceeded. In the course ofappropriate pinching stress testsa limit value of 300 N/cm was de-termined, up to which value no in-crease in attenuation wasdetected.

On laying OPTOFLEX cables,care must be taken to ensure thatimpermissible torsional stressesare not applied to the cables. Un-der no circumstances may thecable be drawn from the ring orthe drum “head over heels“, sinceotherwise a torsion through 360 °would occur for each turn of thecable.

Tensile load

Bending radius

Pinching stress

Torsional stress

PIRELLI

PIRELLI

Incorrect Correct

Fig. 4/6

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In the case of PROTOLON trailing cables, the semiconductive rub-ber layer over the insulation must be stripped carefully in order tomount the cable sealing end. To this end, the stripping point ismarked and a circular indentation is made on the cable by slightlypressing a pipe cutter (Fig. 4/7).Make a notch at the stripping point by means of a triangular-section file while bending the cable slightly. It is important herebythat the bright core insulation should not be damaged (Fig. 4/8).Carefully cut throughapprox. 2/3 of thesemiconductive rubberlayer using between 2 to4 longitudinal cuts. Warmthe core end slightly usinga propane gas flame andlift off the semiconductivelayer at the end of thecore using a wood rasp.Strip off the semiconduc-tor layer in strips and re-move it completely(Fig. 4/9).

RemarkProblems can arisewhen stripping off thesemiconductive layerdue to tearing out of partof the insulation layer. Ifthis happens, the strip-ping procedure must bebegun from the oppositeside. Use a smooth file,where necessary.

Stripping semiconductive layers from PROTOLON (M) cables

The distinguishing feature of these cables is the cold-strippablesemiconductive layer. In this case heating by means of a propanegas flame can be completely dispensed with. The work sequenceshould otherwise be carried out as described above.

Fig. 4/7 Marking the stripping point

Fig. 4/8 Notching the stripping point

Fig. 4/9 Removal of the semiconductivelayer

Stripping semiconductive layers from PROTOLON (SB) and PROTOLON (ST) cables

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Selection and Dimensioning Criteria 4

13

Both in open-cast mines and also in other industrial applications(e.g. construction sites) flexible cables must sometimes be sus-pended above guideways (Fig. 4/10).In such cases maintenance of the minimum permissible bendingradius at the cable suspension point and of the max. permissibletensile force for each type of cable design must be observed.As an aid to planning of cable installation, the following three dia-grams are provided, which depict the sag as a function of thespan.In the case of PROTOLON trailing cables for the main voltage lev-els of 3.6/6 kV; 6/10 kV and 8.7/15 kV, the sag should be takenfrom the diagram for the desired span. A max. permissible ten-sile load of 15 N/mm2 has been incorporated as a parameter inthe diagram.

Sag[m]

Span [m]Fig. 4/ 11 3.6/6 kV

Sag[m]

Span [m]Fig. 4/12 6/10 kV

Sag[m]

Span [m]Fig. 4/13 8.7/15 kV

Fig. 4/10

Determination of the sag on mast mounting

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Flexible cables Rated Max. permissible operating voltage Test voltage applied to the complete cable

voltage in in DC systems

U0/U

AC systems

U0/U

unearthed

UkV

single-phaseearthedUkV

Powercores

kV

Controlcores

kV

Pilotcores

kV

Tele-comm.coreskV

250/250 V 275/275 V 0.412 1.5

300/500 V 318/550 V 0.825 0.413 2

450/750 V 476/825 V 1.238 0.619 2.5

0.6/1 kV 0.7/1.2 kV 1.8 0.9 2.5 2

0.6/1 kV 0.7/1.2 kV 1.8 0.9 4 2 2 1

1.8/3 kV 2.1/3.6 kV 5.4 2.7 6 2 2 1

3.6/6 kV 4.2/7.2 kV 10.8 5.4 11 2 2 1

6/10 kV 6.9/12 kV 18 8 17 2 2 1

8.7/15 kV 10.4/18 kV 27 14 24 2 2 1

12/20 kV 13.9/24 kV 36 18 29 2 2 1

14/25 kV 17.3/30 kV 45 23 36 2 2 1

18/30 kV 20.8/36 kV 54 27 43 2 2 1

Table 4/5 20/35 kV 24.3/42 kV 63 32 50 2 2 1

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14

Electrical parameters

CORDAFLEX, PROTOMONT (M)

PROTOMONT MSR-Mining

PROTOLON (M)

PROTOLON (SB)

PROTOLON (ST)

PROTOLON 1-core

SUPROMONT

PROTOMONT tunnel driving

VoltagesFor the rated, operating and test voltages of cables, the defini-tions given in DIN VDE 0298, Part 3, apply. Some of these arementioned in table 4/5 below.

AC - alternating currentDC - direct current

Rated voltageThe rated voltage of an insulated electric cable is the voltagewhich is used as the basis for the design and the testing of thecable with regard to its electrical characteristics.The rated voltage is expressed by the two values of power fre-quency voltage U0/U in V.U0 rms value between one conductor and “earth“U rms value between two conductors of a multi-core cable

or of a system of single-core cablesIn a system with AC voltage, the rated voltage of a cable must beat least equal to the rated voltage of the system for which it isused. This requirement applies both to the value U0 and thevalue U.In a system with DC voltage, its rated voltage must not be morethan 1.5 times the value of the rated voltage of the cable.

Operating voltageThe operating voltage is the voltage applied between the con-ductors and earth of a power installation with respect to time andplace with trouble-free operation.

l Cables with a rated voltage U0/Uup to 0.6/1 kVThese cables are suitable for use in three-phase AC, sin-gle-phase AC and DC installations, the maximum continuouslypermissible operating voltage of which does not exceed the ratedvoltage of the cables by more than

l 10% for cables with a rated voltage U0/U up to and including450/750 V20% for cables with a rated voltage U0/U = 0.6/1 kV.

l Cables with a rated voltage U0/Ugreater than 0.6/1 kVThese cables are suitable for use in three-phase and sin-gle-phase AC installations, the maximum operating voltage ofwhich does not exceed the rated voltage of the cable by morethan 20%.

l Cables in DC installationsIf the cables are used in DC installations, the continuously per-missible DC operating voltage between the conductors must notexceed 1.5 times the value of the permissible AC operating volt-age. In single-phase earthed DC installations, this value shouldbe multiplied by a factor of 0.5.

Test voltageRegarding the test voltage of flexible cables, the values given inthe corresponding parts of DIN VDE 0250 apply. If the relevantshield is missing, as for example with CORDAFLEX andPROTOMONT cables,”core against core” is tested in appropriatecombinations. The values are to be regarded as AC test voltages(unless stated otherwise) for single-phase testing, i.e. the AC testvoltage is applied between the core and the correspondingshielding (e.g. semiconductive layer, earth conductor, shield).Telecommunication cores (pairs) and other shielded pairs (e.g.(2x1)C) are tested “core against core“ and “core against shield“whereby the test voltages are correspondingly different.With single-core cables without shielding, the correspondingopposite pole is a water bath.

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CORDAFLEX (S)

PROTOLON, SUPROMONT rubber up to 10 kV

PROTOMONT

Selection and Dimensioning Criteria

Current-carrying capacityIf, after all selection criteria have been taken into account, the type offlexible electric cable to be used for mining applications has been de-cided on, the necessary cross-section of the conductor can be de-termined either from the current to be transmitted or from the power.

Installation conditions (stretched laying, suspended freely in theair, reeled), variations in ambient temperature, grouping, type ofoperation (continuous duty, intermittent periodic duty) and theuse of multi-core cables are to be taken into account.Table 4/6 is valid for continuous duty at 30 °C ambient tempera-ture and three loaded cores, rubber-insulated or PVC-insulatedcables.

