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TECHNICAL GUIDE
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C A B L O F I L ®the global solution
High-quality steel wire cable supports
Unique safety edge
Fast install system
High level mechanical and electrical
performance
Power
Data
Control Process
TECHNICAL
GUIDE
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Applications - Sustainable development ............04
Mechanical resistance ............06
Metals and surface treatments ............08
Food industry safety ............10
Electromagnetic compatibility ............12
Electrical continuity – Earth network ............14
Power cables ............16
Efficient data cabling ............18
Fibre optic cables ............19
Copper data cables ............20
Standards and directives ............22
Fire resistance ............24
Fire protection: EZ-Path® ............26
References ............32
Decision-making software ............33
Specifications ............34
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BUILDING SERVICES
HEAVY INDUSTRY
INFRASTRUCTURE
PROCESSING INDUSTRIES
Applications
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Sustainable developmentSustainable development, once the preserve of
legislators and governments, has become a factof life for all stakeholders within society. Today'sproject managers, whether in an industrial, servicesor infrastructure context, need to respect theenvironment and consider the human impact of theiractions.CABLOFIL® is fully aware of these issues and behavesresponsibly across all its sites and organisationalstructures. The company also extends this approachto its partners, with a view to developing a lastingcommitment in this area.
PRODUCT DESIGNHealth and environment Directive
IMPROVED ENERGY EFFICIENCY - ISO 9001
on-site cable ventilation
SITE MANAGEMENT: ISO 14001
environmental management at sites
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SAFE WORKING LOADS FOR CABLETRAYS
1/100th th
LOAD TESTS: TEST CONFIGURATION ACCORDING TO STANDARD IEC 61537 th
th
1/200th
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Mechanical resistanceFirst and foremost, a cable tray must act as an effective, resistant and durable support for
cables.The mechanical performance of all products and accessories is tested against the verydemanding requirements imposed by the international standard IEC 61537.
SAFETY becomes like a hammock.
SAFE WORKING LOAD FOR SUPPORTS
Calculation rules:Total F = F1 + F2 + F3
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POSITIONING OF THE SUPPORTS
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P2000 > Exclusive to CABLOFIL®: 25% savings with the P2000 (span of 2 m at full capacity). 1.5 m span.
0.4 m.
L/5 L/2
1/5th
POSITIONING OF THE COUPLERS (general scenario applicable to all spans)
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Optimum Possible
0.5 m 0.5 m
2 m1.5 m 2 m 2 m
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Metals and surface treatmentsUncontrolled corrosion is a recurrent problem with all ap-plications involving metals, it may lead to a reduction in theperformance and lifetime of the installation.Cable trays are mainly exposed to atmospheric corrosion.The environment in which the cable trays are installedis therefore the main criteria in the choice of surfacetreatment, or type of steel.
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GALVANIC CORROSION
COATED STEELS
PG/GS: Continuous galvanisation beforemanufacture using the Sendzimir process
continuous immersion on the steel sheets or wires. The
Electrogalvanising after manufacture
R e c o m m e n d e d
P o s s i b l eEZGS GC DC 304L 316L
normal environment
urban environment
Halogen environment
Differences in potential are expressed in millivolts.Beneath the red line, the metal involved is attacked.
PG
GS
EZ
> Ongoing protection
Zn anod
Zinc hydroxide
Fe cathod
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Wire cable trays Accessories
EZ/PG EZ/GS GC GC/DC
304L 304L & 316L 316L 316L
Corrosion is electrochemicalp h e n o m e n o n potential between or between a metal
It is important to
S t a i n l e s s s t e e l
Stainless steel 0
Nickel 180
Copper 320 140 0
Brass 400 220 80 0
Tin 550 370 230 150 0
Steel 750 570 430 350 200 0
Aluminium 840 660 520 440 290 90 0
Chromium 950 770 630 550 400 200 110 0
Zinc 1150 970 830 750 600 400 310 200 0
S t e e l
A l u m i n i u m
N i c k e l
C o p p e r
B r a s s
Partner metal
Metal involved
C h r o m i u m
Z i n c
T i n
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PG
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Hot dipped galvanised after manufacture
Geomet®
Geomet®
Epoxy
STAINLESS STEELS coating. CABLOFIL uses two austenitic stainless
Stainless steel 304 L AISI 304L – X2CrNi18.09 – 1.4307
Stainless steel 316 L AISI 316L – X2CrNiMo17.12.2 – 1.4404
316L is able to resist intergranular corrosion. This
> Decontamination of stainless steels Pickling in greasing eliminatespollutants. Passivation 2 processes.
