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Mining power flexible screened cables

Mining power flexible screened cables

TU U 1.3-31850229-015:2003
IEC 60502-1 (1998-11)

 

Application

KGESHV 1.14 kV; 3.3 kV; KGESHV-Pu 1.14 kV
( 1,14 ; 3,3 ; - 1,14 )

Cables are designed to connect mining movable machines and mechanisms to power systems:

  • at rated voltage of 1.14 kV AC, 50 Hz at main conductors and up to 0.220 kV 50 Hz at auxiliary conductors (KGESHV 1.14 kV);
  • at rated voltage of 1.14 kV AC, 50 Hz up to 3.3 kV 150 Hz at main conductors and up to 0.220 kV 50 Hz at auxiliary conductors (KGESHV-Pu 1,14 kV);
  • at rated voltage of 3.3 kV 50 Hz at main conductors and up to 0.220 kV 50 Hz at auxiliary conductors (KGESHV 3.3 kV).

Cables are designed for operation at ambient temperature from -30 C up to +50 C and (98±2)% relative air humidity at temperature (35±2) C.

 

Construction

Conductors
Multicore copper round conductors (not less 5 class in accordance with GOST 22483 – 77).

Insulation of main and auxiliary conductors
Polyvinylchloride (PVC) compound of low hardness.

Screen over main conductors
Electroconductive compound.

Earth conductor
Copper uninsulated round earth conductor (for four-core and seven-core cables and KGESHV-Pu (-)). Earth conductor is divaricated on individual cores and consists from three cores; the total cross-section is not less than 10 mm for six main conductors cables and KGESHV at rated voltage of 3.3 kV. Elastic screen from electroconductive compound laid over each of the individual cores of earth conductor.

Auxiliary conductors
For seven-core KGESHV and KGESHV-Pu cables insulated auxiliary conductors stranded among themselves, polyvinylchloride (PVC) compound oversheath or winding by PVC tape laid over of auxiliary conductors. Four insulated auxiliary conductors and three screened earth conductors are twisted together in cable core for KGESHV cables and cables with six main conductors at rated voltage of 3.3 kV. The elastic screen from electroconductive compound is laid over the cable core.

Stranding
Screened main conductors and earth conductor stranded among themselves for KGESHV four-core cables; screened main conductors and group of auxiliary’s conductors in oversheath or winding stranded around earth conductor for seven-core cables KGESHV and KGESHV-Pu cables. Insulated main conductors stranded around screened cable core of cables with six main conductors. Main insulated conductors of KGESHV cables at rated voltage of 3.3 kV and screened cable core are stranded around bundle on synthetic thread.
Main insulated cable leads with six main leads are stranded around the screened cable core.

Oversheath
One-layer or two-layer polyvinylchloride compound oversheath with filling is laid over stranded conductors of KGESHV and KGESHV-Pu cables. Polyurethane oversheath is laid over two-layer polyvinylchloride compound oversheath in KGESHV-Pu cables. Two-layer polyvinylchloride compound oversheath reinforced by steel-copper braiding is laid over stranded conductors of KGESHV cables at rated voltage of 3.3 kV.

Technical characteristics

Conductors resistance calculated for 1 km at 20C complies:

  • for main and earth conductors complies with GOST 22483-77 at acceptance and delivery;
  • for auxiliary conductors of cross-section 1.5 mm - no more 15.7 Ohm; 2.5 mm - no more 8.85 Ohm; 4 mm - no more 5.8 Ohm;
  • for operational and storage period – no more 120% from normalized at acceptance and supply.

Insulation resistance of conductors calculated for 1 km at 20 C is at least:

  • at acceptance and delivery:
    • for main conductors - 50 MOhm;
    • for auxiliary conductors – 20 MOhm;
  • for operational and storage period for main and auxiliary conductors – 1 MOhm.

Resistance of cable screens and earth conductors, and screen of cable core resistance at temperature 20 C no more:

  • at acceptance and delivery – 1.5 kOhm;
  • for operational and storage period - 2.0 kOhm.

