FESTOON C-PUR-HF: Durable Power and Control Cable for High Mechanical Stress and Frequent Bending in Industrial Applications

The FESTOON C-PUR-HF represents a pinnacle in high-performance power and control cable for industrial use, specifically engineered to withstand the most demanding operational conditions. This sophisticated cable system delivers exceptional performance in applications characterised by very high mechanical stress and frequent bending cycles, making it an indispensable component for modern industrial infrastructure.

Designed with versatility in mind, the FESTOON C-PUR-HF for trolley systems and drag chains operates reliably across diverse environmental conditions, from dry and humid indoor facilities to wet environments and challenging outdoor installations. The cable's robust construction ensures consistent performance whether deployed in controlled factory settings or exposed to the harsh realities of industrial outdoor applications.

The engineering excellence behind this durable cable for frequent bending applications addresses the critical challenges faced by modern industrial operations, where equipment mobility, automation, and continuous operation demand cables that can endure millions of flex cycles without compromising electrical integrity or mechanical stability. This makes the FESTOON C-PUR-HF particularly valuable for applications involving moving machinery components, automated production lines, and material handling systems.

Product Specifications

Electrical Properties and Performance

The FESTOON C-PUR-HF operates with a nominal voltage rating of 0.6/1 kV, providing robust electrical performance suitable for both power transmission and control signal applications. The cable undergoes rigorous testing at 2.5 kV to ensure electrical integrity under stress conditions, demonstrating its reliability in demanding industrial environments.

The conductor construction utilises bare copper stranding in Class 5 configuration according to DIN VDE 0295 and IEC 60228, ensuring maximum flexibility whilst maintaining excellent electrical conductivity. This flexible cable for high mechanical requirements features polyester-based core insulation that provides superior electrical properties and enhanced durability under mechanical stress.

Current-carrying capacity varies according to conductor cross-section and follows DIN VDE standards, ensuring safe and efficient power transmission across the complete range of available configurations. The cable's electrical design accommodates both single-core configurations for high-power applications and multi-core arrangements for complex control and power distribution requirements.

Mechanical Properties and Durability

The mechanical design of this industrial cable with PUR insulation prioritises flexibility and longevity under continuous motion applications. The minimum bending radius of 6 times the cable diameter for fixed installations and 7.5 times for mobile applications ensures optimal performance without compromising cable integrity.

Operating at speeds up to 240 metres per minute on trolley systems, the cable demonstrates exceptional dynamic performance. The maximum tensile stress of 15 N/mm² on conductors ensures reliable operation even under significant mechanical loading conditions commonly encountered in industrial applications.

Temperature performance ranges from -50°C to +90°C for fixed installations and -40°C to +90°C for mobile applications, with conductor temperatures not exceeding 90°C. This broad temperature range makes the reliable cable for harsh industrial environments suitable for diverse climatic conditions and industrial processes.

Environmental Compliance and Safety Features

The RoHS-compliant industrial cable meets stringent environmental and safety standards, being completely halogen-free during production. This characteristic eliminates the risk of toxic gas emission during fire conditions, making it safer for personnel and equipment.

Compliance with the 2014/35/EU Low Voltage Directive and CE marking ensures the cable meets European safety standards. The flame-retardant properties follow IEC 60332-2-1 standards, whilst oil resistance meets EN 60811-2-1 specifications, ensuring reliable operation in industrial environments where exposure to oils and chemicals is common.

A unique feature of this cable for conveyor facilities and moving machine parts is its optional availability for permanent underwater use in non-potable water applications up to 50 metres depth, expanding its applicability to specialised industrial processes and marine applications.

Applications

Trolley Systems and Drag Chains

The primary application domain for FESTOON C-PUR-HF encompasses trolley systems where cables must maintain electrical continuity whilst following moving equipment across extended distances. The cable's construction specifically addresses the unique mechanical stresses encountered in these systems, including torsional forces, tension variations, and repetitive bending cycles.

In drag chains applications, the cable excels due to its optimised flexibility characteristics and robust outer sheath construction. The polyurethane outer jacket provides excellent abrasion resistance, whilst the internal construction with central textile support element ensures maintained cable geometry under continuous flexing conditions.

Moving Parts of Machines and Conveyor Facilities

Modern manufacturing and material handling systems increasingly rely on automated equipment with moving components requiring reliable power and control connections. The cable for conveyor facilities and moving machine parts addresses these requirements through its specialised construction that accommodates the complex motion patterns typical of industrial machinery.

Robotic applications particularly benefit from the cable's flexibility and durability characteristics. The consistent electrical performance under motion ensures precise control signal transmission, whilst the mechanical robustness supports the demanding duty cycles common in automated production environments.

Industrial Automation and Robotics

The screened power and control cable for EMI protection variant provides additional electromagnetic interference shielding through a tinned copper braid with approximately 85% coverage. This feature proves essential in environments with high electromagnetic activity, ensuring signal integrity in sensitive control applications.

Automation systems requiring both power and data transmission benefit from the available screened pair configurations, allowing consolidated cable installations that reduce complexity whilst maintaining performance. The cable's ability to handle both power transmission and control signalling within a single installation simplifies system design and reduces maintenance requirements.

