solar system solutions for photovoltaic installations

RADOX® SOLARSYSTEM SOLUTIONS FORPHOTOVOLTAIC INSTALLATIONS

HUBER+SUHNER

Edition 2006

Excellence in Connectivity Solutions

HUBER+SUHNER 1

- RADOX® solar connector 2.5mm2 page 15

- RADOX® solar connector 4mm2 page 16

- RADOX® solar connector 4mm2 with integrated twist locking page 17

- RADOX® solar connector 6mm2 with integrated twist locking page 18

RADOX® Solar Connectors

PRODUCT SURVEY AND EFFICIENCY RANGE

- RADOX® solar cable single-core page 10

- RADOX® solar cable multicore page 11

- RADOX® solar cable multicore,with screen and rodent protection page 12

RADOX® Solar Cables

- Solar junction box page 20

- Solar inverter connector page 21

- Solar branch connector page 22

- Solar outdoor tool box page 23

- Solar measuring adapter page 24

- Dust protection hoods for 2.5mm2, 4mm2 and 6mm2 page 24

Accessories and Tools

- Customized assemblies

- Express shop

- Customized applications

- Assembled connections and systems

Service

General information 2-3Connectivity solutions from one source 4High quality for long service life 5Wiring from module to inverter 6-7Current carrying capacity 25-31

THE HUBER+SUHNER GROUP is a leading global supplier of components and systems for electrical and optical connectivity. Our customers in telecom-munications, industrial applications and transporta-tion appreciate that we are specialists with detailed knowledge of practical applications. We offer technical expertise in radio frequency technology, fibre-optics, cables and polymers under one roof, thus providing a unique basis for continual innova-tion focused on the needs of our customers all over the world.

Our motto is: «EXCELLENCE IN CONNECTIVITY SOLUTIONS». At the heart of our offering is a broad range of products that can be relied on to meet high quality standards, backed up by flex-ible, dependable services with fast response times worldwide. We concentrate on complex applica-tions that allow us to stand out by adding value with special product features, customer- specific innovations, engineering and other services.

Connections that enrich our lives

Our broad range of products and services make an essential contribu-tion to set up and expand fixed-line and mobile communication networks. We offer radio frequency components and broadband antennas for all com-mon standards, fiber optic cable, con-nectors and distribution systems for telecom and local networks. Coaxial cable, connectors for radio networks, test and measurement and lightning protection components are also avail-able.

COMMUNICATIONOUR COMPANY

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Connections that get us moving

As one of Europe’s leading suppli-ers, HUBER+SUHNER offers a wide range of products which provide the platform to build modern rail transport systems. These products are developed for high quality needs and specifically designed for applications such as: train positioning as in GPS, cellular dis-tribution for mobile telephone access, WiFi distribution for on-train internet access, CCTV for video surveillance, passenger infotainment systems for real time passenger information and entertainment, OTMR for train diag-nostics during operation, inter vehicle jumper systems and profiles for safety and comfort.

TRANSPORTATION

Connections that add value

Our components and system solutions are suitable for specialised applica-tions in aviation, space, defense, and medical technology. Our products are superior, providing constant reliability even under extreme conditions: from copper cable to optical connections and high frequency components.

INDUSTRY

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CONNECTIVITY SOLUTIONS FROM ONE SOURCE

Due to globally growing environmental respon sibility and increased prices for primary energies, photovoltaic technology is experiencing greater growth and acceptance. Generating current directly from omnipresent, powerful sunlight is a fascinating fact. Our high quality systems add an important con-tribution to this technical implementation.

HUBER+SUHNER has developed a high perform-ance connectivity solution for the wiring of photo-voltaic plants. High reliability even under extreme conditions is standard for our products. This connectivity solution includes our high-quality, TÜV-certified RADOX® solar cables, corresponding connectors and other practical accessories. Complete wiring of a solar power plant can thus be implemented with HUBER+SUHNER systems in a continuous and non-polluting way. Assembly time and easy product han-dling are as important as cost efficiency.

We develop customized applications based on spe-cific requirements from our customers. We can offer integrated components from one source and custom-ized connectivity solutions based on years of experi-ence. The latest technologies are involved in product development in cooperation with our customers. Due to our own R&D departments and testing laboratories we are not only able to react very rapidly to market requirements and customer demands, but also to be at the forefront of engineering.

Our extensive knowledge is gained from decades of material technology, high quality, and a long service life of our products. HUBER+SUHNER is certified to ISO 9002 and ISO 14001.

