Cable TXG / TXG-D: Neoprene Round Cable for Heavy-Duty Festoon Systems
A practical engineering guide to a highly resilient round cable family for container-crane trolleys, process cranes, foundries, steel mills, stacker/reclaimers, car dumpers, ship unloaders and transport carriers. TXG combines class-5 copper, EPR insulation, layered stranding and a wear-resistant synthetic-rubber sheath for continuous dynamic duty in severe atmospheric conditions.
What is Cable TXG / TXG-D?
TXG is a neoprene / synthetic-rubber round cable for continuous heavy-duty festoon service. TXG-D extends the family to paired data and optical-fibre transmission. The design is intended for moving power, control, bus and communication media where high travel speed, repeated bending, abrasion and atmospheric exposure must be managed together.
The supplied record specifies U₀/U = 0.6/1 kV and a travel speed of up to 240 m/min. Typical applications include container-crane trolley power supply, process-crane trolleys, cranes in foundries and steel mills, stacker and reclaimers, car dumpers, ship unloaders and transport carriers.
TXG is not only a “soft rubber cable”. Its engineering value comes from the combination of finely stranded class-5 copper, EPR core insulation, a layered core arrangement, a wear-resistant synthetic-rubber sheath and optional tinned-copper screening. For screened power cables, the supplied description specifically identifies three-phase conductors plus split earth conductors, which can deliver a compact package for high-current mobile equipment.
Public engineering context. Conductix-Wampfler describes festoon cables as engineered for heavy-duty operation, high dynamics and harsh environments, with finely stranded conductors and robust sheathing. That supports the design logic explained here; all exact TXG / TXG-D values and order rows below are transcribed from the supplied record.
Electrical, mechanical, thermal and chemical envelope
Electrical
Rated voltage: U₀/U = 0.6/1 kV.
AC test voltage: 3.5 kV.
Ampacity: according to DIN VDE 0298-4.
Operational conductor temperature: 90°C; short-circuit conductor temperature 250°C.
Mechanical
Travel speed: up to 240 m/min.
Dynamic minimum radius: according to DIN VDE 0298 Part 3.
Optical-fibre cable radius: 125 mm.
Load data: each row gives a permitted tensile-load value; the complete machine load path still requires engineering review.
Thermal
TXG flexing: −35°C…+80°C.
TXG fixed: −50°C…+80°C.
TXG-D 24 FO flexing: −30°C…+60°C.
TXG-D 24 FO fixed: −40°C…+80°C.
Chemical and atmospheric
Ozone resistant · oil resistant according to DIN EN 60811-404 · UV resistant · flame retardant according to IEC 60332-1 · free from silicone.
The supplied record states unlimited resistance to atmospheric corrosion. The actual media, salt, cleaning chemistry, temperature and mechanical exposure still require project compatibility review.
| Parameter | Supplied value | Engineering reading |
|---|---|---|
| Family | Cable TXG / TXG-D | Neoprene round cable for continuous heavy-duty festoon |
| Rated voltage | U₀/U = 0.6/1 kV | Power, control, bus and optical-fibre cable family rating |
| Travel speed | up to 240 m/min | Application limit supplied; actual life depends on the machine |
| Minimum dynamic radius | according to DIN VDE 0298 Part 3 | Use the applicable installation category and exact outer diameter |
| Optical-fibre cable radius | 125 mm | Specific supplied value for optical-fibre cables |
| TXG ambient | flexing −35…+80°C; fixed −50…+80°C | TXG ambient envelope |
| TXG-D 24 FO ambient | flexing −30…+60°C; fixed −40…+80°C | TXG-D 24 FO ambient envelope |
| Conductor / short circuit | 90°C / 250°C | Conductor limits, not ambient limits |
| AC test voltage | 3.5 kV | Release test report must identify the applicable test |
| Flame retardance | IEC 60332-1 | Supplied family statement |
| Atmospheric corrosion | Unlimited resistance stated | Confirm actual environment and cleaning media |
| Colour | Black; optical-fibre data rows marked orange | Confirm marking and colour for the selected construction |
Construction: the design choices behind TXG durability
The conductor is finely stranded bare electrolytic copper, class 5 according to VDE 0295. The cores are arranged in layers and insulated with an EPR compound. The outer sheath is an abrasion-resistant special rubber compound; the additional data identifies at least 5GM3. This combination is intended to control bending stress while resisting wear from trolley guides, chain separators and industrial handling.
