Crane cables

Approvals / Standards

Flexible electric cables for cranes and material handling equipment have to be able to cope with the expected
operation and installation conditions. Details are given in the application and installation guidelines. In addition,
flexible electric cables for cranes and material handling equipment are described with regard to designs and test
as laid down in national and international standards (design regulations).

Application and installation guidelines

DIN VDE 0298, Part 3 Application of cables and flexible cords in power installations
- General information on cables
DIN VDE 0298, Part 4 Application of cables and flexible cords in power installations
- Recommended values for current-carrying capacity of cables
DIN VDE 0100, Part 726 Erection of power installations with rated voltages up to 1000 V
- Cranes
DIN VDE 0101 Erection of power installations with rated voltages above 1 kV
DIN VDE 0118 Specification for the erection of electrical installations in underground mines
DIN VDE 0168 Specification for the erection of electrical installations in open-cast mines, quarries
and similar works
EN 81, Part 1 Safety regulations for the construction and installation of passenger lifts, goods lifts
and service lifts

Design regulations

The summary in the following table shows all the design regulations/standards, according to which the flexible
electric cables for cranes and material handling equipment are designed and manufactured. The following
distinctions are made between national and international regulations:
National standard
DIN VDE (DIN = German Standards Institute; VDE = Association of German Electrical Engineers)
Germany is the only country which has issued special design regulations for flexible electric cables for cranes and
material handling equipment. The tough rubber-sheathed flexible reeling cables CORDAFLEX and
TROMMELFLEX NSHTÖU, the MV reeling cables PROTOLON and TENAX NTS..WÖU and the flat rubber-sheathed
flexible cables PLANOFLEX NGFLGÖU are described and standardized in DIN VDE 0250. This set of standards has
found recognition in Europe and in many countries outside Europe and is accepted as or specified as „state of the
art“.
The new generation of reeling cables (described in this catalog) generally conforms to these standards, however,
they deviate in a number of points, where it is necessary to achieve an enhanced feature profile. Efforts are being
made to have these modifications incorporated in the relevant standards.
No such design regulations exist for RONDOFLEX, SPREADERFLEX, OPTOFLEX, FESTOONFLEX, TROMMELFLEX
PUR. These are Prysmian special cables, the design of which is based on existing design regulations or general
regulations of DIN VDE.

122
 International standard
International standards have been taken into account for all our cables where this was possible.
For use on an international level, some design features of flexible electric cables for cranes and material handling
equipment covered by DIN VDE are also listed or certified in line with UL or MSHA.
UL = Underwriters Laboratories Inc.
UL is an approval and standardization institute in the USA. The UL standard is requested in North America and
also to some extent in the Far East.
MSHA = Mine Safety and Health Administration
The MSHA listing was specially issued for the corresponding electric cables by the „Deep Mine Safety“ office at
Harrisburg, USA. The flame-retardant behaviour of the cables was tested.

Flexible cables Type German stand. DIN VDE International stand.

CORDAFLEX (SMK) (N)SHTÖU Based on DIN VDE 0250-814; VDE Reg. Nr. Gost-R
7519
EASYFLEX (N)7YRDGÖU -
TROMMELFLEX PUR-HF D12Y11YU11Y -
TROMMELFLEX KSM-S (N)SHTÖU Based on DIN VDE 0250-814
TROMMELFLEX (K) NSHTÖU DIN VDE 0250-814
CORDAFLEX (SMK)-V (N)SHTÖU Based on DIN VDE 0250-814 Gost-R
SPREADER REEL PUR-HF D12YST11YU11Y -
SPREADERFLEX 3GSLTÖ Based on DIN VDE 0250 Gost-R
RONDOFLEX (N)GRDGÖU Based on DIN VDE 0250-814; VDE Reg. Nr. Gost-R
7841
RONDOFLEX(C)-FC (N)GRDGCGÖU Based on DIN VDE 0250-814; VDE Reg. Nr. Gost-R
7841
RONDOFLEX(CHAIN) (N)GRDGÖU Based on DIN VDE 0250-814 Gost-R
FESTOONFLEX PUR-HF D12Y11Y -
FESTOONFLEX C-PUR-HF D12YC11Y -
PLANOFLEX NGFLGÖU DIN VDE 0250-809 UL File R 113313, Gost-R
M(StD)HÖU M(StD)HÖU Based on DIN VDE 0250-809 UL Style 4540
OPTOFLEX Based on DIN VDE 0888 and DIN VDE 0168 Based on FDDI, ISO/IEC 9314 (Part3)
PROTOLON (SMK) (N)TSCGEWÖU Based on DIN VDE 0250-813 Gost-R
PROTOLON (SMK) LWL (N)TSKCGEWÖU Based on DIN VDE 0250-813 Gost-R
TENAX TTS/LWL (N)TSCGEWÖU Based on DIN VDE 0250-813
PROTOLON (FL)/LWL (N)TSFLCGEWÖU Based on DIN VDE 0250-813