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The electron-beam cross-linked and non-polluting RADOX® solar cables are extremely robust, highly resistant against heat, cold and weather influ-ences like UV-radiation or ozone and hydrolysis. Additionally, these cables are halogen free, flame retardant, and do not generate corrosive gases or low smoke in case of fire.

Tight production tolerances and reduced outside diameters allow for assembly with our connectors resulting in water and dust-free connections.

RADOX® solar connectors are also equipped with outstanding mechanical properties with high weather resistance and are also halogen free. They are espe-cially characterized by a narrow design and a high current carrying capacity due to a low electrical resistance.

HUBER+SUHNER supplies completely assembled wiring systems in required lengths or raw cable and connectors with an outdoor assembly kit.

All our cables fulfill the Restrictions of the use of cer-tain Hazardous Substances (RoHS).

HIGH QUALITY FOR LONG SERVICE LIFE

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WIRING FROM MODULE TO INVERTER

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RADOX® SOLAR SINGLE-CORE AND MULTI-CORE CABLES

Halogen free, high temperature resistance,

weatherproof and extremely robust

RADOX® solar cable means flexible single and multi-core cables specially designed for wiring solar plants.

RADOX® solar cables are extremely robust and resist high mechanical load and abrasion. High temperature resistance and excellent weather-proofing characteristics provide a long service life. Due to RADOX® tech-nology, these outstanding properties have been achieved with small cable diameters.

Tight production tolerances – specifically for automated processes – enable easy assembly of cables. This represents a special advantage for molding, casting or soldering with no shrinking or other changes in electron-beam cross-linked material. There is no cold flow with RADOX® cables which guarantees long-term, optimum tightness for connectors or transitions.In case of fire there is no occurrence of corrosive or toxic gases. Smoke production in case of fire is very low.

Characteristics

- Temperature range for application -40°C up to +120°C

- Short circuit resistance up to +280°C

- High resistance against UV, ozone and hydrolysis

- Very high mechanical robustness and resistance against water, oil and chemicals

- Halogen free- RADOX® electron-beam cross-linked materials do not melt or flow, even at high temperatures

- Compact and flexible- Multi-core cables with potential com pensation or shielding and rodent protection

- Years of approved applications worldwide

- TÜV approval

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RADOX® SOLAR CABLE SINGLE-CORE

Conductor stranded tin-plated copper, fine wired acc. to IEC 60228, class 5Insulation RADOX® blackCoating RADOX®, see schedule for colors

General characteristicsCable made of electron-beam cross-linked insulation and coating; high resistance against heat, cold, oil, abra-sion, ozone, UV and weather; with improved reaction in case of fire, low smoke, halogen free, flame retardant; flexible, easy to strip, very low space requirement, extremely mechanically robust, very long lifetime.

ApplicationSpecifically designed for connecting photovoltaic system components inside and outside of buildings and equip-ment with high mechanical requirements and extreme weather conditions. For permanent installations.

Cables have passed the following fire tests:Vertical flame spread of a single cable IEC 60332-1, EN 50265-2-1Content of halogen hydracid 0mg/g IEC 670754-1, EN50267-2-1Corrosivity of combustion gases IEC 60754-2, EN 50267-2-3Smoke density IEC 61034-2, EN 50268-2

Cross section

mm2

Conductor designn x mm

Conductordiameterrated mm

Cable diameterrated mm

Colour Weight rated

kg/100m

Item no.

2.5 * 50 x 0.26 2.01 ± 0.05 5.2 ± 0.15 black 4.6 12529714

4.0 * 56 x 0.31 2.54 ± 0.05 5.8 ± 0.15 red 6.6 12545801

4.0 * 56 x 0.31 2.54 ± 0.05 5.8 ± 0.15 blue 6.6 12537896

4.0 * 56 x 0.31 2.54 ± 0.05 5.8 ± 0.15 black 6.6 12545802

6.0 * 81 x 0.31 3.30 ± 0.10 6.9 ± 0.20 black 9.2 12552756

6.0 * 81 x 0.31 3.30 ± 0.10 6.9 ± 0.20 red 9.2 12568182

6.0 * 81 x 0.31 3.30 ± 0.10 6.9 ± 0.20 blue 9.2 12568183

10.0 78 x 0.40 4.30 ± 0.10 8.1 ± 0.15 black 14.4 12537897

16.0 119 x 0.40 5.30 ± 0.10 9.5 ± 0.20 black 21.0 12567377Selection from range; different sizes and colors on request*Approvals: TÜV Rheinland design tested, certificate R 02210086

Technical Data

Voltage Rating 1000V DC or 600/1000V AC

Alternating test voltage 4000V AC (50Hz, 1min.)