For screened types, the supplied family design identifies (N)GRDGOEU and (N)GRDGCGOEU. The overview describes an overall tinned-copper braid with approximately 85% optical coverage. The additional data specifies at least 80% overall shield coverage, at least 60% for individually screened cores and at least 80% for twisted and shielded pairs. These are different screen objects and are intentionally not collapsed into one value.
| Construction item | Supplied design detail | Service significance |
|---|---|---|
| Conductor | Finely stranded bare electrolytic copper | Supports repeated movement and current transfer |
| Conductor class | Class 5 acc. to VDE 0295 | Flexibility class for dynamic installation and termination |
| Core arrangement | Cores arranged in layers | Reduces package diameter and controls the round load path |
| Core insulation | EPR compound | Electrical and thermal insulation for the mobile cable |
| Conductor coding | Up to 5 cores: coloured acc. to VDE 0293; from 6: light-coloured insulation with black numerals, with/without GN/YE | Wiring and replacement control |
| Outer sheath | Abrasion-resistant special rubber compound, at least 5GM3 in additional data | Wear barrier in medium-to-high speed and acceleration service |
| Colour | Black | Optical-fibre data rows separately state orange |
| Screened types | (N)GRDGOEU, (N)GRDGCGOEU | Braided copper screen for electromagnetic-interference resistance |
| Overall screen | Tinned copper braid; overview approx. 85%, detailed data at least 80% | Coverage statement depends on the referenced screen object |
| Individually screened cores | At least 60% surface coverage | Confirm individual-core construction where required |
| Twisted and screened pairs | At least 80% surface coverage | Confirm pair-level screen and termination |
Engineering interpretation. “Unlimited resistance to atmospheric corrosion” is valuable for coastal terminals, ship unloaders, steel plants and bulk-handling equipment, but the cable still needs a controlled installation. Corrosive atmosphere, abrasion and acceleration act through different failure mechanisms.
Complete TXG / TXG-D order matrices
The tables preserve all supplied conductor schedules, part numbers, diameter ranges, copper indexes, approximate weights, permitted tensile loads and minimum-order quantities. A dash is retained as supplied. The optical-fibre rows use a dash for copper index because the supplied record does not assign a copper-index value to those fibre constructions.
| Cable family | Conductors / construction | Part No. | Outer Ø min/max [mm] | Cu approx. [kg/km] | Weight approx. [kg/km] | Permitted tensile load [N] | U₀/U | Minimum order quantity [m] |
|---|---|---|---|---|---|---|---|---|
| Control cable TXG | 12 G 2.5 | 131220-R12G2,5# | 18.0 – 20.0 | 288 | 600 | 450 | 0.6/1 kV | – |
| Control cable TXG | 18 G 2.5 | 131220-R18G2,5# | 21.5 – 23.5 | 432 | 870 | 670 | 0.6/1 kV | – |
