YOUR ENERGY, OUR SYSTEMS, ANYWHERE Flexible Cables 2010
FLEXIBLE CABLES PRYSMIAN TECHNICAL MANUALS COMMUNICATION CONSTRUCTION DATA & INSTRUMENTATION FIBRE TO THE PREMISES FIRE PERFORMANCE FLEXIBLE CABLES MEDIUM VOLTAGE MINING & INDUSTRIAL OVERHEAD CONDUCTORS
CONTENTS Page No. INTRODUCTION 02 CABLE USAGE CHARACTERISTICS 03 PVC Light Duty Flexible Cord 04 Ordinary Duty Flexible Cord 06 Heavy Duty Flexible Cord 08 Welding Flex 10 FLEXTREME Single Core Cable 12 Multicore Cable 14 Multicore Control Cable 16 Multicore Screened Cable 18 Cable Selection 20 General Information 25 01
INTRODUCTION Prysmian Cables & Systems manufacture a wide range of flexible cables for domestic, coercial and industrial use. Prysmian's flexible cables range falls into two categories, PVC insulated and sheathed cables for use in applications exposed to little or no mechanical stress and elastomeric insulated and sheathed cables for use in industrial or more aggressive environments. PVC cables are subdivided into light, ordinary and heavy duty requirements for domestic and light coercial use. Prysmian s range of Flextreme elastomeric cables have been developed to optimise cable choice and reduce cost by providing a cable that suits a variety of conditions. Four key areas are addressed with Prysmian's Flextreme Cable: Extreme flexibility with superior bending radii and able to withstand continuous cycling duties. Applications include cranes, mobile equipment, robotics, materials handling, industrial trucks, rotating or vibrating equipment, compressors, generators, building sites, theatres, entertainment halls etc. Extreme resistance to mechanical shocks, temperature and hostile environments such as building sites, workshops, chemical plants, production facilities etc. Extreme water tightness suitable for permanent submersion to 100m in applications such as dams, ports, submersible pumps, swiing pools, golf courses, sewage works, water treatment plants, gardens etc. Extreme versatility with one range of cables suitable for a variety of applications. All of these qualities lead to increased security and peace of mind and Prysmian's cables are subject to stringent testing and quality control, ensuring the highest possible standards. MATERIALS INFORMATION CONDUCTORS All conductors are annealed copper, complying to AS/NZS 1125. INSULATION PVC cables Flexible cables are insulated with V-90 PVC Welding cables are insulated with V-90HT PVC Flextreme elastomeric cables Flextreme cables are insulated with an R-EP-90 cross-linked elastomer SCREENS Where provided, screens are manufactured from tinned annealed copper in a close woven braid. SHEATHS PVC cables Flexible cables are sheathed with 5V-90 PVC Welding Flex is sheathed with V-90HT PVC Flextreme elastomeric cables All Flextreme cables are sheathed with a HD-90-CPE heavy duty cross linked elastomer 02
CABLE USAGE CHARACTERISTICS LAYING CONDITIONS AMBIENT TEMPERATURE Maximum operating temperature Minimum operating temperature MINIMUM BENDING RADIUS Minimum bending radius of installed cables MINIMUM BENDING RADIUS DURING INSTALLATION MINIMUM INSTALLATION TEMPERATURE MECHANICAL IMPACT RESISTANCE 1 Light impact 2 Moderate impact 3 Heavy impact 4 Very heavy impact RESISTANCE TO SOLAR RADIATION AND WEATHER Excellent Permanent Very good Frequent Good Occasional Acceptable Accidental Poor None IN TRENCH IN GROUND IN FREE AIR IN GROUND WITH PROTECTION RESISTANCE TO WATER Negligible Water drops Spray Splashes Heavy sea Iersion Submersion No humidity Occasional condensation Water run off Exposed to water splashes Exposed to waves Temporarily covered by water Permanently covered by water IN DUCT IN CONDUIT CHEMICAL RESISTANCE Excellent Very good Good Acceptable Poor BEHAVIOUR IN FLAME AND FIRE Reaction To Fire C1 Fire retardant C2 Flame retardant C3 No fire performance LOW SMOKE EMISSION AS/NZS 4507 Permanent Frequent Occasional Accidental None Resistant To Fire Level 1 Ultimate fire survival Level 2 Two hours fire survival Level 3 Restrained spread & self extinguishing DOMESTIC APPLIANCES MACHINES MOBILE EQUIPEMENT OUTDOOR APPLIANCES FESTOON INTERNAL WIRING FLEXIBILITY Rigid Semi-rigid Flexible Very flexible SUBMERGED INDUSTRIAL EQUIPEMENT HALOGEN FREE AS/NZS 4507 OVERHEAD AERIAL EXTERNAL BUILDING In accordance with research, new material developments and changes in relevant standards, published details may change without notice. 03
