Halogen-Free Flexible Cable for Mining and Tunneling
TUNNELFLEX防扭转无卤柔性电缆 1千伏 · 用于矿山和隧道工程
TUNNELFLEX-R-PUR HF with Antitwisting Protection 1 KV
安徽飞纯特种电缆有限公司
Product Overview 产品概述
The TUNNELFLEX-R-PUR HF represents a specialized category of halogen-free, flame-retardant flexible power cables engineered specifically for the demanding requirements of underground mining and tunneling operations. This cable combines advanced polyurethane (PUR) sheathing technology with integrated antitwisting protection to deliver exceptional mechanical durability, environmental resistance, and most importantly, enhanced safety through its halogen-free construction that significantly reduces toxic gas emissions during fire incidents.
TUNNELFLEX-R-PUR HF电缆是专为地下采矿和隧道作业的苛刻要求而设计的无卤阻燃柔性电力电缆。该电缆结合了先进的聚氨酯护套技术和集成的防扭转保护，提供卓越的机械耐久性、环境抵抗力，以及通过无卤结构在火灾事故中显著减少有毒气体排放的增强安全性。
Safety Innovation: Halogen-Free Technology 安全创新：无卤技术
According to international fire safety research, halogen-free cables meeting IEC 60754 standards produce dramatically less toxic and corrosive gases compared to conventional PVC cables during combustion. When PVC-based cables burn, they release hydrogen chloride (HCl), creating dense black smoke and corrosive acid gases that can incapacitate evacuees at concentrations as low as 500 ppm and corrode electronic equipment within hours. In contrast, HFFR (Halogen-Free Flame Retardant) cables like the TUNNELFLEX-R-PUR HF emit minimal smoke with a halogen acid content below 5 mg/g and maintain pH values above 4.3, ensuring clearer visibility for evacuation and reduced equipment damage in confined underground environments.
根据国际消防安全研究，符合IEC 60754标准的无卤电缆在燃烧过程中产生的有毒和腐蚀性气体远少于传统PVC电缆。PVC基电缆燃烧时释放氯化氢(HCl)，产生浓密黑烟和腐蚀性酸性气体，在浓度低至500 ppm时就能使疏散人员失去行动能力，并在数小时内腐蚀电子设备。相比之下，TUNNELFLEX-R-PUR HF等HFFR（无卤阻燃）电缆排放的烟雾极少，卤酸含量低于5 mg/g，pH值保持在4.3以上，确保在封闭的地下环境中有更清晰的疏散能见度和减少设备损坏。
Applications 应用场合
The TUNNELFLEX-R-PUR HF cable is specifically designed for power supply to mobile equipment operating in underground mining and tunneling environments where there is high risk of mechanical damage from rock falls, equipment impact, cable dragging, and severe environmental conditions. Industry research on mining cables indicates that these applications demand exceptional abrasion resistance, tear strength, and protection against oil, chemicals, and moisture while maintaining flexibility for frequent movement and reeling operations.
Underground Mining Equipment 地下采矿设备
Mobile mining machinery including continuous miners, load-haul-dump (LHD) vehicles, roof bolters, and shuttle cars operating in confined underground spaces where fire safety and smoke emissions are critical concerns for worker safety.
Tunnel Boring Machines 隧道掘进机
Tunnel boring machines (TBMs) and roadheaders used in civil engineering and mining tunnel construction, requiring cables capable of withstanding continuous mechanical stress while being dragged through rough tunnel surfaces.
Mobile Conveyor Systems 移动式输送系统
Portable conveyor belts and material handling systems in mines and tunnels where cables must flex repeatedly during equipment repositioning while resisting abrasion from contact with rock, coal dust, and mineral materials.
Drilling Equipment 钻孔设备
Mobile drilling rigs and rock drills used for exploration, ventilation shaft construction, and production drilling where cables experience torsional stress, pulling forces, and exposure to drilling fluids and rock fragments.
