1. Drum Reeling Duty & PUR vs. Rubber / PVC Selection
TEBAOFLEX Heavy-Duty PUR Reeling Cable 0.6/1 kV (`D12Y11Y-J / (N)12Y11Y-J` family) supplies dynamic low-voltage power and control to spring-driven cylindrical reels, motorized monospiral drums, rail-mounted transfer cars, portal cranes, and automated logistics gantries where compact drum diameter, oil/cut immunity, and sub-zero flexibility (`-40°C`) are decisive.
Target Mobile Machinery & Reels
- Spring-Driven & Level-Wind Motorized Drums: Lower linear mass (`15-25%` lighter than equivalent rubber cable) reduces spring torque fatigue and flange build-up on multi-layer drums.
- Rail Transfer Cars, AGV Chargers & Electro-Magnets: High-visibility Safety Yellow `11YM1` PUR jacket resists steel swarf cutting, forklift wheel run-over, and cutting fluids.
- Port Gantries, Timber Yards & Wastewater Scrapers: Polyether-grade PUR prevents seawater hydrolysis, microbial attack, and arctic stiffening down to
-40°Cdynamic flexing.
Related TEBAOFLEX Reeling & Crane Siblings
- High-Torque Motorized Drum Variant: For heavy anti-torsion braided motorized reels, compare Motorized-Reel 0.6/1 kV Reinforced PUR Cable.
- Vertical Spreader Duty: For STS container spreader baskets, select 0.6/1 kV Yellow PUR Spreader Reeling Cable.
- Hot-Slag / Heavy Polychloroprene Rubber Option: Compare (N)SHTÖU 0.6/1 kV Rubber Reeling Cable or spring-reel 0.6/1 kV Flexible PVC Reeling Cable in Industrial & Control Cables.
| Jacket System | Outer Diameter & Weight | Dynamic Cold Limit | Cut, Oil & Hydrolysis Resistance | Best-Fit Reeling Duty |
|---|---|---|---|---|
| 11YM1 Polyether PUR (This Page) | Smallest OD & lightest weight | -40°C mobile / -50°C fixed | Highest notch/cut, oil & microbe immunity | Spring reels, motorized drums, ports, transfer cars & cold storage |
| 5GM3 / 5GM5 Rubber ((N)SHTÖU) | 15-25% larger OD & heavier | -35°C mobile / -50°C fixed | High impact & hot welding/slag splash tolerance | Steelworks hot-metal cranes, heavy mining & bulk terminals |
| Flexible PVC Spring-Reel | Moderate OD | -5°C mobile / -25°C fixed | Moderate indoor oil/abrasion tolerance | Light indoor workshop hoists & dry warehouse spring reels |
2. Composite Power + PE + Control Construction
Matching the stepped studio cutaway (`3 black/brown/grey power cores + 2 split green/yellow earth cores + 2 white/blue pilot control cores`), TEBAOFLEX winds short-lay fine-stranded bare copper cores around a tension-stabilized center so repeated drum winding never causes core corkscrewing (“bird-caging”).