123
Crane cables

Installation of reeling cables

To ensure proper and trouble-free opera-

Incorrect Correct
tion of flexible electric reeling cables for
cranes and material handling equipment
such as PROTOLON, TENAX, CORDAFLEX
and TROMMELFLEX, it is necessary to
observe certain rules for cable attachment
(installation on the operating drum).
The cable can be directly wound from
Supply drum Supply drum
the supply drum to the operating drum.
Pulling off the drum and laying stretched
on the ground or „dekinking“ prior to
taking up the cable on the operating drum
should not be carried out.

Supply drum Supply drum

Fig. 4/1
The direction of lay employed in
manufacture of power cables is always Incorrect Correct
left-hand (S-type). It is therefore
recommended that the start of the
winding of reeling power cables on
cylindrical reels should always be at the
left side.
This measure ensures a clean and correct
winding pattern, even when no guidance
helical slot has been provided on the reel
body.
The direction of lay employed in
manufacture of control cables is always
right-hand, for this reason such cables
should be operated with the start of the
winding at the right side.

Never: draw the cable over the flange

„head over heels“, because this would Incorrect Correct
cause 360° torsion with each loop.

Special installation instructions for other applications (e.g. festoon cables, spreader cable for basket operation)
are available upon request.

124
Centre feeding point

In many installations, e.g. bunke-

ring equipment, the power infeed
point is located at the centre of the
guideway. The flexible electric reeling
cables such as PROTOLON, TENAX,
CORDAFLEX and TROMMELFLEX are
normally connected through underf-
loor infeeds (see picture).
In order to achieve effective strain
relief in conjunction with cable-
wear minimizing deflection from
the infeed point, we recommend
the use of underfloor infeeds (see
figure below). It is important that the
specified bending radius is maintai-
ned and that the cable is fastened at
the compensation cylinder by means
of a clip, which, however, should be
attached only after the 2nd winding.

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 Fig. 4/4
and bending radius of
compensation cylinder

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

Flexible cables CORDAFLEX, TROMMELFLEX PROTOLON, TENAX
Rated voltage Uo/U Up to 0.6/1kV Above 0.6/1kV
d in mm Up to 8 Above 8 to 12 Above 12 to 20 Above 20
Rmin 3xd 4xd 5xd 5xd 10 x d

125
Crane cables

Electrical parameters

Voltages
For the rated, operating and test voltages of cables, the definitions given in DIN VDE 0298, Part 3, apply. Some of
these are mentioned in the table below.
AC = alternating current
DC = direct current

Rated voltage
The rated voltage of an insulated electric cable is the voltage which is used as the basis for the design and the
testing of the cable with regard to its electrical characteristics.
The rated voltage is expressed by the two values of power frequency voltage Uo/U in V.
Uo = 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 cables
In a system with AC voltage, the rated voltage of a cable must be at least equal to the rated voltage of the sys-
tem for which it is used. This requirement applies both to the value Uo and the value U.
In a system with DC voltage, its rated voltage must not be more than 1.5 times the value of the rated voltage of
the cable.

