TXP / TXP-D: PUR Round Cable for Heavy-Duty Festoon and Energy-Guiding Applications
A practical engineering guide to a halogen-free polyurethane round cable family for continuous heavy-duty conveying machinery, container-crane trolleys, process cranes, conveyors and moveable stage equipment. The design target is not merely flexibility; it is stable performance while speed, acceleration, guide forces, abrasion, temperature and atmospheric exposure act at the same time.
What is TXP / TXP-D?
TXP is a halogen-free PUR round cable for continuous heavy-duty festoon and energy-guiding duties. TXP-D is the data branch of the same design philosophy, covering paired copper data and fibre-optic constructions. The round cable architecture is chosen when the machine imposes repeated bending, acceleration and guide interaction rather than a static installation.
The supplied type designation is D12Y11Y. The family is aimed at horizontal or vertical machinery with energy guiding chains, including container-crane trolley power supply; process cranes and conveyor equipment indoors or outdoors; and theatres or scenic machinery where halogen-free and flame-retardant compounds are required. The stated electrical rating is U₀/U = 0.6/1 kV for TXP, while the detailed data-cable table identifies the supplied TXP-D data branch as 300 V.
The design combines highly flexible class-5 copper conductors, a polyester-based halogen-free insulation system, a twisted core arrangement around a central element, and a PUR outer sheath described as abrasion- and cut-resistant. This is a sensible architecture for a cable that must survive frequent continuous bending, but the machine guide and end restraint still determine the actual service life.
Public engineering context. Conductix-Wampfler describes festoon cables as products engineered for heavy-duty operation, high dynamics and harsh environments, with finely stranded conductors and robust sheath compounds. That context supports the engineering logic of this family; the exact TXP / TXP-D values and order rows below are transcribed from the supplied record.
Electrical, mechanical, thermal and chemical envelope
Electrical
TXP rated voltage: U₀/U = 0.6/1 kV.
TXP-D data row: U₀/U = 300 V.
AC test voltage: 2.5 kV.
Ampacity: according to DIN VDE 0298-4.
Mechanical
Travel speed: up to 210 m/min.
Front dynamic radius statement: TXP 6×Ø; TXP-D 10×Ø.
Additional table: 6×Ø fixed, 6×Ø festoon, 7.5×Ø energy guiding chains.
These values are preserved as separate source statements.
Thermal
TXP flexing: −40°C…+80°C.
TXP fixed: −50°C…+80°C.
TXP-D flexing: −30°C…+70°C.
TXP-D fixed: −40°C…+80°C.
Maximum conductor service temperature is 90°C; short circuit is 250°C.
Chemical and environmental
Halogen free · ozone resistant · oil resistant according to DIN EN 60811-2-1 · UV resistant · free of lacquer-damaging substances and silicone during production.
TXP flame retardant according to IEC 60332-1; TXP-D flame retardant according to IEC 60332-2-1. General colour: black.
| Parameter | Supplied value | Engineering interpretation |
|---|---|---|
| Family | TXP / TXP-D | PUR round cable for heavy-duty festoon and conveying machinery |
| Type | D12Y11Y | Type designation in the supplied record; final print marking must be confirmed |
| TXP rated voltage | U₀/U = 0.6/1 kV | Power and control branch |
| TXP-D data voltage | U₀/U = 300 V | Data branch; do not quote it as the 0.6/1 kV power rating |
| Travel speed | up to 210 m/min | Application limit supplied for dynamic travel |
| TXP front dynamic radius | 6 × Ø | Use with TXP construction and released duty |
| TXP-D front dynamic radius | 10 × Ø | Use with TXP-D construction unless the final release states otherwise |
| Additional radius table | 6 × Ø fixed; 6 × Ø festoon; 7.5 × Ø energy guiding chains | Separate source statement; resolve against the selected duty |
| Ambient TXP | flexing −40…+80°C; fixed −50…+80°C | TXP ambient range |
| Ambient TXP-D | flexing −30…+70°C; fixed −40…+80°C | TXP-D ambient range |
| Conductor / short circuit | 90°C / 250°C | Conductor limits, not ambient limits |
| AC test voltage | 2.5 kV | Release test report must identify the applicable circuit and standard |
| Colour | black | TXP-D copper pair row separately states green PVC outer sheath |
Construction: why the round PUR architecture is used
The conductor is finely stranded bare copper, class 5 according to VDE 0295. The cores are twisted around a central element, which gives the cable a controlled round load path as it passes through an energy chain or festoon guide. The insulation compound is polyester-based and free of halogen; the outer sheath is polyurethane and free of halogen.