PVC LIGHT DUTY 250/250V LIGHT DUTY FLEXIBLE CORD TO AS/NZS 3191 CABLE DESIGN CONDUCTOR: Annealed copper conductor to AS/NZS 1125 Maximum continuous operating temperature: 75 C INSULATION: V-90 PVC Colours: 2C Brown, Light Blue 3C Brown, Light Blue, Green/Yellow SHEATH: 5V-90 PVC Colours: Grey, White, Black, Orange INSTALLATION CONDITIONS 6D IN CONDUIT IN DUCT DOMESTIC APPLIANCES CABLE CHARACTERISTICS Flexible 4D Level 1 Negligible Good +75 C C3-15 C Good Suitable in dry locations only. Use in radios, shavers, desk lamps and small portable equipment or use in office machines, hair dryers etc. and for appliances requiring an earth connection. Also suitable for use with double insulated appliances where the cord is not subject to mechanical stress. 04
LIGHT DUTY FLEXIBLE CORD TO AS/NZS 3191 Product Code C.S.A. ² Insulation Thickness Sheath Thickness O.D. Approx. Mass kg/100m 2 Core Flat.52CLDFXF 0.5 0.5 0.6 5.2 3.3 2.8.752CLDFXF 0.75 0.5 0.6 5.6 3.5 3.4 2 Core Circular.52CLDFX 0.5 0.5 0.6 5.2 3.7.752CLDFX 0.75 0.5 0.6 5.6 4.5 3 Core Circular.753CLDFX 0.75 0.5 0.6 5.9 5.4 Parallel Webbed, 2 Core Flat, Unsheathed.52CLDFXPW 0.5 0.8-5.2 2.6 2.2.752CLDFXPW 0.75 0.8-5.6 2.8 2.7 1.02CLDFXPW 1.0 0.8-6.0 3.0 3.3 1.52CLDFXPW 1.5 0.8-6.6 3.3 4.5 2.52CLDFXPW 2.5 0.9-7.9 3.9 6.6 4.02CLDFXPW 4 1.0-9.3 4.7 11.0 05
PVC ORDINARY DUTY 250/440V ORDINARY DUTY FLEXIBLE CORD TO AS/NZS 3191 CABLE DESIGN CONDUCTOR: Annealed copper conductor to AS/NZS 1125 Maximum continuous operating temperature: 75 C INSULATION: V-90 PVC Colours: 1C - Red, White, Light Blue, Black 2C - Brown, Light Blue 3C - Brown, Light Blue, Green/Yellow 4C - Brown, Light Blue, White, Green/Yellow 5C - Brown, Light Blue, Orange, White, Green/Yellow SHEATH: 5V-90 PVC Colours: Grey, White, Black, Orange INSTALLATION CONDITIONS 6D IN MACHINES IN CONDUIT DUCT DOMESTIC APPLIANCES CABLE CHARACTERISTICS Flexible 4D Level 1 Water Drops Good +75 C -15 C C3 Good 06 Wiring in dry locations only, in conduit or enclosures, such as switchboards, control panels, appliances and electrical equipment. such as radios, desk lamps and office machines, etc. Also used for extension leads in sizes 1 ² and above. Multicore cords containing an earth core are suitable for a number of applications in dry and damp conditions, such as domestic appliances (washing machines, dishwashers). Leads for industrial and office equipment requiring a three-phase supply and an earth connection.
ORDINARY DUTY FLEXIBLE CORD TO AS/NZS 3191 Product Code C.S.A. ² Insulation Thickness Sheath Thickness O.D. Approx. Mass kg/100m Single Core.51CODFX 0.5 0.6-2.2 0.9.751CODFX 0.75 0.6-2.4 1.2 1.01CODFX 1.0 0.6-2.5 1.5 1.51CODFX 1.5 0.7-3.0 2.1 2.51CODFX 2.5 0.8-3.7 3.4 41CODFX 4 0.8-4.2 4.8 2 Core Flat.52CODFXF 0.5 0.6 0.8 6.0 3.9 3.6.752CODFXF 0.75 0.6 0.8 6.4 4.1 4.3 2 Core Circular.752CODFX 0.75 0.6 0.8 6.4 5.7 1.02CODFX 1.0 0.6 0.8 6.7 6.5 1.52CODFX 1.5 0.7 0.8 7.7 8.9 2.52CODFX 2.5 0.8 1.0 9.4 14 42CODFX 4 0.8 1.0 10.5 18 3 Core Circular.753CODFX 0.75 0.6 0.8 6.8 6.8 1.03CODFX 1.0 0.6 0.8 7.1 7.9 1.53CODFX 1.5 0.7 0.9 8.4 11 2.53CODFX 2.5 0.8 1.1 10.2 17 43CODFX 4 0.8 1.1 11.4 23 4 Core Circular.754CODFX 0.75 0.6 0.8 7.4 8.2 1.04CODFX 1.0 0.6 0.9 8.0 9.9 1.54CODFX 1.5 0.7 1.0 9.4 14 2.54CODFX 2.5 0.8 1.1 11.2 21 44CODFX 4 0.8 1.1 12.5 29 5 Core Circular.755CODFX 0.75 0.6 0.9 8.3 10 1.05CODFX 1.0 0.6 0.9 8.7 12 1.55CODFX 1.5 0.7 1.1 10.5 17 2.55CODFX 2.5 0.8 1.2 12.4 26 45CODFX 4 0.8 1.3 14.1 36 07
PVC HEAVY DUTY 0.6/1kV HEAVY DUTY FLEXIBLE CORD TO AS/NZS 5000.1 AND AS/NZS 3191 CABLE DESIGN CONDUCTOR: Annealed copper conductor to AS/NZS 1125 Maximum continuous operating temperature: 75 C INSULATION: V-90 PVC Colours: To AS/NZS 3191 ( 4 ²) 1C - Red, White, Light Blue, Black 2C - Brown, Light Blue 3C - Brown, Light Blue, Green/Yellow 4C - Brown, Light Blue, White, Green/Yellow 5C - Brown, Light Blue, Orange, White, Green/Yellow To AS/NZS 5000.1 ( 6 ²) 3C - Red, Black, Green/Yellow 4C - Red, White, Black, Green/Yellow 5C - Red, White, Blue, Black, Green/Yellow INSTALLATION CONDITIONS SHEATH: 5V-90 PVC Colour: Black, Orange OD 25 6D OD>25 9D IN FREE AIR MACHINES IN DUCT DOMESTIC APPLIANCES LIGHT EQUIPMENT For ease of installation in switchboards and control panels where confined spaces and tortuous routes are encountered, or where flexibility is needed for hinged panels. For fixed wiring within other enclosures where the cable is not accessible without the use of tools. Suitable for extension leads in sizes 1 ² and above. Suitable for supply to small industrial and coercial equipment requiring three phase power. CABLE CHARACTERISTICS Flexible OD 25 4D OD>25 6D Level 2 Splashes Good +75 C C3-15 C Good 08 Also suitable for equipment requiring three phase and single phase supply and an earth connection, for example equipment containing a three phase motor and single phase pilot lights, such as industrial sweepers, vacuum cleaners, welders, etc. Suitable for use with double insulated appliances where the cord is subject to higher mechanical stress, in damp and wet conditions.
