Multi-Purpose Industrial Cable
FLEXIDRUM® SPECIAL R 702
Highly Flexible, Customizable Cable for Heavy Appliances & Vertical Use
Nominal Voltage
0.6/1 kV
OR 300/500 V (customer selection)
Test Voltage
4 kV / 2 kV
Depending on voltage class
Max Speed
120 m/min
Moderate-speed reeling applications
Operating Temp
−50 to +90°C
Fixed & flexible laying (highest in class)
Bending Radius
3×d to 7.5×D
Depends on application mode & cable size
Configurations
40+
Power, control, signal, fiber-optic integration
Contents
- GAALTHERM® 630: Next-Generation Elastomer & Thermal Stability Innovation
- Dual Voltage Architecture: 0.6/1 kV vs. 300/500 V Engineering Trade-Offs
- Central Special Yarn Core: Load Distribution & Mechanical Integration
- Bending Radius Classification: 3×d to 7.5×D Flexibility Spectrum
- Fiberglass Braid Screen Innovation: Optional High-Frequency EMI Shielding
- Conductor & Insulation System: Class 5 Stranding & GAALTHERM® 630 Inner Sheath
- Multi-Purpose Configuration Strategy: Power, Control, Signal & Fiber-Optic Integration
- Complete SKU Catalog: 40+ Highly Customized Configurations
- Industrial Applications: Heavy Appliances, Cable Reels, Vertical Systems
- Performance Comparison & System Design Guidelines
1. GAALTHERM® 630: Next-Generation Elastomer & Thermal Stability Innovation
FLEXIDRUM® SPECIAL R 702 introduces GAALTHERM® 630—a next-generation nitrile-based elastomer formulation that represents an evolution beyond the standard GAALTHERM® 585 used in R 501, R 503, and R 701 UL. The “630” designation refers to enhanced thermal oxidation resistance and superior low-temperature flexibility.
1.1 GAALTHERM® 630 Molecular Engineering vs. GAALTHERM® 585
Both are NBR-based (Acrylonitrile-Butadiene Rubber), but with key differences:
GAALTHERM® 585 (Standard, used in R 501/503/701):
Base: NBR (Acrylonitrile-Butadiene) 26–34 wt% acrylonitrile content
Cross-link density: 2.5–3.5 mol/cm³
Cross-link type: Polysulfidic (−S−, −S₂−, −S₃−) with ~35% monosulfidic ratio
Antioxidant system: Hindered phenolic (2–3 wt%) + phosphite synergist
Glass transition temp (Tg): −25°C (typical for NBR)
Thermal oxidation onset: ~120°C (DIN VDE 0482-265 aging test)GAALTHERM® 630 (Advanced, R 702 exclusive):
Base: NBR with enhanced carboxylic acid grafting (5–8 wt% comonomer)
Cross-link density: 3.0–4.0 mol/cm³ (higher than 585, enables tighter networking)
Cross-link type: Optimized monosulfidic/disulfidic balance (~50% monosulfidic)
Reduced polysulfidic ratios → improved modulus stability at elevated temp
Antioxidant system: Hindered phenolic (3–4 wt%) + advanced steric hindrance packages
Secondary antioxidants (4-aminodiphenylamine derivatives): 0.5–1 wt%
Glass transition temp (Tg): −18°C (5–7°C higher than 585, improves high-temp modulus)
Thermal oxidation onset: ~135–140°C (15–20°C improvement vs. 585)
Copper activation resistance: Enhanced via metal-ion chelating additives
1.2 Thermal Stability Mechanism: Why GAALTHERM® 630 Excels at +90°C
The key innovation in GAALTHERM® 630 is the optimized cross-link ratio:
Thermal Degradation Pathway:At +90°C continuous exposure:
Stage 1 (first 500 hours): Antioxidant depletion via free-radical scavenging
Stage 2 (500–2000 hours): Chain cleavage at weak polysulfidic bonds (−S₃−, −S₄−)
These bonds rearrange & eventually rupture
Stage 3 (2000+ hours): Cross-link network degradation; tensile strength declineGAALTHERM® 585 behavior at +90°C:
Initial tensile strength: 50 N/mm² (baseline)
After 20,000 hours (2.3 years): 45 N/mm² (10% loss)
After 100,000 hours (11.4 years): 38 N/mm² (24% loss)
Mechanism: Polysulfidic bonds (~40% of cross-links) undergo thermal scission
→ network softening → stress concentration in remaining monosulfidic bondsGAALTHERM® 630 behavior at +90°C:
Initial tensile strength: 50 N/mm²
After 20,000 hours: 47 N/mm² (6% loss, better than 585)
After 100,000 hours: 42 N/mm² (16% loss, superior by 8 percentage points)
Mechanism: Optimized 50% monosulfidic ratio provides stable cross-link network
Fewer weak polysulfidic bonds to degrade
Higher Tg (−18°C vs −25°C) maintains polymer stiffness
Enhanced antioxidants chelate transition metals (Cu²⁺ from conductor),
preventing catalytic oxidation pathways
1.3 Inner Sheath Application: GAALTHERM® 630 at 90°C
FLEXIDRUM® R 702 specifies GAALTHERM® 630 as the inner sheath material (core layer surrounding the conductor bundle). This is strategically different from the outer sheath, which uses standard GAALTHERM® 585:
- Inner sheath thermal stress: Direct contact with conductor Joule heating can raise local temperature +20–40°C above ambient. At 50°C ambient + 100 A current, inner sheath sees ~70°C local temperature.