For heavy moving machinery, the outer sheath is not a cosmetic layer. The supplied design calls for an abrasion- and cutproof PUR material and also specifies resistance to ozone, oil and UV. These properties are valuable when the cable sees guide friction, steel dust, outdoor radiation, oil mist, humidity or repeated contact with trolley hardware. They do not remove the need to finish guides, control clamp pressure and eliminate sharp edges.
| Construction item | Supplied design detail | Service significance |
|---|---|---|
| Conductor | Finely stranded bare copper | Supports repeated bending and carries the electrical load |
| Conductor class | Class 5 acc. to VDE 0295 | Use the specified flexibility class for termination and bending review |
| Core arrangement | Cores twisted around central element | Creates a controlled round cable geometry for dynamic movement |
| Insulation | Compound based on polyester; free of halogen | Supports the stated halogen-free and dynamic-duty design |
| Conductor coding | Up to 5 cores: coloured acc. VDE 0293-308; from 6 cores: light insulation with black numerals, with/without GN/YE | Controls wiring and replacement accuracy |
| Outer sheath | Polyurethane, free of halogen | Abrasion- and cut-resistant PUR protection for heavy-duty service |
| General chemical properties | Ozone resistant; oil resistant acc. DIN EN 60811-2-1; UV resistant | Useful for severe atmospheric conditions, subject to actual media and concentration |
| Production cleanliness | Free from lacquer-damaging substances and silicone during production | Important in theatres, scenic machinery, painted steel plants and clean assembly zones |
| Colour | Black | TXP-D copper pair exception: supplied row states PVC outer sheath, green |
Round-cable discipline. A round cable is not automatically torsion-proof. The selected TXP duty should control the bending plane, guide clearance, end grip and return path. Where the machine creates multi-axis torsion or uncontrolled helical movement, the application should be reviewed as a different cable duty.
Complete TXP / TXP-D order matrices
The following tables preserve all supplied conductor schedules, part numbers, outer-diameter ranges, copper indices, approximate weights, permitted tensile loads and minimum-order fields. A dash is retained exactly as a supplied field. Thousands separators such as 1.050, 1.152 and 1.200 are also retained as written.
| 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 |
|---|---|---|---|---|---|---|---|---|
| Control cable TXP | 12 G 1.5 | 131240-R12G1,5# | 14.3 – 15.5 | 173 | 320 | 270 | 0.6/1 kV | – |
| Control cable TXP | 18 G 1.5 | 131240-R18G1,5# | 14.5 – 15.7 | 259 | 380 | 400 | 0.6/1 kV | – |