DC
316L
304L
100
200
400
600
800
1000
1200
1400
1500
P i c k l e d
& p
a s s i v a t e d
P i c k l e d
& p
a s s i v a t e d
316L
U n -
t r e a t e d
U n -
t r e a t e d
Stainlesssteel
Carbonsteel
304L
316L
EZPGPG
GC 304L
x 4 x 5
300
GC
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Food industry safetySafety in the food processing industry is critical. Production lines must be kept clean. Eventhe smallest risk of contamination can result in operational losses and have dramaticrepercussions for public health and a company's image.
HACCP DIRECTIVES
COMPLETE FOOD SAFETY
inspections.
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AN ADAPTABLE SYSTEM
PREMIUM SERVICE
DURABILITY GUARANTEEDCABLOFIL has two low-carbon stainless steel ranges resistant to the corrosion processes or agents. As to last longer.
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PHENOMENON
THE GOLDEN RULES!
please contact our technical support service.
Electromagnetic compatibilityUnderstanding EMC involves the analysis of electromagnetic pollution between a source ofdisturbance and its victim.
Make sure electrical
to the earthing
at right angles.
Remember the separate.*
Source Coupling Victim
Metallic cable trays with excellent electricalcontinuity which are integrated into an installation'sequipotential earthing network reduce the effectsof coupling and therefore improve an electricalinstallation's EMC.
THE CABLOFIL® SOLUTION
EXCELLENT POSSIBLE
Excellent EMC performanceCable arrangement can be inspected visually.
Similar performance to wire cable trays,
but limited scope for visual inspection
Do not mix power and data cables in the same
compartment
When integrated into the earthing network, CABLOFIL's metallic cable trays help electrical installations
achieve excellent EMC levels.
EMC TESTS electrical installation.
CAUTION
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CONFIGURATION OF THE 1ST TEST:
Data cable in an external electromagnetic field
> Results and interpretations
These tests show that there is no significant differencein "Faraday cage" effect offered by wire mesh orperforated cable tray.
CONFIGURATION OF THE 2ND TEST:
Data cable alongside a power cable
> Results and interpretationsThis second test configuration confirms that metalcable trays reduce interference (wire mesh or per-forated tray).
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Cable with no metal tray (forcomparison) Cable in CABLOFIL® Cable in perforated sheet
Cable in CABLOFIL® with cover
Generation of electromagnetic interference byinjecting current into the power cable
Measurement of the interference generated in the data cable
A comparison of the impact of 3 of the 118 configurations
Interference within
the cable in dBµV
Frequency
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Cable in raceway with cover
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DEFINITION
THE IMPORTANCE OF HAVING EXCELLENT ELECTRICAL CONTINUITY
TESTED FOR ELECTRICAL CONTINUITYCABLOFIL traysTests show that CABLOFIL more than meets the 5 m /m.
CABLOFIL couplers . The test involves running an
TEST RESULTS
All CABLOFIL couplers
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Electrical continuityFundamental to providing safety to people and property, electrical continuity also plays anessential role in the EMC performance of an electrical installation.
No couplers = DANGER
Guarantee the safety of people and property:avoiding any risk of electrocution.
Couplers = SAFE
Promotes good EMC within an installation:by dissipating noise currents generated by interference.
Electromagnetic interference
The metal structureof the cable trayabsorbs some of theelectromagneticdisturbance andconverts it intonoise current.
Test configuration
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DEFINITION metallic -potential.
BENEFITS OF AN EQUIPOTENTIALEARTHING NETWORK
-
level
CABLOFIL® INTEGRATED IN THE EARTHNETWORK
Role of the protective conductor: The protective
DEDICATED ACCESSORIES
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Earth network Earthing(1) an installation is vital for the safety of people and property. Furthermore it playsan active role in EMC.
Protectiveconductor
Earth
Earth conductor
Earth rod
Grifequip: 2
Bimetal terminal: Bimetal 2
Terminal support + bimetalterminal: For earthing in
Grifequip 2:
35 mm2
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ASSESSMENT
2
SOLUTIONS
ENERGY SAVING EVALUATIONS
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Power cablesElectricity transfer generates energy losses in the form of heat. By improving the heat dissi-pation of power cables, substantial savings can be made. The open structure of CABLOFIL® maximises ventilation and therefore reduces installation and operational costs.
temperature.