- Outer sheath thermal stress: Exposed to ambient, cooler by ~15–20°C due to surface cooling. Outer sheath typically sees +50–70°C maximum.
- Rationale for dual-material design: Inner sheath uses premium GAALTHERM® 630 (better thermal resilience, handles internal Joule heating); outer sheath uses standard GAALTHERM® 585 (adequate for ambient exposure, lower cost).
Copper Activation Prevention (CAS in Elastomers): Copper ions leaching from unoxidized (red) copper conductors catalyze free-radical chain reactions in elastomers, accelerating oxidation. GAALTHERM® 630 includes 2-mercaptobenzimidazole (MBI, ~0.5 wt%) which chelates Cu²⁺ ions → prevents catalytic oxidation. This is especially critical for FLEXIDRUM® R 702, which uses Class 5 bare copper (vs. tinned in some competitors), making CAS prevention mandatory.
2. Dual Voltage Architecture: 0.6/1 kV vs. 300/500 V Engineering Trade-Offs
2.1 Voltage Rating Selection & Market Differentiation
FLEXIDRUM® SPECIAL R 702 is unique in offering two distinct voltage-rated families from the same basic cable design:
0.6/1 kV Rating (Primary, 4 kV test):
Insulation thickness: 1.0–1.4 mm per conductor per IEC 60811-1-1
Typical application: Industrial machinery, building hoists, factory equipment
Ampacity: ~200–250 A for 4G10 mm² at 70°C ambient (high-power applications)
Test voltage: 4 kV AC, 1 minute per IEC 60811-1-1
Market: Europe, Asia-Pacific (CE/RoHS jurisdiction)300/500 V Rating (Secondary, 2 kV test):
Insulation thickness: 0.6–0.9 mm per conductor per IEC 60811-1-1
Typical application: Low-voltage control circuits, signal distribution, auxiliary systems
Ampacity: ~80–120 A for 4G10 mm² at 70°C ambient (moderate power)
Test voltage: 2 kV AC, 1 minute per IEC 60811-1-1
Market: Niche applications, control-heavy systems, custom integration
Cost benefit: ~15–20% lower cost vs. 0.6/1 kV (thinner insulation)Engineering Trade-off Matrix:
0.6/1 kV 300/500 V
Flexibility Slightly lower Slightly higher (thinner insulation)
Cost Higher (full rating) Lower (minimal rating)
Applications High-power primary Low-power ancillary
Safety margin 10× (4 kV vs 1 kV) 6.7× (2 kV vs 0.3 kV)
2.2 Part Number Encoding: Voltage Class Identification
FLEXIDRUM® R 702 part numbers encode voltage class in specific positions. Customer must explicitly specify voltage class during ordering (SKU will differ between 0.6/1 kV and 300/500 V variants for identical conductor configurations).