| Layer Sequence | Material & Standard Specification | Dynamic Reeling Function |
|---|---|---|
| 1. Conductors | Fine- or extra-fine-stranded bare copper, Class 5 / Class 6 per IEC 60228 / DIN VDE 0295 (tinned Cu optional) | High reverse-bending fatigue life over drum barrels and S-bend guide roller sheaves. |
| 2. Core Insulation | High-tensile halogen-free thermoplastic polyester elastomer (TPE-E / 12Y) or cross-linked 3GI3 EPR | Thin, high-dielectric-strength wall (`0.6/1 kV`) prevents core-to-core pinch-through under high drum radial tension. |
| 3. Core Identification & Symmetry | HD 308 S2 colour code (`4G / 5G`), white-numbered black control cores, or symmetrical 3P + 2G/Y + Control composite lay | Splitting protective earth into outer interstices balances cross-sectional stiffness and eliminates rotational bias. |
| 4. Central Support & Bedding | Synthetic high-tenacity central strain core + low-friction fleece wrap / extruded inner elastomer bedding | Absorbs axial pulling forces (`15-20 N/mm²`) and decouples core bundle twist from the outer jacket. |
| 5. Optional Anti-Torsion / EMC Layer | Open-mesh polyester/aramid anti-torsion braid (motorized builds) or ≥85% tinned-copper braid (`D12YC11Y` EMC option) | Specified when motorized travel exceeds 120 m/min or VFD motor cables run adjacent to encoder circuits. |
| 6. Outer Sheath (11YM1 PUR) | Ether-based Polyurethane compound Type 11YM1 per DIN EN 50363-10-2 in High-Visibility Yellow (Black/Orange optional) | Halogen-free, tear- and notch-resistant, immune to mineral/ester oils (EN 60811-404), seawater hydrolysis, and UV. |
3. Electrical, Mechanical & Drum Installation Parameters
Every 0.6/1 kV PUR reeling build is evaluated against actual drum barrel diameter, guide-sheave geometry, acceleration, and ambient temperature in accordance with DIN VDE 0298-3 and DIN VDE 0298-4.
| Parameter | Specification Value | Parameter | Specification Value |
|---|---|---|---|
| Rated Voltage (Uo/U) | 0.6/1 kV AC (Max Um = 1.2 kV; up to 1.5 kV DC) | 50 Hz AC Dielectric Test | 3,500 V AC for 5 minutes (routine factory test) |
| Ambient Temp (Dynamic Reeling) | -40°C to +80°C (+90°C conductor limit) | Ambient Temp (Fixed Laying) | -50°C to +90°C |
| Min Drum Bending Radius | 10 × OD (OD ≤ 21.5 mm) | 12 × OD (OD > 21.5 mm or S-bend) | Min Fixed Bending Radius | 5 × OD stationary routing |
| Max Continuous Tensile Load | 15 N/mm² standard | 20 N/mm² reinforced motorized build | Permissible Torsional Stress | ±25°/m during drum guiding |
| Horizontal Reeling Speed | Up to 60-80 m/min spring reel | Up to 120-180 m/min motorized | Halogen-Free & Oil Standards | IEC 60754-1 halogen-free | DIN EN 60811-404 oil resistant |
4. 0.6/1 kV PUR Drum Reeling Cable Sizing Schedule (Power, Control & Composite)
The 12 reference constructions below span 4-core/5-core power reels, multi-core control reels, and Power + Split PE + Control composite schedules (matching the 3P + 2PE + Control studio cutaway) so OEM reel designers can size drum pocket widths and spring torque directly.
| Part Code | Core Formation (mm²) | Duty Category | Nom. Outer Ø (mm) | Min Drum Radius (mm) | Copper Wt. (kg/km) | Approx. Total Wt. (kg/km) | Max Pull 15-20 N/mm² (N) |
|---|---|---|---|---|---|---|---|
PUR-061KV-4G2.5 | 4G2.5 | 3P+PE Spring/Motor Reel | 11.4 | 115 | 96 | 195 | 150 – 200 |
PUR-061KV-4G6 | 4G6 | 3P+PE Spring/Motor Reel | 15.2 | 155 | 230 | 395 | 360 – 480 |
PUR-061KV-5G10 | 5G10 | 3P+N+PE Hoist/Gantry Reel | 20.8 | 210 | 480 | 760 | 750 – 1,000 |