Emergency & Safety Systems 应急与安全系统
Power supply for emergency lighting, ventilation fans, and safety monitoring equipment in tunnels where the halogen-free properties ensure that smoke and toxic gas emissions do not compromise evacuation procedures during fire emergencies.
Standards & Approvals 标准与认证
- DIN EN 60228 / IEC 60228 / VDE 0295 – Conductor specifications defining Class 5 flexible copper conductor construction for optimal flexibility in dynamic applications
- DIN VDE 0298-300 – Core identification standards ensuring proper color coding for safe installation and maintenance
- IEC 60754-1 – Halogen-free verification: Determination of halogen acid gas content (must be ≤ 5 mg/g for HFFR classification)
- IEC 60754-2 – Corrosivity testing: Acidity measured by pH value (≥ 4.3) and conductivity (≤ 10 µS/mm) to verify non-corrosive combustion products
- DIN EN 60332-1-2 / IEC 60332-1-2 – Fire performance testing for flame propagation on single vertical insulated wire or cable, ensuring self-extinguishing properties
- DIN VDE 0298-3 – Mechanical parameters including bending radius requirements and installation guidelines
Note: Halogen-free cables meeting IEC 60754 standards are mandatory in many jurisdictions for underground mining and tunnel construction to minimize toxic gas release and corrosion during fire incidents. The TUNNELFLEX-R-PUR HF complies with all relevant European and international safety standards for confined space applications.
Cable Construction with Antitwisting Protection 防扭转保护电缆结构
The TUNNELFLEX-R-PUR HF features an advanced multi-layer construction optimized for the extreme mechanical stresses encountered in mining and tunneling operations. The key innovation is the synthetic mesh antitwisting layer (Layer 7) that prevents cable deformation and conductor damage during high-speed reeling operations up to 120 m/min. This protection is critical for mobile equipment that requires frequent cable extension and retraction.
Layer-by-Layer Construction 逐层结构
Conductor 导体
Plain copper, flexible, Class 5 according to IEC 60228. The Class 5 construction provides maximum flexibility with conductor strands fine enough to withstand millions of flexing cycles without fatigue failure.
Core Insulation 芯线绝缘
XLPE (Cross-Linked Polyethylene) special compound with color coding: Brown – Black – Grey for phase conductors. XLPE provides excellent electrical properties with temperature rating up to 90°C continuous operation and 250°C short-circuit capability.
Core Arrangement 芯线排列
Phase cores laid up with earth cores in the interstices, optimizing cable roundness and mechanical strength while minimizing overall diameter for easier handling and installation.
Earth Core 接地芯
Plain copper conductor, flexible, Class 5 with Yellow/Green insulation. The earth cores positioned in the interstices provide comprehensive grounding protection and fault current capacity.
Control Cores (Optional) 控制芯（可选）
Additional control conductors for signaling and control applications, integrated within the same cable assembly to reduce the number of separate cables required for mobile equipment operation.
Inner Sheath 内护套
HFFR (Halogen-Free Flame Retardant) thermoplastic polyurethane compound. This layer provides primary mechanical protection for the cores while maintaining the halogen-free properties of the cable assembly.
Antitwisting Protection 防扭转保护
Synthetic mesh reinforcement – This critical layer prevents cable twisting and deformation during high-speed reeling operations (up to 120 m/min), maintaining cable integrity and preventing conductor damage that could lead to electrical faults or fires.
Outer Sheath 外护套
HFFR thermoplastic polyurethane compound with exceptional properties: abrasion resistant, tear resistant, oil & chemical resistant, and hydrolysis resistant. The polyurethane formulation is specifically designed for underground mining conditions where exposure to mineral oils, hydraulic fluids, and aggressive chemicals is common.