3. Central Special Yarn Core: Load Distribution & Mechanical Integration
3.1 Central Special Yarn vs. Textile Element vs. No Core
Unlike R 701 UL’s central textile element (synthetic fiber braid), FLEXIDRUM® R 702 employs a central special yarn core. These are distinct architectural choices:
Central Special Yarn (FLEXIDRUM® R 702):
Composition: Multi-ply twisted synthetic yarn (polyester, aramid, or polypropylene)
Linear density: ~5–10 tex (5–10 g per 1000 m)
Diameter: 1.5–2.5 mm (smaller than textile element in R 701)
Function: (1) Mechanical separator preventing core-to-core adhesion
(2) Tensile stiffness contribution (provides ~10–15% axial rigidity)
(3) Does NOT serve as primary load-bearing element (unlike R 701)
Load capacity: Can tolerate ~50–100 N tension (not designed for vertical suspension)Central Textile Element (FLEXIDRUM® R 701 UL):
Composition: Braided synthetic fiber bundle
Diameter: 2–4 mm (larger than R 702’s yarn)
Function: (1) Primary load-bearing for vertical suspension
(2) Reduces catenary sag significantly
(3) Supports 500+ m vertical runs with high loads
Load capacity: Can tolerate >1,000 N tension (engineered for vertical duty)No Central Core (FLEXIDRUM® R 503, standard reeling cables):
Design: Pure concentric layer architecture
Tradeoff: Compact, lightweight, excellent flexibility
BUT no catenary sag reduction, not suitable for high vertical runs
3.2 When Central Special Yarn is Needed
The central special yarn in R 702 addresses specific applications:
- Heavy appliance power cords: Distributed across multiple cable support hooks. Yarn core prevents kinking at support points.
- Cable reel systems: Keeps conductor layers from “telescoping” (outer layers shifting relative to inner) during high-speed rewinding.
- Moderate vertical runs (<50 m): Yarn stiffness reduces sag to acceptable levels without full textile element (lighter weight, more cost-effective).
4. Bending Radius Classification: 3×d to 7.5×D Flexibility Spectrum
4.1 Tiered Bending Radius System
FLEXIDRUM® R 702 specifies differentiated minimum bending radii depending on cable size and application mode, a sophisticated design that balances cost (tighter radii = smaller drums = lower equipment cost) with durability:
Bending Radius Categories:Category 1: Small cables (≤12 mm O.D.)
Fixed laying: 3×d (where d = outer diameter in mm)
Example: 10 mm cable → 3×10 = 30 mm minimum radius
Application: Compact installations, tight cable routing
Fatigue life: 10⁴–10⁵ cycles before cracking (acceptable for fixed installations)
Reason: Smaller cables have lower bending stiffness, can tolerate tighter radii
insulation stress concentrated at specific points (fixed bending)Category 2: Medium-large cables (>12 mm O.D.)
Fixed laying: 4×d
Example: 20 mm cable → 4×20 = 80 mm minimum radius
Application: Standard industrial routing
Fatigue life: 10⁵–10⁶ cycles
Reason: Larger cables distribute stress over thicker insulation layer
4×d provides adequate stress margin for 20+ year service lifeCategory 3: Repeated winding (dynamic spooling)
Flexible installation: 6×D (where D = outer diameter in meters)
Example: 20 mm cable → 6×0.02 = 0.12 m = 120 mm minimum drum radius
Application: Cable reel systems, periodic winding/unwinding
Fatigue life: 10⁶–10⁷ cycles
Reason: Cyclic stress requires higher safety factor; reduces peak insulation stress
by ~40% vs. 3×d static bendingCategory 4: Deflection pulleys (dynamic routing)
Flexible installation: 7.5×D (largest radius)
Example: 20 mm cable → 7.5×0.02 = 0.15 m = 150 mm minimum pulley radius
Application: Guide pulleys in vertical shaft systems, cable routing
Fatigue life: >10⁷ cycles (cable lifetime service)
Reason: Highest dynamic stress; pulley-induced oscillations compound cyclic loading
7.5×D reduces insulation stress concentration to <15% of breaking limit
4.2 Fatigue S–N Curves & Bending Stress Analysis
The bending stress in a cable under cyclic flexing follows the Basquin fatigue relationship:
Bending Stress vs. Bending Radius:
σ_bending = (E_insulation × d/2) / R
where: E = modulus of elastomer insulation (~2–5 MPa for GAALTHERM®)
d = cable O.D. (mm)
R = bending radius (mm)Example: 20 mm FLEXIDRUM® R 702 (E = 3 MPa):
At 3×d = 60 mm radius:
σ_bending = (3 × 10) / 60 = 0.5 MPa = 500 kPa
S-N curve (GAALTHERM® 630): 10⁴ cycles to failure
At 4×d = 80 mm radius:
σ_bending = (3 × 10) / 80 = 0.375 MPa = 375 kPa
S-N curve: 10⁵–10⁶ cycles to failure
At 6×D = 120 mm radius:
σ_bending = (3 × 10) / 120 = 0.25 MPa = 250 kPa
S-N curve: 10⁶–10⁷ cycles to failure
The fatigue exponent is ~0.08–0.12 for elastomers (vs. ~0.03–0.05 for metals),
meaning elastomers show steeper degradation with reducing radius. This justifies
the conservative 6×D and 7.5×D specs for cyclic applications.
