Features of single core cables for wind applications

Some basic components of a wind turbine are as follows:

1.1 Nacelle

The nacelle houses the key components that convert the kinetic energy of the wind into mechanical energy to generate electricity. It is mounted on top of a tall steel or concrete tower, which can be up to 50 ft tall and weigh up to 300 tons or more, depending on the manufacturer and rated capacity.

The blades are essential components of a wind turbine, capturing wind energy and converting it into kinetic energy in the hub. The rotor, which consists of the blades, plays a vital role in generating electricity.

The hub is the center of the rotor, where the rotor blades are attached. Typically made of cast iron or steel, the hub redirects the energy from the blades to the generator.

1.2 Loop

In a wind turbine, a "loop" typically refers to the loops of cables or wiring systems designed to provide enough length and flexibility as the turbine operates. As the turbine blades rotate and other components move, the cables need to be able to stretch or shift to avoid being overly strained or damaged. These loops are often arranged in areas like the nacelle (the housing for the engine) or the tower of the turbine to ensure that the cables remain stable and safe throughout the turbine's operation.

1.3 Wind tower and base

The wind tower supports the nacelle and is typically made of steel. The taller the tower, the more wind energy can be captured, resulting in greater electricity generation. The base stabilizes the wind turbine, anchoring it securely to the ground.

1.4 Lift

During installation, repair, and maintenance, all operations occur within the wind tower. As a result, most wind turbines are equipped with additional corridors and elevators to transport spare parts and small tools into the nacelle.

1.5 Connectors

The complex design of wind turbines necessitates a variety of cables to perform different functions. To fasten the installation and maintenance of turbine systems, designers are increasingly adopting "plug and play" solutions. The objective is to enhance the ease of installing and maintaining cable systems, thereby accelerating and simplifying the overall process of wind power system installation and maintenance.

3.1 Abrasion resistance

In wind turbine systems, single core cables are used in nacelles, generators, and wind towers. The twisting motion during turbine operation can wear down the cable's outer layer, leading to insulation damage and eventually affecting the copper conductors. Therefore, single core cables used in wind turbines need to be made of thermoplastic elastomer or PUR materials, offering enhanced protection for the cables. Additionally, the outer layer of the single wire should have low adhesion to ensure that the cables can slide smoothly against one another.

3.2 High-temperature resistance

Wind turbines are installed in diverse environments: on land, offshore, or in high-altitude areas - often operating in extreme temperatures with wide temperature fluctuations. Certain single core cables are made from specialized synthetic materials that can function effectively in a temperature range from -55°C to +145°C.

3.4 Oil resistance

Many mechanical components in wind turbines, such as gearboxes, bearings, and control systems, require lubricating and hydraulic oils to function. These oils can leak or spread to surrounding areas, coming into direct contact with the power cables. Prolonged exposure to oil can weaken, crack, or harden the cable sheath, leading to cable failure, safety risks, and reduced lifespan of the cables. To address this, HELUWIND WK single wire products undergo extensive testing for long-term durability, beyond the standard VDE or UL testing procedures (Oil Res I, Oil Res II).

3.5 Single core cables need to be halogen-free

Some wind turbines are installed in remote or offshore locations where access for maintenance and troubleshooting is difficult. In case of fire, a halogen-free cable system can limit fire spread, protect the electrical system, and reduce risks to people and equipment. Additionally, halogen gases can form acids when exposed to moisture in the air, causing corrosion of metal components and damage to surrounding systems. In wind turbines, this is especially critical as the electrical and control systems need protection from corrosive effects, thereby enhancing the lifespan and reliability of the equipment.

>>Find out more: HELUKABEL's portfolio of single core cables

Various versions of the HELUWIND® WK POWERLINE ALU single core cables are suitable for a wide range of energy and plant engineering applications. Due to their high flexibility and low weight, installation times on-site can be significantly reduced. HELUWIND® WK POWERLINE ALU products can only be processed using the HELUKABEL® C8 crimping method, which is certified according to IEC 61238-1 Class A. Notably, the 1.8/3 kV version is suitable for direct burial, while the ROBUST version offers high resistance to abrasion and mechanical stress.

4.2 H05Z-K and H07Z-K / 07Z-K single core cables

These are two single core cables that are halogen-free, flame-retardant, ozone-resistant, and suitable for applications that require low smoke and corrosive gas emissions in the event of a fire. In addition, these two types of cables come in a variety of colors and cross-sections, making it easy for users to distinguish between wire types according to function such as phase wire, neutral wire, earthing wire, etc.

Datasheet of H05Z-K

Datasheet of H07Z-K / 07Z-K

4.3 FIVENORM H07V2-K / 07V2-K / H07V-K / 07V-K single core cables

FIVENORM single core cables meet popular quality standards such as HAR - UL AWM - UL MTW - CSA AWM - CSA TEW, suitable for use worldwide. In addition, this cable line also has many color options, cross-section ranges from 1.5 - 150 mm², voltage range up to 1000 V (AC) and 1250 V (DC).

4.4 HELUTHERM® 145 and HELUTHERM® 145 UL/CSA 600V single core cables

HELUTHERM® 145 and HELUTHERM® 145 UL/CSA 600V single conductors have an operating temperature range of -35°C to +120°C (moving applications) and -55°C to +145°C (fixed installations). Available in a wide range of colors and cross sections, these are two heat-resistant single conductors for lighting, heating, electrical machinery, switching systems and distribution units in industrial equipment as well as building plant and machinery; suitable for installation in conduits, above and below plasterboard, in closed ducts, as well as for traffic systems and outdoor applications.