Technical Parameters 技术参数
Thermal Parameters 热参数
| Parameter 参数 | Value 数值 | Notes 备注 |
|---|---|---|
| Max. conductor temperature 最大导体温度 | 90°C | Continuous operation 连续运行 |
| Max. conductor temperature at short circuit 短路时最大导体温度 | 250°C | Short-term condition (5 seconds) 短时状态 |
| Ambient temperature fixed installation (min) 固定安装最低环境温度 | -40°C | Static application 静态应用 |
| Ambient temperature fixed installation (max) 固定安装最高环境温度 | 80°C | Static application 静态应用 |
| Ambient temperature flexible installation (min) 移动安装最低环境温度 | -30°C | Dynamic/mobile application 动态/移动应用 |
| Ambient temperature flexible installation (max) 移动安装最高环境温度 | 80°C | Dynamic/mobile application 动态/移动应用 |
Chemical & Fire Safety Parameters 化学与消防安全参数
| Property 性能 | Performance 表现 | Standard 标准 |
|---|---|---|
| Fire behaviour 燃烧行为 | Self-Extinguishing 自熄性 | Per IEC 60332-1-2 |
| Flame retardant 阻燃性 | Yes – In accordance with EN/IEC 60332-1-2 | IEC 60332-1-2 |
| Halogen free 无卤 | Yes – HFFR Certified | IEC 60754-1 (≤ 5 mg/g) |
| Halogen acid content 卤酸含量 | ≤ 5 mg/g | IEC 60754-1 |
| pH value (acidity) pH值（酸度） | ≥ 4.3 | IEC 60754-2 |
| Conductivity 导电率 | ≤ 10 µS/mm | IEC 60754-2 |
| Smoke density 烟密度 | Low smoke emission 低烟排放 | Typical for LSZH cables |
Mechanical Parameters 机械参数
| Parameter 参数 | Value 数值 | Significance 重要性 |
|---|---|---|
| Maximum travel speed 最大移动速度 | 120 m/min | Higher than standard tunneling cables (typically 60 m/min) |
| Bending radius (fixed installation) 弯曲半径（固定安装） | 6 × D (Acc. to VDE 0298-3) | Where D is the cable outer diameter |
| Bending radius (on drums) 弯曲半径（卷筒上） | 10 × D | Protects cable during reeling operations |
| Abrasion resistance 抗磨损性 | Excellent 优异 | Polyurethane sheath designed for harsh underground conditions |
| Tear resistance 抗撕裂性 | High 高 | Critical for preventing cable damage from sharp rocks |
| Oil resistance 耐油性 | Yes 是 | Resists mineral oils, hydraulic fluids, and lubricants |
| Chemical resistance 耐化学性 | Good 良好 | Polyurethane formulation resists most mining chemicals |
| Hydrolysis resistance 抗水解性 | Excellent 优异 | Maintains properties in wet underground conditions |
Electrical Parameters 电气参数
| Parameter 参数 | Value 数值 | Notes 备注 |
|---|---|---|
| Rated voltage U₀/U (Uₘ) 额定电压 | 0.6/1 (1.2) kV | Standard low voltage rating for mining equipment |
| Max. operating voltage Uₘ 最大工作电压 | 1.2 kV | Maximum continuous voltage |
| Test voltage 试验电压 | 3.5 kV | Factory acceptance test voltage |
Detailed Cable Specifications 详细电缆规格
The following tables provide comprehensive technical specifications for various cable configurations. All cables feature the same advanced construction with antitwisting protection and halogen-free materials. The configurations are optimized for different power requirements in mining and tunneling applications.