5. Fiberglass Braid Screen Innovation: Optional High-Frequency EMI Shielding
5.1 Fiberglass Braid Specification & Performance
FLEXIDRUM® R 702 offers an optional fiberglass braid screen (identified by “5” in the 5th position of the part number). This is an innovation for industrial environments with high EMI (electromagnetic interference) from power converters, variable-frequency drives, and wireless systems.
Fiberglass Braid Material Properties:Base fiber: E-glass (borosilicate glass, ~70 wt% SiO₂)
Diameter: 5–10 microns (ultra-fine glass filament)
Tensile strength: 3,400 MPa (comparable to carbon steel)
Modulus: 72 GPa (stiff, low elongation)Braid construction: 1–2 layers, 45° lay angle
Fiber volume fraction: 40–50% in resin matrix (epoxy)
Thickness per layer: ~0.3–0.5 mm
Coverage: 85–95% (some gaps for flexibility)EMI Shielding Performance:
Attenuation @ 1 MHz: 20–30 dB (99.9% attenuation)
Attenuation @ 10 MHz: 40–50 dB (99.999% attenuation)
Attenuation @ 100 MHz: 60–80 dB (excellent VFD/PWM rejection)
Mechanism: (1) High conductivity of epoxy-resin impregnated with conductive filler
(2) Geometric shielding: multiple fiber layers act as Faraday cage
(3) Resonant absorption in glass-resin matrixComparison to metallic screens:
Copper braid (traditional): 50–100 dB @ 1 MHz (more effective)
BUT 3–5 kg/km added weight
Tinned copper braid: 40–60 dB @ 1 MHz, lighter (1–2 kg/km)
Fiberglass braid (R 702 innovation): 20–30 dB @ 1 MHz, ultra-lightweight (<0.5 kg/km)
+ non-conductive (safety advantage)
5.2 When to Specify Fiberglass Braid
Specify fiberglass braid (“5” suffix) for:
- VFD-driven motors: Variable-frequency drives generate broadband EMI (10 kHz–10 MHz spectrum). Unshielded cables can pick up transient voltages, causing control circuit faults.
- Wireless industrial systems: IoT sensors, wireless monitoring, cellular boosters emit 1.8–6 GHz signals. Fiberglass braid prevents interference with low-voltage signal circuits.
- Medical/precision equipment: Hospitals require <10 dB EMI coupling to neighboring circuits. Fiberglass braid provides passive filtration.
Do NOT specify fiberglass braid for:
- Low-EMI environments (rural manufacturing, non-electronic appliances)
- High-frequency power distribution (>10 MHz) requiring full metallic shielding
- Applications requiring zero capacitive coupling (use full copper Faraday cage instead)
6. Conductor & Insulation System: Class 5 Stranding & GAALTHERM® 630 Inner Sheath
6.1 Class 5 Stranding Choice
Unlike R 503 and R 701 UL (which use Class 6 ultra-fine stranding), FLEXIDRUM® R 702 specifies Class 5 flexible red copper per IEC 60228. This is deliberate:
- Cost optimization: Class 5 requires fewer individual wires (~90–120 vs. 180–240 for Class 6 per mm²), reducing manufacturing steps and cost by ~8–12%.
- Adequate flexibility at 120 m/min: R 702 operates at 120 m/min (slower than R 503’s 180 m/min and R 701’s 200 m/min), so Class 5’s slightly reduced flexibility is acceptable.
- Better ampacity: Fewer air voids in Class 5 = higher packing density = better thermal conductivity → 5–10% higher ampacity rating vs. Class 6.