| Control cable TXG | 24 G 2.5 | 131220-R24G2,5# | 24.0 – 27.0 | 576 | 1140 | 900 | 0.6/1 kV | – |
| Control cable TXG | 30 G 2.5 | 131220-R30G2,5# | 26.4 – 29.4 | 720 | 1360 | 1120 | 0.6/1 kV | – |
| Control cable TXG | 36 G 2.5 | 131220-R36G2,5# | 28.7 – 31.7 | 864 | 1550 | 1350 | 0.6/1 kV | 500 |
| Cable family | Conductors / construction | Part No. | Outer Ø min/max [mm] | Cu approx. [kg/km] | Weight approx. [kg/km] | Permitted tensile load [N] | U₀/U | Minimum order quantity [m] |
|---|---|---|---|---|---|---|---|---|
| Data cable TXG-D | 6 × (2×0.5)C | 131222-R6X(2X0,5)C# | 21.6 – 24.6 | 358 | 800 | 90 | TXG-D data rows — voltage not stated in supplied line | 500 |
| Data cable TXG-D | 6 × (2×1)C | 131322-R6X(2X1)C# | 27.0 – 30.2 | 427 | 1230 | 180 | TXG-D data rows — voltage not stated in supplied line | – |
| Data cable TXG-D | 9 × (2×1)C | 131322-R9X(2X1)C# | 35.3 – 38.3 | 641 | 1930 | 270 | TXG-D data rows — voltage not stated in supplied line | 300 |
| Data cable TXG-D | * 24 G 62,5/125 | 131320-R24G62,5/125-X# | 10.0 – 11.0 | – | 110 | 2000 | TXG-D data rows — voltage not stated in supplied line | – |
| Data cable TXG-D | * 24 G 50/125 | 131320-R24G50/125-X# | 10.0 – 11.0 | – | 110 | 2000 | TXG-D data rows — voltage not stated in supplied line | – |
| Data cable TXG-D | * 24 E 9/125 | 131320-R24E9/125-X# | 10.0 – 11.0 | – | 110 | 2000 | TXG-D data rows — voltage not stated in supplied line | – |
| Cable family | Conductors / construction | Part No. | Outer Ø min/max [mm] | Cu approx. [kg/km] | Weight approx. [kg/km] | Permitted tensile load [N] | U₀/U | Minimum order quantity [m] |
|---|---|---|---|---|---|---|---|---|
| Power cable TXG | 1 × 35 | 131120-R1X35# | 12.3 – 13.9 | 336 | 430 | 520 | 0.6/1 kV | – |
| Power cable TXG | 1 × 70 | 131120-R1X70# | 16.3 – 18.3 | 672 | 830 | 1050 | 0.6/1 kV | – |
| Power cable TXG | 1 × 95 | 131120-R1X95# | 18.5 – 20.5 | 912 | 1070 | 1420 | 0.6/1 kV | – |
| Power cable TXG | 1 × 120 | 131120-R1X120# | 20.3 – 22.3 | 1152 | 1330 | 1800 | 0.6/1 kV | – |
| Power cable TXG | 1 × 150 | 131120-R1X150# | 22.7 – 24.7 | 1440 | 1640 | 2250 | 0.6/1 kV | – |
| Power cable TXG | 1 × 185 | 131120-R1X185# | 24.6 – 27.6 | 1776 | 2010 | 2770 | 0.6/1 kV | 500 |
| Power cable TXG | 4 G 4 | 131120-R4G4# | 13.6 – 15.2 | 154 | 350 | 240 | 0.6/1 kV | – |
| Power cable TXG | 4 G 6 | 131120-R4G6# | 15.9 – 17.9 | 230 | 480 | 360 | 0.6/1 kV | – |
| Power cable TXG | 4 G 10 | 131120-R4G10# | 18.0 – 20.0 | 384 | 680 | 600 | 0.6/1 kV | – |
| Power cable TXG | 4 G 16 | 131120-R4G16# | 23.3 – 25.3 | 614 | 1110 | 960 | 0.6/1 kV | – |
| Power cable TXG | 4 G 25 | 131120-R4G25# | 26.9 – 29.9 | 960 | 1610 | 1500 | 0.6/1 kV | – |
| Power cable TXG | 4 G 35 | 131120-R4G35# | 30.1 – 33.1 | 1344 | 2100 | 2100 | 0.6/1 kV | 300 |
| Power cable TXG | 4 G 50 | 131120-R4G50# | 36.1 – 39.1 | 1920 | 3010 | 3000 | 0.6/1 kV | – |
| Power cable TXG | 5 G 4 | 131120-R5G4# | 15.7 – 17.7 | 192 | 450 | 300 | 0.6/1 kV | – |