| Control cable TXP | 24 G 1.5 | 131240-R24G1,5# | 16.5 – 17.8 | 346 | 500 | 540 | 0.6/1 kV | – |
| Control cable TXP | 4 G 2.5 | 131240-R4G2,5# | 9.2 – 10.2 | 96 | 160 | 150 | 0.6/1 kV | – |
| Control cable TXP | 5 G 2.5 | 131240-R5G2,5# | 9.8 – 11.0 | 120 | 180 | 180 | 0.6/1 kV | – |
| Control cable TXP | 7 G 2.5 | 131240-R7G2,5# | 11.5 – 12.7 | 168 | 250 | 260 | 0.6/1 kV | – |
| Control cable TXP | 12 G 2.5 | 131240-R12G2,5# | 16.5 – 17.7 | 288 | 460 | 450 | 0.6/1 kV | – |
| Control cable TXP | 18 G 2.5 | 131240-R18G2,5# | 16.7 – 17.9 | 432 | 580 | 670 | 0.6/1 kV | – |
| Control cable TXP | 24 G 2.5 | 131240-R24G2,5# | 19.2 – 20.4 | 576 | 760 | 900 | 0.6/1 kV | – |
| 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 |
|---|---|---|---|---|---|---|---|---|
| Screened control cable TXP | 7 G 1.5C | 131249-R7G1,5C# | 10.9 – 12.1 | 192 | 220 | 150 | 0.6/1 kV | – |
| Screened control cable TXP | 12 G 1.5C | 131249-R12G1,5C# | 15.0 – 16.2 | 250 | 360 | 270 | 0.6/1 kV | – |
| Screened control cable TXP | 18 G 1.5C | 131249-R18G1,5C# | 15.0 – 16.2 | 341 | 420 | 400 | 0.6/1 kV | – |
| Screened control cable TXP | 4 G 2.5C | 131249-R4G2,5C# | 12.1 – 13.2 | 157 | 250 | 150 | 0.6/1 kV | – |
| Screened control cable TXP | 5 G 2.5C | 131249-R5G2,5C# | 12.8 – 14.0 | 190 | 280 | 180 | 0.6/1 kV | – |
| Screened control cable TXP | 12 G 2.5C | 131249-R12G2,5C# | 17.4 – 18.6 | 250 | 530 | 450 | 0.6/1 kV | – |
| Screened control cable TXP | 18 G 2.5C | 131249-R18G2,5C# | 17.5 – 18.8 | 341 | 650 | 670 | 0.6/1 kV | – |
| 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 |
|---|---|---|---|---|---|---|---|---|
| Power cable TXP | 1 × 25 | 131140-R1X25# | 9.9 – 11.1 | 240 | 270 | 370 | 0.6/1 kV | – |
| Power cable TXP | 1 × 35 | 131140-R1X35# | 11.7 – 12.9 | 336 | 380 | 520 | 0.6/1 kV | – |
| Power cable TXP | 1 × 50 | 131140-R1X50# | 13.9 – 15.1 | 480 | 530 | 750 | 0.6/1 kV | – |
| Power cable TXP | 1 × 70 | 131140-R1X70# | 16.2 – 17.4 | 672 | 740 | 1.050 | 0.6/1 kV | – |
| Power cable TXP | 1 × 95 | 131140-R1X95# | 17.9 – 19.1 | 912 | 940 | 1.420 | 0.6/1 kV | – |
| Power cable TXP | 1 × 120 | 131140-R1X120# | 20.2 – 21.5 | 1.152 | 1.200 | 1.800 | 0.6/1 kV | – |
| Power cable TXP | 1 × 150 | 131140-R1X150# | 21.8 – 23.2 | 1.440 | 1.490 | 2.250 | 0.6/1 kV | – |
| Power cable TXP | 4 G 4 | 131140-R4G4# | 10.3 – 11.5 | 154 | 230 | 240 | 0.6/1 kV | – |
| Power cable TXP | 4 G 6 | 131140-R4G6# | 12.1 – 13.2 | 230 | 320 | 360 | 0.6/1 kV | – |
| Power cable TXP | 4 G 10 | 131140-R4G10# | 15.0 – 16.2 | 384 | 520 | 600 | 0.6/1 kV | – |
| Power cable TXP | 4 G 16 | 131140-R4G16# | 17.7 – 18.9 | 614 | 750 | 960 | 0.6/1 kV | – |
| Power cable TXP | 4 G 25 | 131140-R4G25# | 21.1 – 22.5 | 960 | 1.160 | 1.500 | 0.6/1 kV | – |
