Self-Supporting Hybrid Lift Cable for Power, Control and Data
Hybrid lift cable combines power and control circuits with construction-specific mechanical support. Select BAULIFT-T for basket storage, BAULIFT-W for trolley guidance, B101/B102/B103 for their respective hoist feeds, or a screened-data PUR construction for aircraft assembly positioning equipment.
A self-supporting hybrid lift cable carries the electrical circuits needed by moving lifting equipment while its selected support arrangement manages the vertical route. This family covers construction-hoist power and control cables, plus a distinct power, control and data construction for aircraft assembly positioning systems. Select the cable by its feed method before selecting the conductor schedule.
BAULIFT-T returns into a cable basket; BAULIFT-W follows a cable trolley. B101, B102 and B103 provide different drum, carriage and spring-drum arrangements for vertical construction hoists. CONSTRUCTION LIFT-T uses a central sisal support cord and PVC construction for suspended hoist routes. These versions have separate dimensions, temperature limits and bending requirements, so a matching conductor count alone does not identify the correct cable.
The screened-data PUR version combines supply and control cores with twisted pairs for positioning equipment. Its support braid, screened data elements and selected insulation system belong to that construction. It serves mobile support and positioning equipment in aircraft assembly; select its circuit schedule and movement path independently from a construction-hoist basket cable.
The specification tables keep the configurations under their exact designations and separate power-core and control-core voltage ratings where these differ. For selection, provide the lift or machine type, basket, trolley or drum arrangement, free-hanging length, movement speed, minimum guide diameter, conductor schedule and required data circuits. The termination and support design should carry the mechanical load through the intended support components.
Explore the industrial cable range for related configurations.
Use the selected construction values with the cable bending-radius calculation guide when checking bends, guides and the specified movement duty.
Construction
The representative CONSTRUCTION LIFT-T 4G2.5+8X1.5 illustration contains four larger power cores, including one green-yellow protective core, eight smaller white control cores and a central sisal support cord inside a round black PVC sheath. It is a representative structure illustration for this configuration; the other listed families use their own support, insulation and screening arrangements.
| Component | Material and construction |
|---|---|
| Conductors | Tinned copper, Class 5 fine-stranded conductors to DIN EN IEC 60228 (VDE 0295) in the representative CONSTRUCTION LIFT-T build. |
| Power and control cores | Four 2.5 mm² power cores and eight 1.5 mm² control cores. Power-core identification is green-yellow, brown, black and grey; control cores are white with black numbers. |
| Core insulation | PVC TI4 insulation around each conductor in the representative build. |
| Central support | A central sisal cord provides the integrated support element for the CONSTRUCTION LIFT-T construction. |
| Outer sheath | Black PVC TM5 sheath around the round assembly. This representative build has no metallic screen or armour. |
| Other construction options | BAULIFT-T/W include a central carrier element. B102 carriage versions use support braiding and a PUR sheath. Flugzeugheber-T uses an integrated support braid and screened data pairs within a PUR-sheathed hybrid assembly. |
Applications
Match the cable to the way the equipment stores and guides it. Basket storage, trolley guidance, spring-drum feeding and trailing positioning routes impose different bending and tensile conditions.
- BAULIFT-T: cable-basket feeds on construction lifts carrying persons and material, with a listed free-suspended height up to 80 m for the specified construction.
- BAULIFT-W: construction-lift cable trolley routes; select the trolley geometry and the corresponding cable build together.
- B101: vertical drag arrangement drawn from a drum through the load platform; special constructions cover lift heights up to approximately 150 m.
- B102: carriage-guided feeds supplied at the centre of the lift tower for greater heights. B103: spring-loaded drum feeds on construction hoists.
- CONSTRUCTION LIFT-T: vertical construction-hoist routes with an integrated sisal support cord and suspended lengths up to 80 m.
- Flugzeugheber-T: power, control and positioning-laser circuits for mobile support robots and load-relieving lifters in aircraft assembly.
- Confirm the support grips, free-hanging length, guide diameters, basket size and entry arrangement, drum or trolley geometry, movement cycle and termination load transfer for the selected cable. Protect the route from sharp edges and unintended twisting.