Temperature range -40°C up to +120°C

Temperature range (TÜV) -40°C up to +110°C

Max. conductor temperature at short circuit +280°C (max. 5s)

Min. bending radius cable diameter < 8mm: 4xD; cable diameter > 8mm: 6xD

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Conductor stranded tin-plated copper, fine-wired acc. to IEC 60228, class 5Insulation RADOX®

Coating RADOX® blackCore colors 2-5 cores acc. to CENELEC, HD 308 as of 6 cores BK-numbered with protection conductor YEGN (different colors on request)

RADOX® SOLAR CABLE MULTICORE

Cross section

mm2

Conductordesignn x mm


Corediameterrated mm

Cable diameterrated mm

Weightrated

kg/100 m

2 x 2.5 50 x 0.25 2.05 3.50 ± 0.10 9.1 ± 0.3 13.0

3 x 2.5 50 x 0.25 2.05 3.50 ± 0.10 10.1 ± 0.4 16.6

4 x 2.5 50 x 0.25 2.05 3.50 ± 0.10 11.3 ± 0.4 20.9

5 x 2.5 50 x 0.25 2.05 3.50 ± 0.10 12.4 ± 0.4 24.9

7 x 2.5 50 x 0.25 2.05 3.50 ± 0.10 15.3 ± 0.5 37.9

2 x 4.0 56 x 0.30 2.60 4.15 ± 0.15 11.0 ± 0.4 18.7

4 x 4.0 56 x 0.30 2.60 4.15 ± 0.15 13.0 ± 0.4 29.8

5 x 4.0 56 x 0.30 2.60 4.15 ± 0.15 14.6 ± 0.4 36.7

4 x 6.0 81 x 0.30 3.40 4.95 ± 0.15 15.5 ± 0.5 41.8

2 x 10.0 78 x 0.40 4.40 6.15 ± 0.15 15.8 ± 0.5 -

3 x 10.0 78 x 0.40 4.40 6.15 ± 0.15 17.0 ± 0.5 -

4 x 10.0 78 x 0.40 4.40 6.15 ± 0.15 19.0 ± 0.5 -

5 x 10.0 78 x 0.40 4.40 6.15 ± 0.15 21.4 ± 0.5 -

Technical Data

Voltage rating 1000V DC or 600/1000V AC

Alternating test voltage 3500V AC (50Hz 1min.)

Temperature range: -40°C up to +125°C


Min. bending radius cable diameter fixed wiring: 3x cable-Ø; open wiring: 5x cable-Ø

Cables have passed the following fire tests:Vertical flame spread of a single cable EN 50265-2-1, IEC 60332-1Vertical flame spread of bunched cables EN 50266-2-4, IEC 60332-3-24 test type CContent of halogenous hydracid EN 50267-2-1, IEC 60754-1 0mg/gCorrosivity of combustion gases EN 50267-2-2, IEC 60754-2Smoke density EN 50268-2, IEC 61034-2

General characteristicsHigh resistance against heat, cold, ozone and weather, halogen free, flame retardant, no corrosive gases and low smoke occurrence in case of fire, soldering iron resistant, flexible, easy to strip, extremely mechanically robust, very long lifetime.

ApplicationFor connecting photovoltaic system components inside and outside of buildings and equipment with high mechani-cal requirements and extreme weather influences. For permanent installations.

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Conductor: stranded tin-plated copper, fine-wired acc. to IEC 60228, class 5Insulation: RADOX®

Screen: copper braid tin-plated, covering ≥ 85%Coating: RADOX® blackCore colors: 2-5 cores acc. to CENELEC, HD 308 as of 6 cores BK-numbered with protective conductor YEGN (different colors on request)

Cross section

mm2

Conductor designn x mm


Corediameterrated mm

Screen Cable diameterrated mm

Weightrated

kg/100 m

2 x 2.5 50 x 0.25 2.05 3.50 ± 0.10 7.7 10.2 ± 0.4 17.5

3 x 2.5 50 x 0.25 2.05 3.50 ± 0.10 8.3 10.8 ± 0.4 20.6

4 x 2.5 50 x 0.25 2.05 3.50 ± 0.10 9.8 12.4 ± 0.4 26.8

5 x 2.5 50 x 0.25 2.05 3.50 ± 0.10 10.4 13.1 ± 0.4 30.9

7 x 2.5 50 x 0.25 2.05 3.50 ± 0.10 13.2 16.3 ± 0.5 45.9

2 x 4.0 56 x 0.30 2.60 4.14 ± 0.15 9.2 11.9 ± 0.4 24.4

4 x 4.0 56 x 0.30 2.60 4.15 ± 0.15 11.2 14.1 ± 0.4 37.1

3 x 6.0 81 x 0.30 3.40 4.95 ± 0.15 11.6 14.5 ± 0.4 38.8

4 x 6.0 81 x 0.30 3.40 4.95 ± 0.15 13.3 16.5 ± 0.5 51.7

Technical Data

Voltage rating 1000V DC or 600/1000V AC

Alternating test voltage 3500V AC (50 Hz 1min)