HEAVY DUTY FLEXIBLE CORD TO AS/NZS 5000.1 AND AS/NZS 3191 Product Code C.S.A. ² Insulation Thickness Sheath Thickness O.D. Approx. Mass kg/100m Single Core (insulated only).51chdfxu 0.5 0.8-2.6 1.1.751CHDFXU 0.75 0.8-2.8 1.4 1.01CHDFXU 1.0 0.8-2.9 1.6 1.51CHDFXU 1.5 0.8-3.2 2.1 2.51CHDFXU 2.5 0.9-3.9 3.3 41CHDFXU 4 1.0-4.7 5.5 Single Core.751CHDFX 0.75 0.8 1.3 5.4 3.8 1.01CHDFX 1.0 0.8 1.3 5.6 4.2 1.51CHDFX 1.5 0.8 1.4 6.1 5.2 2.51CHDFX 2.5 0.9 1.4 6.8 6.9 41CHDFX 4 1.0 1.5 7.7 9.4 2 Core Circular.752CHDFX 0.75 0.8 1.3 8.2 8.4 1.02CHDFX 1.0 0.8 1.3 8.6 9.3 1.52CHDFX 1.5 0.8 1.5 9.5 12 2.52CHDFX 2.5 0.9 1.7 11.2 17 42CHDFX 4 1.0 1.8 13 25 3 Core Circular (2 Core and Earth).753CHDFX 0.75 0.8 1.4 8.8 10 1.03CHDFX 1.0 0.8 1.4 9.2 11 1.53CHDFX 1.5 0.8 1.6 10.2 15 2.53CHDFX 2.5 0.9 1.8 12.1 21 43CHDFX 4 1.0 1.9 13.9 30 63CHDFX 6 1.0 2.9 16.0 44 103CHDFX 10 1.0 3.1 20.5 69 163CHDFX 16 1.0 3.3 24.1 90 253CHDFX 25 1.2 3.7 29.4 140 353CHDFX 35 1.2 4.0 32.5 181 503CHDFX 50 1.4 4.4 37.7 241 4 Core Circular (3 Core and Earth).754CHDFX 0.75 0.8 1.5 9.8 12 1.04CHDFX 1.0 0.8 1.5 10.2 14 1.54CHDFX 1.5 0.8 1.7 11.3 18 2.54CHDFX 2.5 0.9 1.9 13.3 26 44CHDFX 4 1.0 2.0 15.4 38 64CHDFX 6 1.0 3.0 17.6 54 104CHDFX 10 1.0 3.3 22.6 85 164CHDFX 16 1.0 3.5 26.1 122 254CHDFX 25 1.2 3.9 32.0 191 354CHDFX 35 1.2 4.2 35.3 246 504CHDFX 50 1.4 4.7 41.2 332 704CHDFX 70 1.4 5.1 48.3 460 954CHDFX 95 1.6 5.7 53.3 577 1204CHDFX 120 1.6 6.1 60.0 731 5 Core Circular (4 Core and Earth).755CHDFX 0.75 0.8 1.6 10.8 15 1.05CHDFX 1.0 0.8 1.6 11.2 17 1.55CHDFX 1.5 0.8 1.8 12.4 21 2.55CHDFX 2.5 0.9 2.0 14.6 30 45CHDFX 4 1.0 2.2 17.1 46 09
PVC WELDING FLEX 0.6/1kV PVC WELDING FLEX TO AS/NZS 1995 CABLE DESIGN CONDUCTOR: Annealed copper conductor to AS/NZS 1995 Maximum continuous operating temperature: 90 C INSULATION: V-90HT PVC Where it is possible to guard against plastic flow and where reduced insulation resistance can be tolerated, V-90HT can be operated at atemperature up to 105 C for an average of 500 hours per annum during the cable service life.the use of the higher temperature insulationcompounds does not permit a higher currentcarrying capacity. AS/NZS 3008.1 recoends 75 C for currentcarrying capacity calculations. COLOUR: Black INSTALLATION CONDITIONS 6D IN FREE AIR INTERNAL WIRING LIGHT EQUIPMENT CABLE CHARACTERISTICS Flexible 4D Level 2 Splashes Good +90 C C2-15 C Good For use in welding applications, in areas with limited exposure to welding splash, and power and switchboard applications, to AS/NZS 1995 and AS/NZS 5000.1. 10
PVC WELDING FLEX TO AS/NZS 1995 Product Code C.S.A. ² Insulation Thickness Sheath Thickness O.D. Approx. Mass kg/100m Single Core Welding Flex 101CWELDPVC 10 2.0-8.9 14 161CWELDPVC 16 2.0-10.0 21 251CWELDPVC 25 2.0-12.0 30 351CWELDPVC 35 2.0-13.0 40 501CWELDPVC 50 2.2-15.4 58 701CWELDPVC 70 2.4-17.1 79 951CWELDPVC 95 2.6-20.1 105 1201CWELDPVC 120 2.8-22.0 130 1501CWELDPVD 150 3.0-23.9 160 11
FLEXTREME 0.6/1kV SINGLE CORE CABLE TO AS/NZS 5000.1 WHERE APPLICABLE CABLE DESIGN CONDUCTOR: Annealed copper conductor to AS/NZS 1125 Maximum continuous operating temperature: 90 C INSULATION: R-EP-90 elastomer Colours: Natural SHEATH: HD-90-CPE heavy duty cross-linked elastomer Colours: Black INSTALLATION CONDITIONS INDUSTRIAL EQUIPMENT OD 25 6D OD>25 9D IN FREE AIR MACHINES LIGHT EQUIPMENT FESTOON MOBILE SUBMERGED EQUIPEMENT CABLE CHARACTERISTICS Very Flexible OD 25 4D OD>25 6D Level 3 Submersion Excellent +90 C C1-25 C Very Good 12 Flexible elastomeric insulated and sheathed cables are manufactured with extra fine stranding, suitable for use in welding flex (10² - 240²) and for LV mains connected equipment (eg. switchgear). Cables are oil and solvent resistant and suitable for permanent iersion to 100m. Used for flexible supply to equipment subject to movement or vibration and for ease of installation in confined spaces, or where tortuous routes are encountered.