| Power cable TXP | 4 G 35 | 131140-R4G35# | 25.8 – 27.4 | 1.344 | 1.650 | 2.100 | 0.6/1 kV | – |
| Power cable TXP | 4 G 50 | 131140-R4G50# | 31.0 – 33.0 | 1.920 | 2.410 | 3.000 | 0.6/1 kV | – |
| Power cable TXP | 5 G 4 | 131140-R5G4# | 11.6 – 12.7 | 192 | 290 | 300 | 0.6/1 kV | – |
| Power cable TXP | 5 G 6 | 131140-R5G6# | 14.0 – 15.2 | 288 | 420 | 450 | 0.6/1 kV | – |
| Power cable TXP | 5 G 16 | 131140-R5G16# | 19.4 – 20.6 | 768 | 920 | 1.200 | 0.6/1 kV | – |
| 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 |
|---|---|---|---|---|---|---|---|---|
| Screened power cable TXP | 1 × 25C | 131141-R1X25C# | 10.3 – 11.5 | 310 | 330 | 370 | 0.6/1 kV | – |
| Screened power cable TXP | 1 × 35C | 131141-R1X35C# | 12.3 – 13.5 | 406 | 430 | 520 | 0.6/1 kV | – |
| Screened power cable TXP | 1 × 50C | 131141-R1X50C# | 15.4 – 16.6 | 550 | 610 | 750 | 0.6/1 kV | – |
| Screened power cable TXP | 1 × 70C | 131141-R1X70C# | 17.0 – 18.3 | 747 | 810 | 1.050 | 0.6/1 kV | – |
| Screened power cable TXP | 1 × 95C | 131141-R1X95C# | 18.9 – 20.1 | 1.066 | 1.030 | 1.420 | 0.6/1 kV | – |
| Screened power cable TXP | 4 G 4C | 131149-R4G4C# | 13.6 – 14.7 | 221 | 330 | 240 | 0.6/1 kV | – |
| Screened power cable TXP | 4 G 6C | 131149-R4G6C# | 15.1 – 16.3 | 300 | 420 | 360 | 0.6/1 kV | – |
| Screened power cable TXP | 4 G 10C | 131149-R4G10C# | 18.4 – 19.6 | 454 | 640 | 600 | 0.6/1 kV | – |
| Screened power cable TXP | 4 G 16C | 131149-R4G16C# | 21.2 – 22.5 | 694 | 940 | 960 | 0.6/1 kV | – |
| Screened power cable TXP | 4 G 25C | 131149-R4G25C# | 24.5 – 26.2 | 1.050 | 1.360 | 1.500 | 0.6/1 kV | – |
| Screened power cable TXP | 4 G 35C | 131249-R4G35C# | 29.6 – 31.6 | 1.444 | 1.870 | 2.100 | 0.6/1 kV | – |
| Screened power cable TXP | 4 G 50C | 131149-R4G50C# | 35.1 – 37.6 | 2.030 | 2.560 | 3.000 | 0.6/1 kV | – |
| 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 |
|---|---|---|---|---|---|---|---|---|
| Data cable TXP-D | * 2X2X0,75C PN IE TP | 131349-R2X2X0,75C-TP# | 6.3 – 6.7 | 29 | 68 | 150 | 300 V | – |
| Data cable TXP-D | 12 G 62,5/125 | 131340-R12G62,5/125# | 13.0 – 15.0 | – | 170 | 300 | 300 V | – |
| Data cable TXP-D | 12 G 50/125 | 131340-R12G50/125# | 13.0 – 15.0 | – | 170 | 300 | 300 V | – |
131249-R4G35C# for the 4 G 35C row; it is preserved exactly and not corrected by assumption.How to read the order table
The bending-radius issue that must not be hidden
The supplied record contains two mechanical descriptions. The opening product summary says TXP 6×Ø and TXP-D 10×Ø for the dynamic minimum bending radius. The additional technical data later lists minimum radii for free movement as 6×Ø for fixed installation, 6×Ø for festoon and 7.5×Ø for energy guiding chains.