Rubber-insulated

Cross-section Stretched Suspended Reeled in

mm2layingA

freely in airA

1 layerA

2 layersA

3 layers1)

A4 layersA

5 layersA

6 layersA

7 layersA

Factor 1 1.05 0.8 0.61 0.49 0.42 0.38 0.27 0.22

1 18 19 14 11 9 8 7 5 4

1.5 23 24 18 14 11 10 9 6 5

2.5 30 32 24 18 15 13 11 8 7

4 41 43 33 25 20 17 16 11 9

6 53 56 42 32 26 22 20 14 12

10 74 78 59 45 36 31 28 20 16

16 99 104 79 60 49 42 38 27 22

25 131 138 105 80 64 55 50 35 29

35 162 170 130 99 79 68 62 44 36

50 202 212 162 123 99 85 78 55 44

70 250 263 200 153 123 105 95 68 55

95 301 316 241 184 147 126 114 81 66

120 352 370 282 215 172 148 134 95 77

150 404 424 323 246 198 170 154 109 89

185 461 484 369 281 226 194 175 124 101

240 540 567 432 329 265 227 205 146 119

300 620 651 496 378 304 260 236 167 136

16 105 84 64 51 44 40 28 23

25 139 111 85 68 58 53 38 31

35 172 138 105 84 72 65 46 38

50 216 172 131 105 90 82 58 47

70 265 212 162 130 111 101 72 58

95 319 255 195 156 134 121 86 70

120 371 297 226 182 156 141 100 82

150 428 342 261 210 180 163 116 94

185 488 390 298 239 205 185 132 107

240 574 459 350 281 241 218 155 126

300 660 528 403 323 277 251 178 145

PVC-insulated PE-insulated 1) The reduction factor is also valid for flatreeling cables (spirally)

25 96 2 x 2 x 1 12

35 119 5 x 2 x 1 8.5

50 144 10 x 2 x 1 6.5

70 184 20 x 2 x 1 5Table 4/6Current-carrying capacity of flexible electriccables for mining applications

95 223

120 259

PROTOMONT, PROTOLON, SUPROMONT rubber from 15 kV

Electrical parameters

SUPROMONT PVC MSR-Mining

Pire

lliB

UIS

2.3

·200

0

De-rating factorsThe de-rating factors take into account the installation and op-erating conditions, such as temperature, grouping, intermittentperiodic duty and the number of simultaneously loaded cores.They are to be used for determining the current-carrying capac-ity in accordance with table 4/6 (page 4/15).

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

1.18 1.14 1.10 1.05 1.00 0.95 0.89 0.84 0.77 0.71 0.63 0.55 0.45

1.18 1.14 1.10 1.05 1.00 0.95 0.89 0.84 0.77 0.71 0.63 0.55 0.45

1.18 1.14 1.10 1.05 1.00 0.95 0.89 0.84 0.77 0.71 0.63 0.55 0.45

1.18 1.14 1.10 1.05 1.00 0.95 0.89 0.84 0.77 0.71 0.63 0.55 0.45

1.22 1.17 1.12 1.06 1.00 0.94 0.87 0.79 0.71 0.61 0.50

Table 4/7

CORDAFLEX

PROTOMONT

SUPROMONT rubber

PROTOLON

SUPROMONT PVC

De-rating factors for groupingArrangement 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 20Bunched directly at thewall, the floor, in conduitor ducting, on or in thewall

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 wallor 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 orfloor, spaced with aclearance of 1 x cablediameter between adja-cent 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 clearanceof 1 x cable diameterbetween 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 4/8

= ===

= =

4

16

Electrical parameters

Pire

lliB

UIS

2.3

·200

0

4

17

De-rating factors for multi-core cables with conductor cross-sections up to 10 mm2

Number ofloadedcores

De-ratingfactors

5 0.75

7 0.65

12 0.53

18 0.44

24 0.40

30 0.37

36 0.36

42 0.35

61 0.30

Table 4/10

De-rating factors for intermittent periodic duty

Ambienttemperature 30 °C

Nominalcross-section

Duty factor ED %

mm2 60 40 25 15

Duty cycle 10 min 0.75 1.00 1.00 1.00 1.00

1 1.00 1.00 1.00 1.00

1.5 1.00 1.00 1.00 1.00

2.5 1.00 1.00 1.04 1.07

4 1.00 1.03 1.05 1.19

6 1.00 1.04 1.13 1.27

10 1.03 1.09 1.21 1.44

16 1.07 1.16 1.34 1.62

25 1.10 1.23 1.46 1.79

35 1.13 1.28 1.53 1.90

50 1.16 1.34 1.62 2.03

70 1.18 1.38 1.69 2.13

95 1.20 1.42 1.74 2.21

120 1.21 1.44 1.78 2.26

150 1.22 1.46 1.81 2.30

185 1.23 1.48 1.82 2.32

240 1.23 1.49 1.85 2.36

300 1.23 1.50 1.87 2.39

Table 4/9

De-ratingfactor

Number of simultaneously loaded cores

Permissible short-circuit current at max. permissible short-circuit temperatures of the conductor surface and for a fault duration tkr = 1 s

Cross-section mm2 1 1.5 2.5 4 6 10 16 25 35 50 70 95 120 150 185 240 300

Short-circuit current (kA)

0.122 0.183 0.305 0.488 0.732 1.22 1.952 3.05 4.27 6.10 8.54 11.59 14.64 18.30 22.57 29.28 36.60

0.143 0.215 0.358 0.572 0.858 1.43 2.29 3.58 5.01 7.15 10.01 13.6 17.16 21.45 26.46 34.32 42.9

0.109 0.164 0.273 0.436 0.654 1.109 1.744 2.73 3.82 5.45 7.63 10.36 13.08 16.35 20.17 26.16 32.7

Table 4/11

PROTOLON (M)

SUPROMONT PVC

Selection and Dimensioning Criteria

Electrical parameters

CORDAFLEX

PROTOMONT

PROTOLON (SB)

PROTOLON (ST)

SUPROMONT rubber

The short-circuit current-carrying capacity Ithzfor a short-circuit duration tk deviating from tkr = 1s, is: Ithz = Ithr ⋅ ttkr

k

Pire

lliB

UIS

2.3

·200

0

The different temperature limits of the individual flexible electriccables for mining applications are summarized in table 4/12.Under no circumstances may the values shown be exceededdue to interaction of internal Joule heat and the ambient tem-perature.If cables are exposed to radiation, e.g. sunlight, the temperatureof the outer sheath of the flexible electric cable can rise to a levelwhich is significantly higher than the ambient temperature. Thissituation must be compensated for by corresponding reductionof the current-carrying capacity.The temperatures on the surface of the cable are limits for theambient temperature.

All insulating and sheathing compounds of the flexible electric ca-bles become stiffer as the temperature drops. If the temperaturefalls below the specified limit, a point can be reached below whichthe compounds used become brittle.In addition to this, more force (sometimes considerably more) isneeded for bending a flexible electric cable due to the increase ofstiffness of the insulating and sheathing compounds at lowertemperatures. This can create problems in the use of the flexibleelectric cables (e.g. with the reel drive).

Temperature limits

Flexible cables Type Temperature limit during operation, storage, installation and transport (°C)

of the conductorduring operation

of the conductorduring short-circuit

on the surface of thecable,fixed installation

on the surface of thecable, fullyflexible installation

(N)TSCGEWÖU 90 250 – 40 to + 80 – 25 to + 60

NTSCGEWÖU 90 200 – 40 to + 80 – 20 to + 60

NTSCGEWÖU 90 200 – 40 to + 80 – 25 to + 60

NTMCGCWÖU 90 200 – 40 to + 80 – 25 to + 60

(N)SHÖU 90 250 – 40 to + 80 – 25 to + 60

NSSHÖU 90 200 – 40 to + 80 – 25 to + 60

– – – 40 to + 80 – 30 to + 60

2YSLGCGÖU 60 150 – 40 to + 60 – 25 to + 60

NSSHCGEÖU 90 200 – 40 to + 80 – 20 to + 60

NTMTWÖU 90 200 – 40 to + 80 – 25 to + 80

NYHSSYCY 70 150 – 40 to + 60 + 5 to + 60

N3GHSSYCY 90 250 – 40 to + 80 + 5 to + 80

NSHTÖU 90 200 – 40 to + 80 – 25 to + 60

Table 4/12

PROTOLON (M)

PROTOLON (SB)

PROTOLON (ST)

PROTOLON 1-core

PROTOMONT

OPTOFLEX

PROTOMONT MSR

Thermal parameters

4

18

PROTOMONT (Z) and (V)

PROTOLON mine hoist

SUPROMONT PVC

CORDAFLEX (S)

SUPROMONT rubber

PROTOMONT (M)

Pire

lliB

UIS

2.3

·200

0

The relationship between the bending stiffness of flexible electric cables formining applications and the temperature is shown in Fig. 4/14.The ratio of the bending force is given as F/F0, withF0 = F20 ºC.