Cables endure AC voltage test and 50 Hz frequency during 5 minutes without immersing in water as follows:

  • at acceptance and delivery:
    • 3.5 kV for main conductors at voltage of 1.14 kV;
    • 9.5 kV for main conductors at voltage of 3.3 kV;
    • 1.5 kV for auxiliary conductors.
  • for operational and storage period – no more 75% from normalized at acceptance and supply.

Cables resist bending with axial torsion and endure number of cycles as follows:
Nominal main conductor cross-section, mm Four-core cables Seven-core cables Cables with six main conductors
Number of cycles Angle of twist ±π radian Number of cycles Angle of twist ±π radian Number of cycles Angle of twist ±π radian
4,0 4000 7 4000 6
6,0 4000 6 4000 5
10 4000 5 4000 5
16 4000 5 4000 4 3000 3
25 4000 4 4000 4 3000 3
35 4000 4 4000 3 2500 3
50 3000 4 3000 3 2500 3
70 3000 3 3000 3 2000 3
95 3000 3 3000 3
120 2500 3 2500 3


Operating directions

Cables are delivered on wooden or metallic drums.

Cables can be used as part of chain cable-laying machine.

Cable-laying machine must provide laying of cable without jamming.

Min. tolerable bending radius of cables at installation and operation must equal min. 5 overall diameters of the cable.

Cables must not be twisted to the angle larger than 2π radian per 1 meter in either direction.

Durable permissible heating temperature of conductors must not exceed 75 C.

Cable must not be used in case its oversheath is damaged.

KGESHV cables at rated voltage of 3.3 kV resist bending with axial torsion and endure number of cycles as follows:

  • to angle ± π/2 radian - 4500 cycles. Minimum bend radius of the cable – 130 mm.
  • number of cycles at bending with axial torsion at angle ±3 π radianmust not be less than 2500 cycles.
  • to strike he firing pin, without damage of sheath and insulation, three strike by the firing pin in one place with energy not less 70 joule.

Oversheath of cables KGESHV-Pu is resistant to abrasion.

Cables are flame retardant with a single laying.

Oxygen index of the insulation cable conductors – min. 25%. Oxygen index of oversheath of cables – min. 27%.

Cables resist destructive effect of lubricating oils and diesel oil.

Construction of cables is hermetical.

Service life: 1.5 years.

The manufacturer can ensure compliance of cable quality with requirements of current technical specification, provided all terms of transportation, storage, installation and use have been observed.

Guarantee period: 6 months from the commissioning date.

Manufactured cable length: not less 200 m.

Cables of variable lengths may be delivered upon request.

All products are certified.

Current loads on cables at durable permissible conductors temperature at 25 C must not exceed values provided in the table:

Nominal main conductors cross-section, mm Current loads for cables for durable permissible heating temperature of conductors 75 C, A
4.0 45
6.0 58
10 75
16 105
25 136
35 168
50 200
70 250
95 290
120 331

Technical Data (reference values)

