Lightweight Low Fire Hazard Cables according to VG95218 part 28. for Marine applications with a cross reference of VG95218 part 61 to 66

Transcription

1 Lightweight Low Fire Hazard Cables according to part 28 for Marine applications with a cross reference of part 61 to 66

2 VG-CABLE TYCO ELECTRONICS YOUR PARTNER FOR INNOVATION Tyco Electronics is a leading global provider of engineered electronic components, network solutions, undersea telecommunication systems and wireless systems to customers in more than 150 countries. The Aerospace, Defense & Marine Business Unit offers components that are not only aligned to strict military and civil specification standards but also adapted to the respective environmental conditions from space to sub sea platforms. As we have a worldwide sales, engineering, production and logistical network we actively support our customers and its suppliers in global development of new airplanes, ships and defense solutions. The product range includes passive electronic components such as cables, connectors, relays, harness protection products and more. Areas of Product Applications Passive electronics for inside the box Box input/output and outside the box Environmental controlled frame installations Harsh environmental conditions installations AEROSPACE, DEFENSE & MARINE FLAGSHIP PRODUCT GROUPS Interconnect Harness Protection Wire & Cable Relay DELIVERING RELIABLE AND INNOVATIVE PRODUCTS Global Sourcing with One-Stop-Shop capabilities Technology access to all market developments within Tyco Electronics Ability to achieve specific product customization between military and COTS technologies New product development consultancy Partnership for new industry standardizations Manufacturing cooperation & Inventory management Offset programs Design-to-cost

3 Content Introduction 2 Spec Details 3 System Compatibility with improved performance in case of fire 5 Primary Wire technical description 6 Wire Coding 7 Color codes in the drawings 10 VG-CABLE Marking on the cable jacket 10 Cross reference to Part 61 to Cable data 13 Technical Innovation 21 Questions & Answers 32 This document is a presentation, issued by Tyco Electronics, a member of the VG Cable Technical Committee of the Normenstelle Elektrotechnik (public agency for electrotechnical standards). This document has been issued in all conscience. In case of discrepancies in this presentation the original VG Spec applies. All performance information provided with regard to Tyco Electronics products herein is by way of example only and no representation or warranty is created thereby. The only warranty applicable to Tyco Electronics products is as stated in Tyco Electronics standard published warranty and the applicable product specification. Literature number: CFK

4 VG-CABLE Introduction This document is a presentation of the specification part 28, whose lawful causer is the Bundesamt für Wehrtechnik und Beschaffung (BWB). The series of standards Part 28 Type C and E comprises halogenfree cables with an improved performance in case of fire. It has been developed in accordance with the state-of-the-art in cabling techniques with thinwall insulation for primary wires and process optimisation concerning the construction of the cable with a maximum reduction in weight and diameter. In the past, cables of Part 60 to 66 have been used for marine applications. This series of standards has been issued more than ten years ago. The technical development in the range of electronic products also entailed changes in shipbuilding. There is a constant essay to convert the increasing demands on functionality and range of tasks of military vessels by employing modern technology in the electrical equipment. This causes a more and more voluminous and complex structure of electrical supply, electronic systemes and networks, which have to be connected by an efficient and reliable cabling system. By means of technical improvements in the following sectors we made a deciding step forwards with VG Part 28 C and E, accomodating the changed demands in shipbuilding as well as empirical values from the past. Increased life time (service life) Longterm resistance against environmental impact Reduction in weight and diameter Increased EMI demands You can find more details about these improvements in chapter Technical Innovation. These records contain technical data about cables according to Part 28 Type C and Type E as an alternative for Part 61 to 66 of Spec. The spectrum of tests for the cables of Part 28 Type C and E was construed in accordance with the requirements of modern marine technics and features, besides the electrical and mechanical demands, also the benefits of limited fire hazard: halogen free flame retarded low smoke generation low acid gas emission low toxicity index The Spec has been released for marine applications. 2 Literature number: CFK 09-08

5 Spec Details Part 28 Type C and E Part 28 contains in general a set of different types of cables for various applications. These cables cut into the five types A, B, C, D and E, including the relevant test requirements. The instructions on how to carry out the tests and what national and international standards are to be quoted are stated in the specification Part 2. Halogen free cables with an improved performance in case of fire are required for marine applications. Cables that meet these requirements can be found in Type C and Type E. At present, 81 different constructions are available in Type C (single braid), numbered C001 to C081. In Type E (double screen) there are currently 11 different constructions, numbered E001 to E011. VG-CABLE The types of cables which can be compared directly to Part 61 to 66 are specified in Part 28 under part no.s C033 to C078 and E004 to E011. Only these constructions will be described in the following document. All other constructions of Types C and E fulfill similar requirements, but differ significantly in construction, number of components, conductor sizes and combination of single wires, as they have been customized according to the special requirements of a single, user-defined application. Literature number: CFK

