Continuous High-Flex Cable for Automated Systems flexlife-20 cable designs

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1 Take advantage of the proven, 20 million flex cycle capabilities of any of flexlife-20 cable designs and eliminate the risk of plant downtime due to cable failure. Continuous High-Flex Cable for utomated Systems Shorten Installation Time with Quick Disconnect Options Reduce Equipment and Plant Downtime Provide Higher Reliability with Longer Cable Life Lower Maintenance and Operating Costs

2 TURCK Industrial Connectivity Products High Performance Wiring Solution for utomated Systems The selection of high performance cable for automated equipment, often an afterthought in system design, is an effective solution that can reduce costly plant downtime due to cable failure. s a manufacturer of connectivity, sensing and network products, TURCK takes plant downtime seriously. t TURCK, we create specific cable and wiring designs for automated robotic, material handing and assembly systems used for product manufacturing and processing applications in the automotive, food/beverage, biotechnology and semiconductor industries. These plants can experience downtime costs from hundreds to thousands of dollars per minute, and depend on the reliability of TURCK products to keep their automated systems running. We uild "Flex" into Every Cable We Design flexlife-20 Our standard PVC and PUR control cables are designed to meet a minimum of 2 million flex cycles. These control cables are still in use years and 7 to 8 million flex cycles later. flexlife-20, our latest innovation in high flex cable design, guarantees increased performance to 20 million cycles of continuous flexing, bending and twisting motion found in C-track, robotic and other motion systems. Your Choice: flexlife-20 Spooled Cable or Molded Connector Cordsets Specified by a major automotive manufacturer for all robotic applications. Selecting the best cable design can be confusing and costly. Some cable manufacturers assign a different cable to each axis of motion, which may not accurately reflect your application needs. flexlife-20 cable provides the same superior performance for all types of motion. Choosing flexlife-20 takes the risk out of specifying for motion applications. minifast Spooled Cable versafast 7/8", 1" and 1-1/8" UN thread connector, 2 to 12-pins for C and DC systems up to. M1 connector, 5-8,, 12 and 14-pins for C and DC systems up to 125 V. multifast eurofast M23 connector, 12 and -pins for C and DC systems, wire consolidation and multi-pin devices. M12 connector in 3-, 8, and 12-pins for DC systems up to 300 V standard to extra heavy duty designs. picofast M8 connector in 3, 4 and -pins for C and DC systems, snap-lock or threaded metal coupling nut. 1 TURCK Inc Campus Drive Minneapolis, MN pplication Support: Fax: (73)

3 Industrial utomation Design So Revolutionary it Outperforms ll Other Robotic Cable! The superior performance of flexlife-20 is due to a unique, low-stress cable construction using custom compounded TPE and PUR. The flexlife-20 design generates less heat while flexing, which prevents deformation and stress to the cable. Other robotic cables often contain high amounts of fillers and less of the high cost base polymer as a cost savings measure. This compromises the flexing properties of the cable, lowering performance and product life. Continuous Flex Products for Every Industry TPE or PUR jacket PTFE flex facilitator Polyester elastomer lloy conductors The flexlife-20 design includes finely stranded, custom alloy conductors and proprietary blended thermoplastic insulation and cable jacket compounds. flex facilitator made of Teflon is wrapped around the conductors preventing heat build-up due to friction between the cable jacket and conductors during the flex cycle. TURCK's flexlife-20 continuous flex cable offers a wide range of standard and custom connectivity solutions, from machine tools and automotive assemblies to medical devices and semiconductor manufacturing. Industry Exclusive - 20,000,000 Cycle Warranty To avoid costly downtime of your manufacturing operations, you need reliable cables and connectors. That is why TURCK has spent over 5 years developing flexlife-20 cables and why TURCK can offer a 20,000,000 cycle warranty. If your cordset product made with flexlife-20 cable fails before 20,000,000 cycles, we will replace it. The warranty becomes effective when you complete the 20,000,000 Cycle Warranty Registration and return it to TURCK. TURCK authorized representative will visit your site to make any recommendations necessary on the proper installation of your cordset product. Contact TURCK at for the full details of the warranty. TURCK Inc Campus Drive Minneapolis, MN pplication Support: Fax: (73)

