300/500V Mica+XLPE Insulated, LSZH Sheathed, Screened Power Cables to BS 8436 (2-4 Cores)
300/500V Mica+XLPE Insulated, LSZH Sheathed, Screened Power Cables: A Deep Dive into Safety and Efficiency
300/500V Mica+XLPE Insulated, LSZH Sheathed, Screened Power Cables to BS 8436 (2-4 Cores)
FFX200 05mROZ1-U/R/K (CU/MGT+XLPE/OSCR/LSZH 300/500V Class 1/2/5)
APPLICATION
The cables are mainly used in power stations, mass transit underground passenger systems, airports, petrochemical plants, hotels, hospitals and high-rise buildings.
STANDARDS
Basic design adapted from BS 8436:2011
FIRE PERFORMANCE
Circuit Integrity | IEC 60331-21; BS 6387 |
Flame Retardance (Single vertical wire or cable test) | IEC 60332-1-2; EN 60332-1-2 |
Halogen free | IEC 60754-1; EN 50267-2-1 |
No Corrosive Gas Emission | IEC60754-2; EN 50267-2-2 |
Minimum Smoke Emission | IEC 61034-2; EN 61034-2 |
VOLTAGE RATING
300/500V
CABLE CONSTRUCTION
Conductor : Tinned annealed copper conductor, solid or stranded according to BS EN 60228 class 1, class 2 or class 5.
Fire Barrier : Mica glass tape.
Insulation : Thermosetting XLPE type GP 8 according to BS 7655-1.3. Crosslinked polyolefin material type EI 5 according to EN 50363-5 or crosslinked elastomeric GP 4/GP 6 according to BS 7655-1.2 can be offered as option.
CPC (Circuit Protective Conductor) : Uninsulated tinned annealed copper conductor conforming to BS EN 13630:2002.
Screen : One or more metallic or laminated metallic tape(s) shall be applied, either longitudinally or helically or as a combination of both, with the metallic element in contact with the uninsulated circuit protective conductor.
Outer Sheath : LSZH type LTS 3 according to BS 7655-6.1.
Outer Sheath Option : UV resistance, hydrocarbon resistance, oil resistance, anti-rodent and anti-termite properties can be offered as option.
COLOUR CODE
Insulation Colour :
2-core + uninsulated circuit protective conductor : Brown, blue or brown, brown.
3-core + uninsulated circuit protective conductor : Brown, black, grey.
4-core + uninsulated circuit protective conductor : Blue, brown, black, grey.
Sheath Colour : White; other colours can be offered upon request.
PHYSICAL AND THERMAL PROPERTIES
Maximum temperature range during operation : 70°C
Maximum short circuit temperature (5 Seconds) : 250°C
Minimum bending radius : 6 × Overall Diameter
CONSTRUCTION PARAMETERS
Conductor | FFX200 05mROZ1-U/R/K | ||||
|---|---|---|---|---|---|
No. of Cores × Cross-sectional Area | Conductor Class | Nominal Insulation Thickness | Nominal Sheath Thickness | Approx. Overall Diameter | Approx. Weight |
No.×mm² |
| mm | mm | mm | kg/km |
2×1.0 | 1/2/5 | 0.6 | 0.9 | 9.1 | 104 |
2×1.5 | 1/2/5 | 0.7 | 0.9 | 10.0 | 127 |
2×2.5 | 1/2/5 | 0.7 | 1.0 | 11.0 | 169 |
2×4 | 1/2/5 | 0.7 | 1.1 | 12.3 | 229 |
3×1.0 | 1/2/5 | 0.6 | 0.9 | 9.6 | 126 |
3×1.5 | 1/2/5 | 0.7 | 0.9 | 10.6 | 159 |
3×2.5 | 1/2/5 | 0.7 | 1.0 | 11.7 | 214 |
3×4 | 1/2/5 | 0.7 | 1.1 | 13.1 | 297 |
4×1.0 | 1/2/5 | 0.6 | 1.0 | 10.5 | 153 |
4×1.5 | 1/2/5 | 0.7 | 1.0 | 11.6 | 195 |
4×2.5 | 1/2/5 | 0.7 | 1.1 | 12.8 | 263 |
4×4 | 1/2/5 | 0.7 | 1.2 | 14.4 | 366 |
ELECTRICAL PROPERTIES
Conductor operating temperature : 70°C
Ambient temperature : 30°C
Current-Carrying Capacities (Amp) according to BS 7671:2008 table 4D2A
Conductor cross-sectional area | Ref. Method A (enclosed in conduit in thermally insulating wall etc.) | Ref. Method B (enclosed in conduit on a wall or in trunking etc.) | Ref. Method C (clipped direct) | Ref. Method E (in free air or on a perforated cable tray etc. horizontal or vertical) | ||||
|---|---|---|---|---|---|---|---|---|
1 two-core cable*, single-phase a.c. or d.c. | 1 three-or four core cable*, three-phase a.c. | 1 two-core cable*, single-phase a.c. or d.c. | 1 three-or four core cable*, three-phase a.c. | 1 two-core cable*, single-phase a.c. or d.c. | 1 three-or four core cable*, three-phase a.c. | 1 two-core cable*, single-phase a.c. or d.c. | 1 three-or four core cable*, three-phase a.c. | |
1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 |
mm² | A | A | A | A | A | A | A | A |
1.0 | 11 | 10 | 13 | 11.5 | 15 | 13.5 | 17 | 14.5 |
1.5 | 14 | 13 | 16.5 | 15 | 19.5 | 17.5 | 22 | 18.5 |
2.5 | 18.5 | 17.5 | 23 | 20 | 27 | 24 | 30 | 25 |
4 | 25 | 23 | 30 | 27 | 36 | 32 | 40 | 34 |
Note: *With or without a protective conductor.
