High-Performance REELPUR HF Halogen-Free Cable | Oil-Resistant Mobile Reel Cable Selection Guide

1. Introduction

1.1 Overview of the REELPUR HF Model

The REELPUR HF represents a significant advancement in halogen-free power and control cable technology, specifically engineered for applications requiring exceptional mechanical resilience and environmental durability. This specialised cable combines cross-linked polyethylene (XLPE) insulation with a robust polyurethane (PUR) outer jacket, creating a solution that excels in demanding industrial environments where conventional cables fail.

Designed to meet the stringent requirements of mobile equipment and reeling applications, the REELPUR HF addresses the critical need for cables that can withstand continuous flexing, mechanical stress, and exposure to oils and harsh weather conditions. Its halogen-free construction aligns with contemporary environmental regulations whilst maintaining superior performance characteristics that make it indispensable for modern industrial applications.

1.2 Industry Trends and Halogen-Free Cable Standards

The global shift towards halogen-free cables reflects growing environmental consciousness and stricter safety regulations. Traditional PVC cables release toxic and corrosive gases when burned, posing significant risks in enclosed spaces and contributing to environmental degradation. The REELPUR HF's compliance with RoHS 2015/863/EU and CPR 305/2011 standards positions it at the forefront of this regulatory evolution.

Modern industrial facilities increasingly demand cables that not only perform reliably but also contribute to safer working environments and reduced environmental impact. The halogen-free designation ensures that in the event of fire, the cable produces minimal toxic emissions and corrosive gases, protecting both personnel and sensitive electronic equipment. This trend is particularly pronounced in sectors such as renewable energy, automotive manufacturing, and food processing, where environmental compliance and worker safety are paramount.

2. Key Features and Technical Specifications

2.1 Construction: XLPE Insulation with PUR Jacket

The REELPUR HF's sophisticated construction begins with bare, annealed copper conductors manufactured to class 5 multi-stranded specifications according to EN 60228. This configuration provides optimal flexibility whilst maintaining excellent electrical conductivity, essential for mobile applications where the cable experiences frequent movement.

The insulation system utilises cross-linked polyethylene (XLPE) conforming to IEC 60502-1 standards. XLPE offers superior thermal stability and electrical properties compared to conventional thermoplastic insulation, enabling higher current-carrying capacity and extended service life. The cross-linking process creates a three-dimensional molecular structure that resists thermal degradation and maintains integrity under extreme conditions.

The cable's unique core arrangement features three main conductors laid up with protective earth conductors around an aramide strain-relief element, with pilot cores positioned in the outer interstices. This configuration optimises mechanical strength whilst maintaining electrical performance. The inner sheath utilises a special PUR compound that provides additional protection against mechanical damage and chemical exposure.

The outer sheath, manufactured from high-grade PUR in a distinctive yellow finish, serves as the primary defence against environmental factors. PUR's exceptional properties include superior abrasion resistance, excellent oil resistance, and outstanding weatherability, making it ideal for outdoor installations and industrial environments.

2.2 Thermal Performance: –40°C to +80°C Operating Range

The REELPUR HF demonstrates remarkable thermal performance across an extensive temperature range. For fixed installations, the cable operates reliably from -40°C to +80°C, whilst flexible operations are rated from -30°C to +80°C. This broad operating window accommodates diverse climatic conditions and industrial environments, from arctic installations to high-temperature industrial processes.

The maximum permissible conductor temperature of 90°C provides substantial thermal headroom for demanding applications, whilst the short-circuit temperature rating of 250°C ensures safety during fault conditions. These thermal characteristics result from the XLPE insulation's excellent thermal stability and the PUR jacket's resistance to temperature extremes.

2.3 Mechanical Properties: Oil Resistance, Wear Resistance, Tensile Strength, Short-Circuit Rating

The cable's mechanical properties represent its greatest strength in industrial applications. With a maximum tensile load of 20 N/mm² per conductor, the REELPUR HF withstands the stresses associated with frequent reeling and unreeling operations. The minimum bending radius requirements – 6 times the outer diameter for fixed installations and 8 times for reeling applications – ensure mechanical integrity during installation and operation.

