Technical Data - Cable

Instructions for the safe application of cables

The cables manufactured by S Bröckskes are only appropriate for the transmission of electric energy for supply and
signalling purposes.

First of all the valid construction and installation prescriptions for the corresponding machine or equipment has to be observed.
The valid VDE prescription 0100 can be regarded as base. Furthermore, the following security advice has to be observed for the
use of cables.

■ For each cable type you can find under ”technical data” information on fields
that can also be found under the following standards. Among others these are
▶ Nominal voltage, Peak operating voltage: HD 516

▶ Test voltage: VDE 0250 T1, EN 50525-1, as well as relevant cable standards

▶ Minimum bending radius: HD 516

▶ Temperature range: HD 516

▶ Fire performance : standards of series IEC 60332 as well as relevant cable standards

▶ Resistances: IEC 60811-404 as well as relevant cable standards

▶ Further special technical data

■ The safe application is described under ”security requirements” and ”boundary conditions”.
Under ”security requirements” you will find information on fields that can also be found under the following standards. Among
others these are
▶ Basic requirements: HD 516 pos. 4.1

▶ General requirements: HD 516 pos. 4.2

▶ Current-carrying capacity for undisturbed service: VDE 0298-4 pos. 5

▶ Operating conditions: VDE 0298-4 pos. 5.3.1

▶ Ambient conditions: VDE 0298-4 pos. 5.3.3

▶ Requirements for fixed installation: HD 516 pos. 4.3

▶ Requirements for flexible cables: HD 516 pos. 4.4

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 Technical Data - Cable
Instructions for the safe application of cables

Under ”boundary conditions” you will find information on fields that can also be found under the following standards.
Among others these are:
▶ Operating conditions: HD 516 pos. 5

▶ Voltage: HD 516 pos. 5.1

▶ Current-carrying capacity: HD 516 pos. 5.2

▶ Current-carrying capacity:
- Capacity, cables with a nominal voltage up to 1000 V and heat resistant cables VDE 0298-4 table 11

- Conversion factors for deviating ambient temperatures VDE 0298-4 table 17+18

- Conversion factors for the accumulation on walls, in tubes and conduits, on the floor and at the ceiling VDE 0298-4 table 21

- Conversion factors for multi-core cables with conductor cross sections up to 10 mm² VDE 0298-4 table 26

▶ Thermal influences: HD 516 pos. 5.3

▶ Mechanical stress: HD 516 pos. 5.4

▶ Tensile load: HD 516 pos. 5.4.1

▶ Bending load: HD 516 pos. 5.4.2

▶ Compression stress: HD 516 pos. 5.4.3

▶ Torsional stress: HD 516 pos. 5.4.4

▶ Compatibility: HD 516 pos. 5.5

▶ Application in rooms
and in the open air: HD 516 Anhang A

▶ Stress classification: HD 516 Anhang B

▶ Construction of strands: IEC 60228 + VDE 295

Besides the generally known technical rules, please consider especially the following prescriptions for the application
of our products
VDE...
0100, 0105, 0106, 0108, 0110, 0113, 0116,
0165, 0166, 0170, 0171, 0271, 0298, 0700,
0720, 0727, 0730, 0737, 0740, 0745, 0750,
0800, 0804, 0805, 0839, 0860, 0891, 1000, etc.

O ▶ You will find under the individual item groups further instructions and the description of the special application
possibilities of our cables.
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Technical Data - Cable
Instructions for the safe application of cables

■ Security requirements

■ Basic requirements
Cables can be regarded to be safe in case that they are used for their intended purpose and don’t mean any unacceptable
risk for life and real values. If not otherwise specified, insulated cables shall only be used for the transmission and division of
electric energy.

■ General requirements
Cables have to be chosen in a way that they meet the existing voltages and currents occurring in the machines, equipment of
appliances or in their parts for which they are applied under any expected operating condition. Cables should be constructed,
installed, protected and maintained to avoid any risks and harms.

■ Carrying capacity for undisturbed service (general info)

The cable section has to be chosen in a way that the given current-carrying capacity never leads to a heating of the conductor
over the allowed service temperature. The heating resp. carrying-capacity of a cable depends on the construction, material
characteristics and the operating conditions. Additional heating due to a cable accumulation, heating flues, solar radiation, etc.
have to considered resp. avoided. The use of covers requires an undisturbed air circulation.

