Marine cables GERDA-KSd (TU 3586-009-76960731-2007)

flexible, flame-retardant, with insulation and sheath made of polymer materials,
shielded and unshielded, armored and non-armored, including fire-resistant

Cables comply with the standards:
- Rules of the Russian Maritime Register of Shipping
  - “Rules for the Classification and Construction of Sea-going Ships. Part XI. Electrical Equipment”
  - “Rules for Technical Supervision during the Construction of Ships and the Manufacture of Materials and Products for Ships. Part IV. Technical Supervision of Product Manufacturing”
- Rules of the Russian River Register,
- IEC Standards: IEC 60092-350, IEC 60092-353,
- IEC 60092-360, IEC 60092-376.
Application
The cables are designed for fixed installation in power, signaling, control, communication, lighting, and inter-device connection circuits operating at a nominal AC voltage (U₀/U) with a frequency of up to 400 Hz:
- up to 0.15/0.25 kV (or DC voltage up to 0.375 kV),
- up to 0.6/1 kV (or DC voltage up to 1.5 kV).
The cables can be used in automation systems:
- for connecting devices with a “current loop” interface (4-20mA, HART),
- for forming digital information buses (in the frequency range up to 1 MHz),
- in Modbus, Foundation Fieldbus, Profibus systems, and others requiring a “twisted pair” as a data transmission channel,
- as measuring wires for resistance thermometers (twisted “pairs,” “triples,” and “quadruples” for 2-wire, 3-wire, and 4-wire connection schemes).
The cables can be used in circuits of critical devices.
Fire-resistant “FR” cables are designed for connecting devices that must remain operational in fire conditions: emergency signaling; fire extinguishing systems; fire detection signaling; warning signaling for fire suppression system activation; control devices for fire doors with position indicators; control devices for watertight doors with position indicators and warning signaling; emergency lighting; command and broadcasting systems; low-positioned lighting; remote emergency shutdown of systems whose operation may contribute to the spread of fire and/or explosion.
The cables can be used on sea-going vessels of unrestricted navigation areas, river fleet vessels, coastal and floating structures. They can be installed outdoors, in indoor spaces, channels, tunnels, underground (trenches), including areas exposed to stray currents. The cables can be installed in hazardous areas of all classes (subject to the requirements of GOST IEC 60079-14-2013) and used in intrinsically safe electrical circuits. Tables 5 and 6 show the maximum capacitance Cc and inductance Lc values of the cables at a frequency of (1.0±0.1) kHz at a temperature of 20°C, with the measurement methodology corresponding to GOST IEC 60079-14-2013.

Cable design

Conductors
GERDA-KSd cables are manufactured with multi-wire copper conductors or tinned copper “l” conductors (GOST 22483) of class 5. Sector-shaped conductors “ms” with cross-sections from 50 to 240 mm² belong to class 2.
The nominal cross-section of twisted conductors, pairs “x2”, triplets “x3”, and quads “x4” is specified in Table 1. By agreement with the customer, cables can be manufactured with conductors of cross-sections ranging from 0.50 to 35 mm² of class 2 flexibility according to GOST 22483.
In fire-resistant “FR” cables, a wrapping of two mica-containing tapes is applied over the current-carrying conductors, preventing short circuits between them in case of fire.
The conductor insulation can be made of the following materials (see Table 2):
- “P” — halogen-free polymer composition,
- “Ps” — cross-linked polyethylene,
- “T” — thermoplastic elastomer.
The marking of insulated conductors can be color-coded or numeric (Arabic numerals, with a spacing of no more than 50 mm). The preferred insulation color for conductors twisted into a common core is specified in Table 3.
Conductors with cross-sections from 0.35 to 2.5 mm² can be twisted into pairs “x2”, triplets “x3”, or quads “x4”.
Cables with a common conductor twist may include one grounding conductor “(PE)” in yellow-green color.
Individual Shield
In 0.15/0.25 kV cables, each conductor (pair, triplet, quad) can have an individual shield:
- “E” — wrapping with aluminum foil tape (alumoflex) with a multi-wire tinned copper drain wire (drain wire construction is given in Table 4),
- “Em” — copper wire braid,
- “El” — tinned copper wire braid,
- “EEl” — aluminum foil tape wrapping covered with a tinned copper wire braid,
- “Emf” — copper foil tape wrapping with a multi-wire tinned copper drain wire.
In 0.6/1 kV cables, each conductor can have an individual “Em” or “El” shield.
An insulating polymer film is applied over each individual shield to prevent electrical contact between adjacent shields. By agreement with the customer, an extruded layer of polymer material identical to the sheath material can be applied over each individual shield.
Core
In cables with a common conductor twist exceeding 10 mm², the internal space between the conductors is filled with a cord. A water-blocking tape is applied over the cable core to prevent longitudinal moisture penetration in case of external sheath damage.
Overall Shield
Over the water-blocking tape wrapping, an overall shield can be applied:
- “E”, “Em”, “El”, “EEl”, “Emf” — in 0.15/0.25 kV cables;
- “Em”, “El” — in 0.6/1 kV cables, with an extruded inner sheath applied under the overall shield.
Filler
To provide a round shape to the cable and fill the outer gaps between the conductors, the following is applied over the overall shield or water-blocking tape:
- an extruded separation layer — in non-armored cables,
- an extruded inner sheath — in armored cables.
Armor
Cables can have armor:
- “K” — braid of galvanized steel wires with a diameter of (0.30-0.40) mm,
- “B” — galvanized steel tapes with a thickness of (0.20-0.30) mm.
Outer Sheath
The outer sheath can be made of the following materials (see Table 2):
- low-fire-hazard PVC plastic compound,
- halogen-free polymer composition,
- thermoplastic elastomer.
The color of the cable’s outer sheath is determined at the time of order. If not specified, the sheath is manufactured in black.