6 VG-CABLE Spec Details Part 28 Type C and E Cables approved according to Part 28 Typ C and E contain single conductors, components and jacket materials, which have to be approved and licenced indivdually and independently from each other according to the subgroup of the standards. Every sub-standard contains test requirements for electrical and mechanical features, as well as demands for resistance against aggressive fluids and improved performance in case of fire. Part 28 C and E cables comprise. Single Wires, specified according to sub-standard Part 20 Type E available in cross sections of 0,15 mm 2 to 3,0 mm 2 in 11 different colours including green/yellow. Single Wires can be used as components in multicore cables as well as single element for wiring of units or cabinets. Unbraided Components in pairs, triples and quads specified in standard Part 21 Type C. Elements of Part 21 Type C contain single wires of Part 20 Type E and define, additionally, various color combinations of single wires. Braided Components in pairs, triples and quads specified in standard Part 23 Type G. Elements of Part 23 Type G contain elements of Part 21 Type C. Elements that are defined by colors are braided and protected by a wrapped outer layer. These elements can be used only as components in multicore cables. The jacket material and the complete cable are specified in standard Part C and E. This comprises the constructive data of the cables, as well as all test requirements for the complete cable and cable jacket. Spec Part 28 acts on a modular conception, which allows to design and define freely the construction of a cable with tested and approved components according to Part 20 to 23 and the requirements of the user. 4 Literature number: CFK 09-08

7 System Compatibility Cables according to Part 28 Type C and E meet the requirements of standard VG95214 Part 14 System Compatibility, for materials with improved performance in case of fire. This means: these cables have an approved adhesive bonding performance within an the system with halogenfree heatshrinkable tubings of VG95343 Part 5 Type L and halogenfree moulded parts of VG95343 Part 29 (boots) and Part 30 (transitions). The following illustration shall clarify that: Wire & Cable Low fire Hazard Harness-System VG95343 Heat Shrink VG-CABLE T20 E Primary wire (PW) T22 D PW screened Backshell VG95343 T29 Branchesn VG95343 T30 Tubings VG95343 T05 Typ A Typ A Typ L T21 C Open bundle T23C&G Screened comonent 202K -01 one lip 322A Typ B Typ B T27 A T28C&E 202K -02 two lips 342A Unscreened Cable Screened Cable Typ C Typ C 202K three lips 382A Typ D Typ D 222K 462A moulded part/cable T14 combination D 2/1 molded part/tubing T14 combination D 2/2 VG95343 T14 system compatibility Literature number: CFK

8 VG-CABLE Single Wire technical description* Single Wires, specified in Part 20 Type E Part No. Cross- No./diameter Max. Diameter Max. - sectional of strands diameter cable nom. resistance T20 area mm mm C mm 2 Ohm/km E01* 0,25 19/0,13 0,673 1,13 84,40 E02* 0,40 19/0,16 0,838 1,30 50,50 E05* 0,75 19/0,23 1,168 1,61 26,70 E07* 1,20 19/0,29 1,478 1,91 15,30 E08* 1,50 37/0,23 1,648 2,12 13,70 E10* 2,5 37/0,29 2,080 2,57 8,21 The asterisk in the part no. (e.g. -T20-E01*) has to be replaced by the code defining the colour of the insulation: 0 = black; 1 = brown; 6 = blue; 8 = grey; 9 = white; G = green/yellow. These are standard colours, which are used for marine cables. Further colours are available and defined in standard -Part 20 Type E. * (only for wire sizes in this document) 6 Literature number: CFK 09-08

9 Colour Coding Part 28 Type C and E The following colour coding applies only for 28 Type C und E, which are defined as direct alternatives for Part 61 to 66. Other part no.s of Part 28 C and E contain preferably wires with white insulation and number codes. A) Cable overall braid 1,5 mm 2 and 2,5 mm 2 Chart 1 (LMGSGO) Cable with Earthwire green/yellow 3 cores: green/yellow, black, blue 5 cores: green/yellow, black blue, brown, black 7 to 10 cores: green/yellow (outer layer) all other black with white numbers, starting from centre. Cables without Earthwire green/yellow 2 cores: black, blue 3 cores: black, blue, brown 4 cores: black, blue, brown, black 5 cores: black, blue, brown, black, black 7 and more: white with black numbers, starting from centre VG-CABLE B) Cable pairs, with overall braid 0,75 mm 2 Chart 2 (FMGSGO) Cable with 2-pairs (1 star quad cable) Black, blue, grey, brown (black and grey opposite) Cable with 4 pairs 1st Pair: black, blue 2nd Pair: black, brown 3rd Pair: black, grey 4th Pair: black, grey Cable with 6 to 16-pairs (3 to 8 star quad cables) Every star quad: black, blue, grey, brown (black and grey opposite) Literature number: CFK

10 VG-CABLE Colour Coding Part 28 Type C and E C) Cable braided pairs, with overall braid 0,75 mm 2 Chart 3 (FMSGSGO) Cable with 2 pairs (1 star quad cable) 1st Pair: black, blue 2nd Pair: black, brown Cable with 4 to 24-pairs, valid for every layer 1st Pair: black, blue (pilot) 2nd Pair: black, brown (direction) 3rd Pair and further pairs: black, grey Pairs for pilot and direction in every layer. D) Cables pairs with overall braid 0,4 mm 2 Chart 4A (LFMGSGO) Cable with 2 pairs (1 star quad cable) Black, blue, grey, brown (black and grey opposite) Cable with 4 to 54-pairs, valid for every layer 1st pair: black, blue (pilot) 2nd pair: black, brown (direction) 3rd pair and further pairs: black, grey Same position of pairs for pilot and direction in every layer. E) Cables pairs with double overall braid 0,4 mm 2 Chart 4B (LFMGSSGO) Cable with 2 pairs (1 star quad cable) Black, blue, grey, brown (black and grey opposite) Cable with 4 to 54-pairs, valid for every layer 1st pair: black, blue (pilot) 2nd pair: black, brown (direction) 3rd pair and further pairs: black, grey Same position of pairs for pilot and direction in every layer. F) Cables braided pairs with overall braid 0,4 mm 2 Chart 5A (LFMSGSGO) In every layer: 1st pair: black, blue (pilot) 2nd pair: black, brown (direction) 3rd pair and further pairs: black, grey Same position of pairs for pilot and direction in every layer. 8 Literature number: CFK 09-08