These statements may reflect different construction categories, application tables or document versions. It would be poor engineering practice to silently choose the smaller number or to claim that the conflict does not exist. The correct action is to identify the exact product branch, installation mode, guide system and applicable technical edition in the release drawing. Until that is done, both source statements remain visible.
TXP
Front statement: dynamic minimum 6×Ø. Additional table: fixed 6×Ø, festoon 6×Ø, energy guiding chain 7.5×Ø.
TXP-D
Front statement: dynamic minimum 10×Ø. Additional table: fixed 6×Ø, festoon 6×Ø, energy guiding chain 7.5×Ø.
What to confirm
TXP or TXP-D; copper or fibre; energy chain or festoon; fixed / moving category; outer diameter basis; manufacturer release and installation instructions.
What not to do
Do not copy a radius from another PUR cable, a round reeling cable or a flat festoon cable and present it as TXP approval.
Screening, paired data and fibre-optic options
Screened TXP constructions add an inner PUR sheath where specified, PETP foil for contact protection, a tinned copper braid with approximately 80% coverage and polyester fleece protection. The screen is not an isolated accessory: the cable gland, cabinet entry, trolley bonding and shield continuity test must be designed with it.
TXP-D contains three different supplied data concepts: a paired copper cable marked 2X2X0,75C PN IE TP, a 12-core 62.5/125 fibre construction and a 12-core 50/125 fibre construction. The copper data row has a stated 300 V rating; the fibre rows show a dash in the copper-index field because the optical construction is not represented by a copper conductor index in the supplied matrix.
| Fibre property | Singlemode E9/125 | Multimode 50/125 | Multimode 62.5/125 |
|---|---|---|---|
| Maximum attenuation at 850 nm | — | 3.0 dB/km | 3.5 dB/km |
| Maximum attenuation at 1300 nm | 0.5 dB/km | 1.0 dB/km | 1.5 dB/km |
| Maximum attenuation at 1550 nm | 0.3 dB/km | — | — |
| Numerical aperture ±0.02 | — | 0.2 | 0.27 |
| Bandwidth at 850 nm | — | 400 MHz | 200 MHz |
| Bandwidth at 1300 nm | — | 1500 MHz | 600 MHz |
Installation, inspection and failure prevention
In a fast energy-guiding system, the cable is a moving structural member as well as an electrical component. A damaged PUR sheath is often the first visible sign of a guide problem, not the original cause. A trolley that runs unevenly, a chain that twists or a clamp that carries dynamic shock can shorten the life of even a correctly specified cable.
Installation
- Verify the exact outer-Ø range against the energy-chain cavity, guide rollers and clamp.
- Use the applicable radius statement from the final release, not a generic value.
- Keep the cable free of compression, sharp edges and uncontrolled twist.
- Use end grips and strain reliefs that transfer load through the designated cable path.
- Separate power, control, screened and fibre functions according to the system EMC and communication design.
Commissioning
- Run the first cycles at reduced speed and observe the complete guide path.
- Check chain fill, cable position, loop stability and return movement.
- Verify conductor continuity, insulation resistance and screen continuity where applicable.
- For fibre, test attenuation and continuity at the specified wavelengths.
- Record actual speed, acceleration, ambient temperature and guide condition.
Maintenance
- Inspect PUR for notching, cuts, flattening, glazing and local hardening.
- Check guide rollers, chain links, separators and end clamps for damage.
- Inspect screen braid and foil termination on screened variants.
- Look for abnormal electrical heating or intermittent control signals.
- Replace the cable when the sheath, insulation, screen or fibre protection has been compromised.