TUNNELFLEX-R-PUR HF 0.6/1kV – Standard Configurations
| Construction 构造 | Conductor Ø 导体直径 (mm) | Cable Ø (min) 电缆最小外径 (mm) | Cable Ø (max) 电缆最大外径 (mm) | Cable Weight 电缆重量 (kg/km) | Max. Tensile 最大抗拉强度 (N) | Bending Radius 弯曲半径 (mm) | Current 载流量 (A) |
|---|---|---|---|---|---|---|---|
| 4G10 | 4.0 | 18.5 | 20.5 | 630 | 800 | 123 | 74 |
| 4G16 | 5.1 | 21.5 | 23.5 | 930 | 1,280 | 141 | 99 |
| 3×25+3G6 | 6.5 | 24.5 | 26.5 | 1,240 | 1,500 | 159 | 131 |
| 3×35+3G6 | 7.5 | 26.0 | 28.5 | 1,520 | 2,100 | 171 | 162 |
| 3×50+3G10 | 9.1 | 30.0 | 32.5 | 2,130 | 3,000 | 195 | 202 |
| 3×70+3G16 | 10.8 | 34.0 | 37.0 | 3,000 | 4,200 | 222 | 250 |
| 3×95+3G16 | 12.1 | 37.5 | 40.5 | 3,710 | 5,700 | 243 | 301 |
| 3×120+3G25 | 14.3 | 42.5 | 45.5 | 4,830 | 7,200 | 273 | 352 |
| 3×150+3G25 | 16.1 | 47.5 | 50.5 | 5,830 | 9,000 | 303 | 404 |
| 3×185+3G35 | 17.5 | 52.0 | 55.0 | 7,050 | 11,100 | 330 | 461 |
| 3×240+3G50 | 19.9 | 58.0 | 61.0 | 9,240 | 14,400 | 366 | 540 |
TUNNELFLEX-R-PUR HF 0.6/1kV – With Control Cores 带控制芯
| Construction 构造 | Conductor Ø 导体直径 (mm) | Cable Ø (min) 电缆最小外径 (mm) | Cable Ø (max) 电缆最大外径 (mm) | Cable Weight 电缆重量 (kg/km) | Max. Tensile 最大抗拉强度 (N) | Bending Radius 弯曲半径 (mm) | Current 载流量 (A) |
|---|---|---|---|---|---|---|---|
| 3×25+3G6+2×1 | 6.5 | 25.5 | 28.0 | 1,260 | 1,500 | 168 | 131 |
| 3×35+3G6+2×1.5 | 7.5 | 26.5 | 29.0 | 1,560 | 2,100 | 174 | 162 |
| 3×50+3G10+2×1.5 | 9.1 | 30.0 | 32.5 | 2,160 | 3,000 | 195 | 202 |
| 3×70+3G16+2×1.5 | 10.8 | 34.0 | 37.0 | 3,030 | 4,200 | 222 | 250 |
| 3×95+3G16+2×1.5 | 12.1 | 37.5 | 40.5 | 3,740 | 5,700 | 243 | 301 |
| 3×120+3G25+2×1.5 | 14.3 | 42.5 | 45.5 | 4,860 | 7,200 | 273 | 352 |
| 3×150+3G25+2×1.5 | 16.1 | 47.5 | 50.5 | 5,860 | 9,000 | 303 | 404 |
| 3×185+3G35+2×1.5 | 17.5 | 52.0 | 55.0 | 7,080 | 11,100 | 330 | 461 |
| 3×240+3G50+2×1.5 | 19.9 | 58.0 | 61.0 | 9,270 | 14,400 | 366 | 540 |
Note: Control cores provide additional conductors for signaling, instrumentation, and control circuit applications. The 2×1 mm² and 2×1.5 mm² control cores are integrated within the cable assembly, reducing the need for separate control cables and simplifying installation in mobile mining equipment.
Technical Advantages 技术优势
The TUNNELFLEX-R-PUR HF cable incorporates several critical engineering features that distinguish it from conventional mining cables and provide measurable safety and operational benefits. Research on halogen-free cable technology and polyurethane materials demonstrates the superior performance of this cable design in underground mining and tunneling environments.