Number and nominal cross-section of conductors, mm Rated voltage Nominal overall diameter, mm Weight of 1 km cable, kg
KGESHV
3×4.0+1×2.5 1.14 22.2 662
3×6.0+1×4.0 1.14 25.4 883
3×10+1×6.0 1.14 29.1 1196
3×16+1×10 1.14 32.9 1611
3×25+1×10 1.14 37.0 2087
3×35+1×10 1.14 38.8 2466
3×50+1×10 1.14 44.8 3236
3×70+1×10 1.14 48.3 4049
3×95+1×10 1.14 52.7 5071
3×120+1×10 1.14 58.7 6186
3×4.0+1×2.5+3×1.5 1.14 25.1 847
3×6.0+1×4.0+3×2.5 1.14 27.5 1064
3×10+1×6.0+3×2.5 1.14 32.7 1505
3×16+1×10+3×2.5 1.14 34.7 1810
3×25+1×10+3×2.5 1.14 38.0 2254
3×35+1×10+3×2.5 1.14 40.9 2743
3×50+1×10+3×2.5 1.14 47.2 3595
3×70+1×10+3×2.5 1.14 48.3 4175
3×95+1×10+3×2.5 1.14 52.7 5224
3×120+1×10+3×2.5 1.14 58.7 6378
3×16+1×10+3×4.0 1.14 35.8 1927
3×25+1×10+3×4.0 1.14 39.1 2373
3×35+1×10+3×4.0 1.14 40.9 2770
3×50+1×10+3×4.0 1.14 47.2 2622
3×70+1×10+3×4.0 1.14 49.7 4363
3×95+1×10+3×4.0 1.14 52.7 5251
3×120+1×10+3×4.0 1.14 58.7 6408
3×25+1×10+7×2.5 1.14 40.7 2565
3×35+1×10+7×2.5 1.14 43.4 3054
3×50+1×10+7×2.5 1.14 50.2 4000
3×70+1×10+7×2.5 1.14 52.9 4783
3×95+1×10+7×2.5 1.14 55.9 5689
3×120+1×10+7×2.5 1.14 60.6 6697
6×25+3×3.5+4×2.5 1.14 50.2 4120
6×35+3×3.5+4×2.5 1.14 51.8 4774
6×50+3×4.0+4×4.0 1.14 57.8 6025
6×70+3×4.0+4×4.0 1.14 60.9 7381
6×95+3×4.0+4×4.0 1.14 65.0 9049
3×25+3×16+3×3.5+4×2.5 1.14 (3.3) 50.4 3985
3×35+3×16+3×3.5+4×2.5 1.14 (3.3) 51.8 4387
3×25+3×25+3×3.5+4×2.5 1.14 (3.3) 54.2 4835
3×50+3×25+3×4.0+4×4.0 1.14 (3.3) 57.8 5580
3×50+3×35+3×4.0+4×4.0 1.14 (3.3) 57.8 5829
3×70+3×35+3×4.0+4×4.0 1.14 (3.3) 60.9 6710
3×70+3×50+3×4.0+4×4.0 1.14 (3.3) 62.6 7176
3×25+3×3.5+4×2.5 3.3 50.4 3835
3×35+3×3.5+4×2.5 3.3 52.4 4313
3×50+3×4.0+4×2.0 3.3 59.2 5476
3×70+3×4.0+4×2.0 3.3 60.0 6052
3×95+3×4.0+4×2.0 3.3 63.8 7149

Number and nominal cross-section of conductors, mm Rated voltage Nominal overall diameter, mm Weight of 1 km cable, kg
KGESHV-Pu
3×25+1×10+3×2.5 1.14 38.0 2003
3×35+1×10+3×2.5 1.14 40.9 2472
3×50+1×10+3×2.5 1.14 47.2 3282
3×70+1×10+3×2.5 1.14 48.3 3854
3×95+1×10+3×2.5 1.14 52.7 4872
3×25+1×10+3×4.0 1.14 39.1 2115
3×35+1×10+3×4.0 1.14 40.9 2500
3×50+1×10+3×4.0 1.14 47.2 3309
3×70+1×10+3×4.0 1.14 49.7 4032
3×95+1×10+3×4.0 1.14 52.7 4900
3×25+1×10+7×2.5 1.14 40.7 2527
3×35+1×10+7×2.5 1.14 43.4 3013
3×50+1×10+7×2.5 1.14 50.2 3925
3×70+1×10+7×2.5 1.14 52.9 4732
3×95+1×10+7×2.5 1.14 55.9 5636

©
2003–2021 CJSC Production Association Berdyansk Cable Plant
71101, Ukraine, Zaporozhye region,
Berdyansk, Promyshlennaya St., 2b
Phone: +380-6153-20000 (reception)
Made by 
Phantom, 2012