63 %
77 %78 %
91 %96 %
100 %
63 %
- 10 %
- 22 % - 23 %
- 37 % - 37 %
- 4 %
-60%
-40%
-20%
0%
20%
40%
60%
80%
100%
120%
Lost energy
Useful energy
Cablofil
Perf. trayCablofil +
cover Perf. tray +
cover Plastictrunking
Metallic
conduit
Metallic
trunking
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ρ ρ x
L
S
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SHORT CIRCUITS
SHORT CIRCUIT TESTS repulsion between the power cables.
coupling 1/5th
using cleats.
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Copper oraluminium core
Insulatingcover
Sheath
In spite of the electrical protection equipment of the network, energy transfer will alwayspresent risks to people and property. CABLOFIL® is able to manage these risks with itshigh performance cable supports.
During test
CONCLUSION
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Class 1 Class 2
70 kA
100 kA
130 kA
Class
Intensity
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DATA SECURITY AND INTEGRITY
is able
MAINTAINING AND DEVELOPING THEINSTALLATION
COST MANAGEMENT
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Efficient DATA cablingIn order to manage data installations and master their complexity, it is necessary to havea high performance cabling system which has the capacity to evolve.With the relevant standards in mind, CABLOFIL® helps design, organise and arrange a varietyof cabling systems, whilst also ensuring system safety.
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DEFINITION
.
TYPES OF FIBRE OPTIC> Single-mode fibre optic
> Multi-mode, step-index fibre optic
> Multi-mode, graded-index fibre optic
ADVANTAGES
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Fibre optic data cablesThe development of fibre optics is a direct result of the growing demand for fast datatransmission between different terminals. Given its immunity to electromagnetic interferenceand its characteristics in terms of signal transmission, fibre optics are the ideal support forhigh-speed data transmission.
COMPONENTS OF A FIBRE OPTIC CABLE along the optical core
- -
ensures the optical wavesremain in the core. The against the barriers
.
Categories OS1
Diameter 9/125 µm
Throughput ≥ 10 Gbits/s
Bandwidth ≥ 25 Gbits.km
Primary cladding
Optical cladding
Protectivecovering
Opticalcore
Light ray
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Categories OM1 OM2 OM3
Diameter 62.5/125 µm 62.5/125 µm, 50/125 µm 50/125 µm
Throughput 100 Mbits/s to 1Gbit/s ≤ 1 Gbit/s ≤ 10 Gbits/s
Bandwidth for 850 nm 200 MHz.km 500 MHz.km 1500 MHz.km
Bandwidth for 1350 nm 500 MHz.km 500 MHz.km 500 MHz.km
THE CABLOFIL® SOLUTION
CF54/100
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NEW STANDARDS FOR NEW PERFOR-MANCE
The category
6 approval.The class a combination involving more than one component
COAXIAL CABLE level.
TWISTED PAIR
U/UTP the cheapest.
F/UTP
S/FTP or S-STP
Copper data cablesThe development of communications cable technology is rapidly changing and the use ofhigh-speed networks is growing exponentially. CABLOFIL® has become accepted as the idealsupport for copper communication cables (coaxial cables and twisted pairs).
Protective sheath
Metal braid
Dielectric
Copper core
Category Class Throughput Frequency
Cat. 5 D ≤ 100 Mbits/s 100 Mhz
Cat. 5e D ≤ 100 Mbits/s 155 Mhz
Cat. 6 E ≤ 1 Gbit/s 250 Mhz
Cat. 6a Ea ≤ 10 Gbits/s 500 Mhz
Cat. 7 F ≤ 10 Gbits/s 600 Mhz
Cat. 7a Fa ≤ 10 Gbits/s 1000 Mhz
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> Independent tests
> Measurements parisonpurposes is Return Loss. to return to its source.
RELIABILITY AND DURABILITY
The two major considerations for the network infrastructures are the reliability and durabilityof the installation. In order to measure the positive contribution made by CABLOFIL®, even whenoverloaded with cables, a series of independent tests were carried out.
> Test for reliability under load
Results:
base.
> Test of durability under load
Results:
CABLOFIL® not loaded
CABLOFIL® under load
Flat surface notloaded
Flat surfaceunder load
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Difference between a directive and astandard
DIRECTIVES
> The "LVD" Directive
> The "CE Marking" Directive
THE RoHS DIRECTIVE
st
> The EMC Directive 89/336/EEC, repealedby the 2004/108/EC Directive
Standards and directivesThe manufacture and use of cable trays are subject to strict and precise regulations. CABLOFIL® gives an update on the applicable texts and ensures its products are compliant.