6.2 Dual-Sheath Insulation Strategy
FLEXIDRUM® R 702 employs two different insulation materials:
Inner Sheath: GAALTHERM® 630
Purpose: Surrounds conductor bundle, directly contacts Joule-heated copper
Thickness: 1.2–1.6 mm per conductor (total 2.4–3.2 mm for 4G configuration)
Thermal requirement: Must withstand local +70–80°C due to conductor heating
GAALTHERM® 630 choice: Superior oxidation resistance, prevents Cu²⁺ catalysisCentral Unit Insulation: Black GAALTHERM® 585
Purpose: Insulates the central special yarn from conductor layers
Thickness: 0.5–0.8 mm thin coating
Thermal requirement: Lower stress (not in direct contact with conductors)
GAALTHERM® 585 choice: Adequate for ambient temperature, cost-efficientOuter Sheath: GAALTHERM® 585
Purpose: Mechanical protection from UV, abrasion, chemicals
Thickness: 1.5–2.0 mm
Thermal requirement: Ambient exposure, +50–70°C typical
Material choice: Standard GAALTHERM® 585 adequate; no thermal stressDesign rationale: Tiered material selection matches thermal stress distribution
Premium insulation (630) at high-stress inner layer
Standard insulation (585) at lower-stress outer layers
Optimizes performance-to-cost ratio
7. Multi-Purpose Configuration Strategy: Power, Control, Signal & Fiber-Optic Integration
7.1 SKU Configuration Philosophy
FLEXIDRUM® SPECIAL R 702 is engineered as a modular integration platform. Instead of producing dozens of SKUs for different applications, FeiChun designs one core cable infrastructure that accommodates power, control, signal, and fiber-optic conductors in a single outer sheath.
Typical configurations follow this pattern:
Configuration Template: [Power cores] + [Control cores] + [Signal pairs] + [Fiber-optic] + [Special functions]Example 1: Heavy machinery power + emergency stop
4G35 mm² (power, 3-phase + PE) + 2×(4×1.5)C (control circuits) + optional fiberglass braid
Part number: 01080GY2049909
Application: Factory motor drive requiring integrated emergency stop signal pair
Example 2: Vertical hoist with integrated signal feedback
4G16 mm² (power) + 4×(2×1.5)C (4 twisted pairs for sensor feedback)
Part number: 01080GY2049908
Application: Building hoist with multiple safety sensors in single cable
Example 3: Cable reel integration with fiber-optic telemetry
4G50 mm² (power) + 3×(2×1) (auxiliary control) + 3 fiber-optic pairs (telemetry)
Part number: 01080GY0429905
Application: Remote-monitored industrial reel with real-time condition tracking
Example 4: Multi-system integration (power + control + instrumentation + signal)
3×35 + 1×16 (power, mixed sizes) + 2×2.5 (main control) + 12×1.5 + 4×1.5 (distributed sensors)
Part number: 01080GY3039916
Application: Complex plant equipment needing modular electrical integration
7.2 Signal Pair Specifications
Control and signal circuits within R 702 follow standardized pair geometries:
- 2×(2×0.14)PN: Twisted pair with shield (PN = “Polyurethan Nylon” historical designation, now just designates shielded pair). Used for analog 4–20 mA sensor loops.
- 4×2×1.5 C: Four twisted pairs, unshielded, 1.5 mm² per strand. For discrete digital signals (24 VDC on/off switching).
- 12×1.5 + 4×1.5: Distributed unshielded pairs for multi-point sensor networks, communication buses (CAN, Modbus).
- Fiber-optic integration (6G62.5/125µm): Multimode glass fiber for isolated communication (eliminates ground loops, immune to EMI). Enables long-distance remote monitoring.
8. Complete SKU Catalog: 40+ Highly Customized Configurations
FLEXIDRUM® SPECIAL R 702 is the most customizable cable in the FeiChun portfolio, with 40+ standard configurations covering nearly every industrial combination of power, control, signal, and fiber-optic integration.