■ Operating conditions
The temporary flow of current describes the operating conditions. Continuous operation means a constant current which is at
least sufficient to reach the thermal equilibrium of the electrical equipment without any other time limit. The capacity values of
cables are based on continuous service reaching the allowed operating temperature of the conductor.

■ Environmental conditions
Environmental conditions are among others characterized by the ambient temperature, heat loss and heat radiation. The
ambient temperature is the temperature of the surrounding air, without any load on the respective cable. The reference point is
a temperature of +30°C. The operating conditions of cables can change by heat loss for example in closed rooms, cable
ducts or similar, as well as by heat radiation (e. g. solar radiation).

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 Technical Data - Cable
Instructions for the safe application of cables

■ Conditions and requirements for fixed installation

■ The fixed installation of cables requires among others

▶ The cable shall not be installed in direct or close contact with hot surfaces if they are not suitable for this application.
▶ Cables are not suitable for direct underground laying.
▶ Cables have to be fixed properly. The weight of the cable is important for the choice of the fixing distance.
▶ The used mechanical fixing devices shall not damage the cable.
▶ Cables that have been used for a long time may be damaged in case of removal. This can be a natural effect due to the aging of the
physical characteristics of insulation and jacket material - they become brittle.

■ Requirements for flexible cables

▶ Flexible cables should be used for mobile electrical equipment.
▶ The length of the connection cable has to be chosen in a way that the reaction of short-circuit protective equipment is ensured.
▶ For mobile electrical equipment the cable should be as short as possible.
▶ Elevated stress due to tension, pressure, abrasion, torsion or knicking has to be avoided.
▶ The cables shall not be damaged by strain relief or connection devices.
▶ The cables shall not be layed under carpets or other devices. There is a risk due to elevated thermal covering and mechanical
damage due to walking, furniture or operating material.
▶ The cables shall not be in direct or close contact with hot surfaces.

▶ For further requirements please see HD 516 S2 pos. 4.4.

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Technical Data - Cable
Instructions for the safe application of cables

■ Boundary conditions

■ Operating conditions
The used cables have to be appropriate for the corresponding operating conditions as well as for the device protection class.

■ Operating conditions are among others:

▶ Voltage
▶ Current
▶ Safety apparatus
▶ Cable accumulation
▶ Type of laying
▶ Accessibility

The used cables have to be appropriate for all possible external impacts.

■ External impacts are among others:

▶ Ambient temperature
▶ Rain
▶ Steam or water
▶ Presence of corrosive, polluting or other chemical bodies
▶ Mechanical stress (e.g. sharp edges of metal constructions)
▶ Animals (e.g. rodents)
▶ Plants (e.g. mold fungus)
▶ Radiation (e.g. solar radiation)

Note: In this connection it has to be considered that the color is of greatest importance. The color black offers much more protection at
radiation than all other colors.

■ Voltages
The nominal voltage of a cable means the voltage for which the cable has been constructed and defines the electrical tests. The nominal
voltage is expressed in Volt by the relation of two values Uo/U; Uo is the r.m.s. value of the voltage between external conductor and earth
(metal jacketing of the cable or surrounding medium). U is the r.m.s. value between two external conductors of a multi-conductor cable or
of a system of mono-conductor cables. In a system of alternating current (a.c.), the nominal voltage of a cable has to be at least equal to
the values Uo and U of the system. In a system of direct-current (d.c.) the nominal voltage of the system shall not be higher than 1.5
times of the nominal voltage of the cable.

Note: The operating voltage of a system is allowed to be continuously 10% higher than the nominal voltage of the system.

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 Technical Data - Cable
Instructions for the safe application of cables

■ Operating condictions
The nominal cross section of each conductor has to be chosen that the current-carrying capacity is not smaller than the max. constant
current, passing the conductor under normal conditions. The limit temperatures to which the current-carrying capacity refers to, shall not
be exceeded for the insulation and jacket of the corresponding cable types. A defined condition is also the type of laying of the used
cable. This has to be considered for the determination of the allowed load currents. Conditions that have to be considered are among
others
▶ Ambient temperature
▶ Cable accumulation
▶ Type of excess-current protection
▶ Heat insulation
▶ Wound up cables
▶ Current frequency (deviating from 50 Hz)
▶ Effects of harmonic waves

The current-carrying capacity is not the only criteria for choosing the cable section, furthermore, the requirements for the protection
against harmful body currents, overload, short-circuit currents and voltage drop have to be considered. In case that cables are used for a
longer period with temperatures exceeding the allowed values, they can be damaged considerably leading to an early failure and an
important deterioration of its characteristics.