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> The IEC 61 537 standard
CE MARKING
STANDARDSThe IEC 61 537 standard, "Cable tray systems and cable ladder systems for electrotechnicalinstallations", defines the characteristics of cable trays.
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CERTIFICATIONS FOR CABLOFIL®
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ISO 9001
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STANDARD DIN 4102-12
RECOGNISED INDEPENDENTLABORATORIES
TEST CONFIGURATION with a
Cable s are
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Fire resistanceSafety is a major concern for everyone, but can only be achieved with knowledge of how elec-trical equipment behaves in the event of a fire. CABLOFIL® has been successfully tested andproven to meet all fire-safety requirements.
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Period Certification
> 30 minutes E 30 > 60 minutes E 60
> 90 minutes> 90 minutes> 90 minutes> 90 minutes E 90
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CABLOFIL® is certified to E90 for a number of configurations that meet the requirements of datatransfer facilities designed to ensure the protection of property and people in the event of a fire.Below are 9 representative samples of the more than 20 configurations tested.
Light duty
Medium duty
Heavy duty
CF54/50
CF54/100200
CF54/300
CF54/50
CF54/50400
CF30/100
CF54/100300
CF54/150400 CF54/100400
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PFREDF
CU500
CU500
EDF600
TF8/10/12
CF54/300
CF105/400
CF105/40020 kg/m
20 kg/m
10 kg/m
P41S 300 to 1000
TF8/10/12
C41S200
CF54/150
CF54/300
C41S 400
C41S 500
CF54/400
P41S 300 to 1000
TF12
CF54/400
CF54/400
CF54/400
C41S 500
C41S 500
C41S 500
CU500
CF105/400
CF30/200
TF8
CAT 30
CF54/50
TF8
UC 50
R21S
CF54/50
CF30/100
CM50XL
TF8
CF54/100200
TF8
CSNC 150300
CF54/400
CF54/300 CF54/50
CF30/200 CF30/200
TF8
R41S
20 kg/m
20 kg/m 1 kg/m
5 kg/m 5 kg/m
TF8
TF10
TF12
CSN150
CF54/100
CSN200
CF54/150
CSN400CF54/300
1250 mm 10 kg/m 1200 mm 1 kg/m to 20 kg/m
1250 mm 10 kg/m
1200 mm 1 kg/m to 20 kg/m
1250 mm 10 kg/m 1250 mm 10 kg/m
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1200 mm 2 kg/m 1200 mm 5 kg/m 1200 mm 5 kg/m
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Fire protectionPreventing a fire from spreading not only saves lives but can significantly reduce furtherdamage to property.Fire prevention is a critical factor in an electrical installation. Specialist designers have the
task of making these installations safe and flexible whilst respecting the rules relating topassive protection.
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FIRE PROTECTION RULES
N o n - c o m
p l i a n t
C o m p l i
a n t
Compartmentation ofdifferent zones
Stop fire from spreading
Restore the integrity ofcompartments - -
the original wall.
SOLUTIONS> Conventional firestops
> EZ-Path firestop device
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PROTECTION OF PEOPLE
vex shape
As soon as EZ-Path
COMPLIANCE GUARANTEED
ADDITIONAL FEATURES AND BENEFITS rate to 0.5 m3
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EZ-Path®The relentless development of electrical and datacom installations demands readily adaptablefirestop solutions. EZ-Path®, the firestop solution from CABLOFIL®, is able to satisfy boththe requirements associated with modern buildings and those imposed by fire protectionregulations.
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GUARANTEED FIRE PROTECTION MAINTENANCE AND DEVELOPMENT
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A FAST AND FLEXIBLE SYSTEM
COST MANAGEMENT
EZ-Path®
0
0,5
1
1,5
2
2,5
3
3,5
S o l u t i o n
c o s t
initial installation 1st Modification 2nd Modification 3rd Modification 4th Modification
Mortar Intumescent foam EZ-Path
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STANDARDS AND CERTIFICATIONS
> Standard applications
Definition
Aim
Procedure Example:
> Results of each standard
> Specific marine applications
Metallic partitions in the WFRC test wall
Aim
a ship.
Procedure
Results
> Noise barrier and leakage rateThe STC rating The L Rating
The EQLA
Zone Standard Class
Europe EN1366-3 EI120
United Kingdom BS 476: Part 20 EI60
Germany DIN 4102-9 S90 or EI90
Russia NPB ( ) 237-97 IET90 or EI90
America ASTM E814 (UL1479) F rating – 4 h or E240
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1 EZP144W 250230 x
1 to 5 EZP544W 250250
120x105 mm
Ø 152 mm
120x105 mm
120x206 mm
120x308 mm
120x410 mm
120x511 mm
118
102
353
mm mm
78 97
EZD 44
DRY PARTITIONS & CONCRETE WALL Framework
Ø Coring
Cablesin place
Numberof modules
Module 44 Installation Plates* Code
Implementing Ez-Path® make an opening.
