Application & Operating Conditions
(N)3GRDC5G-J/O is a 0.6/1 kV EMC-screened heavy-duty rubber power and control cable engineered with reference to DIN VDE 0250-812 for high mechanical stress and frequent cyclic bending in a single plane. It operates reliably at festoon travel speeds up to 240 m/min across indoor dry, humid, and wet rooms as well as outdoor crane installations.
High-Speed Crane Festoon Trolleys
Built for motorized I-beam and C-track festoon trolley systems on ship-to-shore (STS) container cranes, RTGs, steelworks ladle cranes, and bulk material handling bridges running up to 240 m/min.
VFD Drives & Linear Drag Chains
Symmetrical 3+3 split-earth cores and an 80% tinned copper/synthetic braid suppress electromagnetic interference on inverter-fed hoist and travel motors in unidirectional drag chains (5×Ø min. bend).
Wet, Oily & Outdoor Port Duty
The black CR 5GM5 polychloroprene outer sheath resists mineral oils (EN 60811-404), UV radiation, coastal salt mist, and vertical flame spread (IEC 60332-1-2) from −30 °C to +80 °C in moving service.
Mechanical Bending Plane Notice: (N)3GRDC5G-J/O is specifically constructed for frequent cyclic bending in one direction (single bending plane), such as suspended festoon loops and linear energy chains. For vertical gravity-fed spreader baskets or multi-plane torsional twisting, consult our Port, Crane & Festoon Cables engineering catalog.
Cable Construction (DIN VDE 0250-812 Reference)
Constructed with a dual-sheath elastomer core-locking architecture, (N)3GRDC5G-J/O combines Class 5 bare copper conductors and 90 °C HEPR insulation inside a pressure-extruded GM1b rubber inner sheath, an 80% hybrid tinned copper/synthetic braid screen, and an abrasion-resistant 5GM5 outer jacket.
| Layer | Material & Engineering Specification |
|---|---|
| 1. Conductor | Electrolytic bare copper wire, finely stranded Class 5 flexible per DIN EN 60228 / IEC 60228 |
| 2. Insulation | High-grade ethylene-propylene elastomer (HEPR), rated for +90 °C continuous conductor temperature and low dielectric loss under PWM inverter voltage spikes |
| 3. Core Identification | -J version: Green-yellow protective earth (PE / split 3G) + black cores with white numbers -O version: Without green-yellow protective conductor (single-core feeder cables 1×95, 1×185) |
| 4. Inner Sheath | Pressure-extruded rubber compound GM1b filling core interstices to stabilize core lay and prevent corkscrewing under rapid trolley acceleration |
| 5. EMC Braid Screen | Hybrid braid of tinned copper wires + synthetic reinforcing fibres over inner sheath; approx. 80% optical coverage for flex-fatigue endurance and low transfer impedance |
| 6. Outer Sheath | Heavy-duty polychloroprene elastomer (CR compound 5GM5), colour black; flame-retardant, oil-resistant, UV-stabilized, and weather-resistant |
Cross-Sectional Comparison: Symmetrical 3+3 VFD motor supply geometry (e.g., 3×50 + 3G10, left) places three split earth cores in the outer interstices to balance capacitive coupling, alongside 4G / 24G multi-core power and control constructions (right).
Technical Characteristics
Electrical, thermal, dynamic mechanical, and environmental test parameters for (N)3GRDC5G-J/O cables are rated at Uo/U = 0.6/1 kV (maximum three-phase system voltage 1.2 kV, AC test voltage 2.5 kV) with a tight 5×Ø moving bend radius and 15 N/mm² dynamic tensile capacity.