The temperature limits on the surface of the cable are specified to ensureproblem-free and healthy operation during forced guidance of flexible electriccables for mining applications, especially while trailing over ground and dur-ing reeling operation.Higher temperatures influence the hardness, abrasion, resistance to tearpropagation and the transverse pressure stability of the insulating andsheathing compounds and can thus lead to a reduction of their service life.Flexible electric cables should be selected, installed and operated so that theexpected dissipation of Joule heat is not hindered in any way and thereforeno risk of fire is incurred.

4

19

Fig. 4/14

Selection and Dimensioning Criteria

Thermal parameters

dL = Overall cable diameterF = Force

RatioofbendingforceF/F0

Bending temperature (°C)

Pire

lliB

UIS

2.3

·200

0

Tensile loadsThe tensile loads of copper conductors in flexible electric cables for mining applications as specified byDIN VDE 0298, Part 3, should not exceed 15N/mm². However, higher values are allowed for some ca-bles as shown in table 4/13. These values refer to tensile load only.

These maximum permissible limits of tensile load are to be regarded as the sum of the static and dy-namic loads.

When the permissible tensile force is being calculated, shields, concentric conductors and split protec-tive-earth conductors as well as integrated control cores and monitoring cores of power cables mustnot be included in the calculation.

For higher tensile loads, appropriate steps have to be taken such as increasing the bending radii orusing special cable designs with stress relieving support elements. In some cases, a shorter service lifecan be expected. In this case, the cable manufacturer should be consulted.

The maximum permissible tensile load for installing fixed laying flexible cables is 50 N/mm² referredto the cross-section of the conductor.

Flexible cables Type DIN VDEN/mm2

PirelliN/mm2

R-(N)TSCGEWÖU 15 20

F-(N)TSCGEWÖU 15 15

NTSCGEWÖU 15 15

NTSCGEWÖU 15 15

NTMCGCWÖU 15 15

(N)SHÖU, NSSHÖU 15 15

– 2000 N for the cable

2YSLGCGÖU 15 15

NSSHCGEÖU 15 > 40 kN breaking load of thebraid

NSSHCGEÖU 15 15

NTMTWÖU 15 Max. 200 m free suspensionlength

NYHSSYCY,N3GHSSYCY

15 15

NSHTÖU 15 30

Table 4/13

PROTOLON (M)

PROTOLON (M)

PROTOLON (SB)

PROTOLON (ST)

PROTOLON 1-core

PROTOMONT

PROTOMONT (Z)

PROTOMONT MSR-Mining

PROTOMONT (V)

PROTOMONT mine hoist cable

SUPROMONT PVC and rubber

OPTOFLEX (M)

CORDAFLEX (S)

Maximum tensile loadsduring installation and op-eration of flexible electriccables for mining applica-tions

4

20

Mechanical parameters

Pire

lliB

UIS

2.3

·200

0

Torsional stressesAs a general rule the torsional stresses occurring during operation of flexible electric cables for min-ing applications are low. In certain applications, such as for example laying on large mobile equip-ment (cable booms), torsional stresses are unavoidable.The maximum permissible torsional stresses which occur during operation at entries, slewing gears,windmills, etc., are summarized in table 4/14.If the limits are exceeded, this can lead to a reduction in service life. In critical cases, the cablemanufacturer should be consulted.Torsional stresses created by the systems involved (e.g. due to misalignment of cable guidance sys-tems, oblique cable pay out) should be avoided and are not included here.

Selection and Dimensioning Criteria

Maximum torsionalstresses during operationof flexible electric cablesfor mining applications

Flexible cables Type α (°/m)

With semiconductiverubber layer

With copper coreshield

(N)TSCGEWÖU ± 100 –

NTSCGEWÖU ± 100 ± 25

NTSCGEWÖU ± 100 ± 25

NTMCGCWÖU – ± 25

(N)SHÖU, NSSHÖU ± 100 ± 25

± 100 –

2YSLGCGÖU ± 25 –

NSSHCGEÖU ± 10 –

NSSHCGEÖU ± 25 –

NTMTWÖU ± 50 –

NYHSSYCY,N3GHSSYCY

– ± 25

NSHTÖU ± 50 –

Table 4/14

PROTOLON (M)

PROTOLON (SB)

PROTOLON (ST)

PROTOLON 1-core

PROTOMONT

PROTOMONT (Z)

PROTOMONT MSR-Mining

PROTOMONT (V)

PROTOMONT mine hoist cable

SUPROMONT PVC and rubber

OPTOFLEX (M)

CORDAFLEX (S)

Mechanical parameters

4

21

Pire

lliB

UIS

2.3

·200

0

Minimum bending radiiIf the bending radii are smaller than those permitted, a reducedservice life can be expected depending on the stress conditions.The values given in table 4/15 should be taken as a basis.

The minimum bending radii are shown as the product of the over-all diameter of the cable and a factor, which is dependent on thediameter of the cable (e.g.: 3 x d).

The minimum permissible bending radii are valid within the speci-fied ambient temperature range (see thermal parameters, page4/18) subject to the provision that the permissible tensile loads arenot exceeded (see mechanical parameters, page 4/20).

In critical cases, the cable manufacturer should be consulted.

Flexible cables CORDAFLEX, PROTOMONT, MSR-Mining PROTOLONSUPROMONT

OPTOFLEX (M)minimum permis-sible bendingradius

Rated voltage U0 / U Up to 0.6/1 kV Above 0.6/1 kV

Maximum overall diameter of the cable ormaximum thickness of the flat cable (mm)

Up to 8 Above 8to 12

Above 12to 20

Above 20mm

Fixed installation 3 x d 3 x d 4 x d 4 x d 6 x d 50

Fully flexible operation 3 x d 4 x d 5 x d 5 x d 10 x d 50

For the entry, e.g. at acentre feed point

3 x d 4 x d 5 x d 5 x d 10 x d –

For forced guidance withreeling operation

5 x d 5 x d 5 x d 6 x d 12 x d –

For forced guidance withpower tracks

4 x d 4 x d 5 x d 5 x d 10 x d –

For forced guidance withsheaves

7.5 x d 7.5 x d 7.5 x d 7.5 x d 15 x d –

Drawing by meansof a roller stirrup

4 x d 4 x d 4 x d 4 x d 8 x d –

Table 4/15

Minimum permissible bending radii R

Mechanical parameters

4

22

PROTOMONT (V) at max. 5 N/mm2: 2.3 x d

d = Max. overall cable diameter

Flexible cables Type Material handlingequipment ontracks

Material handlingequipment on cat-erpillar-type runninggear

Loader operation Rewinding withdrum car

m/min m/min m/min m/min

(N)TSCGEWÖU 60 10 60 100

NTSCGEWÖU No application 10 No application 100

(N)SHÖU No application No application No application 100

NSHTÖU No application No application 180 100

NSSHCGEÖU Max. travel speed of the coal cutter 15 m/min

Table 4/16

Pire

lliB

UIS

2.3

·200

0

Travel speedsFlexible electric cables for mining applications are intended foruse on mobile equipment and are designed to cope with thetechnical requirements of the application.

In order to collect, pay out and move flexible electric cables, thereare different cable guidance systems such as reels, drum cars,power tracks, sheave guided cable storage systems as well assheaves and multi-roller guides.

Mining equipment and consequently also the cable guidancesystems are operated at different travel speeds and are thereforesubjected to stress which can vary from low to very high.

During operation of the mobile equipment, the flexible electriccables are subjected to stress such as tension, transversepressure, torsion and bending. Thus, the travel speed and theacceleration are to be considered as indirect criteria for thestresses applied to the flexible electric cables.

The maximum permissible travel speeds for the individual flexibleelectric cables are summarized in table 4/16.

If the travel-speed limits are exceeded, a reduction in service lifecannot be excluded. The cable manufacturer should be con-sulted.

Maximum travel speed for flexible electric cablesfor mining applications

PROTOLON (M)

PROTOLON (SB)

CORDAFLEX (S)

PROTOMONT (Z) and (V)

Selection and Dimensioning Criteria 4

23

Mechanical parameters

PROTOMONT (M)

Pire

lliB

UIS

2.3

·200

0

Additional testsAdequate testing of the good operatingcharacteristics needed for flexible electriccables for mining applications is not possi-ble with the tests specified by DIN VDE.Pirelli flexible electric cables for miningapplications are therefore subjected to ad-ditional and continuous mechanical testsat the manufacturer’s works (Kabel- undLeitungswerk at Neustadt near Coburg).These additional tests facilitatetime-compressed examination of the run-ning and service characteristics under dif-ferent kinds of mechanical stress, such asreversed bending strength, running oversheaves, flexing work and reeling operationin relation to tensile load and bending radii.The additional tests can be seenin tables 4/17 and 4/18.