Module 22 Cat. No. Code Kit
EZDP 22
250518 45x45 mm x Ø 52 mm
DRY PARTITIONS & CONCRETE WALL
FrameworkØ Coring
Cables
in place
HORIZONTAL INSTALLATION
Module 33 Installation Plates* and accessories Code
1 EZP133R 250210
1 EZP133CW 250240 x
1 EZP133W 250110 80x80 mm x
2 EZP233W 250120 80x155 mm x
3 EZP333W 250130 80x230 mm x
4 EZP433W 250140 80x305 mm x
7 EZP733W 250170 80x535 mm x
1 EZD33E 250078
1 RCM33E 250206
80x80 mm Ø 102 mm
80x80 mm Ø 102 mm
DRY PARTITIONS & CONCRETE WALL Framework
Ø Coring
Cablesin place
Number of
modules
75
75
267
EZD 33
mm mm
56 69
mm mm
23 31
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Module Code Installation Plates* Code
EZD 33 250018 1 EZP133K 250220
Framework: Coring:
FLOOR Framework - Ø Coring
80x80 mm
Ø 102 mm
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VERTICAL INSTALLATION
MAXIMUM MODULE CAPACITY
Ø of cables (mm)
3.5 4.5 5.5 6 7.5 8 10 14 16 18 21 22 24 26 29 32 38 48 60 70 75
Modules Maximum number of cables
EZDP22 58 30 20 17 11 10 6 3
EZD33 280 140 99 75 51 45 29 12 10 6 5 5 4 3 1 1
EZD44 654 331 224 178 127 107 73 33 23 19 13 11 9 7 6 4 3 2 1 1 1
Module Code Installation Plates* Code
EZD 44 250058 1 EZP144F 250260
FLOOR Framework - Ø Coring
120x105 mm
Ø 152 mm
KIT Code Installation Plates* Code
EZDG 444 150x450 mm
4 or 8 EZG844 250280 300x450 mm
EZG1644 250290 610x450 mm
FLOOR Framework
EZD444MB CM250058
118
353
408
EZD 444 MB 250088
Number of
modules
Number of
modules
Number of
modules
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SELECTED REFERENCES> Energy
> Service sector
> Heavy industryChina National Petroleum Corp. – China Lukoil – RussiaNoble Drilling Services – Singapore
IN CABLOFIL® THEY TRUST
Heathrow Airport, England, Terminal 5 (T5)
> Marine
> Infrastructure
> Processing industries Samsung Electronics – South-KoreaMT MembraTec – Denmark
Manufacturing and distribution centre,Nestlé Nespresso S.A. venture. managers love which it can be explains Jacques electrotechnicalimplementation atthe Nespresso site.
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References
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CABLOCAD AUTOCAD®. It is a comprehensive resource containing all
CABLOSOFT -
e-CATALOGUE
3D MODELLING using interactive
Decision-making softwareCABLOFIL® has integrated 4 types of decision-making software to guide users throughoutevery stage of the process, from design through the creation of the bills of material.
> CABLOSOFT: to recommend a solution> CABLOCAD: to help design installations> e-CATALOGUE: to put together a technical specification and generate a request for quotation> 3D MODELLING: CABLOFIL installations can be modelled in 3D by Intergraph Software
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DESCRIPTION
Surface treatments for wire cable trays and related accessories
2
PERFORMANCE LEVELSWire cable trays:
th
Couplers:
Supports: -
Earthing:
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Specifications for power and data cablesupportsWelded steel wire cable trays shall comply with the description and performance levelsdescribed below.
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DESCRIPTION
connecting the earthing cable.
PERFORMANCE LEVELSFirestop
SPECIFICATION ® CABLOFIL®.
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Specifications for the firestop caulking ofcable pathwaysAfter feeding electrical cables through a wall, the integrity of firestop walls must, withoutexception, be restored using a firestop product that offers at least the same level of protection
as the original walls. Firestop products will comply with the description and performancelevels described below.
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3 1 2 8 8
6
1 2 / 1 1 - R C S D I
J O N B
5 6 2 0 0 5 4 4 7 - 1 5 M
Europe
Americas
Asia/Middle East
Africa
Oceania
International