Designation for ordering

Individual shielding of each pair¹
	without individual shielding
E	aluminum foil film (alumoflex)²
Em	braid of copper wires
El	braid of tinned copper wires
EEl	braid of tinned copper wires applied over alumoflex²
Emf	copper foil film²

Conductor cross-section, mm²

0.35; 0.50; 0.75; 1.0; 1.5; 2.5; 4; 6; 10; 16; 25;
35; 50; 70; 95; 120; 150; 185; 240; 300; 400

50ms; 70ms; 95ms; 120ms; 150ms; 185ms; 240ms

Number of cores (pairs, triples, quadruples)

1…61

1…44 х 2

1…27 х 3

1…14 х 4

Tinning of the conductor
	non-tinned conductor
l	tinned conductor

Armor under the outer sheath
	without armor
K	braid of galvanized wires with a diameter of (0.30-0.40) mm
B	tape armor made of galvanized steel strips with a thickness of (0.20-0.30) mm

GERDA
–
KSd

ng(A)

6×4

1.0

El

T

El

0.6/1

Fire hazard rating

ng(A)

ng(A)-LS

ng(A)-HF

ng(A)-FR

ng(A)-FRLS

ng(A)-FRHF

Presence of grounding conductor (only for cables with overall conductor twisting)
	without grounding conductor
(PE)	grounding conductor

Insulation material of conductive cores
P	polymer compounds, halogen-free
Ps	cross-linked polyolefin
T	thermoplastic elastomer

Nominal voltage U₀/U

0.15/0.25 kV

0.6/1 kV

Overall shield over the conductor core
	without overall shield
E	aluminum foil tape (Alumoflex)²
Em	braid of copper wires
El	braid of tinned copper wires
EEl	braid of tinned copper wires applied over Alumoflex²
Emf	copper foil tape²

Note:

¹ all individual shields are electrically insulated from each other by a polymer film

² shield only for cables 0.15/0.25 kV

Example of cable designation when ordering
Cable GERDA-KSd ng(A)-LS 3×2.5 PsEm – 0.15/0.25 TU 3586-009-76960731-2007	Ship cable with three copper conductors of nominal cross-section 2.5 mm², with cross-linked polyethylene insulation, overall shield in the form of a braid of copper wires, in a PVC plastic sheath with reduced fire hazard, for nominal voltage 0.15/0.25 kV
Cable GERDA-KSd ng(A)-HF 2x2x1.0l EPK – 0.15/0.25 TU 3586-009-76960731-2007	Ship cable with two pairs of tinned copper conductors of nominal cross-section 1.0 mm², with individual shields in the form of an aluminum foil wrap, armored, with insulation and sheath made of halogen-free polymer compositions, for nominal voltage 0.15/0.25 kV
Cable GERDA-KSd ng(A) 4×16 ElTEl – 0.6/1 TU 3586-009-76960731-2007	Ship cable with four copper conductors of nominal cross-section 16 mm², with individual and overall shields in the form of a braid of tinned copper wires, without armor, with insulation and sheath made of thermoplastic elastomers, for nominal voltage 0.6/1 kV

Table 1. Nominal conductor cross-section, number of conductors, pairs, triples, and quads