11 Colour Coding Part 28 Type C and E G) Cable braided pairs with overall braid 0,25 mm 2 Chart 5B (LFMSGSGO) Including mulitcore cables 3 x 2 x 1, x 2 x 0,25 Wire and star quad 0,25 mm 2 For every layer: 1st star quad: black, white, grey, blue, core coding: red (pilot) 2nd star quad: black, white, grey, blue, core coding: green (direction) 3rd star quad: black, white, grey blue Coding for wire and pair Cable 3 x 2 x 1, x 2 x 0,25 Wires in every pair: black, white Coding pairs: 1st pair with 1,2 mm 2 : red 2nd pair with 1,2 mm 2 : green 3rd pair with 1,2 mm 2 : nature VG-CABLE For every layer: 1st pair with 0,25 mm 2 : red (pilot) 2nd pair with 0,25 mm 2 : green (direction) 3rd pair and further pairs with 0,25 mm 2 : nature Same position of the pairs for pilot and direction every layer. H) Cable triple wires, braided with double overall braid Chart 6 (LFMSGSSGO) Triple wire colours black, white, grey Coding of triple wire elements in every layer 1st element: red 2nd element: green 3rd element: nature Literature number: CFK

12 VG-CABLE Color coding on drawings The sectional drawings of the cables show depending on the spec to be applied the marking with consecutive numbers or by color codes as per standard: 0 = black 1 = brown 2 = red 3 = orange 4 = yellow 45 = green/yellow 5 = green 6 = blue 7 = violet 8 = grey 9 = white Cable Jacket Marking The jacket has to be marked according to VG with supplier s name, VG-No., VDE Register manufacturer code. Additionally, further information can be printed on the jacket, which helps to identify the construction of the cable, as e.g. according to the following codes: L Light Weight F Communications M Marine G Insulation or Jacket S Braid O without defined maintenance of functions in case of fire Cable Marking: Example Raychem -T28-C050 VDE Reg.Nr K1010 FMGSGO (4 x 2 x 0,75) 10 Literature number: CFK 09-08

13 Cross Reference List for Part 61 to 66 Number of wires x New numbers nominal cross-section VG T28 VG T61 to 66 LMGSG0 T28 T61 (2 x 1,5) C033 A001 (3 x 1,5) C035 A002 (4 x 1,5) C042 A003 (5 x 1,5) C044 A004 (7 x 1,5) C046 A005 (10 x 1,5) C052 A006 (12 x 1,5) C055 A007 (14 x 1,5) C058 A008 (16 x 1,5) C060 A009 (19 x 1,5) C061 A010 (24 x 1,5) C065 A011 (27 x 1,5) C066 A012 (33 x 1,5) C070 A013 (2 x 2,5) C034 A014 (3 x 2,5) C037 A015 (4 x 2,5) C043 A016 (7 x 2,5) C048 A017 (37 x 1,5) C005 A018 (3G1,5) C036 A102 (5G1,5) C045 A104 (7G1,5) C047 A105 (10G1,5) C053 A106 (3G2,5) C038 A115 VG-CABLE FMGSG0 T28 T62 (2 x 2 x 0,75) C040 A001 (4 x 2 x 0,75) C050 A002 (6 x 2 x 0,75) C054 A003 (8 x 2 x 0,75) C059 A004 (10 x 2 x 0,75) C062 A005 (14 x 2 x 0,75) C067 A006 (16 x 2 x 0,75) C069 A007 (1 x 2 x 0,75) C032 A008 Literature number: CFK

14 VG-CABLE Cross Reference List for Part 61 to 66 Number of wires x New numbers nominal cross-section VG T28 VG T61 to 66 FMSGSG0 T28 T63 (2 x 2 x 0,75) C041 A001 (4 x 2 x 0,75) C051 A002 (7 x 2 x 0,75) C057 A003 (11 x 2 x 0,75) C063 A004 (14 x 2 x 0,75) C068 A005 (19 x 2 x 0,75) C072 A006 (24 x 2 x 0,75) C074 A007 LFMGSSG0 T28 T64 (2 x 2 x 0,4) E004 A001 (4 x 2 x 0,4) E005 A002 (7 x 2 x 0,4) E006 A003 (12 x 2 x 0,4) E008 A004 (19 x 2 x 0,4) E010 A005 (27 x 2 x 0,4) E011 A006 (30 x 2 x 0,4) LFMGSG0 C076 B001 (45 x 2 x 0,4) LFMGSG0 C077 B002 LFMSGSG0 T28 T65 (2 x 2 x 0,4) C039 A001 (4 x 2 x 0,4) C049 A002 (7 x 2 x 0,4) C056 A003 (12 x 2 x 0,4) C064 A004 (19 x 2 x 0,4) C071 A005 (27 x 2 x 0,4) C075 A006 (3 x 2 x 1,2 18 x 2 x 0,25) C073 B001 (27 x 4 x 0,25) C078 C001 LFMSGSSG0 T28 T66 (5 x 3 x 0,4) E007 A001 (12 x 3 x 0,4) E009 A Literature number: CFK 09-08