Min. bending radius cable diameter fixed wiring: 4 x cable-Ø, open wiring: 5 x cable-Ø

RADOX® SOLAR CABLE MULTICORE SCREENED

General characteristicsHigh heat, cold, ozone and weather resistance, halogen free, flame retardant, no corrosive gases and low smoke occurrence in case of fire, soldering iron resistant, flexible, easy to strip, with compensation of potential difference within the cable or screening. Screening also retards effects of rodents.

ApplicationFor connecting photovoltaic systems inside and outside of buildings and equipment with high mechanical requirements and extreme weather influences. For permanent installations.

Cables have passed the following fire tests:Vertical flame spread of a single cable EN 50265-2-1, IEC 60332-1Vertical flame spread at bunched cables EN 50266-2-4, IEC 60332-3-24 test type CContent of halogenous hydracid EN 50267-2-1, IEC 60754-1 Omg/gCorrosivity of combustion gases EN 50267-2-2, IEC 60754-2Smoke density EN 50268-2, IEC 61034-2

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CONTACT PRINCIPLE

HUBER+SUHNER solar connectors consist of a housing and contactelement. Lamella contacts made of high-quality copper beryllium are considered to be core of the connectors. Special advantages include:

- Contact security- Small dimensions- Vibration resistance- Corrosion resistance- High current carrying capacity- Wide temperature range- High mechanical endurance (impact resistance)

- Low, constant transition resistance

Without a lamella contact these advantages cannot be achieved. The lamella contact as a flexible element provides mechanical compensation between socket and pin. The lamella produces a large contact surface between the elements and guarantees a low, constant transition resistance.

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43.5

10 10

55.5

RADOX® SOLAR CONNECTOR 2.5 mm2

Characteristics

- Small profile- Wide range of temperature- High current capacity- Constant low transition resistance- High mechanical resistance- Easy assembly- UV- and ozone resistant- Protection mode IP67 in mated condition- TÜV approval

Term: Solar female part 2.5mm2 Solar male part 2.5mm2

Technical data Solar female part Solar male part

Item no. 24101616 24101617

Diameter 4mm

Contact carrier brass tin-plated

Contact principle copper beryllium lamella contact

Disengagement force in mated condition

~ 55N

Compatible cross-sections 2.5mm2 RADOX® solar cable

Termination type crimp with HUBER+SUHNER tongs

Plastic material grip hood lamella connector

Material TPE PA 6.6

Fire resistance UL 94- HB UL 94- VO

Halogen free no halogen acc. to DIN VDE 0472 (part 815)

Chemical resistance UV and ozone resistant


Current carrying capacity 38A

Max. system voltage 1000V/DC

Transition resistance < 4mΩ

Protection type II

Protection mode IP 67 in mated condition

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43.5

10 10

55.5

RADOX® SOLAR CONNECTOR 4 mm2

Characteristics

- Small profile- Wide temperature range - High current capacity- Constant low transition resistance- High mechanical resistance- Easy assembly- UV- and ozone resistant- Protection mode IP67 in mated condition- TÜV approval

Term: Solar female part 4mm2 Solar male part 4mm2

Technical Data Solar female part Solar male part

Item no. 24500072 24500070

Diameter 4mm



Disengagement forcein mated condition

~ 55N




Material TPE PA 6.6

Fire resistance UL 94 – HB UL 94 – VO

Halogen free no halogen, DIN VDE 0472 (part 815)

Chemical resistance UV- and ozone resistant





Protection type II


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66

13 13

66

RADOX® SOLAR CONNECTOR 4 mm2 WITH INTEGRATED TWIST LOCKING

Term: Solar female part with locking 4 mm2 Solar male part with locking 4mm2

Characteristics

- Integrated twist locking- Robust- Wide range of temperature- High current capacity- Constant low transition resistance- High mechanical resistance- Easy assembly- UV- and ozone resistant- Protection mode IP67 in mated condition