Enhanced Fire Safety 增强消防安全
Halogen-free construction meeting IEC 60754 standards produces up to 90% less toxic gas emissions compared to PVC cables during combustion. The low smoke emission improves visibility during evacuation, while the non-corrosive combustion products (pH ≥ 4.3) protect expensive mining equipment and electronics from acid gas damage.
Antitwisting Protection 防扭转保护
The integrated synthetic mesh layer (Layer 7) prevents cable twisting and deformation during high-speed reeling operations up to 120 m/min – double the speed of standard tunneling cables (60 m/min). This protection extends cable service life by preventing conductor damage and insulation failure caused by torsional stress.
Superior Mechanical Durability 卓越机械耐久性
Polyurethane outer sheath provides exceptional resistance to abrasion, tearing, and mechanical damage from rock contact and equipment impact. Industry testing shows polyurethane cables demonstrate 3-5 times greater abrasion resistance compared to conventional rubber or PVC sheathed cables in mining applications.
Chemical & Oil Resistance 化学和耐油性
Advanced polyurethane formulation resists mineral oils, hydraulic fluids, diesel fuel, lubricants, and most chemicals encountered in mining operations. The excellent hydrolysis resistance ensures the cable maintains its properties even in continuously wet underground conditions.
Wide Temperature Range 宽温度范围
Operating temperature range from -30°C to +80°C for flexible installations accommodates extreme conditions from permafrost mining to hot underground coal mines. The 90°C conductor temperature rating provides substantial thermal headroom for high current-carrying capacity.
Regulatory Compliance 法规合规
Full compliance with European and international standards including IEC 60754 (halogen-free), IEC 60332-1-2 (flame retardant), and DIN VDE requirements ensures the cable meets or exceeds safety regulations in all major mining jurisdictions worldwide.
Halogen-Free Technology: Safety Science 无卤技术：安全科学
Understanding the technical basis for halogen-free cable requirements is essential for mining and tunneling engineers. Research published by cable industry organizations and fire safety laboratories demonstrates the dramatic safety improvements achieved by eliminating halogen-containing materials from cable construction.
Why Halogen-Free Matters in Confined Spaces 为什么在受限空间中无卤很重要
When conventional PVC cables burn, they release hydrogen chloride (HCl) gas, which combines with moisture in the air and human respiratory systems to form hydrochloric acid. According to fire safety research, HCl concentrations as low as 500 ppm can incapacitate evacuees within minutes, while concentrations above 1,000 ppm can be immediately lethal. In confined underground environments like mine tunnels, these toxic gases accumulate rapidly and cannot be dispersed by natural ventilation.
Additionally, the corrosive nature of halogen acid gases causes severe damage to electronic equipment, control systems, and metal infrastructure. Fire incident reports from underground facilities show that even minor cable fires involving PVC cables can result in millions of dollars in equipment replacement costs due to acid gas corrosion, far exceeding the direct fire damage.
In contrast, HFFR cables like the TUNNELFLEX-R-PUR HF use polyurethane and polyethylene materials that contain no halogens. When these materials burn, they produce primarily carbon dioxide and water vapor with minimal toxic gas generation. The IEC 60754-1 test measures halogen acid gas content, requiring less than 5 mg/g for halogen-free classification – HFFR cables typically test at 1-2 mg/g, representing a 90-95% reduction compared to PVC cables which can release 250-350 mg/g of halogen acids.