| Power cable TXG | 5 G 6 | 131120-R5G6# | 17.5 – 19.5 | 288 | 580 | 450 | 0.6/1 kV | – |
| Power cable TXG | 5 G 10 | 131120-R5G10# | 20.2 – 22.2 | 480 | 860 | 750 | 0.6/1 kV | 1000 |
| Power cable TXG | 5 G 16 | 131120-R5G16# | 24.5 – 27.5 | 768 | 1340 | 1200 | 0.6/1 kV | – |
| Power cable TXG | 5 G 25 | 131120-R5G25# | 29.9 – 32.9 | 1200 | 1990 | 1870 | 0.6/1 kV | – |
| Power cable TXG | 5 G 35 | 131120-R5G35# | 34.7 – 37.7 | 1680 | 2700 | 2620 | 0.6/1 kV | 500 |
| Cable family | Conductors / construction | Part No. | Outer Ø min/max [mm] | Cu approx. [kg/km] | Weight approx. [kg/km] | Permitted tensile load [N] | U₀/U | Minimum order quantity [m] |
|---|---|---|---|---|---|---|---|---|
| Screened power cable TXG | 4 G 4C | 131129-R4G4C# | 14.8 – 17.8 | 277 | 480 | 240 | 0.6/1 kV | 1000 |
| Screened power cable TXG | 4 G 6C | 131129-R4G6C# | 16.2 – 19.2 | 402 | 640 | 360 | 0.6/1 kV | 1000 |
| Screened power cable TXG | 4 G 10C | 131129-R4G10C# | 19.6 – 22.6 | 610 | 890 | 600 | 0.6/1 kV | – |
| Screened power cable TXG | 3 × 16 + 3G2.5C | 131129-R3X16+3G2,5C# | 22.4 – 25.4 | 758 | 1150 | 720 | 0.6/1 kV | – |
| Screened power cable TXG | 3 × 25 + 3G4C | 131129-R3X25+3G4C# | 25.4 – 28.4 | 1134 | 1590 | 1125 | 0.6/1 kV | – |
| Screened power cable TXG | 3 × 35 + 3G6C | 131129-R3X35+3G6C# | 29.3 – 32.3 | 1547 | 2160 | 1575 | 0.6/1 kV | 500 |
| Screened power cable TXG | 3 × 50 + 3G10C | 131129-R3X50+3G10C# | 35.4 – 38.4 | 2181 | 3060 | 2250 | 0.6/1 kV | 500 |
How to use the matrix in a replacement RFQ
240 m/min movement and bending-radius engineering
A high travel-speed rating is meaningful only when the mechanical system is equally well designed. The supplied TXG / TXG-D record gives up to 240 m/min, while the dynamic minimum radius is referenced to DIN VDE 0298 Part 3. For optical-fibre cables, the same record separately gives 125 mm.
In practical crane work, the cable experiences more than pure bending. Acceleration creates longitudinal force; the chain or trolley creates guide pressure; adjacent cables can rub; and the cable may be forced toward an edge during braking. A correct cable order therefore needs the machine travel profile, trolley spacing, chain dimensions, support method and end restraint—not just a nominal cross-section.
High-cycle movement
Frequent and continuous bending is one of the stated reasons to select TXG. Confirm that the actual speed and cycle profile stay within the released application.
Optical fibre
The supplied 125 mm value is an optical-fibre cable minimum. Do not replace it with a generic power-cable radius or infer a smaller value from the outer diameter.
Acceleration
Permitted tensile load is listed in each row, but dynamic machine force also depends on acceleration, cable mass, span, guide friction and end grip.
Temperature
TXG reaches down to −35°C in flexing use. TXG-D 24 FO has a different flexing upper limit of +60°C. Select the branch before approving the environmental envelope.