Schematic representation of the additional tests

Reversed bending testBased on DIN VDE 0281, Part 2Testing of flexible electric cables for miningapplications under increased loads.

Cable diameter up to 50 mm,maximum tensile load 3000 N.Each movement from one extreme positionto another (180°) is counted as a cycle.

Roller bending test type ATesting the roller bending characteristics offlexible electric cables for mining applicationsbased on DIN VDE 0282, Part 2. Cable di-ameter up to 50 mm. Each movement be-tween the extreme positions is counted as acycle.

Roller bending test type B(Tender test)Practice-oriented testing of flexible electriccables for mining applications with referenceto running and service characteristics.Cable diameter from 20 up to 60 mm.Each movement between the extreme posi-tions is counted as a cycle.

Roller bending test type C(Flexing test)Testing the running characteristics (flexing) offlexible electric cables for mining applicationsfor evaluation of the mechanical service char-acteristics.Cable diameter from 60 up to 120 mm.Each movement between the extreme posi-tions is counted as a cycle.Moving distance 2 m.

Torsional stress testThe cable is alternately twisted left and rightthrough an angle α by application of the ten-sile force F.Torsional angle max. ± 360 °Torsional torque max. 200 NmTensile force max. 4000 N

Table 4/17

Mechanical parameters

4

24

Travel distance 25 m

Movingdistance

Pire

lliB

UIS

2.3

·200

0

4

25

Schematic representation of the additional tests

Selection and Dimensioning Criteria

Sheath shifting testFlexible electric cables for mining applicationsare generally stressed by dragging over theunderground in open-cast mining applica-tions.

The test determines the magnitude of theforce required to slide the sheath along thecore.

Transverse pressure testThis test demonstrates the behaviour ofelectric cables subjected to transversepressure, e.g. as a result of jamming in plantcomponents, being hit by falling stones(blocks of stone), etc.The test is passed when no electrical eventoccurs up to the specified value (earth-faultor short-circuit).

Welding beads testDuring constructional and maintenance workon large mobile equipment such as excava-tors, putting-down machines, etc., weldingbeads can fall on previously installed electriccables. This test verifies the resistance of theouter sheath to such stresses.

Brine resistance

Automatic material handling and reloading in-stallations (e.g. bunkering and blendingplants) are sprayed with brine to preventthem from freezing in order to guaranteesmooth trouble-free operation in winter. Thistest verifies the resistance of the outer sheathof mining-type cables to such stresses.

Water resistanceOn operation of flexible electric cables formining applications, the possibility that theywill be operated over considerable periods oftime in water cannot be excluded. Verificationof the resistance to water is carried out ac-cording to harmonization document HD22.16.

Table 4/18

Mechanical parameters

Pire

lliB

UIS

2.3

·200

0

4

26

Additional testsTable 4/19 depicts the test conditions forthe individual flexible electric cables formining applications. Under the severe con-ditions in mining operation, cables are sub-jected to considerable mechanicalstresses, which by far exceed those de-fined in the requirement profile accordingto the VDE standards. These additionaltests assure compliance with the specialrequirement profile for mining applicationsand document the suitability of our electriccables for all applications in open-cast andunderground mines in a convincing man-ner. The tensile loads and the bending andsheave radii are specified and the mini-mum number of cycles which must beachieved. The decisive criterion for passingthe mechanical test is the number of indi-vidual broken wires in the copper conduc-tor and/or non-continuity of the electricalconductor. In the roller bending tests typeA and B, the degree of deformation (cork-screwing effect) is tested additionally.

Mechanical parameters

Fig. 4/15 Reversed bending test

Additional mechanical tests

R-(N)TSCGEWÖU F-(N)TSCGEWÖU

Reversed bending test Tensile load 20 N/mm2 5 N/mm2

Bending diameter 10 x D 10 x D

Number of cycles 15 000 30 000

Roller bending test(test type A)D < 50 mm

Tensile load 15 N/mm2 2.5 N/mm2

Bending diameter 10 x D 10 x D

Number of cycles 50 000 30 000

Roller bending test(test type B)20 mm <D < 60 mm

Tensile load

Bending diameter

Number of cycles

Roller bending test(test type C)60 mm <D < 120 mm

Tensile load 20 N/mm2 20 N/mm2

Bending diameter 10 x D 10 x D

Number of cycles 30 000 15 000

Torsional stress test Tensile load 10 N/mm2 10 N/mm2

Torsional angle ± 100 °/m ± 100 °/m

Number of cycles 50 000 50 000

Sheath shifting test Pulling speed 20 mm/min 20 mm/min

Shifting force > 20 kN > 10 kN

Transverse pressure test Pressure force > 150 kN > 150 kN

Degree of deformation < 50 % < 50 %

Resistance towelding beads

Testing temperature 450 °C 450 °C

Criterion No damage No damage

Brine resistance Storage in 27 % brine solution 27 % brine solution

Temperature 60 °C 60 °C

Duration 14 days 14 days

Water compatibilityaccording to HD 22.16

Duration of storage inwater

100 days 100 days

Temperature 50 °C 50 °C

Table 4/19

PROTOLON (M) PROTOLON (M)

Pire

lliB

UIS

2.3

·200

0

BU

IS_0

23.ti

f

Pire

lliB

UIS

2.3

·200

0

4

27

Auswahl- und Auslegungskriterien

Fig. 4/16 Roller bending test (test type A)

NSHTÖU NTSCGEWÖU NTSCGEWÖU NSSHCGEÖU NSSHCGEÖU (N)SHÖU

20 N/mm2 5 N/mm2 300 N

10 x D 10 x D 250 mm

60 000 30 000 50 000

5 N/mm2 2.5 N/mm2 300 N

10 x D 10 x D 250 mm

200 000 30 000 75 000

5 N/mm2

320 mm

300 000

20 N/mm2 30 N/mm2 5 N/mm2 15 N/mm2

10 x D 10 x D 5 x D 10 x D

30 000 5 000 3 000 30 000

10 N/mm2 300 N

± 100 °/m ± 120 °/m

50 000 50 000

20 mm/min

> 10 kN

> 50 kN

< 50 %

450 °C 450 °C 450 °C 450 °C 450 °C 450 °C 450 °C

No damage No damage No damage No damage No damage No damage No damage

27 % brine solution 27 % brine solution

60 °C 60 °C

14 days 14 days

100 days 100 days 100 days

50 °C 50 °C 50 °C

PROTOLON (SB)CORDAFLEX (S) PROTOLON (ST) PROTOMONT (Z) PROTOMONT (V) PROTOMONT (M) OPTOFLEX (M)

Selection and Dimensioning Criteria

BU

IS_0

22.ti

f

Pire

lliB

UIS

2.3

·200

0

Resistance to chemicalsThe individual basic types of materials used for flexible electriccables for mining applications, such as PCP or EPR can be verydifferent from each other in their resistance to chemicals depend-ing on the required properties. Furthermore, the properties of thematerials can vary greatly from manufacturer to manufacturer.

Other factors which influence flexible electric cables for miningapplications, such as the concentration and degree of wetting ofthe chemicals, their temperature and the penetration time havedifferent effects on the resistance to chemicals and have to be in-vestigated from case to case.The chemical industry has drawn up a table which shows arough summary of the resistance to chemicals of various basictypes of material; the overview in table 4/20 is not to be deemeda substitute for a detailed examination.