Specifications
| Parameter | Value |
|---|---|
| Product family | Self-supporting hybrid lift cable with version-specific basket, trolley, drum or trailing guidance. |
| BAULIFT-T voltage | 300/500 V for the listed basket construction. |
| B101/B102/B103 voltage | Power cores 0.6/1 kV; control cores 300/500 V. |
| Flugzeugheber-T voltage | Power cores 600/1000 V; control cores 300/500 V. |
| Representative PVC build | CONSTRUCTION LIFT-T: tinned copper Class 5, PVC TI4 insulation, central sisal cord and black PVC TM5 sheath. |
| B101/B102/B103 movement limits | Flexing -10 °C to +80 °C; minimum bending radius 10 × cable outside diameter. |
| CONSTRUCTION LIFT-T movement limits | Conductor maximum 70 °C; fixed -40 °C to +70 °C, moving -30 °C to +70 °C; bending 8 × OD fixed and 12 × OD moving. |
| Flugzeugheber-T movement limits | Flexing -20 °C to +80 °C; minimum flexible bending radius 15 × cable outside diameter. |
| Data and screening option | Flugzeugheber-T includes 0.34 mm² twisted data pairs with foil wrapping and tinned-copper braid screening, approximately 85% coverage. |
| Model and conductor configuration (mm²) | Approx. OD (mm) | Copper content (kg/km) | Approx. mass (kg/km) | Tensile load (N) |
|---|---|---|---|---|
| BAULIFT-T 4 G 2.5 + 6 x 1 | 16.3 | 160.0 | 375 | 1000 |
| BAULIFT-T 4 G 6 + 10 x 1 | 21.5 | 340.0 | 717 | 1000 |
| BAULIFT-T 4 G 6 + 12 x 1 | 21.7 | 360.0 | 754 | 1000 |
| BAULIFT-T 4 G 6 + 15 x 1 | 23.2 | 390.0 | 838 | 1000 |
| BAULIFT-T 4 G 10 + 10 x 1 | 23.0 | 500.0 | 918 | 1000 |
| BAULIFT-T 4 G 10 + 15 x 1 | 27.0 | 550.0 | 1086 | 1000 |
| BAULIFT-T 4 G 16 + 10 x 1 | 26.0 | 740.0 | 1298 | 1000 |
| BAULIFT-T 4 G 16 + 15 x 1 | 27.5 | 790.0 | 1753 | 1000 |
| BAULIFT-T 5 G 6 + 10 x 1 | 22.2 | 400.0 | 747 | 1000 |
| BAULIFT-T 5 G 6 + 15 x 1 | 24.9 | 450.0 | 970 | 1000 |
| BAULIFT-T 5 G 10 + 10 x 1 | 23.8 | 600.0 | 1008 | 1000 |
| BAULIFT-T 5 G 10 + 15 x 1 | 25.8 | 650.0 | 1150 | 1000 |
| BAULIFT-T 5 G 16 + 15 x 1 | 30.2 | 950.0 | 1715 | 1000 |
| Model and conductor configuration (mm²) | Approx. OD (mm) | Copper content (kg/km) | Approx. mass (kg/km) | Tensile load (N) |
|---|---|---|---|---|
| BAULIFT-W 4 G 6 + 10 x 1 | 18.1 | 340.0 | 550 | 1000 |
| BAULIFT-W 4 G 6 + 15 x 1 | 18.9 | 390.0 | 597 | 1000 |
| BAULIFT-W 4 G 10 + 10 x 1 | 19.8 | 500.0 | 680 | 1000 |
| BAULIFT-W 4 G 10 + 15 x 1 | 20.8 | 550.0 | 777 | 1000 |
| BAULIFT-W 4 G 16 + 15 x 1 | 25.5 | 790.0 | 1146 | 1000 |
| BAULIFT-W 5 G 2.5 + 12 x 1 | 15.8 | 245.0 | 480 | 1000 |
| BAULIFT-W 5 G 6 + 15 x 1 | 20.9 | 450.0 | 704 | 1000 |
| BAULIFT-W 5 G 10 + 15 x 1 | 22.4 | 650.0 | 930 | 1000 |
| Model and conductor configuration (mm²) | Version | Minimum basket-service temperature | Copper content (kg/km) |
|---|---|---|---|
| BAULIFT-T si 4 G 10 + 15 x 1 | Silicone construction | -25 °C | 550.0 |
| Model and conductor configuration (mm²) | Approx. OD (mm) | Copper content (kg/km) | Approx. mass (kg/km) |
|---|---|---|---|
| B101 5 G 2.5 + 10 x 1.0 | 20.0 | 220.0 | 306.0 |
| B101 5 G 2.5 + 11 x 1.0 | 20.0 | 225.6 | 320.0 |
| B101 3 G 4 + 7 x 1.0 | 17.4 | 184.0 | 360.0 |
| B101 4 G 6 + 9 x 1.0 | 20.5 | 330.0 | 555.0 |
| B101 4 G 6 + 10 x 1.0 | 21.0 | 340.0 | 575.0 |
| B101 4 G 6 + 15 x 1.0 | 22.0 | 388.0 | 625.0 |
| B101 4 G 10 + 10 x 1.0 | 25.0 | 480.0 | 870.0 |
| B101 4 G 16 + 6 x 1.0 | 26.1 | 700.0 | 1250.0 |
| B101 4 G 16 + 10 x 1.0 | 29.0 | 710.0 | 1300.0 |
| B101 4 G 16 + 15 x 1.0 | 31.5 | 760.0 | 1380.0 |
| B101 4 G 16 + 1 x 2.5 + 4 x 1.0 | 28.5 | 830.0 | 1460.0 |
| Model and conductor configuration (mm²) | Approx. OD (mm) | Copper content (kg/km) | Approx. mass (kg/km) |
|---|---|---|---|
| B102 4 G 16 + 1 x 2.5 + 2 x 2 x 1.0 | 28.5 | 830.0 | 1080.0 |
| B102 4 G 16 + 1 x 2.5 + 2 x 2 x 1.0 | 28.5 | 787.0 | 1080.0 |
| B102 4 G 25 + 1 x 2.5 + 2 x 2 x 1.0 | 33.4 | 1176.0 | 1500.0 |
| B102 4 G 35 + 4 x 2.5 + 2 x 2 x 1.0 + 1 x 1.0 | 38.0 | 1500.0 | 1850.0 |
| Model and conductor configuration (mm²) | Approx. OD (mm) | Copper content (kg/km) | Approx. mass (kg/km) |
|---|---|---|---|