Screened power, bus and optical-fibre engineering
TXG provides a broad family: control, power, bus and optical-fibre versions. The screened power rows include compact three-phase arrangements with split earth conductors, while the screened types use a tinned-copper braid to improve electromagnetic-interference resistance.
Screen coverage must be specified by object. The supplied overview says overall braid coverage is approximately 85%. The additional technical data gives at least 80% overall, at least 60% for individually screened cores and at least 80% for twisted and shielded pairs. A purchase specification should identify which of these is required and how the screen is bonded at the cable entry, trolley and cabinet.
| Data / screen item | Supplied value | RFQ implication |
|---|---|---|
| Overall braid in product overview | Tinned copper braid; optical cover approx. 85% | State whether this is the required overall construction |
| Overall shield in additional data | At least 80% surface covered | Do not silently replace the overview field; state the applicable product document |
| Individually screened cores | At least 60% surface covered | Use for individually screened constructions where applicable |
| Twisted and screened pairs | At least 80% surface covered | Specify pair-level screen and continuity test |
| Optical-fibre cable radius | 125 mm | Include in the chain and guide design |
| FO availability | On request: 12, 18 or 24 fibres | Freeze fibre count before quotation |
| TXG-D FO colour | Orange | Confirm sheath colour and marking on the order |
Fibre selection. The supplied matrix includes 24G62,5/125, 24G50/125 and 24E9/125. These represent different optical media. The connector, attenuation, bandwidth, wavelength and test requirements must follow the chosen fibre type; outer diameter alone is not a sufficient selection rule.
Installation, inspection and failure prevention
TXG is built for harsh mobile machinery, but the guide system remains part of the product. A worn separator, a sharp steel edge, a twisted trolley or a high-friction return path can damage the sheath and increase dynamic force. The right maintenance question is therefore not only “is the cable flexible?” but also “what force is the machine applying to it?”
Installation
- Verify outer-Ø min/max against trolley clip, chain cavity and separators.
- Use the applicable DIN VDE 0298 Part 3 radius and the supplied 125 mm FO value where relevant.
- Keep the cable free from sharp edges, compression and uncontrolled twist.
- Use suitable end grips so tensile force is not transferred into the copper conductors.
- Bond screens continuously at the intended cable-entry and cabinet interfaces.
Commissioning
- Start at reduced speed and observe a complete travel cycle.
- Check loop formation, trolley spacing, chain fill and return motion.
- Verify conductor continuity, insulation resistance and screen continuity.
- For fibre, test the selected type at the required wavelengths.
- Record temperature, speed, acceleration and guide condition as baseline data.
Maintenance
- Inspect rubber for cuts, notches, flattening, glazing and hardening.
- Check trolley clips, chain links, rollers, separators and end clamps.
- Inspect braid terminations and screen bonding for intermittent faults.
- Watch for abnormal heating, control noise or fibre attenuation.
- Replace cable where sheath, insulation, screen or fibre protection is compromised.
| Observed symptom | Likely mechanism | Engineering response |
|---|---|---|
| Sheath wear on one side | Cable rubbing guide, separator or sharp steel edge | Remove the contact source and verify outer-Ø clearance |
| Cable flattens at trolley | Incorrect clip, over-compression or chain fill | Use the correct support and recheck cable package geometry |
| Loops become uneven | Trolley spacing, acceleration or guide friction problem | Recalculate loop formation and inspect trolley running resistance |
| Screen continuity intermittent | Braid damage or poor bonding at termination | Repair the complete shield path and test through travel |
| Fibre attenuation increases | Microbending, excessive chain pressure or tight radius | Inspect radius, chain fill, guide pressure and optical test results |
| Conductor temperature rises | Overcurrent, grouping, ambient or heat dissipation | Recheck DIN VDE 0298-4 ampacity and installation derating |
| End clamp carries shock | Acceleration force or underspecified strain relief | Rework the load path and apply the project safety factor |
Standards, approvals and Feichun certification capability
The supplied TXG record identifies TXG according to DIN VDE 0250-814 and GOST-R. It identifies TXG-D 24 FO according to DIN VDE 0888 and UL. The additional data also references VDE 0295 for conductor class, VDE 0293 for coding and DIN VDE 0298-4 for ampacity. The exact market, construction, test edition and approval scope must follow the final released product.