■ Current-carrying capacity: Tables

Extract from VDE 0298-4 06/13 table: 11, 17, 18, 21, 26 and 27
Current-carrying capacity, cables with a nominal voltage up to 1000 V and
heat resistant cables VDE 0298-4 06/13 table 11, column 2 and 5
column 2 column 5
way of laying in air on or at surfaces
mono conductors multi-conductor cables
(except for house or handheld units)
- rubber insulated - rubber insulated
- PVC insulated - PVC insulated
- heat resistant - heat resistant
number of charged conductors 1 2 or 3
nominal section
AWG/kcmil mm2 capacity
19 0.75 mm² 15 A 12 A
18 1.00 mm² 19 A 15 A
16 1.50 mm² 24 A 18 A
14 2.50 mm² 32 A 26 A
12 4.00 mm² 42 A 34 A
10 6.00 mm² 54 A 44 A
8 10.00 mm² 73 A 61 A
6 16.00 mm² 98 A 82 A
4 25.00 mm² 129 A 108 A
2 35.00 mm² 158 A 135 A
1 50.00 mm² 198 A 168 A
O 2/0 70.00 mm² 245 A 207 A
3/0 95.00 mm² 292 A 250 A
20 4/0 120.00 mm² 344 A 292 A
250 150.00 mm² 391 A 335 A
350 185.00 mm² 448 A 382 A
450 240.00 mm² 528 A 453 A
550 300.00 mm² 608 A 523 A

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Technical Data - Cable
Instructions for the safe application of cables

Conversion factors for Conversion factors

deviating ambient temperatures for multi-conductor cables
VDE 0298-4 06/13 table 17, column 4 1) with a nominal section
ambient factor up to 10 mm²
temperature VDE 0298-4 06/13 table 26.
10°C 1.22 With installation in the open air.
no. of the factor
15°C 1.17
loaded conductors
20°C 1.12
5 0.75
25°C 1.06
30°C 1.00 7 0.65
35°C 0.94 10 0.55
40°C 0.87 14 0.50
45°C 0.79 19 0.45
50°C 0.71 24 0.40
55°C 0.61 40 0.35
60°C 0.50
61 0.30
65°C 0.35
Please call your S sales specialist
1) for cables with a service temperature regarding 4 conductor amperage
of max. 70 °C at the conductor

Conversion factors for deviating ambient temperatures for heat resistant cables
VDE 0298-4 06/13 table 18, column 3 - 6
column 3 column 4 column 5 column 6
allowed operating temperature
90°C 110°C 135°C 180°C
ambient temperature conversion factors, to apply to the capacity of heat resistant cables in table 11, column 2 and 5
up to 50°C 1.00 1.00 1.00 1.00
55°C 0.94 1.00 1.00 1.00
60°C 0.87 1.00 1.00 1.00
65°C 0.79 1.00 1.00 1.00
70°C 0.71 1.00 1.00 1.00
75°C 0.61 1.00 1.00 1.00
80°C 0.50 1.00 1.00 1.00
85°C 0.35 0.91 1.00 1.00
90°C — 0.82 1.00 1.00
95°C — 0.71 1.00 1.00
100°C — 0.58 0.94 1.00
105°C — 0.41 0.87 1.00
110°C — — 0.79 1.00
115°C — — 0.71 1.00
120°C — — 0.61 1.00
125°C — — 0.50 1.00
130°C — — 0.35 1.00
135°C — — — 1.00
140°C — — — 1.00
145°C — — — 1.00
150°C — — — 1.00 O
155°C — — — 0.91
160°C — — — 0.82 21
165°C — — — 0.71
170°C — — — 0.58
175°C — — — 0.41

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 Technical Data - Cable
Instructions for the safe application of cables

Conversion factors for the accumulation

on walls, in tubes and conduits, on the floor and at the ceiling
VDE 0298-4 06/13 table 21
no. of multi-conductor cables
factor
(2 or 3 current-carrying conductors)
1 1.00
2 0.80
3 0.70
4 0.65
5 0.60
6 0.57
7 0.54
8 0.52
9 0.50
10 0.48
12 0.45
14 0.43 The maximum current-carrying capacity
16 0.41 acc. to DIN VDE 0891 part 1, point 7
18 0.39 has to be considered for the application of insulated cables
in telecommunications systems and data processing units.
20 0.38

Conversion factors for wound up cables VDE 0298-4 06/13 table 27

1 2 3 4 5 6
no. of layers
on one drum 1 2 3 4 5
conversion factors 0.80 0.61 0.49 0.42 0.38
Note: For spiral winding the conversion factor of 0.80 is valid

■ Thermal influences
Cables have to be chosen, layed or installed in a way that the expected current heat emission is not impeded and thus does not create
any fire risk for adjacent materials. The limit temperatures of the individual cable types are shown in the catalog. The indicated values
shall not be exceeded by the combined effects of internal current heat and environmental conditions.