PUR-061KV-4G16 | 4G16 | 3P+PE Transfer Car / Crane | 21.5 | 215 | 614 | 890 | 960 – 1,280 |
PUR-061KV-4G25 | 4G25 | 3P+PE Motorized Drum | 26.2 | 315 | 960 | 1,360 | 1,500 – 2,000 |
PUR-061KV-4G35 | 4G35 | 3P+PE Heavy Gantry Reel | 29.8 | 360 | 1,344 | 1,840 | 2,100 – 2,800 |
PUR-061KV-4G50 | 4G50 | 3P+PE Port / Portal Crane | 35.0 | 420 | 1,920 | 2,560 | 3,000 – 4,000 |
PUR-061KV-12G1.5 | 12G1.5 | Multi-Core Control Reel | 15.8 | 160 | 173 | 355 | 270 – 360 |
PUR-061KV-18G1.5 | 18G1.5 | Multi-Core Control Reel | 18.6 | 190 | 259 | 505 | 405 – 540 |
PUR-061KV-24G2.5 | 24G2.5 | Heavy Control / Valve Reel | 24.8 | 300 | 576 | 980 | 900 – 1,200 |
PUR-061KV-3X16-2C | 3×16 + 2G10 + 2×2.5 | Composite 3P+2PE+2C | 23.4 | 280 | 701 | 1,045 | 960 – 1,460 |
PUR-061KV-3X35-4C | 3×35 + 2G16 + 4×2.5 | Composite 3P+2PE+4C | 31.6 | 380 | 1,411 | 1,980 | 2,100 – 2,940 |
Multi-Layer Drum Ampacity Derating (DIN VDE 0298-4): Because tightly wound layers on cylindrical cable drums restrict radial heat dissipation, apply drum-layer correction factors to single-core air ratings (`0.80` for 1 layer, `0.61` for 2 layers, `0.49` for 3 layers, `0.42` for 4 layers) and keep at least 2 dead-wrap turns anchored via a braided cable grip on the drum barrel.
5. Frequently Asked Questions & Reel Engineering Review
When should I choose a 0.6/1 kV PUR reeling cable over a rubber (N)SHTÖU or PVC reeling cable?
Polyether PUR (`11YM1`) + TPE-E core insulation yields a
15-25% smaller outer diameter and lower linear weight than rubber (N)SHTÖU of equal ampacity, letting compact spring-driven or cylindrical motorized drums store longer travel lengths while resisting sharp steel swarf, hydraulic oil, diesel, seawater hydrolysis, and sub-zero cold (-40°C dynamic vs -5°C on PVC). Choose rubber (N)SHTÖU primarily when hot slag splash (>+100°C contact) is present.Can TEBAOFLEX combine 3-phase power, split protective earth, and pilot control cores inside one 0.6/1 kV PUR reeling cable?
Yes. As illustrated in our stepped studio cutaway (
3 power cores + 2 split green/yellow PE cores + 2 pilot control cores), composite schedules such as 3×16+2G10+2×2.5 mm² or 3×35+2G16+4×2.5 mm² balance torsional symmetry on the drum while eliminating a second parallel control reel on rail-mounted transfer cars, portal cranes, and tunnel jumbos.What minimum drum barrel diameter and guide-roller radius are required for 0.6/1 kV PUR reeling cables?
For standard spring-driven and motorized drum reeling under DIN VDE 0298-3, size the innermost drum barrel diameter to at least
20 × OD (10 × OD minimum bending radius for cables ≤ 21.5 mm OD, and 12 × OD for larger cross-sections or S-bend deflector sheaves). If your guide rollers reverse bend direction (S-bend), maintain ≥ 20 × OD distance between rollers.Are EMC copper-braid shielded or anti-torsion reinforced 0.6/1 kV PUR reeling builds available?
Yes. Standard spring-reel and moderate motorized drum duties use compact inner-bedded
11YM1 PUR. For high-acceleration monospiral crane reels (>120 m/min) or VFD inverter drives requiring EMC containment, TEBAOFLEX supplies embedded aramid/polyester anti-torsion braids and tinned-copper screened (D12YC11Y) variants, or integrated fibre-optic hybrid cores.Specify Your 0.6/1 kV PUR Drum Reeling Cable
Share your core schedule (power, control, or composite), reel type (spring or motorized), drum barrel diameter, travel length, and speed for an approved drawing and quotation.