FLEXTREME SINGLE CORE TO AS/NZS 5000.1 WHERE APPLICABLE Product Code C.S.A. ² Insulation Thickness Sheath Thickness O.D. Approx. Mass kg/100m 1.51CFLXT 1.5 0.8 1.4 6.7 5.9 2.51CFLXT 2.5 0.9 1.4 7.4 7.5 41CFLXT 4 1.0 1.5 8.4 11 61CFLXT 6 1.0 1.6 9.4 14 101CFLXT 10 1.2 1.8 11.6 21 161CFLXT 16 1.2 1.9 13.0 29 251CFLXT 25 1.4 2.1 15.6 42 351CFLXT 35 1.4 2.2 17.2 54 501CFLXT 50 1.6 2.4 19.6 74 701CFLXT 70 1.6 2.6 22.6 99 951CFLXT 95 1.8 2.8 25.1 129 1201CFLXT 120 1.8 3.0 27.4 160 1501CFLXT 150 2.0 3.2 30.1 196 1851CFLXT 185 2.2 3.4 33.8 238 2401CFLXT 240 2.4 3.5 36.7 302 13
FLEXTREME 0.6/1kV MULTICORE CABLE TO AS/NZS 3191 AND AS/NZS 5000.1 WHERE APPLICABLE CABLE DESIGN CONDUCTOR: Annealed copper conductor to AS/NZS 1125 Maximum continuous operating temperature: 90 C INSULATION: R-EP-90 elastomer Colours: To AS/NZS 3191 ( 4 ²) 2C - Brown, Light Blue 3C - Brown, Light Blue, Green/Yellow 4C - Brown, Light Blue, White, Green/Yellow 5C - Brown, Light Blue, Orange, White, Green/Yellow To AS/NZS 5000.1 ( 6 ²) 2C - Red, Black 3C - Red, Black, Green/Yellow 4C - Red, White, Blue, Green/Yellow 5C - Red, White, Blue, Black, Green/Yellow ( 50 ²), Green ( > 50 ²) SHEATH: HD-90-CPE heavy duty cross-linked elastomer Colours: Black INSTALLATION CONDITIONS INDUSTRIAL EQUIPMENT OD 25 6D OD>25 9D IN FREE AIR MACHINES LIGHT EQUIPMENT FESTOON MOBILE SUBMERGED EQUIPEMENT CABLE CHARACTERISTICS Flexible OD 25 4D OD>25 6D Level 3 Submersion Excellent +90 C C1-25 C Very Good Cables are oil and solvent resistant, and suitable for permanent iersion to 100m. Used for flexible supply to equipment subject to movement or vibration and for ease of installation in confined spaces, or where tortuous routes are encountered. 14
FLEXTREME MULTICORE TO AS/NZS 3191 AND AS/NZS 5000.1 WHERE APPLICABLE Product Code C.S.A. ² Insulation Thickness Sheath Thickness O.D. Approx. Mass kg/100m 2 Core 42CFLXT 4 1.0 1.8 13.8 27 62CFLXT 6 1.0 2.0 15.9 37 102CFLXT 10 1.2 3.1 22.3 68 162CFLXT 16 1.2 3.3 25.2 91 252CFLXT 25 1.4 3.6 30.0 135 352CFLXT 35 1.4 3.9 32.9 170 502CFLXT 50 1.6 4.3 37.8 224 3 Core Cable (2 Core and Earth) 43CFLXT 4 1.0 1.9 14.8 33 63CFLXT 6 1.0 2.1 17.0 46 103CFLXT 10 1.2 3.2 23.1 78 163CFLXT 16 1.2 3.4 26.1 107 253CFLXT 25 1.4 3.8 31.3 162 353CFLXT 35 1.4 4.1 34.4 206 503CFLXT 50 1.6 4.5 40.0 272 703CFLXT 70 1.6 4.8 45.7 373 953CFLXT 95 1.8 5.3 51.3 485 1203CFLXT 120 1.8 5.6 56.9 606 4 Core Cable (3 Core and Earth) 1.04CFLXT 1.0 0.8 1.5 11.1 16 1.54CFLXT 1.5 0.8 1.7 12.2 20 2.54CFLXT 2.5 0.9 1.9 14.2 28 44CFLXT 4 1.0 2.0 16.3 41 64CFLXT 6 1.0 2.2 18.7 57 104CFLXT 10 1.2 3.4 25.4 96 164CFLXT 16 1.2 3.6 28.7 133 254CFLXT 25 1.4 4.0 34.5 203 354CFLXT 35 1.4 4.3 37.8 258 504CFLXT 50 1.6 4.8 43.5 347 704CFLXT 70 1.6 5.2 51.9 485 954CFLXT 95 1.8 5.7 55.7 612 1204CFLXT 120 1.8 6.1 63.3 771 5 Core Cable (4 Core and Earth) 1.05CFLXT 1.0 0.8 1.6 12.2 19 1.55CFLXT 1.5 0.8 1.8 13.4 24 2.55CFLXT 2.5 0.9 2.0 15.6 34 45CFLXT 4 1.0 2.2 18.1 50 65CFLXT 6 1.0 2.4 20.7 70 105CFLXT 10 1.2 2.6 28.0 117 165CFLXT 16 1.2 2.8 31.6 161 255CFLXT 25 1.4 4.3 38.2 248 15
FLEXTREME 0.6/1kV MULTICORE CONTROL CABLE TO AS/NZS 5000.1 CABLE DESIGN CONDUCTOR: Annealed copper conductor to AS/NZS 1125 Maximum continuous operating temperature: 90 C INSULATION: R-EP-90 elastomer Colours: Black with White numbering, Green/Yellow SHEATH: HD-90-CPE heavy duty cross-linked elastomer Colour: Black INSTALLATION CONDITIONS INDUSTRIAL EQUIPMENT OD 25 6D OD>25 9D IN FREE AIR MACHINES LIGHT EQUIPMENT CABLE CHARACTERISTICS Flexible OD 25 4D OD>25 6D Level 3 Submersion Excellent +90 C C1-25 C Very Good Cables are oil and solvent resistant and suitable for permanent iersion to 100m. Used for flexible supply to equipment subject to movement or vibration. Suitable for machine centres and robotics and for ease of installation in confined spaces, or where tortuous routes are encountered. 16