| Observed symptom | Likely mechanism | Engineering response |
|---|---|---|
| Longitudinal cut or notch in PUR | Guide edge, foreign body, excessive chain pressure or cable rubbing | Remove the damage source; verify guide finish, fill and outer-Ø clearance |
| Cable twists or migrates in chain | Incorrect separator, poor chain alignment or multi-axis force | Re-align the guide system and confirm the cable’s intended movement |
| Repeated end-grip pull | Acceleration shock or underspecified strain relief | Recalculate the load path; do not transfer machine shock to the copper |
| Screen intermittently open | Braid break, foil damage or poor termination | Repair the complete screen path and test continuity through travel |
| Fibre attenuation increases | Microbending, crushing, tight bend or damaged protection | Inspect radius, chain pressure, splice and optical test results |
| Conductor temperature high | Overcurrent, grouping, poor heat dissipation or damaged conductor | Recheck DIN VDE 0298-4 basis and installation derating |
Standards, documentation and Feichun certification capability
The supplied TXP / TXP-D record references VDE 0295 for conductor class, VDE 0293-308 for conductor coding and DIN VDE 0298-4 for ampacity. It also identifies DIN EN 60811-2-1 for oil resistance, IEC 60332-1 for TXP flame retardance and IEC 60332-2-1 for TXP-D flame retardance. The final test report must identify the released compound, construction, applicable edition and test configuration.
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 certification scope must match the exact TXP / TXP-D construction, market, voltage branch, screen, fibre option and installation duty; a generic certificate from another product family is not a valid substitute.
| Reference / document | Relevance | Release control |
|---|---|---|
| User-supplied TXP / TXP-D record | All product values, construction features, order matrices, fibre properties and radius statements | Primary source for this article; final Feichun drawing controls production |
| DIN VDE 0295 / IEC 60228 context | Class-5 finely stranded bare copper | Confirm conductor class in the released construction |
| VDE 0293-308 | Core identification and GN/YE option | Confirm marking and protective-conductor arrangement |
| DIN VDE 0298-4 | Ampacity calculation basis | Current rating depends on installation, grouping, ambient and duty |
| DIN EN 60811-2-1 | Oil-resistance reference supplied for TXP / TXP-D | Use the applicable compound and test report |
| IEC 60332-1 | TXP flame-retardant reference | Confirm the applicable test edition |
| IEC 60332-2-1 | TXP-D flame-retardant reference | Confirm the exact data-cable construction and test |
| Halogen-free / RoHS statements | Material and environmental requirements | Provide the declaration for the released product and destination |
| ATEX / IECEx / VDE / CE / UKCA / EAC / Russian Fire Safety | Potential project approval routes | Scope depends on the final product and destination requirements |
Public references used for engineering 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 TXP cable
For a reliable replacement or new-build quotation, send machine information together with the exact electrical schedule. A part number without the movement duty is not enough for a heavy-duty festoon cable.
Machine duty
- Festoon or energy-guiding-chain arrangement
- Horizontal or vertical travel
- Travel speed, acceleration and braking
- Travel length, guide length and duty cycle
- Minimum available bend radius and cavity dimensions
Electrical function
- TXP control, screened control, power or screened power
- TXP-D copper pair, 62.5/125 or 50/125 fibre
- Core count and cross-section
- U₀/U = 0.6/1 kV or 300 V data branch
- Screen, PE / GN/YE and termination requirements
Environment
- Flexing and fixed ambient temperatures
- Oil, ozone, UV, water, humidity and atmospheric corrosion
- Steel dust, foundry heat, theatre scenery or conveyor contamination
- Lacquer-sensitive production environment
- Colour, print marking and traceability
Documentation
- Exact outer Ø range, weight and copper index
- Permitted tensile-load data and system safety factor
- Applicable radius statement and installation category
- 2.5 kV test report and ampacity basis
- Screen / fibre test data and approval package
RFQ line example TXP screened power · 4 G 35C · U₀/U 0.6/1 kV · 131249-R4G35C# reference heavy-duty energy-guiding chain · travel up to 210 m/min outer Ø 29.6–31.6 mm · Cu 1.444 kg/km · weight 1.870 kg/km permitted tensile load 2.100 N · screen braid ≈80% · required length: [project value] radius basis: [TXP / TXP-D + final duty table] · termination drawing: [attach]
The example preserves the supplied 4 G 35C screened-power row, including its unusual part-number prefix. Feichun should confirm the final marking, dimensions, screen details, test evidence, certificates and accessories before production.