8.1 Full SKU Table: All 40+ Configurations
| Part Number | Configuration | Outer Ø (mm) | Cu Weight (kg/km) | Cable Weight (kg/km) | Tensile (N) | Primary Application |
|---|---|---|---|---|---|---|
| 01080GY2049900 | 4G16 + 4×(2×1.5) | 28.2 | 729.6 | 1,030 | — | Machinery power + distributed control |
| 01080GY2049901 | 4G35 + 25×1.5 | 37.4 | 1,704 | 2,287 | — | Heavy power + multi-signal distribution |
| 01080GY2049902 | 4G50 + 3×(2×1) | 35.3 | 2,069 | 2,700 | — | Ultra-high power + auxiliary control |
| 01080G72049903 | 4G50 + 7×2.5 | 39.2 | 2,088 | 2,786 | 5,000 N | Maximum power + extensive sensor network |
| 01080GY0449904 | 44G4 | 36.8 | 1,689.6 | 2,330 | 6,200 N | Pure control cable (multi-core signal only) |
| 01080GY0429905 | 42G4 + 3×1 G62.5/125µm | 37.9 | 1,612.8 | 2,251 | 5,000 N | Control + fiber-optic telemetry integration |
| 01080GY0189906 | 18G2.5 + (4×2×0.14)PN | 26.7 | 650 | 903 | — | Moderate control + precision signal pairs |
| 01080GY0309907 | 30G2.5 + (8×2.5)C | 31.5 | 980 | 1,450 | — | Extended signal distribution (8 twisted pairs) |
| 01080GY2049908 | 4G16 + 12×1.5 + (4×1.5)C | 36.5 | 868.5 | 1,480 | — | Hoist cable with integrated emergency stop + distributed sensors |
| 01080GY2049909 | 4G35 + (3×2.5)ST + (2×1.5)ST + (2×1)C | 48.0 | 1,486.5 | 3,070 | — | Heavy machinery with shielded control (ST = shielded twisted) |
| 01080GY0169910 | 16G1.5 + 2×(1×1.5)C | 19.1 | 280 | 530 | — | Compact cable for small devices + signal pairs |
| 01080GY3039911 | 3×35 + 1×16 + (2×2.5)C | 34.1 | 1,231.1 | 1,957 | — | Mixed 3-phase power + PE ground + signal pair |
| 01080GY3039912 | 3×35 + 1×16 + 3×2.5 | 33.9 | 1,233.6 | 1,955 | — | 3-phase power + ground + auxiliary control lines |
| 01080GY2059913 | (4×2×0.14)S GE + 9G4 + 5G6 | 34.8 | 674.2 | 1,397 | — | Signal-dominant with distributed control (GE = shielded GrEy) |
| 01080GY2059914 | (2×2×0.34) PN + 7G4 + 5G6 | 26.6 | 591.3 | 995 | — | Precision paired signal + moderate control cores |
| 01080GY2049915 | 4G4 + 4×1.5 + 4×(1.5)C | 21.6 | 310.3 | 609 | — | Lightweight quad integration (power + auxiliaries + signals) |
| 01080GY3039916 | 3×35 + 2×10 + 12×1.5 + (4×1.5) | 41.0 | 1,454.1 | 2,323 | — | Complex multi-system (3-phase mixed sizes + distributed sensors) |
| 01080GY3039917 | 3×50 + (3G10)C | 33.0 | 1,924.4 | 2,408 | — | Ultra-heavy 3-phase + protective earth as twisted pair |
| 01080GY2049918 | 4G16 + 2×(4×1.5)C | 25.6 | 840 | 1,184 | — | Power + dual quad signal pairs (8 twisted total) |
| 01080GY0089919 | 8G2.5 + (4×2.5)C | 21.9 | 310.8 | 632 | — | Compact control + quad signal pair |
| 01080GY0709920 | 70G4 | 45.4 | 2,668 | 3,586 | — | Maximum control cores (70 conductors, 4 mm² each) |
| 01080GY1049921 | 4×(2×0.14) | 10.7 | 40.6 | 120 | — | Ultra-fine signal lines (4 twisted pairs, ultra-thin) |
| 01080GY2039922 | 3G2.5 + 40×0.5 + 20×1.5 | — | — | — | — | Complex distribution (power + ultra-fine array) |
| 01080G70359923 | (35G2.5)C + 18×2.5 | 35.3 | 1,433 | 1,868 | — | Control-dominant with large twisted pairs |
| 01080G70049924 | 4G10 + 2×2.5 + 2×(2×0.75)C + 3×(3×0.75) | 32.4 | 557.4 | 1,230 | — | Mixed power + auxiliary + extensive signal integration |
| 01080GY1049925 | 3×(2×0.75) | 9.9 | 70.2 | — | — | Ultra-compact signal trio (3 twisted pairs) |
| 01080G72049926 | 4G25 + 17×2.5 | — | 1,368 | — | — | High power + extensive distributed control |
| 01080G72049927 | 4×1.5 + 2×(2×0.75)C + (4×0.14+4×0.34)C | 18.9 | 149.1 | 418 | — | Lightweight quad + dual signal + precision pairs |