Chemical parameters

4

28

Chemical Material

EPR PVC CSM PCP PU

Kerosine n n n n n

Lactic acid n n n n n

Linseed oil n n n n n

Lubricating oils n n n n n

Magnesium chloride solution n n n n n

Methanol n n n n n

Methyl chloride n n n n n

Methyl ethyl ketone n n n n n

Methyl alcohol n n n n n

Mineral oil n n n n n

Naphta n n n n n

Naphtalene n n n n n

Nitric acid, 10 % n n n n n

Perchlor ethylene n n n n n

Petroleum n n n n n

Phenol n n n n n

Phosphoric acid n n n n n

Picric acid n n n n n

Potassium chloride n n n n n

Pyridine n n n n n

Soap solution n n n n n

Sodium hydroxide, 25 % n n n n n

Sodium hypochloride n n n n n

Soya bean oil n n n n n

Sulphur n n n n n

Sulphurous acid n n n n n

Sulphuric acid <50 % n n n n n

Stearic acid n n n n n

Toluene n n n n n

Transformer oil n n n n n

Tributyl phosphate n n n n n

Trichlorethylene n n n n n

Triethanolamine n n n n n

Turpentine n n n n n

Vegetable oils and grease n n n n n

Water n n n n n

Xylene n n n n n

Zinc chloride solution n n n n n

Chemical Material

EPR PVC CSM PCP PU

Aceton n n n n n

Acetic acid, 30 % n n n n n

Aluminium chloride solution n n n n n

Aluminium sulfate solution n n n n n

Ammonia, analhydrous n n n n n

Ammonium chloride solution n n n n n

Ammonium hydroxide solution n n n n n

Ammonium sulfate solution n n n n n

Amyl acetate n n n n n

Aniline n n n n n

Asphalt n n n n n

Benzine n n n n n

Benzole n n n n n

Borax solution n n n n n

Boric acid solution n n n n n

Butyl acetate n n n n n

Calcium bisulphite solution n n n n n

Calcium chloride solution n n n n n

Calcium hydroxide solution n n n n n

Carbon disulphide n n n n n

Carbon tetrachloride n n n n n

Chlorobenzene n n n n n

Chloroacetic acid n n n n n

Chlorine gas, wet n n n n n

Chlorine gas, dry n n n n n

Chloroform n n n n n

Copper chloride solution n n n n n

Copper sulphate solution n n n n n

Cyclohexane n n n n n

Dibutylphtalate n n n n n

Diesel oils n n n n n

Ethyl acetate n n n n n

Ethyl alcohol n n n n n

Ethylene glycol n n n n n

Ethylen oxide n n n n n

Formaldehyde, 10 % n n n n n

Fuel oil n n n n n

Glycerine n n n n n

Hydaulic oils n n n n n

Hydrochloric acid, 20 % n n n n n

Hydrogen sulphide n n n n n

Table 4/20

n Resistant

n Limited resistance

n Non-resistantn Not tested

Pire

lliB

UIS

2.3

·200

0

The conductors used in flexible electric cables formining applications are summarized in table 4/23.The conductor forflexible electric cablesis designed accordingto DIN VDE 0295, asdescribed in the adja-cent table and espe-cially in table 4/22.The construction ofthe conductor itselfand its design fea-tures are open to vari-ation.

Flexible cable Type Conductor used

ae

Conductors for flexible electric cables are designedaccording to DIN VDE 0295. Nowadays, the con-ductors are made of copper (Cu). Aluminium andother materials have not found general acceptance.An overview of the common kinds of conductors isshown in table 4/21.

In many countries, the design of the conductors ac-cording to DIN VDE 0295 is accepted. The regula-tion corresponds to CENELEC HD 383.S2 andIEC 228.The conductor classes F, FS and FF are employedfor flexible electric cables for mining applications.The conductor classes are divided into nominalcross-sections. The individual conductor classes F,FS and FF and the nominal cross-sections are de-fined by specification of the maximum diameter ofthe single wires and by the maximum resistance ofthe conductor at 20 °C (see also table 4/22).These flexible conductors are made of bare ortinned annealed copper. The conductors are con-structed of many single wires, all of which musthave the same diameter.

PROTOLON (M)

PROTOLON (SB)

PROTOLON (ST)

PROTOMONT

PROTOLON (M)

PROTOMONT (M)

OPTOFLEX (M)

PROTOLON 1-core

R-(N)TSCGEWÖU Electrolytic copper not tinned, very finely stranded, Class “FS”

F-(N)TSCGEWÖU Electrolytic copper not tinned, finely stranded, Class “F”

NTSCGEWÖU Electrolytic copper tinned, finely stranded, Class “F”

NTSCGEWÖU Electrolytic copper tinned, finely stranded, Class “F”

NTMCGCWÖU Electrolytic copper tinned, finely stranded, Class “F”

Fibre-optics, no copper conductors

Table 4/23

Design Features 4

29

(N)SHÖU Electrolytic copper not tinned, finely stranded, Class “F”

NSSHÖU Electrolytic copper tinned, finely stranded, Class “F”

PROTOMONT (Z) and (V) NSSHCGEÖU Electrolytic copper tinned, finely stranded, Class “F”

PROTOLONminehoistcable NTMTWÖU Electrolytic copper tinned, finely stranded, Class “F”

SUPROMONT NYHSSYCY Electrolytic copper not tinned, finely stranded, Class “F”

CORDAFLEX (S) NSHTÖU Electrolytic copper tinned, very finely stranded, Class “FS”

Common types of conductors

Abbreviation Designation Specification/regulation

RE conductor Circular, solid DIN VDE 0295 Class 1

RM conductor Circular, stranded DIN VDE 0295 Class 2

RMV conductor Circular, stranded, compacted DIN VDE 0295 Class 2

F conductor Finely stranded DIN VDE 0295 Class 5

FS conductor Very finely stranded Pirelli specification

FF conductor Extremely finely stranded DIN VDE 0295 Class 6

Table 4/21

Nominalcross-section

Max. diameter of the singlewiresmm

Resistance of theconductor at 20 °CΩ/km

mm2

Fconductor(Class 5)

FSconductor(Pirelli)

FFconductor(Class 6)

Bare singlewires

Tinnedsingle wires

0.5 0.21 0.16 0.16 39 40.1

0.75 0.21 0.16 0.16 26 26.7

1 0.21 0.16 0.16 19.5 20

1.5 0.26 0.21 0.16 13.3 13.7

2.5 0.26 0.21 0.16 7.98 8.21

4 0.31 0.26 0.16 4.95 5.09

6 0.31 0.26 0.21 3.30 3.39

10 0.41 0.26 0.21 1.91 1.95

16 0.41 0.31 0.21 1.21 1.24

25 0.41 0.31 0.21 0.780 0.795

35 0.41 0.31 0.21 0.554 0.565

50 0.41 0.36 0.31 0.386 0.393

70 0.41 0.36 0.31 0.272 0.277

95 0.41 0.41 0.31 0.206 0.210

120 0.41 0.41 0.31 0.161 0.164

150 0.41 0.41 0.31 0.129 0.132

185 0.41 0.41 0.41 0.106 0.108

240 0.41 0.41 0.41 0.0801 0.0817

300 0.41 0.41 0.41 0.0641 0.0654

Table 4/22

Conductors

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Fig. 4/17 shows the design elements of a conductor for flexibleelectric cables for mining applications. Depending on thecross-section of the conductor, a flexible conductor consists ofone or more strands which are laid up around a central strand inseveral layers. In the diagram, six individual strands (secondlayer) are laid up around a central strand (first layer). A third layerwould then be made from 6 + 6 = 12 individual strands, ar-ranged around the second layer.

Fig. 4/17 Conductor design

The strands of the flexible conductors consist of many singlewires bunched together. The single wires can be laid up(bunched) to the right or left, thus determining the direction oflay. This is shown in Fig. 4/18 as the Z direction of lay (right) orthe S direction of lay (left).This also applies to a conductor which is laid up of singlestrands.

Fig. 4/18 Direction of lay

Conductordesign

Bunched Stranded

F conductor up to 10 mm2 from 16 mm2

FS conductor up to 2.5 mm2 from 4 mm2

FF conductor up to 2.5 mm2 from 4 mm2

Table 4/24

Types of conductors

Uniform-layconductor

Design Strand Layer

Centre Z

2nd layer Z Z

3rd layer Z Z

Alternating-layconductor

Design Strand Layer

Centre Z

2nd layer S Z

3rd layer Z S

Opposite-layconductor

Design Strand Layer

Centre S

2nd layer S Z

3rd layer S Z

Table 4/25

The conductor design and the nominal cross-section of the flexi-ble F, FS and FF conductors for flexible electric cables are usu-ally as shows in table 4/24.