Construction Details and Technical Excellence

Core Construction and Insulation

The cable construction begins with high-quality bare copper conductors arranged in Class 5 stranding for maximum flexibility. Core identification follows DIN 0293-308 standards, with coloured cores up to 5 conductors and numbered white cores with black digits for larger configurations.

For multi-core cables exceeding 5 conductors, the cores are stranded in layers around a central textile element, providing mechanical stability whilst maintaining flexibility. The polyester-based insulation offers excellent electrical properties and mechanical durability under repetitive stress conditions.

Shielding and Protection Systems

The halogen-free power cable for outdoor use incorporates multiple protection layers depending on configuration. PETP film provides contact protection for pair-stranded configurations, whilst the overall tinned copper braid shield offers electromagnetic protection with approximately 85% coverage.

The central textile support element in multi-core configurations provides mechanical reinforcement without compromising flexibility. This construction detail proves particularly important in applications involving vertical cable runs or installations subject to tensile loading.

Outer Sheath Performance

The black polyurethane outer sheath delivers exceptional performance across the cable's operating temperature range whilst providing superior resistance to oils, chemicals, and environmental conditions. The material selection ensures long-term durability under UV exposure, making it suitable for outdoor installations.

Surface printing provides clear cable identification and specification information, facilitating proper installation and maintenance procedures. The smooth outer surface reduces friction in drag chain applications whilst the material formulation resists cracking under repeated flexing.

Why Choose FESTOON C-PUR-HF?

Exceptional Durability and Reliability

The engineering excellence demonstrated in FESTOON C-PUR-HF construction delivers unmatched reliability under high mechanical stress conditions. The combination of flexible conductor design, robust insulation systems, and protective outer sheath ensures consistent performance throughout extended service life.

Testing protocols validate the cable's performance under accelerated aging conditions, simulating years of operational stress to confirm long-term reliability. This comprehensive validation process provides confidence in the cable's ability to maintain performance standards throughout its operational lifetime.

Compliance with Safety and Environmental Standards

The halogen-free formulation eliminates toxic gas generation during fire conditions, protecting personnel and equipment. RoHS compliance ensures environmental responsibility whilst meeting regulatory requirements for modern industrial installations.

Safety features extend beyond material selection to include flame-retardant properties and oil resistance, addressing the diverse hazard exposure scenarios common in industrial environments. The comprehensive compliance framework simplifies specification and approval processes for industrial projects.

Customisation Options and Versatility

The FESTOON C-PUR-HF system offers extensive customisation options to meet specific application requirements. Screened versions provide electromagnetic interference protection for sensitive applications, whilst various conductor configurations accommodate diverse power and control requirements.

Special variants include underwater-rated versions for marine and process applications, demonstrating the flexibility of the basic cable design to address specialised requirements. Custom conductor arrangements, insulation colours, and dimensional modifications are available to meet specific project needs.

Frequently Asked Questions

Q: What is the maximum operating temperature for FESTOON C-PUR-HF cables? A: The cable operates reliably up to 90°C for both fixed and mobile installations, with conductor temperatures not exceeding 90°C. The lower temperature limits are -50°C for fixed installations and -40°C for mobile applications.

Q: Can FESTOON C-PUR-HF be used in underwater applications? A: Yes, special variants are available for permanent underwater use in non-potable water applications up to 50 metres depth. This makes the cable suitable for marine applications and industrial processes involving water exposure.

Q: What is the difference between screened and unscreened versions? A: The screened version (FESTOONTEC PUR-HF) includes a tinned copper braid shield with approximately 85% coverage, providing electromagnetic interference protection for sensitive control applications. Unscreened versions are suitable for standard power applications.

Q: How does the cable perform in drag chain applications? A: The cable is specifically designed for drag chain applications with optimised flexibility characteristics, robust outer sheath construction, and internal textile support elements that maintain cable geometry under continuous flexing conditions.

Q: What compliance standards does FESTOON C-PUR-HF meet? A: The cable is RoHS compliant, halogen-free, meets CE marking requirements under the 2014/35/EU Low Voltage Directive, and incorporates flame-retardant properties according to IEC 60332-2-1 standards.

Q: What conductor sizes are available? A: The cable is available in single-core configurations from 25mm² to 240mm², multi-core arrangements from 4×1.5mm² to 18×2.5mm², and various screened pair configurations for control applications.

Q: Can custom configurations be manufactured? A: Yes, custom conductor arrangements, insulation colours, dimensional modifications, and special variants can be manufactured to meet specific project requirements upon enquiry.

Conclusion

The FESTOON C-PUR-HF represents the optimal solution for industrial applications demanding exceptional flexibility, durability, and reliability under challenging operating conditions. Its comprehensive design addresses the critical requirements of modern industrial automation, material handling, and manufacturing systems.

The combination of electrical performance, mechanical durability, and environmental compliance makes this cable system ideal for applications ranging from simple trolley systems to complex automated production lines. The extensive range of available configurations ensures suitable options for virtually any industrial power and control application.

Investment in FESTOON C-PUR-HF technology delivers long-term value through reduced maintenance requirements, improved system reliability, and enhanced operational safety. The cable's proven performance in demanding applications makes it the preferred choice for engineers seeking dependable solutions for critical industrial infrastructure.