15 Cable data for Part 28 Type C and E LMGSGO Part 28 C multicore cables screened FMGSG0 Part 28 C multicore cables screened FMSGSG0 Part 28 C multipair cables screened LFMGSG0 Part 28 C multipair cables screened VG-CABLE LFMGSSG0 Part 28 E multipair cables collectively double screened LFMSGSG0 Part 28 C multipair cables screened LFMSGSSG0 Part 28 E multitriple cables screened Literature number: CFK

16 VG-CABLE LMGSGO Part 28 C multicore cables screened Example T28 C061 Table 1 LMGSGO multicore cables screened 1,5 mm 2 and 2,5 mm 2 Number cores Dash No. Bundle Nominal Wall- Diameter Mass Resistx nominal diameter diameter of thickness of cable ance cross-section screen wire of sheath at 20 C mm 2 T28 mm AWG mm mm mm mm kg/km Ohm/km nom. min. min. max. max. max. 2 x 1,5 C033 4,9 36 0,13 0,7 6,2 6, ,1 3 x 1,5 C035 5,2 36 0,13 0,7 6,5 7, ,1 4 x 1,5 C042 5,7 34 0,16 0,7 7 7, ,1 5 x 1,5 C044 6,3 36 0,13 0,7 7,6 8, ,1 7 x 1,5 C046 6,9 36 0,13 0,7 8,0 8, ,1 10 x 1,5 C052 9,1 34 0,16 0,8 10,2 11, ,1 12 x 1.5 C055 9,5 34 0,16 0,8 10,6 11, ,1 14 x 1,5 C058 10,0 34 0,16 0,8 11,1 12, ,1 16 x 1,5 C060 10,6 34 0,16 0,8 11,5 12, ,1 19 x 1,5 C061 11,2 34 0,16 0,8 12,1 13, ,1 24 x 1,5 C065 13,5 32 0,20 0,8 14,2 15, ,1 27 x 1,5 C066 13,8 32 0,20 0,8 14,5 15, ,1 33 x 1,5 C070 14,9 32 0,20 0,9 15,6 17, ,1 37 x 1,5 C005 14,6 32 0,20 1,3 18,2 19, ,1 3G1,5 C036 5,2 36 0,13 0,7 6,5 7, ,1 5G1,5 C045 6,3 36 0,13 0,7 7,6 8, ,1 7G1,5 C047 6,9 36 0,13 0,7 8 8, ,1 10G1,5 C053 9,1 34 0,16 0,8 10,2 11, ,1 2 x 2,5 C034 5,8 36 0,13 0,7 7,1 7, ,46 3 x 2,5 C037 6,2 36 0,13 0,7 7,5 8, ,46 4 x 2,5 C043 6,9 36 0,13 0,7 8 8, ,46 7 x 2,5 C048 8,4 34 0,16 0,7 9,5 10, ,46 3G2,5 C038 6,2 36 0,13 0,7 7,5 8, ,46 14 Literature number: CFK 09-08

17 FMGSG0 Part 28 C multicore cables screened Example T28 C067 VG-CABLE Table 2 FMGSG0 multipair cables collectively screened 0,75 mm 2 Number cores Dash No. Bundle Nominal Wall- Diameter Mass Resistx nominal diameter diameter of thickness of cable ance cross-section screen wire of sheath at 20 C mm 2 T28 mm AWG mm mm mm mm kg/km Ohm/km nom. min. min. max. max. max. 1 x 2 x 0,75 C032 3,7 36 0,13 0,7 5,2 5, ,5 2 x 2 x 0,75 C040 4,3 36 0,13 0,7 5,6 6, ,4 4 x 2 x 0,75 C050 7,4 34 0,16 0,7 8,5 9, ,4 6 x 2 x 0,75 C054 8,7 34 0,16 0,8 9,8 10, ,5 8 x 2 x 0,75 C059 9,6 34 0,16 0,8 10,7 11, ,5 10 x 2 x 0,75 C062 10,7 34 0,16 0,8 11,6 12, ,5 14 x 2 x 0,75 C067 11,8 34 0,16 0,8 12,7 13, ,5 16 x 2 x 0,75 C069 13,2 32 0,20 0,8 13,9 15, ,5 Literature number: CFK

18 VG-CABLE FMSGSG0 Part 28 C multipair cables screened Example T28 C057 Table 3 FMSGSG0 multipair cables individually and collectively screened 0,75 mm 2 Number cores Dash No. Bundle Nominal Wall- Diameter Mass Resistx nominal diameter diameter of thickness of cable ance cross-section screen wire of sheath at 20 C mm 2 T28 mm AWG mm mm mm mm kg/km Ohm/km nom. min. min. max. max. max. 2 x 2 x 0,75 C041 8,3 36 0,13 0,70 9,4 10, ,4 4 x 2 x 0,75 C051 9,5 34 0,16 0,80 10,6 11, ,4 7 x 2 x 0,75 C057 11,7 34 0,16 0,80 12,6 13, ,5 11 x 2 x 0,75 C063 14,8 32 0,20 0,90 15,5 17, ,5 14 x 2 x 0,75 C068 15,8 32 0,20 0,90 16,5 18, ,5 19 x 2 x 0,75 C072 18,3 32 0,20 0,90 18,8 20, ,5 24 x 2 x 0,75 C074 20,4 32 0,20 1,00 20,7 22, ,5 16 Literature number: CFK 09-08