Item no.: 24500095 24500094

Diameter 4mm



Disengagement forcein mated condition

~ 55N




Material TPE PA 6.6

Fire resistance UL 94 – HB UL 94- VO

Halogen free no halogen, DIN VDE 0472 (part 815)






Protection type II


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66

13 13

66

RADOX® SOLAR CONNECTOR 6 mm2 WITH INTEGRATED TWIST LOCKING

Term: Solar female part with locking 6mm2 Solar male part with locking 6mm2

Characteristics

- Integrated twist locking- Robust- Wide range of temperature- High current capacity- Constant low transition resistance- High mechanical resistance- Easy assembly- UV- and ozone resistant- Protection mode IP67 in mated condition


Item no.: 24500093 24500092

Diameter: 4mm

Contact carrier: brass tin-plated

Contact principle: copper beryllium lamella contact


~ 55N

Compatible cross-sections: 6.0mm2 RADOX® solar cable

Termination type: crimp with HUBER+SUHNER tongs

Plastic material: grip hood lamella connector

Material: TPE PA 6.6

Fire resistance: UL 94 – HB UL 94- VO

Halogen free: no halogen, DIN VDE 0472 (part 815)

Chemical resistance: UV- and ozone resistant

Temperature range: -40°C up to +110°C

Current carrying capacity: 38A

Max. system voltage: 1000V/DC

Transition resistance: < 4mΩ

Protection type: II

Protection mode: IP 67 in mated condition

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156.5

2810

1

156.5

2813

1

SOLAR JUNCTION BOX

DescriptionPV assembly housing for mounting of terminals (without screws) max. 6-pole, with diodes, screwings and mounted assembly leads with plug/coupling. Directly molded recesses in the housing bottom are designed for board assembly.

Please request assembly according to your requirements.

Protection mode acc. to IEC 60529 IP 65

Protective insulation acc. to DIN VDE 0106 protection type II

Overall dimensions Without extension:156.5x101x28mm; With extension:156.5x131x28mm

Assembly Smooth housing bottom for adhesive fixing. Space for fixing pads for position fixation during curing process.

Cover Rapid installation of the cover without tools. Solid Robust click-top system. Cover cannot be lost due to hinges. Cover can simply be fixed in the hinge of the junction box. Opening of cover is only possible with tool (screw-driver).

Technical data

Rated insulation voltage acc. to EN 50298-1/94 resp. EN 60439-1 1994

> AC 1000V

Material polycarbonate black, 15% fiber glass-reinforced

Halogen free acc. to DIN VDE 0472 part 815

Mechanical strength

Impact strength 80°C 1.4 up to 2.0 kJ/m2

23°C 1.4 up to 2.0 kJ/m2

standard ISO 179/1eA/standard flat stick

-40°C 1.4 up to 2.0 kJ/m2

Blow resistance 80°C 6 to 9 kJ/m2

23°C 6 to 9 kJ/m2

standard ISO 179/1eU/standard flat stick

-40°C 5 to 8 kJ/m2

Blow resistance acc. to DIN EN 50102 VDE 0470, part 100

IK 07 = 2 joule

Temperature resistance short-term -40°C up to +85°C

UV resistance: the assembly housing is designed for protected outdoor installation under environmental conditions – excluding the occurrence of damaging chemical effects. Long-term application at solar modules did not show any damaging influence of UV-radiation.

Terminal

Design 3- and 4-pole

Voltage rating 1000V – pollution stage 2 acc. to DIN 0110 part 1

Rated current 32A; diode current acc. to IEC 61215-II up to 8 A

Termination cross-section 0.5 – 4mm2, circular conductor

Termination for flat ribbon max. width 6mm, wider flat ribbons can be folded

Special assemblies on request

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17.4

17.4

SW 1

7

SW 1

0

46.5 46.1

SOLAR INVERTER CONNECTOR

ApplicationThe assembly system is designed for assembly to chassis (cover plate) and sockets with mounting hole Ø 12.5mm – 14.5mm.The RADOX® solar inverter con-nector is compatible (with regard to assembly) with common drillings and mounting holes.

Term: Female Part Male Part

SW 1

0


Item no. 24500089 24500088

Diameter 4mm


Disengagement force in mated condition ~ 55N


4.0mm2 RADOX® solar cable

Plastic material TPE / PA 6.6

Fire resistance UL 94 – HB




Mounting hole Ø 12.5mm – 14.5mm

Panel thickness 1.0mm – 4.0mm

Insulation group acc. to VDE 0110 T70 II

Protection mode acc. to EN 60529 with optional sealing ring IP67 from outside to the cover plate; in mated condition


Max. system voltage 1000V / DC

It is delivered with opposite nut.