FLEXTREME MULTICORE CONTROL TO AS/NZS 5000.1 Product Code No. of Cores Insulation Thickness Sheath Thickness O.D. Approx. Mass kg/100m 1.5 2 1.56CFLXTCON 6 0.8 2.5 15.5 27 1.57CFLXTCON 7 0.8 2.6 15.5 30 1.58CFLXTCON 8 0.8 2.6 17.9 38 1.510CFLXTCON 10 0.8 2.8 19.4 41 1.512CFLXTCON 12 0.8 2.9 20.0 47 1.514CFLXTCON 14 0.8 3.1 21.0 53 1.519CFLXTCON 19 0.8 3.2 23.2 68 1.524CFLXTCON 24 0.8 3.5 27.3 85 1.527CFLXTCON 27 0.8 3.6 27.9 94 1.530CFLXTCON 30 0.8 3.7 28.9 103 1.537CFLXTCON 37 0.8 3.8 31.4 125 2.5 2 2.56CFLXTCON 6 0.9 2.7 16.8 35 2.57CFLXTCON 7 0.9 2.8 16.8 39 2.58CFLXTCON 8 0.9 2.9 18.2 43 2.510CFLXTCON 10 0.9 3.0 21.2 53 2.512CFLXTCON 12 0.9 3.1 21.8 61 2.514CFLXTCON 14 0.9 3.3 22.9 70 2.519CFLXTCON 19 0.9 3.5 25.5 90 2.524CFLXTCON 24 0.9 3.9 30.0 113 2.527CFLXTCON 27 0.9 4.1 30.7 125 2.530CFLXTCON 30 0.9 4.2 32.0 138 2.537CFLXTCON 37 0.9 4.3 34.8 168 4 2 46CFLXTCON 6 1.0 2.9 18.6 50 47CFLXTCON 7 1.0 3.1 18.6 55 48CFLXTCON 8 1.0 3.2 20.1 62 410CFLXTCON 10 1.0 3.4 23.5 76 412CFLXTCON 12 1.0 3.5 24.2 89 414CFLXTCON 14 1.0 3.7 25.5 101 419CFLXTCON 19 1.0 3.9 28.4 133 424CFLXTCON 24 1.0 4.1 33.7 169 427CFLXTCON 27 1.0 4.3 34.7 188 430CFLXTCON 30 1.0 4.6 35.9 207 437CFLXTCON 37 1.0 4.8 39.0 252 17
FLEXTREME 0.6/1kV MULTICORE SCREENED CABLE TO AS/NZS 5000.1 CABLE DESIGN CONDUCTOR: Annealed copper conductor to to AS/NZS 1125 Maximum continuous operating temperature: 90 C INSULATION: R-EP-90 elastomer Colours: To AS/NZS 3191 ( 4 ²) 4C - Brown, Light Blue, White, Green/Yellow 5C - Brown, Light Blue, Orange, White, Green/Yellow To AS/NZS 5000.1 ( 6 ²) 4C - Red, White, Blue, Green/Yellow 5C - Red, White, Blue, Black, Green/Yellow SHEATH: HD-90-CPE heavy duty cross-linked elastomer Colour: Black INSTALLATION CONDITIONS INDUSTRIAL EQUIPMENT OD 25 6D OD>25 9D IN FREE AIR MACHINES LIGHT EQUIPMENT FESTOON MOBILE SUBMERGED EQUIPEMENT CABLE CHARACTERISTICS Flexible OD 25 4D OD>25 6D Level 3 Submersion Excellent +90 C C1-25 C Very Good These four and five core cables are designed for applications where a screen is required. 18
FLEXTREME MULTICORE SCREENED CABLE TO AS/NZS 5000.1 Product Code C.S.A. ² Insulation Thickness Sheath Thickness O.D. Approx. Mass kg/100m 4 Core (3 Core and Earth) Screened 2.54CFLXTSCN 2.5 0.9 1.9 16.8 41 44CFLXTSCN 4 1.0 2.2 19.5 57 64CFLXTSCN 6 1.0 2.4 22.3 79 104CFLXTSCN 10 1.2 3.5 27.9 125 164CFLXTSCN 16 1.2 3.8 31.4 170 254CFLXTSCN 25 1.4 4.2 37.1 240 354CFLXTSCN 35 1.4 4.5 41.3 305 504CFLXTSCN 50 1.6 4.9 46.1 395 5 Core (4 Core and Earth) Screened 2.55CFLXTSCN 2.5 0.9 2.1 18.2 49 45CFLXTSCN 4 1.0 2.2 17.0 46 65CFLXTSCN 6 1.0 2.5 24.1 94 105CFLXTSCN 10 1.2 3.7 30.5 150 165CFLXTSCN 16 1.2 4.0 34.2 200 255CFLXTSCN 25 1.4 4.4 41.1 290 19
CABLE SELECTION CURRENT CARRYING CAPACITY AND VOLTAGE DROP PVC FLEXIBLE CORDS Conductor Area ² Single Phase Current A Single Phase Voltage Drop mv/a.m Three Phase Voltage Drop mv/a.m 0.5 3 90 78 0.75 7.5 62 54 1.0 10 46 40 1.5 15 32 28 2.5 20 19 17 4.0 25 12 10 Current ratings based on ambient temperatures of 25 C and a maximum operating temperature of 60 C. Where a flexible cord is coiled or wound on a spool, the following deratings apply. Number of Layers 1 2 3 4 Derating Factor 0.76 0.58 0.47 0.40 PVC FLEXIBLE CABLES Conductor Area ² Protected from Sun Two Single Core, or One Two Core Exposed to Sun Current-Amperes Three Single Core, or One Three or Four Core Protected from Sun Exposed to Sun Three Phase Voltage Drop mv/a.m* Single Core Cables Two Touching, Three Flat Touching, Three in close Trefoil Multicore Cables Two, Three and Four Core 6 44 34 38 29 6.96 6.95 10 60 46 52 39 4.18 4.17 16 81 60 70 51 2.56 2.55 25 110 80 95 68 1.55 1.55 35 135 95 115 81 1.14 1.14 50 160 110 140 96 0.866 0.682 70 205 140 175 120 0.586 0.581 95 240 160 205 140 0.470 0.465 120 280 185 240 160 0.377 0.371 150 320 215 280 185 0.312 0.305 * For single phase voltage drop, multiply by 1.155 20