■ Mechanical stress
Any possible mechanical stress which could lead to a mechanical damage of the layed cable has to be considered before installation.

■ Tensile load
The following values for the tensile load of each conductor shall not be exceeded. This is valid for a max. value of 1000 N for the tensile
load of each conductor, as far as no other deviating values have been accepted by S Bröckskes. 50 N/mm² for the installation of
cables for fixed installation. 15 N/mm² static tensile load for flexible cables and for fixed installation in case that the cables are used for
fixed installed electric circuits. Wherever those values are exceeded, it is recommended to use separate strain relief elements or similar.
The connection of such a strain relief element with the cable has to be executed without damaging the cable. In case that flexible cables
are exposed to dynamic tensile load (including tensile load due to mass reactance, for example on unwinding spools), the allowed tensile
load or the duration of wear of the cable have to be agreed upon by the user and S Bröckskes. Instructions for the vertical laying of
O cables without any intermediate fixing are shown under EN 50656-1 pos. 5.6.2.
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Technical Data - Cable
Instructions for the safe application of cables

■ Bending load
The inner bending radius of a cable has to be chosen in a way that any damage of the cable is avoided. The inner bending radii for the
different cable constructions are indicated in table 6 of HD 516. The choice of smaller bending radii than indicated in the cable catalog
has to be agreed upon with S Bröckskes.
The stripping of the cable jacket shall not cause any damage to the conductor as otherwise there will be a considerable deterioration of
the bending characteristics.
The indicated bending radii are valid for ambient temperatures of (20 ± 10)°C. For other ambient temperatures please contact
S Bröckskes.
Bendings directly beside external of internal fixing points have to be avoided.

■ Pressure stress
Any pressure causing a cable damage has to be avoided.

■ Torsional stress
Flexible cables are generally not appropriate for torsional stress. In cases where torsional stress cannot be avoided, the construction of
the cable and the way of laying have to be agreed upon between the user and S Bröckskes.

■ Compatibility
For the choice and laying of cables the following points have to be considered
▶ Mechanical and electrical impacts between adjacent electric circuits have to be avoided.
▶ Heat loss of cables or chemical/physical influences of the cable materials on adjacent materials, for example construction or
decoration materials, insulating tubes and fixing device.
▶ The influence of the current heat on the conductor material and connections has to be considered.

For further indications please see tables 3A, 3B, 4A and 4B of HD 516.

■ Room types
▶ Electric shops of the factory are rooms which are generally used for the operation of electric equipment and the access is only
allowed to instructed staff members, for example switch rooms.
▶ Closed electric shops are rooms which are only used for the operation of electric equipment and are generally locked up. The access
is only allowed for instructed staff members, for example closed switch and distribution systems.
▶ Dry rooms are rooms without any condensation water in which the air is not saturated with humidity, for example living rooms and
hotel rooms.
▶ Damp rooms are rooms in which the safety of the operational devices is affected by humidity, condensation water, chemical or similar
influences, for example in large kitchens.

■ General notes:
Rooms can only be classified in one of the above mentioned types by a careful inspection of the rooms and operational conditions. If
there is only much humidity in a certain area of a room but the room is nevertheless dry due to good ventilation, there is no need to
classify the room as a damp one. O
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Instructions for the safe application of cables

■ Application in rooms and in the open air

General
These terms have to be understood in connection with the boundary conditions (for example min. and max. operating temperatures,
influence of ambient temperatures) defined by the construction and the intended application.
Terms for application types:
Application in rooms
The cable is installed or connected to a device which is normally located in a building within “a planned surrounding”. The building can
be used for business, industrial or living purposes.
Limited application in the open air
The cable is appropriate for a short-time use in the open air, ”planned surrounding” for example lawn mower.
Permanent application in the open air
The cable has been constructed for different conditions which can occur in the open air ”planned surrounding” (including different
weather conditions).