19 LFMGSG0 Part 28 C multipair cables screened Example T28 C062 VG-CABLE Table 4A LFMGSG0 multipair cables collectively screened 0,4 mm 2 Number cores Dash No. Bundle Nominal diameter Wall- Diameter- Mass Resistx nominal diameter of screen wire thickness of cable ance cross-section of sheath at 20 C mm 2 T28 mm AWG1 mm AWG2 mm mm mm mm kg/km Ohm/km nom. min. min. max. max. max. 30 x 2 x 0,4 C076 14,2 34 0, ,16 0,9 15,1 16, x 2 x 0,4 C077 17,6 32 0, ,20 0,9 18,1 19, Literature number: CFK

20 VG-CABLE LFMGSSG0 Part 28 E multipair cables collectively double screened Example T28 E006 Table 4B LFMGSSG0 multipair cables collectively double screened 0,4 mm 2 Number cores Dash No. Bundle Nominal diameter Wall- Diameter- Mass Resistx nominal diameter of screen wire thickness of cable ance cross-section of sheath at 20 C mm 2 T28 mm AWG1 mm AWG2 mm mm mm mm kg/km Ohm/km nom. min. min. max. max. max. 2 x 2 x 0,4 E004 4,4 36 0, ,13 0,7 5,7 6, x 2 x 0,4 E005 6,8 36 0, ,13 0,7 7,9 8, x 2 x 0,4 E006 8,3 36 0, ,13 0,7 9,4 10, x 2 x 0,4 E008 10,2 34 0, ,16 0,8 11,3 12, x 2 x 0,4 E010 12,4 34 0, ,16 0,8 13,1 14, x 2 x 0,4 E011 14,8 32 0, ,20 0,9 15,5 17, Literature number: CFK 09-08

21 LFMSGSG0 Part 28 C multipair cables screened Example T28 C056 VG-CABLE Table 5A LFMSGSG0 multipair cables individually and collectively screened 0,4 mm 2 Number cores Dash No. Bundle Nominal Wall- Diameter Mass Resistx nominal diameter diameter of thickness of cable ance cross-section screen wire of sheath at 20 C mm 2 T28 mm AWG mm mm mm mm kg/km Ohm/km nom. min. min. max. max. max. 2 x 2 x 0,4 C039 7,0 36 0,13 0,70 8,1 8, x 2 x 0,4 C049 8,0 34 0,16 0,70 9,1 9, x 2 x 0,4 C056 9,9 34 0,16 0,80 11,0 12, x 2 x 0,4 C064 12,5 32 0,20 0,80 13,2 14, x 2 x 0,4 C071 15,5 32 0,20 0,90 16,2 17, x 2 x 0,4 C075 18,2 32 0,20 0,90 18,7 20, Table 5B LFMSGSG0 multipair cables individually and collectively screened 0,25 mm 2 Number cores Dash No. Bundle Nominal Wall- Diameter Mass Resistx nominal diameter diameter of thickness of cable ance cross-section screen wire of sheath at 20 C mm 2 T28 mm AWG mm mm mm mm kg/km Ohm/km nom. min. min. max. max. max. 3 x 2 x 1, x 2 x 0,25 C073 17,3 32 0,20 0,90 17,8 19, x 4 x 0,25 C078 20,3 32 0,20 1,00 20,6 22, Literature number: CFK

22 VG-CABLE LFMSGSSG0 Part 28 E multitriple cables screened Example T28 E007 Table 6 LFMSGSSG0 multitriple cables individually and double collectively screened 0,4 mm 2 Number cores Dash No. Bundle Nominal diameter Wall- Diameter- Mass Resistx nominal diameter of screen wire thickness of cable ance cross-section of sheath at 20 C mm 2 T28 mm AWG1 mm AWG2 mm mm mm mm kg/km Ohm/km nom. min. min. max. max. max. 5 x 3 x 0,4 E007 10,3 34 0, ,16 0,8 11,2 12, x 3 x 0,4 E009 15,2 32 0, ,20 0,9 15,9 17, Literature number: CFK 09-08

23 Technical Innovation On the following pages you will find details about the main focus of the technical improvements of part 28 C&E compared to cables of part 61 to 66. Increased Service Life Time (Thermal Endurance) Longterm Resistance against environmental impact Reduction in Weight and Diameter Increased EMI Requirements VG-CABLE Literature number: CFK

24 VG-CABLE Service Life Time Service Life Time Thermal Endurance The thermal endurance of cables is defined by the analysis of an Arhenius aging curve. The end point of the thermal endurance is set when the jacket s ability to stretch, which is reduced by aging, of 50 % ultimate elongation has been reached (IEC216). Time = f (temperature, elongation). The Ageing Test is carried out for h and with the measuring points being linear extrapolated up to h (IEC216). The endpoint to be determined states that the jacket at h only can cope with an elongation of 50 % before it cracks. Conferred to the elongation before ageing this means in general a reduction of the elongation features by a factor of 4. The temperature that has been acquired by that method is indicated as operating temperature. The end point acquired does not mean that the cable has to be defective. The operating temperature of Part 28 Type C&E cables is 105 C compared to 85 C for Part 61 to 66 This means... Part 61 to 66: Required end point for h at 85 C With the system being operated at 85 C max, after about 2,3 years the jacket can be stretched only up to 50 % before cracking. This approximates 1 /4 of the jacket s capability before ageing. Part 28 C&E: Required end point for h at 105 C During testing of the system at 85 C max., similar aging status of the Tyco Electronics Part 28 cables was extrapolated only after 17 years ( h). This means an increased service life by factor 7! Tyco Electronics demonstrable end point for h at 115 C During testing of the system at 85 C max., similar aging status of the Tyco Electronics Part 28 cables was extrapolated only after 25 years ( h). This means an increased service life by factor 10! 22 Literature number: CFK 09-08