Depending on the combination of the individual design elementsof a conductor, there are three basic types of conductors (seetable 4/25):The main advantage of the uniform-lay conductor is its highflexibility. As a result of its design, the conductor also has asmaller diameter than other types of conductors. Disadvantagesare its susceptibility to torsional loads (unstable) and its poor re-sistance to axial compression and sharp bending.The alternating-lay conductor is very stable with respect totorsional loads and is not sensitive to axial compression andsharp bending. A disadvantage is its relatively low flexibility. As aresult of its design the many crossing points of the single wirescause a lot of friction, which can lead to early breaking of theconductor, as compared to the other two types of conductors.The alternating-lay conductor has the largest diameter com-pared to the other two types of conductors.The design of the opposite-lay conductor best meets therequirements of flexible electric cables for mining applications. Itcombines the advantages of both the uniform-lay conductor andthe alternating-lay conductor without any of their disadvantages.This conductor is highly flexible, remains stable with respect totorsional loads and exhibits high axial compession and sharpbending strength. It has proven its excellent characteristics inmany years of practice. The opposite-lay conductor is used forCORDAFLEX, PROTOMONT, SUPROMONT and PROTOLON.

Conductors

4

30

Z directionS direction

Strand

Single wire (dED)CentreFirst layer

Secondlayer

S Length of layDL Diameter of conductordL Diameter of strandsdED Diameter of single wires

RightLeft

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Insulating and sheathing compoundsTable 4/26 gives an overview of all common compounds used for flexibleelectric cables.A basic distinction is made between thermoplastics and elastomers.Thermoplastics, generally known as plastic, are usually not cross-linked.Elastomers, generally known as rubber, are always cross-linked.

NotesY: Type designation for a thermoplastic materialG: Type designation for an elastomeric materialX: Type designation for a cross-linked thermoplastic material (the letter “X“

replaces the “Y“ in “2X“ for cross-linked polyethylene)0: Additional designation for foam materials

(the zero is placed in front of the relevant type designation, e.g. “02Y“ for foamed PE)

Design Features

Compounds

4

31

Serial Material Abbreviation Type designation

No. VDE Harm.

Thermoplastics

1 Polyvinyl chloride PVC Y V

2 Cross-linked polyvinyl chloride PVC X V4

3 Polyethylene PE 2Y E

4 Cross-linked polyethylene XLPE 2X X

5 Low-pressure polyethylene PE 2Yn E2

6 Foam polyethylene PE 02Y

7 Polystyrene PS 3Y Q3

8 Polyamide PA 4Y Q4

9 Polytetrafluor ethylene PTFE 5Y E4

10 Perfluor ethylene propylene PEP 6Y E5

11 Ethylene tetrafluor ethylene ETFE 7Y E6

12 Polyimide PI 8Y Q5

13 Polypropylene PP 9Y E7

14 Polyvinylidene fluoride PVDF 10Y Q6

15 Polyurethane TPU/PU 11Y Q

16 Polyterephthalic acid ester PETP 12Y Q2

17 Polyester thermoplastic 13Y

18 Perfluor ethylene oxyalkane PFA 14Y

19 Polychlorotrifluor ethylene ECTFE 15Y

Elastomers

20 Natural rubber NR G R

21 Synthetic rubber SR G R

22 Styrene-butadiene rubber SBR G R

23 Silicon rubber SIR 2G S

24 lsobuthylene-isoprene rubber IIR 3G B3

25 Ethylene-propylene rubber EPR/EPDM 3G B

26 Ethylene vinylacetate EVA 4G G

27 Chloroprene rubber CR/PCP 5G N

28 Chlorosulfonated polyethylene CSM 6G N4

29 (Hypalon)

30 Fluor elastomers 7G

31 Nitrile butadiene rubber NBR 8G N5

32 Chlorated polyethylene CM/CPE

Table 4/26

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*1 Normally

Type of cable Compounds to VDE Pirelli compounds Flexible cables

Insulation Intersti-ces

Innersheath

Outersheath

Insulation Intersti-ces

Innersheath

Outersheath

GI1 GM1b 5GM2 3GI3 5GM5 5GM5 5GM5

NR/SR*1 SR*1 CR*1 EPR PCP PCP PCP

3GI3 GM1b GM1b 5GM5

3GI3 GM1b 5GM5 EPR EPR EPR PCP

NR/SR*1 SR CR*1 3GI3 GM1b GM1b 5GM5

EPR EPR EPR PCP

3GI3 GM1b 5GM3 3GI3 GM1b 5GM5

EPR SR CR EPR Jute PCP

ETFE 5GM57YI1 PCP

2YI1 EM2 EM2PE CM CM

3GI3 5GM5 5GM5 5GM5

3GI3 GM1b 5GM3 EPR PCP PCP PCP

EPR*1 SR*1 CR*1 3GI3 GM1b GM1b 5GM3

EPR SR SR CM

YI4 Fillercom-pound

YM1 YM3 YI4 Fillercom-pound

YM1 YM3

PVC PVC PVC PVC PVC PVC

3GI3 Fillercom-pound

YM5 YM5 3GI3 Fillercom-pound

YM5 YM5

EPR PVC PVC EPR PVC PVC

Table 4/27

In table 4/27, the compounds normally used for flexible electriccables for mining applications are compared to the compoundsspecified for these cables by DIN VDE standards.In many cases, a compound of a higher quality is used than thatspecified by DIN VDE standards.Nowadays, the insulating and sheathing compounds of flexibleelectric cables are made almost exclusively of elastomeric materi-als. Thermoplastic materials have not been widely accepted.The great advantage of elastomers under heavy-duty operatingconditions lies in their very good mechanical properties, such asreversible (elastic) force-elongation characteristic and their highresistance to abrasion and tear propagation. In addition, thesecompounds are excellently suited for unrestricted use outdoors.They are characterized by their good resistance to the weather,temperature variations, chemicals and their flame retardance.

Furthermore, elastomeric materials can be adapted to matchtheir technical properties for particular applications.The elastomer EPR / EPDM with its high resistance to ozone andUV and its superior flexibility under cold conditions combined withexcellent electrical characteristics is worthy of special mention asan insulating material. CORDAFLEX, PROTOLON, PROTOMONTand SUPPROMONT employ this insulation material.The tough, flame-retardant and weather-resistant PCP is atried-and-tested sheathing compound for flexible electric cables.This sheathing compound is used in 5GM3 and 5GM5 quality forCORDAFLEX, PROTOLON, PROTOMONT and OPTOFLEX ca-bles.Exceptions are PROTOMONT MSR-Mining and SUPROMONTcables. Here, compounds such as PVC and PE are used, whichon account of their technical properties have been selected forthese flexible cables for particular applications.

Flexible reeling cablesNSHTÖU

Mine hoist cablesNTMTWÖU

Rubber-sheathed flexiblefibre-optic cables

Medium-voltage flexiblecablesNTS …WÖU

PROTOMONT MSR-Mining2YSLGCGÖU

PVC-insulatedmedium-voltage cablesNYHSSYCY

Rubber-insulatedmedium-voltage cablesN3GHSSYCY

CORDAFLEX(S)

PROTOMONT

PROTOMONT (Z) and (V)

OPTOFLEX (M)

PROTOMONT mine hoist

PROTOMONT MSR-Mining

PROTOLON (SB)

Outer sheath

Inner sheath

Insulation

Interstices

Conductor

Compounds

4

32

Rubber-sheathed flexiblecables NSSHÖU

PROTOLON (ST)

SUPROMONT PVC

SUPROMONT rubber

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Design Features 4

33

Compounds

The insulating and sheathingcompounds, which are em-ployed in flexible electric cablesfor mining applications con-structedaccording to the existingVDE standards listed below, arecompared with respect to theindividual requirements in table4/28. The characteristics arespecified in DIN VDE 0207 andallow a preliminary estimation ofthe properties of these com-pounds.Please refer to table 4/29 for thecompounds employed forPROTOLON (M) andPROTOMONT (M) cables.