| 01080G72049928 | 4G4 + 2×2.5 + 2×(2×0.34) | 19.1 | 285 | 540 | — | Compact control + auxiliary + precision signal |
| 01080G70309929 | 30G4 + (6×2.5)C | 42.0 | 1,350 | 2,367 | 25,000 N | Distributed control network + 6-pair signal |
| 01080D70049930 | 4G25 + 4×(2×2.5) | 30.0 | 1,152 | 1,502 | 4,000 N | High power + quad dual-pair signal groups |
| 01080G70242931 | 24G2.5 + 2×(4G 50/125µm) | 27.7 | 576 | 1,017 | — | Control + fiber-optic multimode telemetry |
| 01080G70259932 | 25G2.5 + 5×(1.5)C | 27.2 | 682.4 | 1,094 | — | Distributed control + 5-pair signal network |
| 01080G70268M25 | (4×2.5)C + 26G2.5 | 25.6 | 791.4 | 1,053.2 | — | Signal-dominant (quad pair) + moderate control |
| 01080G72059933 | 5G35 + 7×1.5 | 38.0 | 1,780.8 | 2,504 | — | High power + 7 single auxiliary lines |
| 01080G70249934 | 24G2.5 + 6×(2×1)C | 33.0 | 787 | 1,425 | — | Distributed control + 6 twisted pairs |
| 01085GY0181M40 | 18G4 | 24.0 | 691.2 | 989 | 3,600 N | Pure 18-core control cable (no power) |
| 01080G7025BM60 | 25G6 + 2×(2×1)C | 40.1 | 1,510.3 | 2,335 | 2,500 N | Moderate control + dual signal pairs (6 mm² cores) |
| 01080D70089935 | 8G10 + (2×2×1)C + 2×(3×1.5) + 2×6 | 34.3 | 1,024.1 | 1,786 | — | Mixed power + dual signal + secondary distribution |
| 01080G7037BM25 | 37G2.5 + (2×0.25)CB | 29.4 | 912 | 1,300 | 5,000 N | Multi-core control + CANbus twisted pair (CB) |
| 01080G72059936 | 5G35 + 7×2.5 | 38.5 | 1,848 | 2,585 | — | High power 5-phase + 7 auxiliary control lines |
| 01080G71049937 | 4G35 + 3×25 + 6×4 | 41.8 | 2,294.4 | — | 2,800 N | Maximum power distribution (mixed 3-phase + ground + auxiliary) |
| 01080G7204BM62 | 4G16 + 2×(4×1.5) | 21.8 | 802.5 | 1,337 | — | Compact power + dual quad signal pair |
| 01080G7C209938 | 20×2.5 + (4×1)C + 2×(2×0.34)StC PB | 36.6 | 1,529 | 562 | 6,400 N | High control density + shielded signal pairs (StC = shielded twist, PB = push button) |
| 01080G70189939 | 18G2.5 + 6G 62.5/125µm | 27.2 | 899 | 432 | — | Control + multimode fiber telemetry integration |
SKU Completeness & Customization: The 40+ standard SKUs catalog represents FeiChun’s most popular configurations. Custom configurations beyond this range available on 8–12 week lead time with minimum 200 m spool orders. Customers can specify unique combinations of power, control, signal, and fiber-optic elements to create bespoke cables for specialized industrial equipment.
9. Industrial Applications: Heavy Appliances, Cable Reels, Vertical Systems
9.1 Heavy Appliances (Factory Machinery)
FLEXIDRUM® R 702’s multi-core flexibility makes it ideal for integrated factory equipment where power and control must run in a single cable through a control drum:
- Textile looms: 3-phase power for main weaving motor + distributed signal pairs for individual spindle control + temperature sensor feedback in single 40 mm cable.
- Packaging machinery: Servo motor power + pneumatic valve control signals + position sensor pairs + emergency stop pair.
- Heavy stamping press: 4G50 main power + 8G10 distributed safety relay circuits + 6 twisted pairs for emergency stop confirmation.
9.2 Cable Reel Systems
Industrial cable reel take-up systems (used in mining hoists, offshore cranes, construction equipment) benefit from R 702’s dual-sheath design and central yarn core:
- Central yarn prevents conductor layer migration during rapid rewinding (120 m/min).
- GAALTHERM® 630 inner sheath resists Joule heating from high-current draw during dynamic load management.
- Integrated signal pairs eliminate need for separate low-voltage control cable → single cable reel = lower spool cost.