4 TURCK Industrial Connectivity Products flexlife-20 Cable Specification Guidelines for Motion Systems utomation systems have special cable design requirements. When making a cable selection it is essential to consider the operating environment, the type of motion and any special mechanical requirements of the system. Understanding the environmental factors of the application will help determine cable insulation materials, bend radius and other essential cable characteristics. Environmental Operating Conditions utomation systems operate under a variety of environmental conditions that require cable insulation to be resistant to extremes in temperature, chemicals and abrasion. TURCK Thermoplastic Elastomer (TPE) is a specially blended polymer of high molecular weight that provides the flexibility of PVC with the wear and chemical resistance of rubber. Excellent for use in most automated applications. TURCK Polyurethane (PUR) provides the highest abrasion resistance and is impervious to hydraulic fluids and hydrocarbons. Recommended for use in automotive manufacturing applications. Typical Flexing Motions end Flexing The cable flexes back and forth with one end of the cable in a stationary position. This type of motion is often the result of installation around fixed objects in addition to the applications listed below. ll flexlife-20 Cables Provide: Excellent oil resistance Cold temperature flexibility to C (F) Flame retardant designs - CS FT-1 Meets UL and CS approvals Special Mechanical Requirements Mechanical considerations for applying the proper bend radius, termination and strain relief need to be observed from system design through installation and first flex cycle. The best method of termination and stress relief for flex cable is molded connectors. Cordsets with molded connecters provide dependable termination and built-in strain relief. Specifying cable with molded connecters will provide added value later by reducing installation time, preventing miss-wiring and making system changes and maintenance a more efficient process. Continuous Flex The cable is rolling or flexing back and forth in a linear motion. C-track is a typical continuous flex application. Torsional Flex (longitudinal twisting) The cable is twisting and flexing continuously in a clockwisecounter clockwise fashion. ngles can range from 90 to 30. Torsional flexing is typically found in robotic applications. 3 TURCK Inc Campus Drive Minneapolis, MN pplication Support: Fax: (73)

5 Industrial utomation Proper installation techniques will maximize the full service life of continuous flex cable. Good installation practices include adhering to local codes and following the installation recommendations of cable, conduit, cable tray and flexible carrier manufacturers. Due to its high quality construction, flexlife-20 can be directly installed into C-tracks and other applications without prior steps to un-stress the cable. Many cable manufacturers recommend suspending or laying out cable prior to installation for a minimum of 24 hours. With flexlife-20, you can skip this step and shorten the installation time. y installing cable with connectors, you can be up and running even faster. Whether you use cordsets or spooled cable, the following installation guidelines should be observed. Installing Spooled Cable Unwind cable from the outer layer of the spool without twisting or creating loops. Do not pull directly from a fixed reel. end Radius and Free Movement of Cable The recommended bend radius for flexlife-20 is x cable diameter. The cable must be able to move freely along the bend radius when installed in C-tracks and other motion applications. Check for adequate freedom of movement through several test flex cycles to verify proper installation. Cables of various diameters installed in cable carriers need a minimum space allowance of % of the cable diameter and even weight distribution. flexlife-20 will not adhere to other cables in a cable carrier. Cables secured with ties to a stationary support or bundled together need to slide freely under the tie without pinching conductors or cables. Whether a molded connector or hardwired cable is used, each end of the cable needs proper strain relief. Cable undling Techniques end Radius for Moving pplications C-Track Providing sufficient bend radius will allow the cable to absorb the energy of bending over a greater portion of its length, increasing its effective working life. Small increases in the radius of the bend can produce substantial increases in cable life. TURCK Inc Campus Drive Minneapolis, MN pplication Support: Fax: (73)

6 TURCK Industrial Connectivity Products flexlife-20 is available in 30, 0 and 200 meter lengths in spooled, self-feeding packages, or as cordsets, with a choice of industry standard molded connectors. flexlife-20 cable specifications, part numbers and suitable connector styles are listed below. Consult TURCK's Connectivity Catalog for more information on connector styles and cordset options or contact TURCK application support at for custom designs. flexlife-20, TPE cable styles, UL and CS approvals, operating temperature,+c (+221 F), cold flexibility C (F),. flexlife-20, PUR cable styles, UL and CS approvals, operating temperature, +90 C (+4 F), cold flexibility C (F),. eurofast flexlife-20 TPE FL-20 Cable No. Of Cond. WG Jacket ID Number Ship Wt. (lbs) Conductor Colors UL CS Type Temp. ( C) Connector mm OD, TPE, GY, FL mm OD, 5.7 mm OD, TPE, GY, FL mm OD, TPE, GY, FL mm OD, TPE, GY, FL mm OD, TPE, K, FL mm OD, TPE, GY, FL mm OD, TPE, K, FL-20, 7.0 mm OD, TPE, K, FL-20 RF M RF M RF M RF M RF5098-0M RF M RF M RF M RF M RF M RF M RF M RF509-30M RF509-0M RF M RF M RF M RF M RF M RF M RF M RF577-30M RF577-0M RF M RF M RF M RF M N, U, K K, U, WH, N N, WH, U, K GY, N, WH, U, K GY, N, WH, PK, U, K GN, YE, GY, N, U, WH U, WH, N, GN, YE, GY, PK, RD GN, GY, OG, YE, TN, WH, RD, N, PK, U RD, GN, OG, TN, GY, VT, YE, K, WH, N, U, PK, C, C ) Standard M12 ) "C" Style Medium M12 C) "G" Style Large M12 flexlife-20 cables are available in 30, 0 or 200 meter lengths, delivered to you in a spooled, self-feeding package or as a complete molded cordset. Consult factory for cordset options. 5 TURCK Inc Campus Drive Minneapolis, MN pplication Support: Fax: (73)