Requirements Unit Compound

Sheath Sheath Sheath Insulation

PCP PCP SR EPR

5GM3 5GM5 GM1b 3GI3

Max. permissible operating temperature atthe conductor

°C 90 90 90 90

Tensile strength before ageing min. N/mm2 10.0 15.0 4.2 4.2

Elongation at break before ageing min. % 300 300 200 200

Ageing at °C 100±2 100±2 100±2 135±2

over d 7.0 7.0 7.0 7.0

Change in tensile strength after ageing max. % ±30 ±30 – ±30

Elongation at break after ageing min. % 250 250 200 –

Change in elongation at break after ageing max. % ±40 ±40 – ±30

Abrasion max. mm3 – 300 – –

Resistance to tear propagation min. N/mm – 30 – –

Thermal expansion at °C 100±2 100±2 – 200±3

over min. 15 15 15 15

with N/cm2 20 20 20 20

loaded max. % 175 175 175 175

relieved max. % 25 25 25 25

Resistance to oil at °C 100±2 100±2 – 127±1

over h 24 24 – 40

with bar – – – 5.5±0.2

Change in tensile strength max. N/mm2 ±40 ±40 – ±30

Change in elongation at break max. % ±40 ±40 – ±30

Surface resistance at 20 °C min. Ω 109 109 109 –

Volume resistance at 20 °C min. Ω ⋅ cm – – – 1012

Table 4/28

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In the case of flexible electric cables for mining applicationsPROTOLON (M) and PROTOMONT (M), whose design is basedon VDE, more stringent requirements apply to the insulating andsheathing materials. These values are listed in the following table.

Requirements Unit

R-(N)TSCGEWÖU F-(N)TSCGEWÖU (N)SHÖU

Insulation Innersheath

Outersheath

Insulation Sheath system Insulation Sheath system

EPR EPR PCP EPR SR/CM EPR SR/CMPermissible operating temperature ofthe conductor

max. °C 90 90 90 90 90 90 90

Tensile strength before ageing min. N/mm² 5 6 15 5 12 5 12

Elongation at break before ageing min. % 300 400 400 300 300 300 300

Ageing in heat chamberat °C 135±2 100±2 100±2 135±2 100±2 135±2 100±2

during d 7 7 7 7 7 7 7

Tensile strength after ageing min. N/mm² – 6 – – – – –

Change in tensile strength after ageing max. % ±30 – ±30 ±30 ±30 ±30 ±30Elongation at break after ageing min. % – 400 300 – 250 – 250

Change in elongation at break afterageing

max. % ±30 – ±30 ±30 ±40 ±30 ±30

Ageing in the pressure chamber

at °C 127±1 – – 127±1 – 127±1 –during d 40 – – 40 – 40 –

Pressure bar 5.5±2 – – 5.5±2 – 5.5±2 –

Tensile strength after ageing min. N/mm2 – – – – – – –

Change in tensile strength after ageing max. % ±30 – – ±30 – ±30 –Elongation at break after ageing min. % – – – – – – –

Change in elongation at break afterageing

max. % ±30 – – ±30 – ±30 –

Abrasion max. mm³ – – 300 – 350 – 350Resistance to tearing min. N/mm – – 40 – 40 – 40

Resistance to tear propagation min. N/mm – – 30 – 5 – 5

Shore hardness A min. – – 70 – 70 – 70

Thermal expansion

at °C 250±3 250±3 250±3 250±3 250±3 250±3 250±3during min 15 15 15 15 15 15 15

with N/cm² 20 20 20 20 20 20 20

loaded max % 100 100 100 100 100 100 100

relieved max. % 15 25 25 15 25 15 25Resistance to oil

at °C – – 100±2 – 100±2 – 100±2

during d – – 7 – 7 – 7

Change in tensile strength max. % – – ±40 – ±40 – ±40

Change in elongation at break max. % – – ±40 – ±40 – ±40Ozone resistance

at °C 40 – 40 40 40 40 40

during h 72 – 72 72 72 72 72

Ozone concentration pphm 200 – 200 200 200 200 200Relative humidity % 55 – 55 55 55 55 55

Flow velocity mm/s 0.5 – 0.5 0.5 0.5 0.5 0.5

Requirement Notearing

– Notearing

Notearing

Notearing

Notearing

Notearing

Surface resistance at 20 °C min. Ω – – 1010 – 109 – 109

Volume resistance at 20 °C min. Ω x cm 1016 – – 1016 – 1015 –

Volume resistance at 90 °C min. Ω x cm 1012 – – 1012 – 1011 –

Dielectric factor at 20 °C εR 2.8 – – 2.8 – 3.2 –

Loss factor at 20 °C tanδ 10-2 – – 10-2 – 10-2 –

Table 4/29

PROTOLON (M) PROTOLON (M) PROTOMONT (M)

4

34

Compounds

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4

35

The shield is a “barrier” against electromagnetic fields and pro-tects electric signals against external signals. The aim is toweaken or stop unwanted signals to such an extent that thewanted data signals can be transmitted without interference inthe endangered signalling conductor. There are three basic typesof shield structure:

l Overall shield over several coresl Shielded pairsl Individually shielded cores.An overall sheath over several cores, which as a rule is situatedbetween the inner and outer sheath of a cable, has not foundgeneral acceptance for reeling cables, because as a result of fre-quent bending the tensile and pressure forces within the cablelead to premature destruction of the shields and to failure of thecable.Shielded pairs and individually shielded cores, on the other hand,have proven themselves in practice and are successfully used inCORDAFLEX, PROTOLON and PROTOMONT cables.Braided screens are characterized by their transfer impedancewhich is defined as the ratio of the voltage drop along the shieldon the interfered side to the parasitic current on the other side.The transfer impedance RK (DIN 40500) is given for a specific fre-quency in mΩ/m and is usually plotted with respect to frequency.The lower the transfer impedance of a shield, the better thescreening effect. The transfer impedance of the braided screensusually used for flexible electric cables for mining applications isoptimized at 30 MHz and is therefore focussed ondata-processing quality.A typical transfer impedance characteristic is shown in the dia-gram in Fig. 4/19.

Design Features

Fig. 4/19

RK (m Ω/m)

Frequency (kHz)

Shield

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Electrical field control with cables

The cores of PROTOLON trailing cables of voltage level 6 kV andabove are always equipped with inner and outer semiconductivelayers made of semiconductive rubber.The inner and outer semiconductive layers are extruded with theinsulation in a single-pass operation. Secure bonding to the insu-lation is obtained as a result of this method of extrusion.The inner semiconductive layer prevents build-up of excessiveelectrical field strength at the individual wires of the flexible con-ductor and partial discharges between the conductor and the in-sulation.The outer semiconductive layer serves as a core shield and per-forms the following tasks:

l Protection against electric shockl Avoidance of partial discharges in the conductor assemblyl Generation of the radial electrical field in the insulationl Discharge of current in the event of a fault.The core shield is thus an integral component of the protec-tive-earth conductor.The resistance between the protective-earth conductor and anypoint on the outer semiconductive layer must not exceed 500 Ω.The protective-earth conductor, which touches the core shield, iscovered with semiconductive rubber and ensures longitudinalconductivity of the system. Fig. 4/20 shows the cross-section ofa PROTOLON trailing cable with inner and outer semiconductivelayers.In addition to the electrical requirements, the core shield in flexibleelectric cables for mining applications must also be able to copewith the high (sometimes very high) mechanical stresses.Metal shields are more liable to become defective when used inflexible electric cables for mining applications and are inferior toshields made of semiconductive rubber material.

Fig. 4/20

2nd + 3rd sheath

Power conductor

1st sheath

Protective-earth conductorwith semiconductive rubbercovering

Semiconductive rubbercovering as a core shield

Inner limitation of the electricfield, semiconductive rubbercovering

Insulation

Electrical field control in hybrid sealing ends

In order to control the electrical field in medium-voltage cablessuch as PROTOLON trailing cables, use of an innersemiconductive layer is required, which is applied as a smoothinglayer directly on the metallic conductor, the insulation coveringand the outer semiconductive layer, which is in contact with theprotective-earth conductor. In cable systems the sealing ends areassigned the task of containing the electrical field. Our hybridsealing ends, which are specially designed for the operational re-quirements of flexible electric cables for mining applications, op-erate on the principle of resistive electrical field control, whichachieves potential reduction as a result of the ohmic and capaci-tive characteristics and thus reduces the electrical field strengthto an acceptable level over the length of the serving.

Conductor

Inner semiconductive layer

Insulation covering

Outer semiconductive layer

Shield

Cable sheath

Field control sleeve

4

36

Fig. 4/21

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The basic criteria of the core arrangementfor flexible electric cables for miningapplications are summarized in the adja-cent table.In round flexible electric cables, the individ-ual cores are arranged by laying them up.Up to four cores are laid up without a cen-tral element. Five cores and above are laidup around a centre, which can also consistof three-core stranded elements.A stretched core in the centre of the flexiblecable (as the actual centre or placed in thecentre) is not permitted according to theDIN VDE standards. A stretched core at thecentre of the flexible cable would quickly re-sult in premature failure of the conductordue to breakage, especially in flexible elec-tric cables for mining applications.A maximum of three core layers is best forthe conductor assembly. Investigationshave shown that, if there are more thanthree layers, the internal stability of the flexi-ble cable and in consequence the servicelife is reduced as a result of increasing sec-ondary and relative forces between thecores.The length of lay S is a design feature usedfor laying up the conductor assembly (seetable 4/30) and influences the bending flexi-bility and the bending stability. The length oflay is an important factor for the service lifeof flexible electric cables for mining applica-tions.