For export projects, Feichun Cable can prepare a project-specific technical file and support the applicable certification / approval route, including ATEX, IECEx, VDE, CE, UKCA, EAC and the Russian Fire Safety Certificate. The approval scope must match the actual TXG / TXG-D construction, screen, fibre count, voltage, destination and installation duty; a generic certificate from a different product is not a substitute.
| Reference / approval | Relevance in the supplied record | Release control |
|---|---|---|
| DIN VDE 0250-814 | TXG standard / approval field | Confirm the exact TXG construction and edition |
| GOST-R | TXG approval field | Confirm destination-market scope and current document |
| DIN VDE 0888 | TXG-D 24 FO standard / approval field | Confirm fibre construction and test documents |
| UL | TXG-D 24 FO approval field | Confirm the exact cable marking and UL scope |
| VDE 0295 | Class-5 copper conductor | Verify conductor class in the released construction |
| VDE 0293 | Core identification | Confirm colour / numeral / GN/YE arrangement |
| DIN VDE 0298-4 | Ampacity calculation basis | Current rating depends on installation, grouping and ambient |
| DIN VDE 0298 Part 3 | Dynamic bending-radius reference | Use exact installation category and outer diameter |
| DIN EN 60811-404 | Oil-resistance reference | Use the applicable compound and test report |
| IEC 60332-1 | Flame-retardance reference | Confirm applicable edition and test configuration |
| ATEX / IECEx / VDE / CE / UKCA / EAC / Russian Fire Safety | Potential export approval routes | Scope depends on final product and destination |
Public references used for context: Conductix-Wampfler official festoon cable overview; Conductix-Wampfler cable catalogue PDF; IEC 60811-404 publication context; IEC 60332-1-2 publication context.
RFQ checklist: information that prevents the wrong TXG cable
A strong RFQ gives the cable manufacturer enough information to check electrical loading, mechanical travel and approval scope together. For TXG-D, the media type must be fixed before commercial comparison.
Machine duty
- Container-crane trolley, process crane, stacker/reclaimer or ship unloader
- Horizontal / vertical travel and guide type
- Travel speed, acceleration, braking and duty cycle
- Travel length, trolley spacing and chain fill
- End restraint, clip and termination arrangement
Electrical / media
- TXG control, power or screened power
- TXG-D paired copper, bus or optical fibre
- Core count and cross-section
- 3-phase plus split-earth arrangement where required
- Fibre type: 62.5/125, 50/125 or E9/125
Environment
- Flexing and fixed temperatures
- Ozone, oil, UV, humidity, salt and atmospheric corrosion
- Foundry heat, steel dust, coal dust or ship-unloader contamination
- Cleaning chemistry and exposure duration
- Black or orange sheath / marking requirement
Documents
- Outer Ø min/max, weight and copper index
- Permitted tensile load and safety factor
- Dynamic radius and 125 mm FO requirement where applicable
- Screen coverage object and termination method
- DIN VDE / GOST-R / DIN VDE 0888 / UL / destination approval scope
RFQ line example TXG screened power · 3 × 35 + 3G6C · U₀/U 0.6/1 kV · 131129-R3X35+3G6C# container-crane festoon · travel up to 240 m/min · outer Ø 29.3–32.3 mm Cu 1547 kg/km · weight 2160 kg/km · permitted tensile load 1575 N minimum order quantity 500 m · tinned-copper braid · screen termination drawing attached radius basis: DIN VDE 0298 Part 3 · destination: [state market]
The example retains the supplied screened-power row. Feichun should confirm the final print, conductor identification, screen construction, outer dimensions, tests, certificates, accessories and project interface before production.