Structural element	Nominal conductor cross-section, mm²	Number of conductors, pairs, triples, quads	Nominal voltage, kV
			AC (U₀/U)	DC
Pair (x2)	0.35; 0.50; 0.75; 1.0; 1.5; 2.5	1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 24, 27, 30, 37, 40, 44	0.15/0.25	0.375
Triple (x3)		1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 24, 27
Quad (x4)		1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14
Conductor	0.35; 0.50; 0.75; 1.0; 1.5; 2.5	1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 24, 27, 30, 37, 40, 44, 48, 52, 61
	1.0; 1.5; 2.5	1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 24, 27, 30, 37	0.6/1	1.5
	4; 6; 10	1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 13, 14
	16, 25, 35, 50, 70, 95, 120, 150, 185, 240	1, 2, 3, 4, 5
	50ms, 70ms, 95ms, 120ms, 150ms, 185ms, 240ms	3, 4, 5
	300, 400	1
Note: “ms” — indicates sector-shaped conductors

Table 2. Fire hazard rating depending on sheath and insulation material

Insulation material designation	Fire hazard rating	Description of sheath and insulation material, as well as cable type according to Fire hazard rating (per GOST 31565-2012)
Ps	ng(A)-LS	cables with cross-linked polyethylene insulation, with a PVC sheath of reduced fire hazard, do not propagate fire in group installations under category A, with reduced smoke and gas emissions
	ng(A)-FRLS	fire-resistant cables with cross-linked polyethylene insulation, with a PVC sheath of reduced fire hazard, do not propagate fire in group installations under category A, with reduced smoke and gas emissions
	ng(A)-HF	cables with cross-linked polyethylene insulation, with a halogen-free polymer sheath, do not propagate fire in group installations under category A and do not emit corrosive gaseous products during combustion and smoldering
	ng(A)-FRHF	fire-resistant cables with cross-linked polyethylene insulation, with a halogen-free polymer sheath, do not propagate fire in group installations under category A and do not emit corrosive gaseous products during combustion and smoldering
P	ng(A)-HF	cables with insulation and sheath made of halogen-free polymer compositions, do not propagate fire in group installations under category A and do not emit corrosive gaseous products during combustion and smoldering
P	ng(A)-FRHF	fire-resistant cables with insulation and sheath made of halogen-free polymer compositions, do not propagate fire in group installations under category A and do not emit corrosive gaseous products during combustion and smoldering
T	ng(A)	cables with insulation and sheath made of thermoplastic elastomers, do not propagate fire in group installations under category A
T	ng(A)-FR	fire-resistant cables with insulation and sheath made of thermoplastic elastomers, do not propagate fire in group installations under category A

Table 3. Preferred insulation color for cables twisted from conductors

Number of conductors in the cable¹	Conductor insulation color²
	Conductor sequential number
	1	2	3	4	5
2	brown	blue	–	–	–
3	brown	black	gray	–	–
3	brown	blue	green-yellow³	–	–
4	brown	black	gray	blue	–
4	brown	black	gray	green-yellow³
5	brown	black	gray	blue	green-yellow³
6 — 61	white with numeric marking (with the last grounding conductor in green-yellow³)
¹ The insulation of single-core cables can be of any color. ² Other insulation color combinations are allowed upon agreement with the customer. ³ The green-yellow grounding conductor is used when the cable order code includes the “(PE)” index.

Table 4. Preferred drainage conductor design

Nominal cross-section of current-carrying conductors in the cable, mm²	Number and nominal diameter of wires in the drainage conductor, mm
0,35	7×0,26
0,50	7×0,26
0,75	7×0,30
1,0	7×0,37
1,5	7×0,37
2,5	7×0,40

Table 5. Cable capacitance at a frequency of (1.0±0.1) kHz at a temperature of 20°C

Nominal conductor cross-section, mm²	Mutual capacitance, nF/km, not exceeding, for cables with insulation
	Made of cross-linked polyethylene		Made of halogen-free polymer composition or thermoplastic elastomer
	Between conductors	Between conductor and screen	Between conductors	Between conductor and screen
0,35 и 0,50	80	200	130	260
0,75 и 1,0	90		150
1,5 и 2,5	100		180

Table 6. Cable inductance at a frequency of (1.0±0.1) kHz at a temperature of 20°C

Nominal cross-section of conductive cores, mm²	Inductance, mH/km, not more than
0,35 и 0,50	0,9
0,75 и 1,0	0,8
1,5 и 2,5	0,7

Table 7. Permissible conductor heating temperature

Insulation material	Permissible conductor heating temperature, ºC
Insulation material	Continuous permissible	Overload mode	Maximum during short circuit	Non-ignition condition during short circuit
Cross-linked polyethylene	90	130	250	400
Halogen-free polymer composition	90	130	200	350
Thermoplastic elastomer	125	150	200	350

Universal marine cable GERDA-KSd