PVC vs HFFR Cable Comparison in Fire Scenarios PVC与HFFR电缆火灾场景对比
| Property 性能 | PVC Cable PVC电缆 | HFFR Cable (TUNNELFLEX) HFFR电缆 |
|---|---|---|
| Halogen acid content 卤酸含量 | 250-350 mg/g | < 5 mg/g (typically 1-2 mg/g) |
| pH value pH值 | ≤ 1.5 (highly acidic) 高酸性 | ≥ 4.3 (near neutral) 接近中性 |
| Smoke density 烟密度 | Dense black smoke 浓密黑烟 | Low smoke, better visibility 低烟，能见度更好 |
| Toxic gas emissions 有毒气体排放 | High (HCl, HBr) 高（氯化氢、溴化氢） | Minimal (CO₂, H₂O primarily) 极少（主要是二氧化碳、水） |
| Equipment corrosion 设备腐蚀 | Severe acid gas damage 严重酸性气体损害 | Minimal corrosion 极少腐蚀 |
| Evacuation time impact 疏散时间影响 | Reduced visibility & breathing difficulty 能见度降低和呼吸困难 | Clearer visibility, less respiratory hazard 更清晰视野，较少呼吸危害 |
Contact Information 联系方式
For technical inquiries, quotations, custom configurations, or detailed specifications on the TUNNELFLEX-R-PUR HF cable, please contact Anhui Feichun Special Cable Co., Ltd. through any of the following channels. Our engineering team can provide application-specific recommendations for mining and tunneling projects.
References & Standards 参考文献与标准
- UTV Cavi. “TUNNELFLEX – Power cable supply to mobile equipment with high risk of mechanical damage especially in mining and tunneling.” Product Documentation. September 2023. UTV Cavi TUNNELFLEX
- UTV Cavi. “UTVFLEX®-PUR HF – Flexible cable designed for power and signalling mobile connections under severe mechanical stresses.” August 2023. UTV UTVFLEX-PUR HF
- SG Cables. “IEC 60754 – Standard for Halogen-Free Cable Testing: Low Smoke & Toxicity Requirements.” Technical Article. May 2025. IEC 60754 Halogen-Free Standards
- Romtronic. “Comparing Halogen-Free vs Standard Wire Insulations: Safety, Performance, and Applications.” September 2025. Halogen-Free Comparison
- LAPP Group. “Halogen-free cables and wires – How, what, when and why?” Technical Documentation. LAPP Halogen-Free Guide
- Zable Cable. “Halogen Free Cable or Fire Resistant Cable: Which One Fits Your Application?” September 2025. Halogen-Free Selection Guide
- Honest Cable. “Halogen-Free Cables: Uses & Benefits for Mining and Industrial Applications.” December 2025. Halogen-Free Benefits
- Veri Cables. “Underground Mining Tunnel Cable – Specialized cables for underground mining and tunneling.” December 2024. Mining Tunnel Cables
- Eland Cables. “Cheat Sheet: Low Smoke Zero Halogen Cables – Technical specifications and testing standards.” LSZH Cable Standards
- International Electrotechnical Commission. “IEC 60754-1 & 60754-2 – Test on gases evolved during combustion of materials from cables.” IEC Standards Database.
- International Electrotechnical Commission. “IEC 60332-1-2 – Tests on electric cables under fire conditions – Part 1-2: Test for vertical flame propagation.” IEC Standards.
- International Electrotechnical Commission. “IEC 60228 – Conductors of insulated cables.” IEC Standards Database.
![MYP cables must obtain MA (煤安) certification before they can be legally used in Chinese coal mines. The MA mark, administered by the National Coal Mine Safety Mark Office (煤矿安全标志办公室), represents mandatory safety certification for all underground coal mining equipment and materials. MYP cables, as mobile power supply cables for coal mining machinery, fall under the strictly regulated product categories defined in the Mining Product Safety Sign Management Catalog and must comply with Chinese national standards MT 818 series and GB 12972.[1][2] 是的，MYP电缆在中国煤矿使用前必须获得MA（煤安）认证。由国家煤矿安全标志办公室管理的MA标志，代表了所有井下煤矿设备和材料的强制性安全认证。MYP电缆作为煤矿机械的移动电源电缆，属于《矿用产品安全标志管理目录》中严格管制的产品类别，必须符合中国国家标准MT 818系列和GB 12972。](https://feichuncables.com/blog/wp-content/uploads/image-653-400x225.avif "PROTOLON (SB-SAM) (N)TSCGEWOEU I 6 - 20 KV 3")