25 Service Life Time Results Life Time... By raising the temperature resistance of the cables from 85 C (Part 61 to 66) to 105 C (Part 28) the thermal endurance will be extended by about 7 times due to the benefits of the materials used but on condition that the electrical load will not be increased and the operation temperature remains 85 % max. The increasing of the thermal endurance from 2,3 years (Part 61 to 66) to about 20 years (Part 28 C&E), at an operating temperature of 85 C max. is an important step to approach the verification of the laboratory tests about the aging characteristics to the virtual service life time of vessels. Arhenius Ageing Graph IEC216 VG-CABLE In Service Life Time (IEC % Elongation) Literature number: CFK

26 VG-CABLE Long term Resistance Against Environmental Influence Longterm Resistance Against Chemicals and Fluids Another important aspect when choosing a cable is, besides the operating temperature, the resistance against the environmental impact within the meaning of chemicals and fluids like oils, propellants, lubricants and cleaning fluids. For testing the chemical resistance of VG cables, the jacket material is laid in various test fluids at raised temperatures over a certain period. Due to the raised temperature the ageing process is accelerated. Cables as per Part 61 to 66 as well as Part 28 C&E have to be tested in the following liquids: Demineralised water Saltwater Test Oil IRM902 Machine oil O-278 Marine Diesel Oil Cold Cleanser The tests ascertain how much liquid the jacket material absorbs (change in mass %). Besides the elongation and tensile strength is tested. 24 Literature number: CFK 09-08

27 Long term Resistance against Environmental Influence Conclusion... Generally cables of Spec Part 28 C&E show a significant improvement in the resistance against chemicals towards cables of part 61 to 66. Concerning tensile strength and elongation features, the requirements of both specifications are on a par and hardly differ from each other. The most serious difference is the change of mass. Due to the requirements of part 28 C&E we could reach a reduction in mass increase of the jacket material of ca. factor Example: Using machine oil O 278, Part 61 to 66 allows for a mass increase of 50 %, whereas Part 28 C&E only admits 5 %. This means an improvement by factor 10. The test results of Tyco Electronics cables even rests with only 1,4 % (Factor 36). VG-CABLE There is a more extensive comparison in the chart on page 26. As the cable materials of Part 28 C&E scarcely absorb other substances in the form of fluids or vapours, the long term alteration of individual features of the cable jacket will be extremely reduced; the cables don t get brittle. Combining the features of increased operating temperature with the distinct resistance against environmental impact, the cables of Part 28 C&E provide a substantial improvement of the anticipated life time in service. Literature number: CFK

28 VG-CABLE Long term Resistance Against Environmental Influence Resistance Against Chemicals/Comparison Part 61 to 66 to Part 28 C&E Mass change % Tensile strenghtn/sqm Acionat (water) IRM 902 IRM 902 O-278 Engine O-278 Engine Oil Seawater 50 C / Navy Diesel Navy Diesel Cleaning fluid 50 C/672h 100 C/24h 90 C/672h Oil100 C/168h 50 C/672h 672h 50 C/168h 23 C/672h 23 C/24h T28 Tensile Strength T28 Mass Change % T60-66 Tensile Strength T60-66 Mass Change % Resistance Against Chemicals/Comparison Part 61 to 66 to Part 28 C&E to Tyco Electronics Cables Mass change % Acionat (water) 50 C/672h IRM C/24h IRM C/672h O-278 Engine Oil 100 C/168h O-278 Engine Oil 50 C/672h Seawater 50 C / 672h Navy Diesel 50 C/168h Navy Diesel 23 C/672h RY Mass change % 5 4,2 4,3 1,39 0,57 0,73 8 7,3 1,73 T28 Mass Change % T60-66 Mass Change % Cleaning fluid 23 C/24h 26 Literature number: CFK 09-08

29 Reduction of Diameter and Weight Reduction of Diameter and Weight, achieved by... A) Thin wall primary wires Wires for Part 28 Cables Dual Wall Insulation Tensile Strength 20 N/mm Elongation 200 % Wires for Part 61 Cables Single Wall Insulation Tensile Strength 10 N/mm Elongation % VG-CABLE Reduction of wall thickness due to optimized materials 0,4 mm to 0,2 mm Literature number: CFK

30 VG-CABLE Reduction of Diameter and Weight Reduction of Diameter and Weight, achieved by... B) concentric and compact construction of the cable bundle, owing to the single wire Part 28 Cable/Wire Part 20 Type E The comparative transfer of a single wire Part 20 into a Part 61 cable illustrates how much space and material can be saved by the single wire. The single wire reduces the diameter of the cable bundle considerably and, thus, affects the diameter of the entire cable. Figure cable part Literature number: CFK 09-08