Oil resistance, certified to DIN EN/IEC 60811-404 standards, makes the cable suitable for environments where petroleum products are present. This characteristic is crucial for applications in manufacturing facilities, mining operations, and marine environments where hydraulic fluids and lubricants are commonly encountered.

The flame propagation behaviour, tested according to DIN EN/IEC 60332-1-2, ensures safe operation in fire-risk environments. Weather resistance properties provide unrestricted indoor and outdoor use, with exceptional resistance to ozone, UV radiation, and moisture ingress.

2.4 Conductor Sizes, Core Identification, and Configuration Table

The REELPUR HF is available in seven standard configurations, ranging from 3×25+3G6+2×1×1 mm² to 3×150+3G25+2×1×1.5 mm², accommodating diverse power requirements. Core identification follows industry standards with black, brown, and grey for main conductors, three green-yellow protective earth conductors, and white and blue pilot cores.

Cable weights range from 1,200 kg/km for the smallest configuration to 5,980 kg/km for the largest, with outer diameters spanning 23.0-24.5 mm to 48.5-52.0 mm. These specifications enable precise selection for specific applications whilst maintaining consistent performance characteristics across the range.

3. Primary Applications

3.1 Cable Reels and Hoisting Equipment

Cable reels represent one of the most demanding applications for electrical cables, requiring exceptional flexibility and mechanical resilience. The REELPUR HF excels in these environments due to its optimised conductor arrangement and PUR jacket construction. In crane operations, hoisting equipment, and industrial cable management systems, the cable's ability to withstand millions of flex cycles whilst maintaining electrical integrity proves invaluable.

The aramide strain-relief element provides crucial support during reeling operations, distributing mechanical stresses evenly across the cable structure. This feature significantly extends service life compared to conventional cables, reducing maintenance costs and operational downtime.

3.2 Conveyor Systems and Mobile Motors

Modern conveyor systems demand cables that can handle continuous movement whilst supplying reliable power and control signals. The REELPUR HF's design specifically addresses these requirements through its enhanced mechanical properties and environmental resistance. In automotive manufacturing, food processing, and logistics applications, the cable's oil resistance and halogen-free construction provide additional safety margins.

Mobile motor applications, particularly in mining and construction equipment, benefit from the cable's exceptional durability and weather resistance. The ability to operate in temperature extremes whilst maintaining flexibility makes it ideal for equipment operating in challenging outdoor environments.

3.3 Indoor/Outdoor Installations Under High Mechanical Stress

Industrial facilities often require cable installations that span indoor and outdoor environments, subjecting cables to diverse stresses and environmental conditions. The REELPUR HF's unrestricted indoor/outdoor rating, combined with its mechanical robustness, makes it suitable for these challenging installations.

Applications include interconnections between buildings, mobile equipment power supplies, and temporary installations where cables may be subject to vehicular traffic or construction activities. The cable's resistance to crushing, abrasion, and chemical exposure ensures reliable operation in these demanding environments.

4. Environmental and Safety Advantages

4.1 Compliance with RoHS 2015/863/EU and CPR 305/2011

The REELPUR HF's compliance with RoHS 2015/863/EU demonstrates its commitment to environmental responsibility by restricting hazardous substances in electrical equipment. This compliance is increasingly important for companies seeking to reduce their environmental footprint and meet sustainability targets.

CPR 305/2011 compliance ensures that the cable meets Construction Products Regulation requirements, providing confidence in building and infrastructure applications. These certifications are essential for projects requiring regulatory compliance and environmental sustainability documentation.

4.2 Flame Propagation and Smoke Density Performance

The cable's flame propagation characteristics, tested to DIN EN/IEC 60332-1-2 standards, provide crucial safety benefits in fire scenarios. Unlike conventional PVC cables, the REELPUR HF's halogen-free construction produces minimal toxic emissions and corrosive gases when exposed to fire.

This characteristic is particularly important in enclosed spaces, underground installations, and buildings where evacuation may be challenging. The reduced smoke density and toxicity contribute to safer evacuation conditions and reduced damage to electronic equipment from corrosive gases.

4.3 Sustainability and End-of-Life Recycling

The halogen-free construction facilitates easier recycling at end-of-life, supporting circular economy principles. The copper conductors retain their value for recycling, whilst the PUR and XLPE materials can be processed through appropriate recycling streams.

