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With its broad range of products, Nexans Deutschland GmbH supplies the right cable or cabling system whatever the area of application. With our accessories and assembly expertise, we optimally fulfil all requirements for implementing a reliable flow of both electricity and information for onshore and offshore wind turbines. Nexans’ WINDLINK® brand provides cables, cabling systems and cabling technology for wind turbines. These include aluminium cables for tower cabling and connectors for attaching them quickly or for the transition from aluminium to copper cables.
With the WINDLINK® brand, Nexans supplies cables and cabling systems for wind turbines. The range includes all areas of application from the nacelle to the foundation. There are also suitable solutions for connecting wind farms to the network – whether onshore or offshore. The product portfolio is completed by accessories.
Using experience from other industries
Since the requirements of cables and cabling systems for wind turbines vary greatly, Nexans offers a special solution for each area of application. Temperatures exceeding 60°C can occur in the nacelle. The low-voltage loop cables are intended for the wide temperature range of -40°C to 90°C. They are designed in such a way that they can cope with the relatively slow rotations of the nacelle with little wear and tear. This means they must be not only wear-resistant but also insulated with respect to the rotational torsion. A highly-flexible cable would become brittle with low dynamic stress. On the other hand, a cable for rigid laying would resist movement. Therefore, Nexans used experience of lignite baggers to develop insulating materials which can handle at least 2,000 complete torsion cycles without damage even at -40°C.
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Experience of offshore systems over three decades are reflected in the weather resistance and durability of the cables and their accessories. |
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Under the name WINDLINK®, Nexans offers cables and conductors for all the relevant applications – from the nacelle to the connection of offshore wind farms to the network. |
Equipped for extreme operating temperatures
Nacelle cables for wind turbines can handle even higher temperatures: This enables the generator and transformer to be connected even with a conductor temperature of 120°C. Using these cables generates sufficient reserves.
Low-weight and low-cost mast cables
Even though cables and cabling systems account for only a small part of a wind turbine’s weight, there are two benefits from reducing this amount of weight: Nexans provides both copper and aluminium cables for the space between the nacelle and the foundation. While the aluminium cables are a little thicker with the same electrical data, they cost less and are only half as heavy.
Connectors ensure successful transition from one tower segment to another, and transition from the copper cable in the nacelle to the aluminium cable in the tower, in particular. As one of the pioneers of this cabling technology in the medium-voltage range, Nexans now has more than two years of experience. Use of the SB70-240 connector is recommended for wind turbines.
Screw technology connects copper and aluminium cables
Mechanical connectors of the SB and M series fulfil the electrical and mechanical specifications of IEC 61238-1. The M70-240 connector can accommodate both copper and aluminium cables with a conductor cross-section between 70 and 240 mm². The SB type also has a connector partition. (available for cross-sections up to 630 mm².) The partition is designed in stages in order to create a robust and permanent connection with minimal electrical resistance (see pictures). The conductor retainer is adapted to the outer contour of the round and sector-shaped conductors.
Mechanical connectors such as these are available for the transition from copper cables (coming from the nacelle) to aluminium cables. They allow different cross-sections to be processed, make assembly work easier and ensure a permanent and reliable connection.
Simple and secure assembly
Simple assembly is achieved using hexagon socket and hexagon insert bit tools. When the cables are installed, multi-stage twist-off screws guarantee the correct contact force at all times – required for durable connections – without damaging the connector.
With separable connectors, both halves can be attached to the cable ends during the pre-assembly stage in a functionally reliable manner. In the standing tower, the connector halves are then connected permanently and reliably with a single screw. With optimal contacting, this shear-off screw offers optimum protection against incorrect assembly and enables safe current transportation even with short-circuit loads and the resulting high cable extraction forces.
Time saving compared with crimp connections
To make the work of installers in the tower easier, reduce the assembly time and increase the quality and functional reliability of the connections, Nexans offers the handy ASKO cordless power driver which is adapted to the screw technology. The assembly time is considerably less than with crimp connections. In addition, you do not have to use expensive and unwieldy pressing tools.
The Nexans mechanical connectors with their high degree of withdrawal resistance and assembly flexibility score over expensive plug connections which are also quick to assemble.
Roll hoses protect against environmental influences
The range is completed by the RS 300-500 roll tube. It provides electrical insulation and seals the connection against environmental influences. The roll tube is located on the cable and after assembly is rolled laterally onto the connector and fixed in place.
Solutions such as this demonstrate that Nexans is working hard to solve the problems which are experienced by users. The recent products offer users a number of advantages: lower investment costs, weight savings, simple and quick assembly and reliability over many years and decades.
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