Operating voltage
The operating voltage is the voltage applied between the conductors and earth of a power installation with res-
pect to time and place with trouble-free operation.
• Cables with a rated voltage Uo/U up to 0.6/1 kV
These cables are suitable for use in three-phase AC, single-phase AC and DC installations, the maximum
continuously permissible operating voltage of which does not exceed the rated voltage of the cables by
more than
10% for cables with a rated voltage Uo/U up to and including 450/750 V
20% for cables with a rated voltage Uo/U = 0.6/1 kV
• Cables with a rated voltage Uo/U greater than 0.6/1 kV
These cables are suitable for use in three-phase and single-phase AC installations, the maximum
operating voltage of which does not exceed the rated voltage of the cable by more than 20%
• Cables in DC installations
If the cables are used in DC installations, the continuously permissible DC operating voltage between the
conductors must not exceed 1.5 times the value of the permissible AC operating voltage. In single-phase
earthed DC installations this value should be multiplied by a factor of 0.5.

126
 Test voltage
Regarding the test voltage of flexible cables, the values given in the corresponding parts of DIN VDE 0250 apply.
If the relevant shield is missing, as for example with CORDAFLEX and PLANOFLEX cables, „core against core“ is
tested in appropriate combinations. The values have to be considered as AC test voltages (unless stated
otherwise) for single-phase testing, i.e. the AC test voltage is applied between the core and the corresponding
shielding (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 correspon-
dingly different. With single-core cables without shielding, the corresponding opposite pole is a water bath.

Flexible cables Rated voltage Max. permissible operating voltage Test voltage applied to the complete cable
in AC systems in DC systems
unearthed single-phase Power Control Pilot cores Twisted
earthed cores cores pairs
U₀/U U₀/U U U
kV kV kV kV kV kV
CORDAFLEX 0.6/1 kV 0.7/1.2 kV 1.8 0.9 3.5 3.5
EASYFLEX 0.6/1 kV 0.7/1.2 kV 1.8 0.9 3.5 3.5
TROMMELFLEX 0.6/1 kV 0.7/1.2 kV 1.8 0.9 4 2
SPREADER REEL 0.6/1 kV 0.7/1.2 kV 1.8 0.9 4 2
SPREADERFLEX 0.6/1 kV 0.7/1.2 kV 1.8 0.9 3.5 3.5
RONDOFLEX 0.6/1 kV 0.7/1.2 kV 1.8 0.9 3.5 2.5
FESTOONFLEX 0.6/1 kV 0.7/1.2 kV 1.8 0.9 4 2
PLANOFLEX 300/500 V 0.7/1.2 kV 1.8 0.9 2.5 2
M(StD)HÖU 0.6/1 kV 0.7/1.2 kV 1.8 0.9 2.5 2
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
PROTOLON 8.7/15 kV 10.4/18 kV 27 14 24 2 2 1
TENAX 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
20/35 kV 24.3/42 kV 63 32 50 2 2 1

127
Crane cables

Electrical parameters

Current-carrying capacity
If, after all selection criteria have been taken into account, the type of flexible electric cable to be used for cranes
and material handling equipment has been decided on, the necessary 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 the air, reeled), variations in ambient temperature,
grouping, type of operation (continuous duty, intermittent periodic duty) and the use of multi-core cables shall be
taken into account.
The table below is valid for continuous duty at 30°C ambient temperature and three loaded cores, rubber-insula-
ted.

Rubber-insulated
LV and MV reeling cables up to 10kV

1)

1) The reduction factor is also valid for flat reeling cables (spirally)

128
Rubber-insulated
MV reeling cables above 10 kV

1)

1) The reduction factor is also valid for flat reeling cables (spirally)

129
Crane cables

Electrical parameters

De-rating factors
The de-rating factors take into account the installation and operating conditions, such as temperature, grouping,
intermittent periodic duty and the number of simultaneously loaded cores. They shall be used for determining
the current-carrying capacity in accordance with the tables on page 128/129.