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74.5 74.510 10

29 29Temperature range –40°C up to + 110°C

Characteristics

The branch connector is used for the safe and easy assembly (parallel or parallel-serial) of PV-modules.- Small profile- Wide temperature range- High current capacity- Constant low transition resistance- High mechanical resistance- Easy assembly- UV- and ozone resistant- Protection mode IP 67 in mated condition

- For HUBER+SUHNER standard solar connectors 2.5 mm2 and 4 mm2.

SOLAR BRANCH CONNECTOR

Term: Solar branch connector type A Solar branch connector type B

Technical data Type A Type B

Item no. 24101773 24101774

Diameter 4mm




~ 55N


Material TPE PA 6.6

Fire resistance UL 94 – HB UL 94 – VO



Temperature range - 40°C up to + 110°C


Max. system voltage 1000V / DC


Protection type II


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SOLAR OUTDOOR TOOL BOX

The outdoor tool box is suited for all cable and connector types and provides all accessories and tools necessary for field installation or assembly. A fast, flexible and low cost assem-bly of solar module connections is possible.

Contents of box

Item no. 24500090

Box with inserts 1

Crimp tongs chromium-plated 1 for 2.5mm2 and 4mm2

Crimp insert 1 for 6mm2

Insulation displacement tongs 1

Cable scissors 1

Set of screw drivers 1

Measuring tape 1

Inverse rectifier assembly connector 1 set

2.5mm2 connector 10 plugs and 10 sockets

4mm2 connector 40 plugs and 40 sockets

4mm2 connector with twist locking 10 plugs and 10 sockets

6mm2 connector with twist locking 10 plugs and 10 sockets

Chassis transition 2

Set of measuring adapters 1

Branch connector for 2.5 mm2 and 4 mm2 1 set

Dust protection hoods for 2.5mm2, 4mm2 and 6mm2 10 per size

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SOLAR MEASURING ADAPTER

DUST PROTECTION HOODS

Characteristics

The solar measuring adapter can be supplied for lead cross-sections 2.5mm2 and 4mm2 and provides connection from HUBER+SUHNER solar connector system to common measuring equipment with 4 mm plug principle. The adapter is available for HUBER+SUHNER standard 2.5mm2 and 4mm2 solar connectors.

Technical data

Item no. 24101541

Diameter 4mm



Disengagement force ~ 55N

Plastic materials Solar system

Material TPE, PA 6.6

Fire resistance UL 94 – HB






Protection type II

Adapters for fixing to common measuring leads.

Item no. Nom. inner Ø

2.5mm2 female part 24101811 7.5mm

male part 24101812 9.5mm

4mm2 female part 24101811 7.5mm


Twist locking:



Twist locking:



Term: Measuring adapter

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CURRENT CARRYING CAPACITY OF RADOX® SOLAR CABLES SINGLE-CORE

1. ScopeThe following tables referring to RADOX® cores give easy and fast support for the layout of apparatus and components.

The following remarks are based on today’s state of the art and practical experience as described in the stand-ards IEC 60216, IEC 60287 and IEC 60364. The application of products will frequently vary from the theoreti-cal values of constant ambient temperature, constant current carrying, homogeneous laying and others. That means, in practice the theoretical current carrying will differ from the real values.

For a safe layout of apparatus and components it is recommended to carry out a test with the installed wire under service conditions.

2. DefinitionsCurrent load: current passed through the cable during operation

Continuous operation: an operation with constant current whose duration is at least long enough to allow the system to reach thermal equilibrium, but may then go on indefinitely

Current rating: maximum permissible current under determined operating

Temperature: maximum permissible conductor temperature during continuous operation temperature

3. General remarks3.1 The current carrying capacity of cables depends on:

Conductor material (copper, copper aloy, aluminium, steel)Surface treatment of the conductor (plain, tinned, silver plated, nickel plated)Conductor cross-sectionThermal capacity of the insulation materialAmbient temperature (air/ground temperature)Installation mode (free in the air, in cable ducts, in earth)Accumulation (single core, several cores spaced, bundles)Other ambient effects (sun--radiation, UV)

3.2. The conductor cross--section has to be selected in such a way that the actual current load does not exceed the current rating, i.e. the ’conductor temperature does not exceed the permissible operating temperature. The determining factor is the appropriate, most unfavourable operating condition, encountered during oper-ation over the whole length of the cable.