■ Stress classification
The term “stress” describes the use of cables in certain areas, connected to or installed in devices and for certain combinations of
external influences which can occur in those areas. On the base of mechanical influences and general expressions the term “stress” has
been divided into four categories.
1. Very light stress
Application areas, in which the risk of mechanical damage and stress is very small, for example electric razor.
2. Light stress
Application areas, in which the risk of mechanical damage and stress is small, for example hair dryer.
3. Normal stress
Application areas, in which the cables are exposed to small mechanical stress and the risk for mechanical damage is small, for
example small stoves.
4. Heavy stress
Application areas, in which the risk of mechanical damage or mechanical stress is of medium impact, for example machines on
construction sites.
4a. Heavy stress (only multi-conductor cables)
Application as before, however in connection with parts of production systems including machine tools and manual mechanical
devices, for example in connection with switch boards of a production machine.

■ Transport and storage

Cable and cords that are not intended for outdoor use must be stored in dry indoor rooms and must also be protected from exposure to
direct sunlight there. With outdoor storage, the ends of cables and cords must be closed off to prevent the entry of moisture. The
ambient temperature during transport and storage is to be in the range from -25°C to +55°C (max. +70°C for not longer than 24 hours).
Furthermore, the temperatures indicated in the tables of HD 516 have be considered for storage. Especially in the range of low
temperatures, mechanical loading by vibration, shock, bending and twisting is to be avoided.

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Technical Data - Cable
Instructions for the safe application of cables

■ Construction of strands acc. to EN 60228, IEC 60228

▶ Fine copper strands for single or multi-conductor cables (class 5)
▶ Extra fine copper strands for single or multi-conductor cables (class 6)

table 3 table 4
Fine copper strands for Extra fine copper strands for
single- or multi-conductor cables (class 5) single- or multi-conductor cables (class 6)
1 2 3 4 1 2 3 4
Nominal largest Conductor resistance at Nominal largest Conductor resistance at
cross section diameter of 20°C max. value cross section diameter of 20°C max. value
single wires single wires
bare metal bare metal
single wires jacketed single wires jacketed
single wires single wires
AWG mm2 mm Ω/km Ω/km AWG mm2 mm Ω/km Ω/km
20 0.50 0.21 39.0000 40.1000 20 0.50 0.16 39.0000 40.1000
19 0.75 0.21 26.0000 26.7000 19 0.75 0.16 26.0000 26.7000
18 1.0 0.21 19.5000 20.0000 18 1.0 0.16 19.5000 20.0000
16 1.5 0.26 13.3000 13.7000 16 1.5 0.16 13.3000 13.7000
14 2.5 0.26 7.9800 8.2100 14 2.5 0.16 7.9800 8.2100
12 4 0.31 4.9500 5.0900 12 4 0.16 4.9500 5.0900
10 6 0.31 3.3000 3.3900 10 6 0.21 3.3000 3.3900
8 10 0.41 1.9100 1.9500 8 10 0.21 1.9100 1.9500
6 16 0.41 1.2100 1.2400 6 16 0.21 1.2100 1.2400
4 25 0.41 0.7800 0.7950 4 25 0.21 0.7800 0.7950
2 35 0.41 0.5540 0.5650 2 35 0.21 0.5540 0.5650
1 50 0.41 0.3860 0.3930 1 50 0.21 0.3860 0.3930
2/0 70 0.51 0.2720 0.2770 2/0 70 0.31 0.2720 0.2770
3/0 95 0.51 0.2060 0.2100 3/0 95 0.31 0.2060 0.2100
4/0 120 0.51 0.1610 0.1640 4/0 120 0.31 0.1610 0.1640
250 MCM 150 0.51 0.1290 0.1320 250 MCM 150 0.31 0.1290 0.1320
350 MCM 185 0.51 0.1060 0.1080 350 MCM 185 0.41 0.1060 0.1080
450 MCM 240 0.51 0.0801 0.0817 450 MCM 240 0.41 0.0801 0.0817
550 MCM 300 0.51 0.0641 0.0654 550 MCM 300 0.41 0.0641 0.0654
750 MCM 400 0.51 0.0486 0.0495

Notes:
The above mentioned information and tables for the “safe application of cables” are extracts from the indicated standards and
can’t be judged to be complete.The responsible user has to be careful in the laying and installing of cables.

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