De-rating factors for varying ambient temperatures

De-rating factors for grouping

Arrangement Number of multi-core cables or number of single or three-phase circuits made up of single-core
cables (2 or 3 loaded conductors)
1 2 3 4 5 6 7 8 9 10 12 14 16 18 20
Bunched directly at the
wall, on the floor, in
conduit or ducts, on or in 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
the wall

Single layer on the wall or

floor, touching
1.0 0.85 0.79 0.75 0.73 0.72 0.72 0.71 0.70 0.70 0.70 0.70 0.70 0.70 0.70

Single layer on the wall or

floor, spaced with a =
clearance of 1 x cable = = = 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
diameter between adjacent
cables

0.95 0.81 0.72 0.68 0.66 0.64 0.63 0.62 0.61 0.61 0.61 0.61 0.61 0.61 0.61
Single layer under ceiling,
touching

Single layer under ceiling,

spaced with a clearance of 1 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
x cable diameter between = =
adjacent cables

130
De-rating factors for intermittent periodic duty

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

De-rating
factor

Number of simultaneously loaded cores

131
Crane cables

Electrical parameters

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) 0.143 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

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

Electromagnetic compatibility
Electromagnetic compatibility is the capability of an electrical or electronic device to function correctly in its
electromagnetic environment and not to cause interference to the environment to an impermissible degree.
This matter is of immediate concern for all those engaged in planning and manufacturing electrical equipment
and installations. On the one hand, the EMC legislation introduced in Germany from 1.1.1996, and, on the other
hand, the high processing speed and transmission rates of modern electronics necessitate increased attention
beeing paid to the question of the influence of transmitted and received interference. Non-observance of the
currently valid EMC standards can lead to imposition of fines.

Standards
Standards, which directly address the question of cable construction or cable characteristics, do not exist.
Whether a cable causes interference or not, is solely dependent on the manner in which it is used. From the point
of view of the user, those standards, which specify limit values for permissible levels of interference, are relevant.
These refer to equipment, plants or other electrical installations and thus refer indirectly to the cables. Those
responsible for erection or manufacture thereof must confirm or prove that their equipment meets the EMC
requirements.
The currently valid standards and regulations, which are important for use of insulated cables, are listed in the
tables on page 128/129.

132
Criteria for EMC cable selection
Selection of the most suitable cable application/connection at site from the point of view of EMC can be carried
out employing the criteria listed below:
• Use of a cable shield with low transfer impedance
• Symmetrical design and operation of the cable
• Choice of suitable materials by reason of the higher voltage stress of the insulation by reflections at frequen-
cies above 100 MHz; low loss figure
• Large clearance between the interference source and the interference sink (power cables layed spatially sepa-
rated from the data cables)
• Earthing at both ends and coaxial connection of the shield
• Use of filters
• Laying on earthed surfaces
The design of a cable is of decisive importance for the evaluation of EMC. The most commonly employed const-
ructional designs of power and control cables regarding their EMC characteristics are listed in the figure on page
135.

Selection of EMC cables for applications on cranes and material handling equipment
Power cables
In recent years, a new generation of high-speed switching transistors (IGBT) has been employed for converters for
variable speed motors. Use of such converters results in high rates of voltage rise and high-frequency harmonics.
For this reason consequent interference must be taken into account. In order to counteract this interference,
special measures are required for the power cables. We recommend the use of RONDOFLEX (C) shielded EMC
cables. As a result of an optimized design regarding shield, materials and geometry, this cable type fulfills all the
requirements with respect to mechanical characteristics for flexible cables for festoon system and cable tender
operation and is also distinguished by superior shield characteristics. Consequently interference emission is redu-
ced to an acceptable degree or even completely suppressed.
Moreover, the RONDOFLEX (C) cable design helps manufacturers and operators of electrical installations to
maintain the limit values specified in the EMC legislation. PROTOLON MV reeling cables and CORDAFLEX (from
35mm² conductor cross-section) are also eminently suitable as EMC cables as a result of their precise and sym-
metrical three-core design.

133
Crane cables

Electrical parameters

Control cables, data transmission and bus cables (e.g. PROFIBUS)

Interference-free data transmission can only be achieved, especially when power and data transmission cables lie
close together, by implementation of special measures.
Cable designs with twisted and shielded pairs have proven their suitability for such applications, in particular as
bus cables. The laid-up length and the shield are matched so that the transfer impedance and the shield attenua-
tion are optimized at 30 MHz. The following cable designs are eminently suitable for use as data and bus cables:
• CORDAFLEX (SMK) with 3, 6, 9 or 12 twisted and shielded paris
• CORDAFLEX (SMK) with combined pairs/single cores
• PLANOFLEX with 4 or 6 twisted and shielded pairs
• RONDOFLEX with 6 or 9 twisted and shielded pairs
The table on the next page shows the specific characteristics of crane cables with twisted and shielded pairs
...x(2x1)C as a function of the frequency.