This sustainability advantage aligns with corporate environmental policies and contributes to LEED certification requirements in green building projects. The extended service life of the REELPUR HF further enhances its environmental credentials by reducing replacement frequency.

5. Selection and Installation Guidelines

5.1 Voltage Rating and Cross-Section Selection Criteria

The REELPUR HF's voltage rating of 0.6/1 kV with a maximum operating voltage of 0.7/1.2 kV AC makes it suitable for low-voltage industrial applications. Cross-section selection should consider current-carrying capacity, voltage drop calculations, and short-circuit protection requirements.

For three-phase motor applications, the three main conductors handle phase currents whilst the protective earth conductors provide safety grounding. The pilot cores enable control and monitoring functions, making the cable suitable for sophisticated motor control systems requiring feedback signals.

5.2 Minimum Bending Radius and Maximum Tensile Load

Installation planning must account for the minimum bending radius requirements to prevent mechanical damage. For fixed installations, the 6× outer diameter requirement ensures long-term reliability, whilst the 8× requirement for reeling applications accommodates the additional stresses of mobile use.

The maximum tensile load of 20 N/mm² per conductor provides guidelines for cable pulling during installation. Proper cable management systems, including strain relief and support structures, are essential for maintaining these limits throughout the cable's service life.

5.3 Maintenance Best Practices and Fault Prevention

Regular inspection of the PUR jacket for signs of wear, cuts, or chemical attack helps prevent premature failure. In reeling applications, monitoring of the cable management system ensures proper spooling and prevents excessive bending or twisting.

Temperature monitoring during operation verifies that thermal limits are not exceeded, particularly important in high-current applications or environments with elevated ambient temperatures. Electrical testing of insulation resistance and continuity provides early warning of potential failures.

7. Conclusions and Recommendations

7.1 Summary of Key Performance Benefits

The REELPUR HF represents a sophisticated solution for demanding cable applications requiring exceptional mechanical durability, environmental resistance, and safety performance. Its halogen-free construction addresses contemporary environmental and safety regulations whilst delivering superior technical performance.

Key benefits include extended service life in reeling applications, reliable operation across extreme temperature ranges, excellent oil and weather resistance, and compliance with current European regulations. The combination of these characteristics makes it particularly suitable for modern industrial applications where safety, reliability, and environmental responsibility are paramount.

7.2 Future Application Opportunities

Emerging applications for the REELPUR HF include electric vehicle charging infrastructure, renewable energy installations, and automated manufacturing systems. The cable's robust construction and environmental credentials align with trends towards electrification and sustainable industrial practices.

As industrial automation continues to advance, the demand for reliable cables capable of handling complex power and control requirements will grow. The REELPUR HF's pilot core configuration and mechanical resilience position it well for these evolving applications.

The continued emphasis on workplace safety and environmental protection ensures strong market demand for halogen-free cables with superior performance characteristics, making the REELPUR HF a strategic choice for forward-thinking installations.

Frequently Asked Questions

Q: What makes the REELPUR HF suitable for oil-resistant applications? A: The cable is certified to DIN EN/IEC 60811-404 standards for oil resistance. The PUR outer jacket and special inner sheath compound provide excellent resistance to petroleum products, hydraulic fluids, and industrial lubricants commonly found in manufacturing environments.

Q: How does the halogen-free construction benefit safety? A: Unlike PVC cables, the REELPUR HF produces minimal toxic emissions and corrosive gases when exposed to fire. This reduces risks to personnel during evacuation and prevents damage to sensitive electronic equipment from corrosive fumes.

Q: What is the expected service life in reeling applications? A: With proper installation and maintenance, the REELPUR HF can withstand millions of flex cycles due to its aramide strain-relief element and optimised conductor arrangement. Service life depends on operating conditions but typically exceeds conventional cables by 50-100%.

Q: Can the cable be used in outdoor installations year-round? A: Yes, the cable provides unrestricted outdoor use with excellent resistance to ozone, UV radiation, and moisture. The operating temperature range of -40°C to +80°C accommodates most climatic conditions globally.