7 Industrial utomation minifast flexlife-20 TPE FL-20 Cable No. of Cond. WG Jacket ID Number Ship Wt. Conductor Colors UL CS Type Temp. ( C) Connector mm OD, 7.2 mm OD, 7.2 mm OD, 8.5 mm OD, 9. mm OD, 9. mm OD,.5 mm OD, RF M RF M RF M RF M RF5098-0M RF M RF M RF M RF M RF544-30M RF544-0M RF M RF549-30M RF549-0M RF M RF550-30M RF550-0M RF M RF551-30M RF551-0M RF M N, U, GN/YE K, U, WH, N K, U, GN/YE, N, WH K, WH, RD, OG, U, GN K, WH, RD, OG, GN, U, WH/L RD, GN, OG, U, WH/K, K, RD/K, WH U, RD/K, GN/K, WH, RD, GN, K, WH/K, OG C 1.5 mm OD, RF552-30M RF552-0M RF M OG/K, RD, GN, OG, U, WH/K, RD/K, GN/K, K, WH C mm OD, RF M RF M RF M OG, U, WH/K, RD/K, GN/K, OG/K, U/K, K/WH, GN, WH, RD, K C ) Standard 7/8" ) "" Style Heavy Duty 1" C) "C" Style Heavy Duty 1-1/8" flexlife-20 cables are available in 30, 0 or 200 meter lengths, delivered to you in a spooled, self-feeding package or as a complete molded cordset. Consult factory for cordset options. TURCK Inc Campus Drive Minneapolis, MN pplication Support: Fax: (73)

8 TURCK Industrial Connectivity Products picofast flexlife-20 PUR-FL-20 Cable No. Of Cond. WG Jacket ID Number Ship Wt. (lbs) Conductor Colors UL CS Type Temp. ( C) Connector mm OD, PUR, K, FL mm OD, PUR, K, FL mm OD, PUR, K, FL-20 RF511-30M RF511-0M RF M RF M RF M RF M RF582-30M RF582-0M RF M N, U, K WM 202 N, WH, U, K WM 202 N, WH, U, K, GY, PK WM ,,, ) M8 Threaded ) M8 Snap-Lock versafast flexlife-20 TPE FL-20 Cable No. Of Cond. WG Jacket ID Number Ship Wt. Conductor Colors UL CS Type Temp. ( C) Connector mm, OD 7.0 mm, OD TPE, K, FL mm, OD TPE, K, FL-20 RF M RF M RF M RF M RF M RF M RF M RF M RF M K, WH, RD, OG, U, GN, WH/K GN, GY, VT, YE, K, WH, RD, N, PK, U RD, PK, YE, GN, WH, U, N, OG, K, GY, TN, VT mm, OD TPE, K, FL-20 RF500-30M RF500-0M RF M N, OG, TN, U, GN, PK, RD, WH, K, RD/U, GY/N, YE, GY, VT mm, OD TPE, K, FL-20 RF M RF M RF M N, TN, U, YE/N, GN, WH/YE, PK, N, GN, K, WH/GN, RD/U, GY/PK, OG, GY, RD, WH, VT, GY/N, YE ) M1 Threaded flexlife-20 cables are available in 30, 0 or 200 meter lengths, delivered to you in a spooled, self-feeding package or as a complete molded cordset. Consult factory for cordset options. 7 TURCK Inc Campus Drive Minneapolis, MN pplication Support: Fax: (73)

9 Industrial utomation multifast flexlife-20 TPE FL-20 Cable No. Of Cond. WG Jacket ID Number Ship Wt. Conductor Colors UL CS Type Temp. ( C) Connector mm OD, RF M RF M RF M U/WH, GN/YE, N, U, WH, OG, YE, GN/WH, N/WH, GY, PK, RD mm OD, RF M RF5091-0M RF M (22 = WH, GN, YE, GY, PK, RD, K, VT, GY/PK, RD/U, WH/GN, N/GN, WH/YE,YE/N,WH/GY, GY/N), (18 = N, U, GN/YE) mm OD, PUR, YE, FL-20 RF M RF5092-0M RF M 3 12 WH, GN, YE, PK, RD, K, VT, U, GY, N, GY/N, YE/N, GN/YE, GY/PK, RD/U, N/GN, WH/GN, WH/YE, WH/GY WM ) M23 Threaded flexlife-20 cables are available in 30, 0 or 200 meter lengths, delivered to you in a spooled, self-feeding package or as a complete molded cordset. Consult factory for cordset options. TURCK Inc Campus Drive Minneapolis, MN pplication Support: Fax: (73)