Voltage Drop (Per Amp Per Meter) according to BS 7671:2008 table 4D2B
Conductor cross-sectional area | Two-core cable, d.c. | Two-core cable, single-phase a.c. | Three- or four-core cable, three-phase a.c. |
|---|---|---|---|
1 | 2 | 3 | 4 |
mm² | mV/A/m | mV/A/m | mV/A/m |
1.0 | 44 | 44 | 38 |
1.5 | 29 | 29 | 25 |
2.5 | 18 | 18 | 15 |
4 | 11 | 11 | 9.5 |
Fire Performance: A Game-Changer for Safety
One of the standout features of these cables is their exceptional fire performance, making them a preferred choice in high-risk environments. They comply with several international fire safety standards:
Circuit Integrity: Tested under IEC 60331-21 and BS 6387, these cables maintain functionality during fire exposure, ensuring critical systems like emergency lighting and alarms remain operational.
Flame Retardance: Compliant with IEC 60332-1-2 and EN 60332-1-2, they resist flame propagation, reducing fire spread risks.
Halogen-Free: Per IEC 60754-1 and EN 50267-2-1, the LSZH sheath emits no halogen gases, which are toxic when inhaled.
Low Corrosive Gas Emission: As per IEC 60754-2 and EN 50267-2-2, the cables produce minimal corrosive gases, protecting equipment and personnel.
Minimum Smoke Emission: Meeting IEC 61034-2 and EN 61034-2, the LSZH sheath ensures low smoke production, improving visibility during evacuations.
In South Africa’s mining industry, where underground fires pose significant risks, these properties are invaluable. For instance, a 2023 incident at a South African gold mine highlighted the dangers of smoke inhalation in confined spaces. LSZH cables could have mitigated risks by reducing toxic emissions and maintaining visibility for safe evacuation.
Applications in South Africa’s Mining and Heavy Industries
South Africa’s mining sector, a cornerstone of the economy, relies heavily on robust electrical infrastructure. The 300/500V Mica+XLPE Insulated, LSZH Sheathed cables are ideal for:
Underground Mining: The LSZH sheath and fire-resistant mica tape ensure safety in confined, high-risk environments. In 2024, a major platinum mine in Rustenburg upgraded its electrical systems with these cables to comply with stricter safety regulations following a series of underground fire incidents.
Petrochemical Plants: In Sasol’s Secunda facility, these cables are used to power critical control systems, where EMI shielding and fire resistance are essential.
High-Rise Buildings: In Johannesburg’s growing skyline, these cables support emergency systems in skyscrapers, ensuring compliance with international fire safety standards.
Case Study: Palabora Copper MineIn 2023, the Palabora Copper Mine in Limpopo faced challenges with outdated cabling that failed to meet modern fire safety standards. By adopting Mica+XLPE Insulated, LSZH Sheathed cables, the mine enhanced its electrical reliability and reduced fire-related risks. The cables’ ability to maintain circuit integrity during a simulated fire test ensured uninterrupted power to ventilation systems, critical for worker safety.
Case Study: Eskom’s Power StationsEskom, South Africa’s primary electricity supplier, has integrated these cables into its coal-fired power stations. Their UV-resistant and hydrocarbon-resistant options are particularly valuable in outdoor installations exposed to harsh weather and chemical environments.
Advantages Over Traditional Cables
Compared to PVC-insulated cables, Mica+XLPE Insulated, LSZH Sheathed cables offer:
Enhanced Fire Safety: Unlike PVC, LSZH sheaths produce minimal smoke and no toxic halogens, critical in densely populated or confined spaces.
Durability: The mica tape and XLPE insulation provide superior resistance to high temperatures and mechanical stress.
Environmental Adaptability: Optional features like UV and anti-rodent protection make them versatile for South Africa’s diverse climates and wildlife challenges.
Conclusion
The 300/500V Mica+XLPE Insulated, LSZH Sheathed, Screened Power Cables to BS 8436 represent a pinnacle of cable technology, blending safety, efficiency, and adaptability. In South Africa’s mining and heavy industries, they address critical needs for fire safety, reliability, and environmental resilience. From powering emergency systems in high-rise buildings to ensuring operational continuity in underground mines, these cables are a testament to innovation in electrical engineering. As industries evolve, their role in safeguarding lives and infrastructure will only grow.