Round flexible cables

Laying up of two to four cores without acentre

Laying up of five or more cores with centreSpecial design: the centre comprises threecores

Maximum three-layer design(standard up to 44 cores)

A stretched core in the centre of a flexiblecable is not permitted

The length of lay S is the length, meas-ured in the direction of the lay, over whicha core circumscribes 360° around the lay-ing axis.It is given as a multiple of the diameter Dover the conductor assembly, e.g.S = 8 x D.

Table 4/30

Design Features 4

37

Core arrangement

Centre

Centre

Cores

Stretched core

Cores

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Table 4/31 shows the normal lengths of lay in flexible electric cables for mining applications.

Type of cable Length of lay for flexible electric cablesfor mining applications

Flexible cables

5 x D

7 x D

Power cableControl cable

15 x D25 x D

10 x D

10 x D

Especially laid-up around a GFK support element

12 x D

12 x D

10 x D

Laid-up pairsLaid-up cores

≥ 25 x D≥ 15 x D

Table 4/31

Flexible reeling cablesNSHTÖU

Rubber-sheathed flexible cables(N)SHÖU and NSSHÖU

Flexible cablesfor trailing operationNTSCGEWÖU

Trailing cables for dredgerNTSCGEWÖU

Rubber-sheathed flexiblefibre-optic cables

Medium-voltage flexible cablesF-(N)TSCGEWÖU

Medium-voltage flexible cablesNYHSSYCY, N3GHSSYCY

CORDAFLEX (S)

PROTOMONT (M)

PROTOLON (SB)

PROTOLON (ST)

SUPROMONT

OPTOFLEX (M)

R-(N)TSCGEWÖU PROTOLON (M)-R

PROTOLON (M)-F

PROTOLON mine hoist c.Mine hoist cablesNTMTWÖU

PROTOMONT MSR-MiningData, signal and control cables formining installations2YSLGCGÖU

Core arrangement

4

38

Length of lay S

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Support elementsFlexible electric cables for mining applications should not bestressed above the limits set out in table 4/13 (page 4/20)for the permissible tensile forces. If higher tensile forces are to beexpected, support elements have to be provided as part of thestructure of the cable. There are several possibilities for integra-tion of support elements in cables.Two variants are normally used:

l A support element located in the centre of the cableor

l A braid between the inner and outer sheathThe force/elongation diagram in Fig. 4/22 shows the characteris-tic of these cables with different arrangements of support ele-ments as compared to a cable without a support element.After a compacting phase, in which the individual cable elementsare initially pulled together, until the copper conductor begins tobear the tensile force, the cable without a support element re-mains linear in the first section of the curve (curve C). In the nextphase elongation increases considerably on a slight increase offorce.Cables with a braid as a support element between the inner andouter sheath behave in the first section of the curve (curve B) in asimilar manner to cables without a support element. The braidbecomes effective as a support element and bears the appliedforce only after the force and the consequent elongation have in-creased over a certain period of time. The tensile force which isborne increases with less elongation than that of the cable with-out a support element. The braid as a support element can pre-vent the cable, e.g. from tearing.Cables with a central support element behave differently providedthat the support element was correctly dimensioned. The sup-port element bears the tensile forces from the very beginning andthus relieves the copper conductor (curve A).The force/elongation characteristics of the support elements andof the copper conductors are decisive for correct design of thesupport element and dimensioning of the flexible cables. The ac-tual design should be worked out in close co-operation with thecable manufacturer.

Anti-torsion braidFlexible electric cables for mining applications are often fitted withan anti-torsion braid between the inner and outer sheath in orderto minimize twisting under torsional loads.This applies to CORDAFLEX (S), PROTOLON (M)-R.The effect of an anti-torsion braid on the angle of torsion α withincreasing torsional moment for comparable cables with andwithout an anti-torsion braid is shown in Fig. 4/23.The flexible cable with anti-torsion braid tends to twist less thanthe flexible cable without a braid for the same torsional moment.

Fig. 4/22

Abb. 4/23

Design Features 4

39

Support elements ⋅ Anti-torsion braid

Tensile force F

Compacting phaseElongation ε

Central supportelement

Braid

Without supportelement

Torsional moment

Angle of torsion α

Without braid

With braid

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Pirelli flexible electric cables for mining applica-tions are marked on the outer sheath as shownin table 4/32.In addition, some flexible cables contain com-pany identification threads and/or VDE identifi-cation threads..

Flexible cables Type Marking on outer sheath Companyidentificationthread

VDEidentificationthread

CORDAFLEX (S)NSHTÖU-J/-O (number of cores) x (cross-section)

in the coreassembly

in the coreassembly

(Year of manufacture) OPTOFLEX (M) 6 x (number of fibres) x(core diameter) / 125 Micron

No No

PROTOLON (M) R- or F-(N)TSCGEWÖU (number of cores) x(cross-section) (rated voltage) (year of manufacture)

No No

<VDE> PROTOLON (SB) (number of cores) x (cross-section)(rated voltage) (year of manufacture) (serial number)

No No

<VDE> PROTOLON (ST) NTS.. (number of cores) x (cross-section) (rated voltage) (year of manufacture) (serial number)

No No

<VDE> PROTOMONT or PROTOMONT (Z) orPROTOMONT (V) NSSH.. or NTMTWÖU or NTS...(number of cores) x (cross-section) (year of manufacture)

No No

PROTOMONT (M) (N)SHÖU (number of cores) x(cross-section) (voltage) (year of manufacture)

No No

<VDE> SUPROMONT N .. HSSYCY(cross-section) (year of manufacture)

No No

PROTOMONT MSR-Mining 2YSLGCGÖU No No

Table 4/32

CORDAFLEX(S)

OPTOFLEX (M)

PROTOLON (M)

PROTOLON (SB)

PROTOLON (ST)

PROTOMONT

PROTOMONT (M)

SUPROMONT

NSHTÖU

R-(N)TSCGEWÖUF-(N)TSCGEWÖU

NTSCGEWÖU

(N)SHÖU

Marking

4

40

NTSCGEWÖU

N.. HSSYCY

PROTOMONT MSR-Mining 2YSLGCGÖU

Design Features

NSSH ...ÖUNTMTWÖUNTSCGECWÖU

Pire

lliB

UIS

2.3

·200

0

4

41

4

41

Catalog index

4

42

Pire

lliB

UIS

2.3

·200

0

Catalog title Designation Order No.

SIENOPYR® Power Cables SK 3.30 E50001-K8133-A101-A1-7600

Installation Cables, Power Cables SK 3.40 E50001-K8134-A101-A2-7600

Cables for Industrial Applications

Flexible Electric Cables for Cranes and Material Handling Equipment BU IS 2.1 E50001-K8112-A101-A2-7600

Flexible Electric Cables for Mining Applications BU IS 2.3 E50001-K8113-A101-A1-7600

Special Purpose Cables for Industrial Applications SK 4.20 E50001-K8142-A101-A1-7600

Application and Export Back Office Berlin Cable Repair Department

BU IS ATAustraße 99D-96465 Neustadt near CoburgGermanyTel: (+49) 9568 93 2376Fax: (+49) 9568 93 2058

BU IS VAGartenfelder Straße 28D-13599 BerlinGermanyTel: (+49) 30 386 30126Fax: (+49) 30 386 30140

BU IS ATAustraße 99D-96465 Neustadt near CoburgGermanyTel: (+49) 9568 93 2587Fax: (+49) 9568 93 2016

E Mail Cranecables@pks.nettec.de

Your partners and support for special cables

Order No.: E50001-K8113-A101-A1-7600Printed in GermanyKGK 0800 3.0 144 En 101623 6101/D6089

Kabel und Systeme GmbH und Co.KGAnwendungstechnik und ExportAustraße 99D-96465 Neustadt bei Coburg

Order No.: E50001-K8113-A101-A1-7600