Cables with fibre-optics

The optimum solution with respect to EMC is the use of glass fibre-optics. In addition to the well-known design
OPTOFLEX, we are in a position to offer all the types of cables manufactured by us as combined copper/fibre-
optic cables to special order. Prices and delivery times are available on request. In most cases, the overall diame-
ter of the combined cables is identical to that of pure copper cables. Attention is drawn here, in particular, to the
PROTOLON design with integrated fibre-optics, which has formed part of our standard delivery program since
1984.

134
Standards and regulations relevant to EMC of cables
IEC 801-3 This standard defines electromagnetic compatibility for instrumentation and control equipment
for industrial process applications. It describes methods for evaluation of the susceptibility
to electromagnetic interference. It further describes tests, by means of which the influence of
electromagnetic interference from external sources on the operational behaviour of cables and
their maximum achievable transmission rates can be determined.
IEC 801-4 Tests based on this standard reveal the maximum loading limits of LAN cables as a result of
uniform, random and periodic interference.
EN 55011 In this standard the limit values and measuring procedures for radio frequency interference
(DIN VDE 0875, caused by industrial, scientific and medical high-frequency equipment (ISM devices) are
Part 11) defined.
EN 55022 This standard corresponds to DIN VDE 0878, Part 3: Limit values and measuring procedures for
radio frequency interference caused by information processing equipment (ITE). The radiated
energy of a cable can be measured in simulated operation. In addition, the limit value classes A
and B for radio frequency interference voltages are defined.
Official Journal This regulation of the German Federal Ministry for Post and Telecommunication deals with
Regulation radio frequency interference voltage emission.
243/1991
Information on this subject is also to be found in FTZ TL-6145-3000 issued by the Research and Technology Cen-
tre of the German Post Office.

Cable characteristics of crane cables with twisted and shielded pairs ... x(2x1)C
Twisted and shielded pairs (2x1)C can be employed without modification in the different cable designs.

135
 Crane cables

Electrical parameters

Construction Shield EMC evaluation

Symmetrical Cu braid Optimum
3+3 (possibly with Cu fleece)

Symmetrical Cu braid Good

3-core (single core)
EMC power cables

Unsymmetrical Cu braid Good

4-core (possibly with Cu fleece)

Symmetrical - Satisfactory
3+3

Unsymmetrical - Mediocre
4-core

Unsymmetrical parallel Cu braid Mediocre

cores or flat cable

Unsymmetrical parallel - Poor

cores or flat cable

Symmetrical Cu braid Optimum

2-core (possibly with Cu fleece)

Symmetrical - Very good

2-core
EMC control cables

Symmetrical - Good
4-core (with symmetrical operation)

Unsymmetrical Cu braid Often adequate

concentrically stranded overall shield (with adjacent cores)

Unsymmetrical Cu braid Often adequate

concentrically stranded individually shielded cores (with adjacent cores)

Unsymmetrical - Poor
concentrically stranded

136
Thermal parameters

The different temperature limits of the individual flexible electric cables for cranes and material handling
equipment are summarized in the table below.
Under no circumstances may the values shown be exceeded due to interaction of internal Joule heat and the
ambient temperature.
If cables are exposed to radiation, e.g. sunlight, the temperature of the outer sheath of the flexible electric cable
can rise to a level which is significantly higher than the ambient temperature. This situation must be compensa-
ted for by corresponding reduction of the current-carrying capacity.
The temperatures on the surface of the cable are limits for the ambient temperature.
All insulating and sheathing compounds of the flexible electric cables become stiffer as the temperature drops. If
the temperature falls below the specified limit, a point can be reached below which the compounds used become
brittle.
In addition to this, more force (sometimes considerably more) is needed for bending a flexible electric cable due
to the increase of stiffness of the insulating and sheathing compounds at lower temperatures. This can create
problems in the use of the flexible electric cables (e.g. with the reel drive).