| Parameter | Rated Value / Applicable Standard |
|---|---|
| Reference Design Standard | DIN VDE 0250-812 (with reference to) |
| Nominal Voltage (Uo / U) | 0.6 / 1 kV AC |
| Max. Permitted Three-Phase Voltage (Um) | 1.2 kV |
| AC Routine Test Voltage | 2.5 kV |
| Max. Conductor Operating Temperature | +90 °C |
| Permitted Outer Cable Temp. (Moved / Flexing) | −30 °C to +80 °C |
| Minimum Bending Radius (Fixed Installation) | 4 × Ø (cable outer diameter) |
| Minimum Bending Radius (Moving Application) | 5 × Ø (unidirectional bending in festoon trolleys and drag chains) |
| Max. Dynamic Tensile Stress at Conductor | 15 N/mm² (see part-specific Fzd ratings from 240 N to 4,275 N below) |
| Max. Operating Speed (Festoon System) | 240 m/min |
| EMC Braid Optical Coverage | Approx. 80% (tinned copper wire + synthetic fibre) |
| Flame Retardancy | DIN VDE 0482-332-1-2 / IEC 60332-1-2 |
| Oil Resistance | DIN EN 60811-404 (IEC 60811-404) |
| UV, Weather & Conformity | UV-resistant; suitable for dry, humid, wet indoor rooms & outdoor crane service; CE compliant |
Specification & Dimensional Data
Dimensional, DC conductor resistance, dynamic tensile force (Fzd), and weight specifications cover 10 standard (N)3GRDC5G-J/O constructions spanning single-core main feeders, 3+3 symmetrical VFD motor cables, 4-core power cables, and 24-core festoon control cables.
| Sub-Series Architecture | Type Code | Cross-Section Range | Approx. OD Range | Dynamic Pull Fzd | Primary Crane Duty |
|---|---|---|---|---|---|
| Single-Core Power Feeder | (N)3GRDC5G-O | 1×95 mm², 1×185 mm² (2 sizes) | 24 – 31 mm | 1,425 – 2,775 N | High-current single-phase / trefoil crane bus & DC link feeders |
| Symmetrical 3+3 VFD Supply | (N)3GRDC5G-J | 3×16+3G2.5 to 3×95+3G16 (5 sizes) | 26 – 49 mm | 757 – 4,275 N | Inverter-driven hoist, trolley & gantry motors (EMC low shaft current) |
| 4-Core Crane Power | (N)3GRDC5G-J | 4G4 mm², 4G35 mm² (2 sizes) | 19 – 36 mm | 240 – 2,100 N | Auxiliary drives, brakes, hydraulic units & conveyor motors |
| Multi-Core Festoon Control | (N)3GRDC5G-J | 24G2.5 mm² (1 size) | 33 mm | 900 N | EMI-protected PLC control, limit switches & trolley signaling |
| Core Configuration (mm²) | Version | Max. Rl (Ω/km) | Ø Min. (mm) | Ø Max. (mm) | Ø Approx. (mm) | Moving Bend 5×Ø (mm) | Dynamic Pull Fzd (N) | Cu Index (kg/km) | Net Weight (kg/km) |
|---|---|---|---|---|---|---|---|---|---|
| 1 × 95 | -O | 0.206 | 21 | 24 | 24 | 120 | 1,425 | 1,065 | 1,190 |
| 1 × 185 | -O | 0.106 | 28 | 31 | 31 | 155 | 2,775 | 1,969 | 2,172 |
| 3 × 16 + 3G2.5 | -J | 1.210 | 24 | 26 | 26 | 130 | 757 | 642 | 1,170 |
| 3 × 35 + 3G6 | -J | 0.554 | 30 | 33 | 33 | 165 | 1,575 | 1,302 | 2,050 |
| 3 × 50 + 3G10 | -J | 0.386 | 36 | 39 | 39 | 195 | 2,250 | 1,973 | 2,875 |
| 3 × 70 + 3G10 | -J | 0.272 | 40 | 43 | 43 | 215 | 3,150 | 2,555 | 3,685 |
| 3 × 95 + 3G16 | -J | 0.206 | 46 | 49 | 49 | 245 | 4,275 | 3,577 | 4,956 |
| 4G4 | -J | 4.950 | 16 | 19 | 19 | 95 | 240 | 381 | 579 |
| 4G35 | -J | 0.554 | 33 | 36 | 36 | 180 | 2,100 | 1,577 | 2,348 |
| 24G2.5 | -J | 7.980 | 31 | 33 | 33 | 165 | 900 | 805 | 1,600 |
Table Legend: Rl = Max. DC conductor resistance at 20 °C (Ω/km); Ø Min. / Ø Max. / Ø Approx. = Outer diameter tolerance window and nominal outer diameter (mm); Fzd = Maximum permissible dynamic tensile force (N) based on 15 N/mm² active copper cross-section; Net Weight = Approximate cable weight per 1,000 m. Custom core counts and cross-sections available on request.