| B103 4 G 2.5 + 3 x 1.0 | 13.0 | 125.0 | 230.0 |
| B103 4 G 2.5 + 3 x 1.0 | 15.3 | 125.0 | 280.0 |
| Model and conductor configuration (mm²) | Approx. OD (mm) | Copper content (kg/km) |
|---|---|---|
| CONSTRUCTION LIFT-T 4G2.5+8X1.5 | 18.0 | 211.2 |
| CONSTRUCTION LIFT-T 4G6+12X1 | 21.1 | 345.6 |
| CONSTRUCTION LIFT-T 4G10+15X1 | 26.8 | 528.0 |
| CONSTRUCTION LIFT-T 4G16+15X1 | 30.6 | 758.4 |
| Model and conductor configuration (mm²) | Approx. OD (mm) | Copper content (kg/km) | Approx. mass (kg/km) | Sheath colour |
|---|---|---|---|---|
| Flugzeugheber-T 5 x 4 + 5 x 3 G 0.75 + 2 x 2 x 0.34 | 25.6 | 390.0 | 600.0 | Grey RAL 7001 |
| Flugzeugheber-T 5 x 2.5 + 18 G 1.0 + 4 x 2 x 0.34 | 27.0 | 461.0 | 750.0 | Orange RAL 2003 |
| Construction | Guidance or equipment | Electrical and mechanical distinction |
|---|---|---|
| BAULIFT-T | Cable basket | 300/500 V; up to 80 m free-suspended height; listed tensile load 1000 N. |
| BAULIFT-W | Cable trolley | Central carrier element; use the dedicated trolley dimensions and installation design. |
| B101 | Vertical drag/drum feed | 0.6/1 kV power plus 300/500 V control; special versions up to approximately 150 m lift height. |
| B102 | Carriage feed | 0.6/1 kV power plus 300/500 V control; support braiding and PUR carriage sheath. |
| B103 | Spring-loaded drum | 0.6/1 kV power plus 300/500 V control; select the finished diameter for the drum system. |
| CONSTRUCTION LIFT-T | Suspended vertical hoist route | Central sisal cord; PVC TI4 insulation and PVC TM5 sheath; up to 80 m suspension. |
| Flugzeugheber-T | Aircraft assembly support and positioning equipment | 600/1000 V power, 300/500 V control and screened 0.34 mm² data pairs; PUR sheath with support braid. |
G indicates inclusion of a green-yellow protective conductor. Configuration strings identify the conductor schedule; use the associated diameter, support system and electrical ratings when selecting a build.
BAULIFT-T and BAULIFT-W dimensional tables below follow their respective constructions. The standard BAULIFT-T basket version is listed for service down to 0 °C; the separate silicone version is listed down to -25 °C. Select the low-temperature version explicitly.
B102 and B103 include listed builds with the same core schedule but different copper content or finished dimensions. Specify the required diameter and mechanical construction together with the conductor schedule.
The CONSTRUCTION LIFT-T table gives finished diameter and copper content for four configurations. Specify the operating circuit voltage, suspended length, support arrangement and final cable mass with the order drawing.
The two Flugzeugheber-T configurations keep their circuit groups separate. The grey construction uses PVC-insulated power/control cores and polyethylene-insulated data pairs; the orange construction uses TPE-E power/control insulation and polypropylene-insulated data pairs.
Approximate dimensions and mass are configuration data for selection. Final bend radius, permissible tension and support transfer should match the cable construction and the machine installation drawing.
Standards
| Standard or specification | Application |
|---|---|
| DIN EN IEC 60228 (VDE 0295), Class 5 | Conductor construction reference for the CONSTRUCTION LIFT-T PVC family. |
| IEC 60228 / DIN VDE 0295 / BS 6360, Class 6 | Extra-fine bare-copper conductor reference for the Flugzeugheber-T PUR hybrid constructions. |
| DIN 47100 | Colour-identification reference for the 0.34 mm² data-pair elements in the PUR hybrid construction. |
| AC test voltage at 50 Hz, B101/B102/B103 | Control cores 1500 V; power cores 3000 V. |
| CONSTRUCTION LIFT-T test voltage | 3 kV test-voltage reference for the PVC lift construction. |
| AC test voltage at 50 Hz, Flugzeugheber-T | Control cores 1500 V; power cores 4000 V. |
| Project documentation | Specify the circuit schedule, support arrangement, installation drawing and required inspection or test documents with the enquiry. |
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