31 Reduction of Diameter and Weight Reduction of Diameter and Weight Summary... thinwall wire result in concentric and compact construction of the cable bundle this allows an optimized extrusion of the jacket (with low pressure) no wraps necessary to separate the layers low tolerances of the nominal thickness of the jacket thus, minimisation of jacket material thus, minimisation of inflammable material on board VG-CABLE Examples: The reduction of weight using part 28 achieves ca. 20 % concerning signal and control cables towards cables of part 61 to 66. Frigate class F-124 ca. 5,5 t Submarine U-212 ca. 1 t and saves approx. 17 % space... according to this more space in the cable trays Literature number: CFK

32 VG-CABLE EMI (Electro-Magnetic Interference) Improvement of the EMI requirements... Within the frame of Part 28 C&E two values have been introduced to evaluate EMI properties. For cables according to part 61 to 66 a maximum mutual impedance at 10 khz is demanded and measured independently of the cable size. This allows only a flatrate valuation of the screening characteristics, as typically up to about 10 khz there is hardly a change in the transfer impedance along the frequency. (Chart, measuring point A) Irrespectively of that, this is a testing frequency that is no longer used by the VDE and the International Standardisation. In part 28 the value at 10 khz is both requested and measured for a better comparison, and as well at 30 khz after International Standard. Here, the maximum transfer impedance is adapted to the size (diameter) of the cable according to the parameters for the braid layout. (Chart, measuring points B) 30 Literature number: CFK 09-08

33 EMI (Electro-Magnetic Interference) Conclusion... The measurement of the transfer impedance in Part 28 at two frequencies dependently of the diameter of the cable, permits a significantly more accurate appraisal of the screening characteristics of the cable Transfer impedance versus frequency; various cables according to part 28 C&E A B VG-CABLE , Frequenz (khz) C051 (FMSGSGO 4x2x0,75) C052 (LMGSGO 10x 1,5) C073 ( LFMGSGO 3x2x1,2+18x280,25) C040 ( FMGSGO 2x 2x 0,75) Literature number: CFK

34 VG-CABLE Questions & Answers about cables of Part I. General Questions about the cable How could we achieve this reduction in weight? On the one hand we achieved the reduction by a thinner insulation of the primary wire. The insulation material we used allows a wall thickness of ca. 0,2 mm without deterioration of the mechanical and electrical characteristics. On the other hand, using this type of wire we obtained a rounder surface (smaller gaps between individual wires) of cable bundle, which enables us to extrude the jacket with regard to the wall thickness more precisely. Moreover we don t use any separating layers or fillers for pairs. Will the cables be approved by the Geman Lloyd? Halogenfree cables with an approval according to VG are generally accepted by the German Lloyd, currently Tyco Electronics aim at a formal certification. How are the cables denominated and marked? The cables are well defined and identified by the complete VG number. This number is printed together with the VDE register number on the cable jacket. Additionally, information on the construction, e.g. LMGSGO (3 x 1,5), can be printed on it. E.g. T28 C040 VDE Reg. xxxx FMGSGO (2 x 2 x 0,75). Are the cables of Part 28 approved for marine applications? The series of standards Part for cables with low fire hazard performances have been adjusted to the demands of the marine market and have been approved for procurement and use. Has this cable technology been developed especially for the German Navy? No, with this technology Tyco Electronics has about 20 years of experience in the international cable market. It is used all over the world for a variety of marine projects and appears in several specifications for marine cables, e.g. UK Def-Stan, the French DCN, the Italian NAV, the Dutch MSSV. Within the frame of the VG Spec the halogenfree cables of Part 28 are generally available since 1998, but only end of 2001 the adaptation to the marine specific demands has been completed and released for approval and procurement. Thus, this technology, which has been used internationally for a long time, is now available also according to a German standard. 32 Literature number: CFK 09-08

35 Questions & Answers about cables of Part Is Part 20 to 28 already available? All products of this series of standards are available. Documents of the standard can be obtained at the Normenstelle Elektrotechnik or at Beuth Verlag. Who has developed and worked out this series of standards? This standard has been developed by the Normenstelle Elektrotechnik in the frame of the standard board NEA410 lead-managed by the German MOD and with participation of representatives of the manufacturing and applying industry. What was the reason for the development of this standard? The basic approach for this standard was the attempt place light weight and technically improved marine cables at the users disposal. Can the user design constructions of his own within the frame of this standard? Part 20 to 28 has been built up as a modular design principle and contains single wires (T20), multi cores (T21; T23) und and complete cables (T27; T28). Each part has to be tested and the approval has to be acquired individually. In this regard, a custom-designed mixed cable can be composed using various single wires or components and a new VG Part 28 number will be assigned to it in the end. This provides maximum flexibility for the users and their applications, although one should always check whether the cable requested does exist already. VG-CABLE In which projects cables of Part 28 have been set in already? Submarine U212 German Navy Corvette MEKO A-200 SAN Navy South Africa Patrol Boat MEKO 100 RMN Royal Navy Malaysia Frigate F-122 (conversion) German Navy Destroyer Marasesti (Romania) Romanian Navy Literature number: CFK