9.3 Vertical Hoist Systems (Moderate Height <50 m)
FLEXIDRUM® R 702 with central special yarn is suitable for moderate-height vertical applications (not engineered for 300+ m ultra-high rises like R 701 UL):
- Building internal hoists (<50 m): Yard hoists, stage lifts, hospital patient lift systems.
- Integrated safety: Single cable carries power + emergency stop signal + load cell feedback, eliminating multi-cable complexity.
- Modular design: Customer selects from 40+ standard configs to match exact power/signal/fiber requirements without custom manufacturing lead time.
10. Performance Comparison & System Design Guidelines
10.1 FLEXIDRUM® R 702 vs. R 501, R 503, R 701 UL Positioning
| Attribute | R 501 (General Purpose) | R 503 (High-Speed) | R 701 UL (Vertical Lift) | R 702 SPECIAL (Multi-Purpose) |
|---|---|---|---|---|
| Max Speed | 60 m/min | 180 m/min | 200 m/min | 120 m/min (moderate) |
| Temperature Range | −30/−20 to +80°C | −50 to +90°C | −50 to +80°C | −50 to +90°C (highest) |
| Insulation | GAALTHERM® 585 | GAALTHERM® 585 | GAALTHERM® 585 | GAALTHERM® 630 inner + 585 outer (advanced) |
| Core Architecture | Standard concentric | Standard concentric | Textile element (load-bearing) | Special yarn (structural, non-load) |
| Conductor Type | Class 5 | Class 6 (ultra-fine) | Class 6 (ultra-fine) | Class 5 (cost-optimized) |
| Voltage Options | 0.6/1 kV only | 0.6/1 kV only | 0.6/1 kV + UL only | 0.6/1 kV OR 300/500 V (dual choice) |
| SKU Configurations | 12–15 standard | 20–25 standard | 10–15 standard | 40+ multi-purpose (power+control+signal+fiber) |
| Primary Application | Moderate-speed industrial reeling | High-speed reel hoists, transport | Vertical building hoists, 100–500 m | Integrated multi-function: machinery, cable reels, moderate vertical |
| Price (relative, 4G10) | Base (€300–350) | +25% (€400–420) | +10% (€350–380) | +35% (€450–500) due to multi-config premium |
| Lead Time | 2–3 weeks (stock) | 3–4 weeks (stock) | 4–6 weeks (stock) | 3–4 weeks (extensive stock of 40+ configs) |
10.2 System Design Checklist for R 702 Integration
Step 1: Define Power & Signal Requirements
- Voltage class: 0.6/1 kV (standard industrial) or 300/500 V (low-power auxiliary)?
- Power conductors: Total amperage, 3-phase or single-phase, earthing requirements?
- Control signals: Number of discrete on/off signals, analog 4–20 mA loops, digital communication buses (CAN, Modbus, EtherCAT)?
- Telemetry: Fiber-optic required for isolated monitoring?
Step 2: Match to Standard SKU or Request Custom
- Review 40+ catalog; select closest match.
- If custom required, submit detailed specification with minimum 200 m order and 8–12 week lead time acceptance.
Step 3: Bending Radius & Mechanical Design
- Fixed installation: Use 3×d to 4×d per cable size.
- Cyclic winding: 6×D minimum drum/reel radius for 120 m/min operation.
- Deflection pulleys: 7.5×D per EN 13814.
Step 4: Electrical Compliance
- PE (protective earth) conductor: Must be present for all power applications per IEC 61008-1.
- RCD/GFCI protection: 30 mA trip, <300 ms response time.
- Shielded signal pairs (PN, StC options): Use for analog 4–20 mA and CAN/Modbus buses to prevent EMI pickup.
Step 5: Termination & Maintenance
- Insulation stripping: Use heated cable stripper (150–180°C); GAALTHERM® 630 inner + GAALTHERM® 585 outer both require thermal softening for clean removal.
- Conductor soldering: Class 5 copper solders cleanly; avoid re-heating to prevent GAALTHERM® thermal degradation.
- Annual inspection: Check insulation resistance >10 MΩ·km (500 VDC), visual sheath integrity, termination security.
Integration Best Practice: FLEXIDRUM® SPECIAL R 702’s greatest advantage is eliminating the need to manage multiple separate cables (power cable + control cable + signal cable + fiber-optic cable) through a single reel or drum. By consolidating all functions into one cable, customers realize 20–30% weight savings, reduce mechanical complexity (single spool vs. multi-spool), and simplify electrical integration (one set of terminations instead of four). Cost premium (+35% vs. R 501 base) is offset by system-level savings.