Flexible cables Type Temperature limit during operation, storage, installation and transport (°C)
of the conductor during of the conductor during on the surface of the on the surface of the
operation short-circuit cable, fixed installation cable, fully flexible
installation
CORDAFLEX(SMK) (N)SHTÖU 90 250 -50 to +80 -35 to +80
EASYFLEX (N)7YRDGÖU 90 250 -50 to +80 -35 to +80
TROMMELFLEX PUR-HF D12Y11YU11Y 90 250 -50 to +80 -40 to +80
TROMMELFLEX (K) NSHTÖU 90 250 -40 to +80 -25 to +80
TROMMELFLEX KSM-S (N)SHTÖU 90 250 -40 to +80 -40 to +80
CORDAFLEX(SMK)-V (N)SHTÖU 90 250 -50 to +80 -35 to +80
SPREADER REEL PUR-HF D12YST11YU11Y 90 250 -50 to +80 -40 to +80
SPREADERFLEX 3GSLTÖ 90 250 -50 to +80 -40 to +80
RONDOFLEX (N)GRDGÖU 90 250 -50 to +80 -35 to +80
RONDOFLEX(C)-FC (N)GRDGCGÖU 90 250 -50 to +80 -35 to +80
RONDOFLEX(CHAIN) (N)GRDGÖU 90 250 -50 to +80 -35 to +80
FESTOONFLEX PUR-HF D12Y11Y 90 250 -50 to +80 -40 to +80
PLANOFLEX NGFLGÖU 90 250 -50 to +80 -35 to +80
M(Std)HÖU M(Std)HÖU 90 250 -40 to +80 -30 to +80
OPTOFLEX - - -40 to +80 -35 to +80
PROTOLON(SMK) (N)TSCGEWÖU 90 250 -50 to +80 -35 to +80
PROTOLON(SMK) LWL (N)TSKCGEWÖU 90 250 -50 to +80 -35 to +80
TENAX TTS/LWL (N)TSCGEWÖU 90 250 -40 to +80 -25 to +80
PROTOLON (FL)/LWL (N)TSFLCGEWÖU 90 250 -50 to +80 -35 to +80

137
Crane cables

Thermal parameters

The relationship between the bending stiffness of flexible electric cables for cranes and material handling
equipment and the temperature is shown in the figure below.
The ratio of the bending force is given as F/F0, with F0=F20°C.

dL = Overall cable diameter

F = Force

The temperature limits on the surface of the cable are specified to ensure problem-free and healthy operation
during forced guidance of flexible electric cables or cranes and material handling equipment, especially while
trailing over ground and during reeling operation.
Higher temperatures influence the hardness, abrasion, resistance to tear propagation and the transverse pressure
stability of the insulating and sheathing compounds and can thus lead to a reduction of their service life.
Flexible electric cables should be selected, installed and operated so that the expected dissipation of Joule heat is
not hindered in any way and therefore no risk of fire is incurred.

138
Mechanical parameters

Tensile loads
The tensile loads of copper conductors in flexible electric cables for cranes and material handling equipment as
specified by DIN VDE 0298, Part 3, should not exceed 15 N/mm². However, higher values are allowed for some
cables as shown in the table below. 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 dynamic loads.
When the permissible tensile force is being calculated, shields, concentric conductors and split protective-earth
conductors as well as integrated control cores and monitoring cores of power cables must not be included in the
calculation.
For higher tensile loads, appropriate steps have to be taken such as increasing the bending radii or using special
cable designs with stress relieving support elements. In some cases, a shorter service life can 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 referred to the
cross-section of the conductor.