10 TURCK Industrial Connectivity Products flexlife-20 Tests to 20,000,000 Flex Cycles and eyond Our Flex Testing Protocol is designed to replicate the application environment continuous flex cables would endure while installed in the most abusive automated systems. pplications such as robotic assembly in automotive plants, pick-and place machines, packaging equipment and automated medical test equipment where the combined multi-axis motions of twisting, bending and continuous flexing occurs 24/7 for many millions of cycles. Torsional Flex Test The cable is subjected to 30 torsion twisting while the cable rolls back and forth over a pulley at a rate of 30 cycles per minute. This test runs continuously to replicate an abusive robotic application. end Flex Test This test simulates cable installed to fit around devices where the cable repeatedly bends on a 180 plane, back and forth over a -8 inch radius at a rate of 30 cycles per minute. This tic toc motion simulates many different extreme motion applications. TURCK flexlife-20 cables are tested on our internal cable 'torture' machine. Test parameters and results are as follows. Note that the cables are still in test as there have not been any failures yet! See test in motion at Rolling/Torsional Test (Twist and Roll) Parameters ending Radius x OD Travel Distance 1.0 ft (30.5 cm) Cycle Time 2 seconds cceleration Varies up to 2 ft/s 2 (792 cm/sec 2 ) Temperature Range +1 C to +23 C (+1 F to +73 F) Speed of Travel.5 to 13 ft/s (8 39 cm/s) Torsional Stress ± /ft (±520 /meter) Results Conductor 24 WG 31 million (still going) 12 Conductor 18 WG 3 million (still going) ending Flex Test (Tic-Toc) Parameters ending Radius x OD ending ngle ±90 from horizontal Cycle Time 2 Seconds cceleration Varies up to 2 ft/s 2 (792 cm/s 2 ) Temperature Range +1 C to +23 C (+1 F to +73 F) Results Conductor 24 WG 33 million (still going) 12 Conductor 18 WG 38 million (still going) Conductor 18 WG 30 million (still going) 9 TURCK Inc Campus Drive Minneapolis, MN pplication Support: Fax: (73)

11 Guaranteed for 20,000,000 cycles Extend your service intervals with flexlife -20 cordsets 20-million cycle warranty and the most durable connectors virtually eliminate unplanned downtime. In two years of continuous torsion stress and flexing tests, the new flexlife-20 outperformed every other cable in robotic, continuous flex, bending, twisting, high speed and C-track applications. Select from connector styles for cordsets in any length - M8 picofast - M12 eurofast, - M1 versafast, - 7/8-1 UN minifast, UN minifast, - 1 1/8-1 UN minifast - M23 multifast Cable diameters from 4.4 to 12.2 mm and gauges from 1 to 2 WG; conductors from 3 to Call us with your next application: turckusa@turck.com TURCK, Inc.

12 ccess to all TURCK catalogs, press releases, white papers and tutorials Search for products by part number, ID number or key word Complete category listing of TURCK products ccess to CD, wiring and pinout diagrams TURCK s US website is your most complete and up-to-date source for product documentation, CD files and more. Search results produce downloadable documentation or request for quote (RFQ). dditional product information or CD files are easily requested and promptly filled. Option to pages Contact a TURCK representative Download or files, request for quote Visit our site for new product releases, approvals, white papers, application support and more. TURCK US TURCK Inc Campus Drive Minneapolis, MN Phone: (73) Fax: (73) pplication Support: TURCK Mexico TURCK MEXICO S. DE R.L. DE C.V. Carr. Saltillo-Zacatecas km 4.5 s/n Parque Industrial La ngostura Saltillo, COH. C.P MEXICO Phone: +52 (844) /4 Fax: +52 (844) Toll free: (Mexico only) ventasmexico@turck.com TURCK Canada CHRTWELL ELECTRONICS, INC. 140 Duffield Drive Markham, Ontario Canada, LG 15 Phone: (905) Fax: (905) Toll Free: TURCK World Headquarters Hans TURCK GmbH & Co. KG Witzlebenstrasse 7 D Muelheim der Ruhr Federal Republic Of Germany Phone: (+49) Fax: (+49) Printed in US 21 /07