CABLE SELECTION CURRENT CARRYING CAPACITY AND VOLTAGE DROP FLEXTREME CABLES CURRENT RATINGS AND VOLTAGE DROP Conductor Area ² Protected from Sun Two Single Core, or One Two Core Current-Amperes Three Single Core, or One Three or Four Core Exposed to Sun Protected from Sun Exposed to Sun Three Phase Voltage Drop mv/a.m* Single Core Cables Multicore Cables 6 54 43 46 37 7.29 7.29 10 74 58 63 50 4.38 4.38 16 99 77 85 66 2.68 2.68 25 135 105 115 88 1.63 1.62 35 165 125 140 105 1.2 1.19 50 195 145 165 125 0.906 0.902 70 250 185 215 155 0.612 0.608 95 290 210 250 180 0.49 0.485 120 340 245 290 210 0.392 0.387 150 390 280 335 240 0.323 0.317 * For single phase voltage drop, multiply by 1.155 WELDING CABLES FOR A FIVE MINUTE PERIOD DUTY CYCLE Conductor Area ² Current Rating (A) Maximum Duty Cycle % 100% 60% 30% 25% 20% Electrical Characteristics Max D.C. Resistance at 20 C Ω/km Max A.C. Resistance at 90 C Ω/km 10 90 120 165 180 195 1.84 2.46 16 125 160 225 245 260 1.16 1.5 25 165 210 300 330 350 0.749 0.906 35 205 265 375 410 440 0.53 0.665 50 260 335 475 520 560 0.375 0.499 70 325 415 590 645 690 0.267 0.33 95 390 505 715 780 840 0.198 0.258 120 455 585 830 910 970 0.153 0.2 150 535 690 975 1070 1140 0.123 0.158 DERATING FACTORS RATING FACTOR AMBIENT TEMPERATURE C Cond Temp C 15 20 25 30 35 40 45 50 75 1.35 1.28 1.21 1.14 1.07 1.0 0.91 0.82 90 1.26 1.20 1.15 1.10 1.05 1.0 0.94 0.88 The current ratings are based on an ambient air temperature of 40 C. It should be adjusted for other ambient temperature, by the following factors. 21
CABLE SELECTION SAFE WORKING FORCE CABLES SUBJECTED TO STRAIGHT TENSION WITHOUT SIGNIFICANT BENDING OR FLEXING - SAFETY FACTOR 4:1 Conductor Area ² Single Core kn Two Core kn Three Core kn Four Core kn More Than Four Cores kn 0.5 0.015 0.030 0.045 0.060 0.015 x N 0.75 0.023 0.045 0.068 0.090 0.023 x N 1.0 0.030 0.060 0.090 0.12 0.030 x N 1.5 0.045 0.090 0.14 0.18 0.045 x N 2.5 0.075 0.15 0.23 0.30 0.075 x N 4 0.12 0.24 0.36 0.48 0.12 x N 6 0.18 0.36 0.54 0.72 0.18 x N 10 0.30 0.60 0.90 1.2 0.30 x N 16 0.48 0.96 1.4 1.9 0.48 x N 25 0.75 1.5 2.3 3.0 0.75 x N 35 1.1 2.1 3.2 4.2 1.1 x N 50 1.5 3.0 4.5 6.0 1.5 x N 70 2.1 4.2 6.3 8.4 2.1 x N 95 2.9 5.7 8.6 11 2.9 x N 120 3.6 7.2 11 14 3.6 x N 150 4.5 9 14 18 4.5 x N 185 5.6 11 17 22-240 7.2 14 22 - - 300 9 18 - - - *Where N equals the number of cores of the same size 22
CABLE SELECTION MOTOR CURRENT SINGLE PHASE MOTOR Power Output Single Phase Voltage (V) Current Rating* (A) kw hp 110 220 230 240 250 0.37 0.5 4.71 2.35 2.25 2.16 2.07 0.56 0.75 7.06 3.53 3.38 3.24 3.11 0.75 1 9.42 4.71 4.50 4.32 4.14 1.1 1.5 14.1 7.06 6.76 6.48 6.22 1.5 2 18.8 9.42 9.01 8.63 8.29 1.9 2.5 23.5 11.8 11.3 10.8 10.4 2.2 3 28.3 14.1 13.5 13 12.4 3.0 4 37.7 18.8 18.0 17.3 16.6 3.7 5 47.1 23.5 22.5 21.6 20.7 4.5 6 56.5 28.3 27.0 25.9 24.9 5.2 7 65.9 33.0 31.5 30.2 29 5.6 7.5 70.6 35.3 33.8 32.4 31.1 6.0 8 75.4 37.7 36.0 34.5 33.2 6.7 9 84.8 42.4 40.5 38.9 37.3 7.5 10 94.2 47.1 45 43.2 41.4 9.3 12.5 118 58.9 56.3 54 51.8 11.2 15 141 70.6 67.6 64.8 62.2 14.9 20 188 94.2 90.1 86.3 82.9 18.7 25 235 118 113 108 104 22.4 30 283 141 135 130 124 *Approximate full load currents for standard A.C. induction motors based on power factor and efficiency of 0.8 and 0.9 respectively 3-PHASE MOTOR Power Output Three Phase Line Voltage (V) Current Rating* (A) kw hp 220 380 400 415 440 500 0.37 0.5 1.36 0.79 0.75 0.72 0.68 0.6 0.56 0.75 2.04 1.18 1.12 1.08 1.02 0.9 0.75 1 2.72 1.57 1.50 1.44 1.36 1.2 1.1 1.5 4.08 2.36 2.24 2.16 2.04 1.79 1.5 2 5.44 3.15 2.99 2.88 2.72 2.39 1.9 2.5 6.80 3.94 3.74 3.6 