Selection, EMC Grounding & Festoon Installation Guidelines
Proper core geometry selection and 360-degree shield termination are critical to achieving full EMC compliance and multi-year flex life on high-speed crane festoons (up to 240 m/min) and inverter-fed linear drag chains.
| Engineering Criterion | Recommended Practice for (N)3GRDC5G-J/O |
|---|---|
| VFD Motor Drives (3+3 Split Earth) | Select symmetrical 3×16+3G2.5 through 3×95+3G16 sizes for PWM frequency-converter hoist and gantry motors. Splitting the protective earth into three interstitial green-yellow cores balances phase-to-earth capacitance and mitigates destructive motor bearing currents. |
| 360° EMC Screen Termination | Terminate the 80% tinned copper braid at both the inverter cabinet and motor terminal box using 360-degree Compression EMC brass cable glands rather than twisted pigtail leads to maintain low high-frequency transfer impedance. |
| Festoon Saddle & Drag-Chain Radius | Size trolley cable saddles and drag-chain bend shoes so the inner bend radius is never tighter than 5 × Ø max in moving service (4 × Ø in fixed clamping zones), and keep peak acceleration tension below the listed Fzd [N] rating. |
| Alternative Sheath & Unscreened Options | For unscreened rubber festoon circuits without VFD EMI exposure, compare our (N)GRDGÖU 0.6/1 kV Rubber Festoon Cable; for halogen-free polyurethane crane duty, see (N)12YRDC11Y-J/O Screened PUR Crane Cable. |
Frequently Asked Questions (FAQ)
Key engineering answers covering DIN VDE type code nomenclature, -J versus -O core coding, dynamic pull limits, and custom manufacturing options for (N)3GRDC5G-J/O cables.
What does the German DIN VDE code (N)3GRDC5G-J/O stand for?
(N) indicates construction based on DIN VDE standards (VDE 0250-812 reference); 3G denotes 90 °C HEPR ethylene-propylene rubber core insulation; RD designates a round cable engineered for dynamic crane festoon and drag-chain flexing; C specifies the overall tinned copper EMC braid screen; 5G denotes the heavy-duty polychloroprene (CR 5GM5) rubber outer sheath; -J includes a green-yellow protective earth core, while -O omits the green-yellow earth core (used on single-core 1×95 and 1×185 power feeders).
Why is the EMC braid made from both tinned copper wire and synthetic fibre?
Pure metallic copper braids can work-harden and snap strands when subjected to millions of rapid unidirectional bending cycles at 240 m/min and 5×Ø tight radii. Interweaving high-tenacity synthetic fibres with tinned copper strands (~80% optical coverage) absorbs mechanical shear stress over the extruded GM1b inner sheath while preserving reliable high-frequency EMI shielding.
How is the maximum dynamic tensile load (Fzd) calculated for crane trolleys and drag chains?
Per DIN VDE 0250-812 mechanical design rules, maximum dynamic conductor stress is capped at 15 N/mm² across the active phase conductor cross-section. For example, 3×50 + 3G10 (150 mm² phase copper) yields Fzd = 2,250 N, whereas 1×185 yields Fzd = 2,775 N.
What parameters are needed to request a custom quotation or project drum length?
Provide your required core configuration (e.g., 3×35+3G6, 1×185, or 24G2.5), individual cut lengths or continuous drum lengths, festoon travel speed or drag-chain inner bend radius, ambient temperature range, and destination port. TEBAOFLEX supplies custom cut-to-length export wooden drums and routine test reports.
Need a Custom (N)3GRDC5G-J/O Festoon or Drag-Chain Cable Quotation?
Share your cross-section, VFD motor power, festoon loop length, and delivery schedule with TEBAOFLEX engineering sales for factory-direct pricing and technical datasheet confirmation.
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