36 VG-CABLE Questions & Answers about cables of Part II. Questions about the cable system Do the cables fulfill the regulations on flammability? The cables fulfill according to the regulations IEC332-1 und IEC What service life do these cables have? Tyco Electronics cables of Part VG Part 28 Type C&E provide a service life of about h at an operating temperature of 85 C maximum, which approximates 25 years. The allowed operating temperature of these cables rests with 105 C. Are there differences between cables according to part 28 and part 61 to 66 concerning the electrical properties? There are no differences in the electrical properties of these standards. Are there differences between cables according to part 28 and part 61 to 66 concerning the mechanical properties? Tyco/Raychem cables differ in the mechanical properties mainly in higher flexibility, better abrasion resistance, flexing properties to 40 C and more robust single wires. Are there differences between cables according to part 28 and part 61 to 66 concerning the chemical resistance With Part 28 a really significant improvement of the chemical resistance could be achieved. The disposition of the jacket materials to absorb other substances in the form of vapours or liquids has been greatly reduced. This becomes clear in the tests about the mass change of the cables after they have been immersed in the test fluids: the mass change could be reduced by factor Tyco Electronics cables partially show even a reduction by factor 35. How are the properties concerning EMI/electromagnetic shielding against part 61 to 66? The EMI properties of cables are characterised by the transfer impedance. For Part 28 cables the more modern measuring method is used (30 hhz) and, at the same time, more test values are demanded. Depending on the frequency (10 khz und 30 khz) and the diameters, this makes a more precise determination of the shielding properties possible. 34 Literature number: CFK 09-08

37 Questions & Answers about cables of Part Are the wires more susceptible because of their thinwall insulation? The components used in Part 28 according to Part 20 have a dual wall insulation. Both layers consist of the same basic material. The outer layer has been optimised in its characteristics regarding the resistance against environmental impact, e.g. abrasion, chemicals etc. According to the specification, the tensile strength of the insulation is double as high as the one of comparable wires of Part 61 to 66. If the outer layer yet will be damaged or cut in, the cut will be stopped at the transition to the inner layer. Thus, the electrical functionality is ensured until the cable will be repaired. Conclusion: the thinner wires are even more robust and less susceptible than other wires because of their double insulation and the material used. Why have been used conductors with a 19 strand construction for diameters of 1,5 mm 2 and 2,5 mm 2? On the one hand, at these diameters 19 cores are much more flexible, on the other hand 19 core constructions leave less space between the single wires. This is especially necessary for the extrusion of thin wall insulations. VG-CABLE III. Questions about the installation Are the cables of Part 28 with reduced diameter round? Yes, the cables are round. The bundles are laid in layers, and, if necessary, fillers are added. We select the wall thickness of the jacket material that it will be avoided as much as possible that the cable jacket follows the contours of the cable bundle. What about the performance of these cables in multi gland packing systems? The tightness of these cables has been tested and certified by Germanischer Lloyd. What about the performance in multi gland potting systems? Jacket materials of Tyco Electronics cables are chemically neutral and can be combined unobjectionably with potting compounds. Are cables of Part 28 more flexible than the ones of Part 61 to 66? Cables of Part 28 C and E are much more flexible than cables of Part 61 to 66. This is to be attributed to the characteristics of the materials, the construction and the dimensions of the cables. Literature number: CFK

38 VG-CABLE Questions & Answers about cables of Part What has to be observed when stripping the insulation? Tyco Electronics cables of Part 28 can be stripped with conventional stripping tools. Are contacts being used for part 61 to 66 cables also suitable for cables of part 28? The rated cross section of the conductors and the construction are the same in both standards. Only in cable types with cross sections of 1,5 mm 2 and 2,5 mm 2 we use conductors with 19 strands in part 28 whereas in part 61 conductors with 7 strands are utilized. Here we recommend to check the connector sizes. Do cables of part 28 fit into connectors that have been used for cables of part 61 to 66? Regarding the number of wires, the conductor size, colour and number coding of the wires both types are identical and, thus, there are no changes in the connectors. As cables of part 28 have a significantly smaller diameter the sealing on the connector back side should be checked and when necessary adapted. For this, we recommend heat shrinkable components according to VG. We will be glad to support you with selective and cross reference lists. Do cables of part 28 fit into feed throughs that have been used for cables of part 61 to 66? Generally, cables of part 28 fit into feed throughs that have been used as yet. Because of the smaller diameter the sealing and the size of the grounding inserts should be checked and, if necessary, adapted. Can cables of part 28 be bonded with halogenfree moulded parts of VG95343 part 29 and 30? Yes, regarding their compatibility the cables are tested and certified as one system within the framework of the standard. Can the jacket be vulcanized? No, the jackets of part 28 are cross linked and, thus, cannot be vulcanized. Are there differences in the installation of the cables? Cables of part 28 have a smaller diameter and are more flexible. Thus, a smaller bend radius can be obtained, which in turn facilitates the installation. Customers told us that the jacket slides easily and that the cables are extremely light weight, by what the cable can be installed easier and even several cables at the same time can be drawn in. 36 Literature number: CFK 09-08

39 Notes VG-CABLE

40 FOR MORE INFORMATION: Alexander Kiéck, Sales Engineer Phone: +49 (0) office Phone: +49 (0) cell Martyn Cook, Market Development Manager Phone: +44 (0) office Phone: +44 (0) cell Tyco Electronics Raychem GmbH Aerospace, Defense & Marine Business Unit Finsinger Feld Ottobrunn/München/Germany Telefon: Telefax: by Tyco Electronics Corporation. All rights reserved. Raychem, TE Logo and Tyco Electronics are trademarks. Literature number: CFK 09-08