3.4 2.99 2.2 3 8.16 4.72 4.49 4.32 4.08 3.59 3.0 4 10.9 6.30 5.98 5.77 5.44 4.79 3.7 5 13.6 7.87 7.48 7.21 6.8 5.98 4.5 6 16.3 9.44 8.97 8.65 8.16 7.18 5.2 7 19.0 11.0 10.5 10.1 9.52 8.37 5.6 7.5 20.4 11.8 11.2 10.8 10.2 8.97 6.0 8 21.8 12.6 12.0 11.5 10.9 9.57 6.7 9 24.6 14.2 13.5 13 12.2 10.8 7.5 10 27.2 15.7 15 14.4 13.6 12 9.3 12.5 34 19.7 18.7 18 17 15 11.2 15 40.8 23.6 22.4 21.6 20.4 17.9 14.9 20 54.4 31.5 29.9 28.8 27.2 23.9 18.7 25 68 39.4 37.4 36 34 29.9 22.4 30 81.6 47.2 44.9 43.2 40.8 35.9 *Approximate full load currents for standard A.C. induction motors based on power factor and efficiency of 0.8 and 0.9 respectively 23
CABLE SELECTION 3-PHASE FORMULAE FORMULAE COMMONLY USED FOR DETERMINING VARIOUS PARAMETERS OF ELECTRICAL SYSTEMS Desired Data Single Phase Three-Phase I When kva * 1000 kva * 1000 kva is known Eo 3*E I When kw * 1000 kw * 1000 kw is known (Eo*pf) 3*E*pf I When hp * 746/ hp * 746/ hp is known (Eo*pf) 3*E*pf kva I * Eo I * E * 3 1000 1000 kw I * Eo * pf I * E * 3 * pf 1000 1000 hp I * Eo * pf I * E * 3 * pf 746 746 The above table lists formulae coonly used for determining various parameters of an electrical system where: Eo = Single phase voltage, in volts. Eg 240V E = Three phase line voltage, in volts. Eg 415V (E = 3 x Eo) I = Current in amperes %Eff = Percent efficiency in decimals (varies from 85% for small motors to 90% and over in large motors) pf = Power factor in decimals kva = Kilovolt-ampere hp = Horsepower kw = Kilowatts Power Output = Power Input x %Eff 3 = 1.732 24
GENERAL INFORMATION CABLE SELECTION The following are some simplified procedures for cable selection. Refer to the Wiring Rules and AS/NZS 3008.1.1 for detailed information. The four main electrical criteria for cable selection are: 1. Current rating 2. Voltage drop 3. Earth loop impedance 4. Short-circuit capacity Generally speaking, for: 1. Short route length, current-carrying capacity requirement will dictate the cable size selection 2. Long route length, voltage drop or earth loop impedance requirement will dictate the cable size selection 3. The short-circuit capacity of a cable shall be such that all short-circuit current occurring at any point of a circuit shall not cause the cable conductor temperature to exceed the maximum permissible limit CURRENT RATING Current rating of a cable depends on: 1. Installation method, eg., In air or ground, enclosed or unenclosed, etc. 2. Installation environment, eg., ambient temperature, depth of laying, presence of other cables or circuits nearby, etc. 3. Limiting temperatures of the cables for normal use, eg., PVC and XLPE insulated cables are 75 C and 90 C respectively. 4. Type of overcurrent protective device used, appropriate derating factor: - 0.8 for semi-enclosed (rewireable) fuses - 0.9 for fuses, e.g. AS 2005 series fuses, with I 2 = 1.6 x I N - No derating is required for circuit breakers, e.g. AS/NZS 4898 circuit breakers, with I 2 = 1.45 x I N Where: I 2 = convertional overcurrent fusing or tripping current I N = nominal current of the fuse or curcuit breaker Current ratings in this technical manual are extracted from AS/NZS 3008.1.1 VOLTAGE DROP Wiring Rules stipulate a maximum voltage drop of 5% of the nominal voltage between the point of supply and any point in the installation when the conductors are carrying maximum demand. Voltage drops in this technical manual are based on: 1. Maximum conductor temperatures of 75 C, 90 C and 110 C as indicated 2. Load power factor to give maximum voltage drop 3. Single core cables are touching in trefoil or flat formation 4. Supply frequency of 50Hz An Equation to determine minimum required cable size due to voltage drop is: Vc = V d x 1000/I x L millivolts/ampere metre Where: Vc Millivolts drop/ampere metre as given in the tables V d Maximum permissible voltage drop in volts I Current in Amperes L Route length in metres A Cable can now be selected such that Vc is equal to or less than calculated, and check that it will carry the current EARTH LOOP IMPEDANCE, AND SHORT CIRCUIT CAPACITY When relevant information on calculating these values is required please consult the Prysmian "Technical Cable Guide." 25