Maximum tensile loads during installation and operation of flexible electric cables for cranes and material
handling equipment
Flexible cables Type DIN VDE N/mm² Prysmian N/mm²
CORDAFLEX (SMK) (N)SHTÖU 15 30
EASYFLEX (N)7YRDGÖU - 15
TROMMELFLEX PUR-HF D12Y11YU11Y - 25
TROMMELFLEX KSM-S (N)SHTÖU 15 20
TROMMELFLEX (K) NSHTÖU 15 15
CORDAFLEX (SMK)-V (N)SHTÖU 15 Increased through additional support element
SPREADER REEL PUR-HF D12YST11YU11Y - Increased through additional support element
SPREADERFLEX 3GSLTÖ 15 Increased through additional support element
RONDOFLEX (N)GRDGÖU 15 15
RONDOFLEX(C)-FC (N)GRDGCGÖU 15 15
RONDOFLEX(CHAIN) (N)GRDGÖU 15 15
FESTOONFLEX PUR-HF D12Y11Y - 15
FESTOONFLEX C-PUR-HF D12YC11Y - 15
PLANOFLEX NGFLGÖU 15 15
M(StD)HÖU M(StD)HÖU 15 15
OPTOFLEX - 500 N for the complete cable
PROTOLON (SMK) (N)TSCGEWÖU 15 20
PROTOLON (SMK) LWL (N)TSKCGEWÖU 15 20
TENAX TTS/LWL (N)TSCGEWÖU 15 20
PROTOLON (FL)/LWL (N)TSFLCGEWÖU 15 15

139
Crane cables

Mechanical parameters

Torsional stresses
Flexible electric cables for cranes and material handling equipment are generally not designed for torsional stres-
ses. The latter can, however, not be avoided during operation.
The maximum permissible torsional stresses which occur during operation at entries, slewing gears, etc., are
summarized in the table below. If the limits are exceeded, this can lead to a reduced lifetime. In critical cases, the
cable manufacturer should be consulted.
Torsional stresses created by the systems involved (e.g. due to misalignment of cable guidance systems, oblique
cable pay out) should be avoided and are not included here.

Maximum torsional stresses during operation of flexible electric cables for cranes and material handling equip-
ment

Flexible cables Type α (°/m)

CORDAFLEX (SMK) (N)SHTÖU ± 50

EASYFLEX (N)7YRDGÖU ± 15
TROMMELFLEX PUR-HF D12Y11YU11Y ± 50
TROMMELFLEX KSM-S (N)SHTÖU ± 50
TROMMELFLEX (K) NSHTÖU ± 50
CORDAFLEX (SMK)-V (N)SHTÖU ± 50
SPREADER REEL PUR-HF D12YST11YU11Y ± 50
Corresponding to application, designed for
SPREADERFLEX 3GSLTÖ best torsional properties
RONDOFLEX (N)GRDGÖU ± 25
RONDOFLEX(C)-FC (N)GRDGCGÖU Not allowed
RONDOFLEX(CHAIN) (N)GRDGÖU Not allowed
FESTOONFLEX PUR-HF D12Y11Y ± 25
FESTOONFLEX C-PUR-HF D12YC11Y Not allowed
PLANOFLEX NGFLGÖU Not allowed
M(StD)HÖU M(StD)HÖU Not allowed
OPTOFLEX ± 50
PROTOLON (SMK) (N)TSCGEWÖU ± 25
PROTOLON (SMK) LWL (N)TSKCGEWÖU ± 25
TENAX TTS/LWL (N)TSCGEWÖU ± 50
PROTOLON (FL)/LWL (N)TSFLCGEWÖU Not allowed

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Minimum bending radii
If the bending radii are smaller than those permitted, a reduced service life can be expected depending on the
stress conditions. The values given in the table below should be taken as a basis.
The minimum bending radii are shown as the product of the overall diameter of the cable (d) and a numerical
factor, which is dependent on the diameter of the cable (e.g.: 3 x d).
The minimum permissible bending radii are valid within the specified ambient temperature range, subject to the
provision that the permissible tensile loads are not exceeded.
In critical cases, the cable manufacturer should be consulted.