••••••••

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4. Current rating under service conditions

I = IN • f1 • f2 • f3

I [A] : Current rating for continuous operation under service conditionsIN [A] : Current rating for continuous operation under standard conditionsf1 : Reduction factor for increased ambient temperature (see # 4.2)f2 : Reduction factor for deviated conductor temperature (see # 4.3)f3 : Reduktion factor for bundeled cables (see tables on pages 27 and following)

4.1 Standard conditions for current rating4.1.1 The tabled values for the current rating were calculated according to IEC 287 for the following standard

conditions:continuous operationsingle circuit for 3--phase current, single conductor for 1--phase current 30 °C ambient temperature and sufficiently large and ventilated spaces, whose ambient temperature is not appreciably increased by the heat coming from the cables.120 °C conductor temperaturefrequency up to 200 Hz

4.1.2 Installation in air, unrestricted heat dissipation, means that the following installation conditions are observed:

distance of the cables from the wall, from the floor, from the ceiling > cable diameterdistance between two adjacent power circuits > 2 x cable diametervertical distance between power circuits laid one upon another for individual cables > 2 x cable

diameter and for layers of cables > 200 mmperforated tray with a perforation > 30 % of the total surface

4.1.3 Open trays are continuous supports with vertical sides, but without cover. A possible perforation accounts for < 30’% of the total surface

4.1.4 Closed ducts are entirely closed. Pipes belong to this category also. The max. filling degree is 70%.

4.2 Reduction factors for increased ambient temperature

•••

••

•••

•

Ambient temperature [°C] 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115

Reduction factor f1 1 0.97 0.94 0.91 0.88 0.85 0.82 0.78 0.75 0.71 0.67 0.62 0.58 0.53 0.47 0.41 0.33 0.22

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PCV, CR 70 °C

PE-X, EPR 90 °C

RADOX® 125 120 °C

160 °C 1'250 h

150 °C 2'500 h

140 °C 5'000 h

130 °C 10'000 h

120 °C 20'000 h

110 °C 40'000 h

100 °C 80'000 h

90 °C 160'000 h

80 °C 320'000 h


4.3 Reduction factors for different conductor temperature

Conductor temperature (°C) 120 110 100 90 80 70

Reduction factor f2 1 0.96 0.91 0.85 0.79 0.72

Maximum permitted typical conductor temperature for various insulaton materials according to IEC 60216 (20'000 h / 50 % elongation at break):

4.4 Lifetime expectationIf crosslinked wires are used at higher temperatures than indicated by the temperature index of IEC 60216, the lifetime is reduced accordingly, conversely, the lifetime will increase at lower temperatures. RADOX® R 125 for example has a life span of 20'000 h at a conductor temperature of +120 °C, which is approx. 2.5 years.If it is used at another temperature, lifetime expectations are as follows:

Example RADOX® solar cables:

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≥ d

≥ d


Installation method Connecting lead in free air or perforated tray

Number of simultane-ous loaded conductors on each tray 1 2 3 4 6 8 10 16 20 4 6

Reduction factor f3 1 0.87 0.81 0.78 0.75 0.74 0.73 0.72 0.71 0.71 0.62

Copper conductor cross section mm2 Current ca

1.5 39 34 32 31 30 29 29 29 28 28 25

2.5 53 47 43 42 40 40 39 39 38 38 33

4 71 62 58 56 54 53 52 52 51 51 45

6 92 81 75 72 69 69 68 67 66 66 58

10 129 113 105 101 97 96 95 93 92 92 80

16 171 149 139 134 129 127 125 124 122 122 107

25 228 199 185 178 171 169 167 165 162 162 142

35 281 245 228 220 211 208 206 203 200 200 175

50 355 309 288 277 267 263 260 256 253 253 221

70 447 389 363 349 336 331 327 322 318 318 278

95 530 462 430 414 398 393 387 382 377 377 329

120 622 542 504 486 467 461 455 448 442 442 386

150 720 627 584 562 540 533 526 519 512 512 447

HUBER+SUHNER 29

Continuous current ratingconductor temperature 120 °C, ambient temperature 30°C

8 10 16 20 4 6 8 10 16 20 4 6 8 10 16 20

0.57 0.53 0.47 0.45 0.67 0.59 0.54 0.50 0.45 0.43 0.71 0.58 0.52 0.48 7.7 7.2

arrying capacity in [A]23 21 19 18 27 24 22 20 18 17 28 23 21 19 16 15

31 29 25 24 36 32 29 27 24 23 38 31 28 26 22 21

41 38 34 32 48 42 39 36 32 31 51 42 37 35 30 27

53 49 44 42 62 55 50 46 42 40 66 54 48 45 38 35

74 69 61 59 87 77 70 65 59 56 92 75 68 62 53 50

98 91 81 77 115 101 93 86 77 74 122 100 89 83 71 65

130 121 108 103 153 135 124 114 103 99 162 133 119 110 94 87

161 149 133 127 189 166 152 141 127 121 200 163 147 135 116 107

203 189 167 160 238 210 192 178 160 153 253 206 185 171 146 135

255 237 211 202 300 264 242 224 202 193 318 260 233 215 184 170

303 281 250 239 356 313 287 265 239 228 377 308 276 255 218 202

355 330 293 280 417 367 336 311 280 268 442 361 324 299 256 237

411 382 339 324 483 425 389 360 324 310 512 418 375 346 296 274

HUBER+SUHNER30


Installation method on floor or wall fixed on a ceiling or under floor

Number of simultane-ous loaded conductors on each tray 1 2 3 4 1 2 3 4 5 6 7 8

Reduction factor f3 1 0.85 0.79 0.75 0.95 0.81 0.72 0.68 0.66 0.64 0.63 0.62

Copper conductor cross section mm2

Current ca1.5 35 30 28 27 34 29 26 24 24 23 23 22

2.5 48 41 38 36 46 39 35 33 32 31 31 30

4 64 55 51 48 61 52 47 44 43 41 41 40

6 84 72 67 63 80 69 61 58 56 54 53 53

10 118 101 94 89 113 96 85 81 78 76 75 74

16 158 135 125 119 151 128 114 108 105 102 100 98

25 212 181 168 159 202 172 153 145 140 136 134 132

35 262 223 207 197 249 213 189 179 173 168 166 163

50 330 281 261 248 314 268 238 225 218 212 208 205

70 420 357 332 315 399 341 303 286 278 269 265 261

95 499 425 395 375 475 405 360 340 330 320 315 310

120 580 493 459 435 551 470 418 395 383 372 366 360

150 670 583 543 523 637 543 483 456 443 429 423 416

HUBER+SUHNER 31

Continuous current ratingconductor temperature 120 °C, ambient temperature 30°C

in conduit in a void or in a pipe

≥ 9 1 2 3 4 5 6 7 8 9 10 12 14 16 20

0.61 1 0.80 0.70 0.65 0.60 0.57 0.54 0.52 0.50 0.48 0.45 0.43 0.41 0.38

arrying capacity in [A]22 29 24 21 19 18 17 16 16 15 14 14 13 12 12

30 39 32 28 26 24 23 22 21 20 19 18 17 16 15

40 52 42 37 34 32 30 29 28 26 25 24 23 22 20

52 66 53 47 43 40 38 36 35 33 32 30 29 28 26

72 92 74 65 60 56 53 50 48 46 45 42 40 38 35

97 120 96 84 78 72 69 65 63 60 58 54 52 50 46

130 160 128 112 104 96 92 87 84 80 77 72 69 66 61

160 196 157 138 128 118 112 106 102 98 95 89 85 81 75

202 248 199 174 162 149 142 134 129 124 120 112 107 102 95

257 309 248 217 201 186 177 167 161 155 149 140 133 127 118

305 457 286 250 233 215 204 193 186 179 172 161 154 147 136

354 426 341 299 277 256 243 231 222 213 205 192 184 175 162

409 485 388 340 316 291 277 262 253 243 233 219 209 199 185

HUBER+SUHNER AGWire+CableCH-8330 Pfäffikon ZHTel. +41 (44) 952 22 11Fax +41 (44) 952 26 70www.hubersuhner.com 84

0176

06/0

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06

HUBER+SUHNER GmbHMehlbeerenstrasse 6D-82024 TaufkirchenTel. +49 (0)89 61 20 10Fax +49 (0)89 61 20 1241www.hubersuhner.de

WAIVERIt is exclusively in written agreements that we provide our customers with warrants and representations as to the technical specifications and/or the fitness for any particular purpose. The facts and figures contained herein are carefully compiled to the best of our knowledge, but they are inten-ded for general informational purposes only.

HUBER+SUHNER is certified according to ISO 9001 and ISO 14001.

HUBER+SUHNER – Excellence in Connectivity Solutions

HUBER+SUHNER is a leading global supplier of compo-nents and systems for electrical and optical connectivity in communications, industrial and transportation markets. HUBER+SUHNER can draw on core compentieces in the areas of high frequency technology, fibre optics, cables and

polymers. Working in close collaboration with our customers around the globe, we strive for excellence in the develop-ment and manufacturing of high quality products.

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