GENERAL INFORMATION Ambient temperature for current - carrying capacity: The temperature of the medium in the iediate neighbourhood of the installed cable: 1. including any increase in temperature due to materials or equipment to which the cables are connected, or are to be connected; but 2. excluding any increase in temperature which may be due to the heat arising from the cables at that point AS/NZS 1125: Conductors in insulated electric cables and flexible cords AS/NZS 1995: Welding Cables AS/NZS 3000: Australian/New Zealand Wiring Rules AS/NZS 3008.1.1: Australian/New Zealand Standard - Electrical installations - Selection of cables Part 1.1: Cables for alternating voltages up to and including 0.6/1kV - Typical Australian installation conditions AS/NZS 3191: Electric flexible cords AS 3147: Superseded by AS/NZS 5000 AS/NZS 3198: Superseded by AS/NZS 5000 AS/NZS 5000: Australian/New Zealand Standard Electric Cables Polymeric insulated Part 1: For working voltages up to and including 0.6/1kV Part 2: For working voltages up to and including 450/750V Bending radius, installed: Refers to minimum bending radius to which the cable can be subjected to in its final position or location Bending radius, installing: Refers to minimum bending radius to which the cable can be subjected to during the installation process Conductor: That portion of a cable which has specific function of carrying current Cu: Copper conductor, usually refers to plain annealed copper Elastomer: Synthetic Rubber Thermosetting Polymer LV: Low voltage: a.c. = 50V and = 1000V; d.c. = >120V and =1500V Overcurrent: A current exceeding the rated value PACW: Plain annealed copper wire PE: Polythylene (see thermoplastic material) Point of Supply: The junction of the electricity distributor's conductors with the consumers mains (formerly known as consumer terminals) PVC: Polyvinyl Chloride R-EP-90: A cross-linked compound based on ethylene propylene copolymer or terpolymer, suitable for a maximum continuous operating temperature of 90 C Short-circuit current: A fault current resulting from a fault of negligible impedance between live conductors having a difference in potential under normal operating conditions TACW: Tinned annealed copper wire TCu: Tinned copper conductor Thermoplastic material: A material that can be readily softened and resoftened by repeated heating e.g. PVC and PE Thermosetting material: A material which cures by chemical reaction and when cured, or crosslinked, cannot be melted and reshaped e.g. XLPE XLPE: Cross linked polyethylene. For LV application, usually refers to X-90 grade (see thermosetting material) 26
28 NOTES
ABN 36 096 594 080 1 Heathcote Road Liverpool NSW 2170 Tel 1300 300 304 Fax 1300 300 307 sales.au@prysmian.com www.prysmian.com.au Whilst every care has been taken in the preparation of this publication, Prysmian Cables & Systems takes no responsibility for any errors and/or omissions. This technical manual is intended as a guide only and reference must be made by any person using this information to the appropriate Australian Standard and/or to local Electricity Supply Authority rulings. Copyright Prysmian Cables & Systems (ABN 36 096 594 080) 2010. All rights reserved. Subject to change without notice. 29
Prysmian Cables & Systems 1 Heathcote Road, Liverpool NSW 2170 Tel 1300 300 304, Fax 1300 300 307 www.prysmian.com.au 04/10