Minimum permissible bending radii R

Flexible cables CORDAFLEX, EASYFLEX, TROMMELFLEX, SPREADER REEL, PROTOLON (*), OPTOFLEX
SPREADERFLEX, RONDOFLEX, FESTOONFLEX, PLANOFLEX, TENAX
M(StD)HÖU

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

Maximum overall diameter of the cable or Up to 8 Above 8 to 12 Above 12 to 20 Above 20 permissible
maximum height of the flat cable (mm) bending radius
mm
Fixed installation 3xd 3xd 4xd 4xd 6xd 125

Fully flexible operation 3xd 4xd 5xd 5xd 10 x d 125

For the entry, e.g. at a 3xd 4xd 5xd 5xd 10 x d 250

centre feed point

For forced guidance with 5xd 5xd 5xd 6xd 12 x d 250

reeling operation

For forced guidance with 3xd 4xd 5xd 5xd 10 x d 125

festoon operation

For forced guidance with 4xd 4xd 5xd 5xd 10 x d 125

power tracks

For forced guidance with 7,5 x d 7,5 x d 7,5 x d 7,5 x d 15 x d 250

sheaves

For forced guidance with 7,5 x d 7,5 x d 7,5 x d 7,5 x d 15 x d 250

cable tenders

Minimum distance with 20 x d 20 x d 20 x d 20 x d 20 x d 50 x d

double or S-type
directional changes

le

(*) For PROTOLON(FL) it is reccomended to consider d = 1,5 x maximum height of flat cable

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Crane cables

Mechanical parameters

Travel speeds
Flexible electric cables for cranes and material handling equipment are intended for use on mobile equipment
and are designed to cope with the technical requirements of the application.
In order to collect, pay out and move flexible electric cables, there are different cable guidance systems such as
reels, festoons, tenders, power tracks, baskets, sheave guided cable storage systems and lifts as well as sheaves
and multi-roller guides. The cranes and material handling equipment, and consequently also the cable guidance
systems, are operated at different travel speeds and are therefore subjected to stress which can vary from low to
very high.
During operation of the mobile equipment, the flexible electric cables are subjected to stress such as tension,
transverse pressure, torsion and bending. Thus, the travel speed and the acceleration are to be considered as
indirect criteria for the stresses applied to the flexible electric cables.
The maximum permissible travel speeds for the individual flexible electric cables are summarized in the table
below.
In the case of gantry crane drives, the travel speed of the actual mobile equipment is implied. Usually, cylindrical
or mono-spiral reels are employed. The trolley drive carries out horizontal movement of the hoisting gear and the
driver‘s cabin. Festoons, tenders and power tracks or sheave guided cable storage systems are used here as cable
guidance systems. In the case of the hoisting gear, the speed of the load-lifting device, such as the spreader or
grab, is implied. Normally, either reels located in the trolley or baskets on the load-lifting device are used for the
cable guidance system.
If the travel-speed limits are exceeded, a reduction in service life cannot be excluded. The cable manufacturer
should be consulted.

Maximum travel speed for flexible electric cables for cranes and material handling equipment
Flexible cables Type Gantry crane drive (reeling) Trolley drive (festoons and Hoist drive (vertical run
tenders) reeling or basket)
m/min m/min m/min
CORDAFLEX (SMK) (N)SHTÖU 240 240 160
EASYFLEX (N)7YRDGÖU 80 no application no application
TROMMELFLEX PUR-HF D12Y11YU11Y 180 180 120
TROMMELFLEX KSM-S (N)SHTÖU 180 180 no application
TROMMELFLEX (K) NSHTÖU 120 120 no application
CORDAFLEX (SMK)-V (N)SHTÖU no application no application 240
SPREADER REEL PUR-HF D12YST11YU11Y no application no application 180
SPREADERFLEX 3GSLTÖ no application no application 160
RONDOFLEX (N)GRDGÖU 60 240 no application
RONDOFLEX(C)-FC (N)GRDGCGÖU 60 240 no application
RONDOFLEX(CHAIN) (N)GRDGÖU no application 240 no application
FESTOONFLEX PUR-HF D12Y11Y no application 210 no application
FESTOONFLEX C-PUR-HF D12YC11Y no application 210 no application
PLANOFLEX NGFLGÖU no application 180 no application
M(StD)HÖU M(StD)HÖU no application 180 no application
OPTOFLEX 120. No random wound reel 240 no application

PROTOLON (SMK) (N)TSCGEWÖU 240 120 no application

PROTOLON (SMK) LWL (N)TSKCGEWÖU 240 120 no application
TENAX TTS/LWL (N)TSCGEWÖU 180 60 no application
PROTOLON (FL)/LWL (N)TSFLCGEWÖU 120 no application no application

142