YOKOGAWA KS8-5 * A signal cable

YOKOGAWA KS8-5 * A signal cable

Product Overview

YOKOGAWA KS2-5 * A is a specialized signal transmission cable developed by Yokogawa Electric for Distributed Control Systems (DSC) in Japan. It belongs to the Yokogawa KS2 series signal cable product line. The core positioning of this cable is to achieve high-precision and low interference transmission of key signals within the DSC system, especially suitable for connection scenarios between signal conditioners and core devices such as system hosts and I/O modules. With Yokogawa Electric's technological accumulation in the field of industrial automation, the KS2-5 * A cable has been rigorously optimized in terms of signal integrity, environmental adaptability, and mechanical reliability, and can meet the stringent requirements for control system stability in high-end industrial scenarios such as petrochemicals, power metallurgy, and biomedicine. It is one of the supporting specialized cables for mainstream DSC systems such as Yokogawa Centum VP and CS1000.

Core Structure and Material Characteristics

The KS2-5 * A cable adopts a multi-layer composite structure design, consisting of conductor, insulation layer, shielding layer, and outer sheath from inside to outside. The materials of each layer have been strictly selected to ensure the quality of signal transmission and service life

1. Conductor layer

Made by twisting multiple strands of fine copper wire, the copper material has a purity of ≥ 99.99%, ensuring excellent conductivity and mechanical flexibility. Compared to single stranded conductors, the multi stranded design not only significantly improves the bending performance of cables, making it easier to lay and install in narrow spaces on industrial sites, but also reduces the risk of conductor breakage during bending. The nominal diameter of the conductor is accurately calculated, combined with the overall structural design, to achieve perfect matching with the DSC system signal impedance and reduce signal reflection loss.

2. Insulation layer

High density polyethylene (HDPE) is used as the core insulation material, which has excellent dielectric properties, stable dielectric constant, and extremely low loss. It can effectively isolate signal crosstalk between adjacent conductors and ensure the integrity of signal transmission. The thickness of the insulation layer is uniform, with a tolerance controlled within ± 0.05mm. It is tightly wrapped around the outside of the conductor through extrusion technology to form an independent insulated wire core, avoiding the problem of uneven electric field distribution caused by uneven insulation layer thickness and further improving the voltage resistance performance of the cable.

3. Shielding layer

Adopting a double-layer shielding structure, the inner layer is woven with tin plated copper wire for shielding, with a weaving density of ≥ 90%, which can effectively resist high-frequency electromagnetic interference (EMI); The outer layer is longitudinally wrapped with aluminum-plastic composite tape for shielding, further enhancing the shielding effect against low-frequency interference and electrostatic interference. The double-layer shielding design forms a fully enclosed electromagnetic protection barrier, which can attenuate external interference signals by more than 90%, ensuring stable transmission of high-precision weak signals (such as 4-20mA analog signals) in complex electromagnetic environments in industrial sites (such as near frequency converters and high-power motors). One end of the shielding layer is grounded to form a complete shielding circuit, avoiding the shielding layer from becoming a new source of interference.

4. Outer sheath

Using low smoke halogen-free flame-retardant polyvinyl chloride (PVC) or cross-linked polyethylene (XLPE) as the outer sheath material (the specific material may vary slightly depending on the style code), it has excellent flame retardant performance, oil resistance, and aging resistance. The surface of the sheath is smooth, with good wear resistance and tear resistance, which can resist mechanical friction and chemical media erosion (such as oil stains and slight acid-base mist) in industrial sites. The low smoke and halogen-free characteristics ensure that the cable will not release toxic and harmful gases and a large amount of smoke in case of fire, improving the safety of personnel evacuation and equipment protection, and meeting the requirements of industrial building fire protection regulations.

Key performance parameters

The performance parameters of KS2-5 * A cable have been rigorously tested and comply with Yokogawa Electric Corporation's standards and relevant international standards for industrial cables. The core parameters are as follows (testing environment: 20 ℃ room temperature):

1. Electrical performance

-Single conductor DC resistance: maximum value ≤ 9.50 Ω/100m, ensuring that energy loss during signal transmission is at an extremely low level and avoiding excessive signal attenuation caused by line losses.

-Unbalanced DC resistance of wire pair: maximum value ≤ 2.5%, ensuring the consistency of resistance between two conductors in the same wire pair, reducing signal distortion caused by resistance differences, especially suitable for differential signal transmission scenarios.

-Dielectric strength: Apply a direct current voltage of 1.0kV between conductors for 1 minute without breakdown or flashover; Applying a direct current voltage of 2.5kV between the conductor and the shielding layer for 1 minute without breakdown or flashover, it has good insulation and voltage resistance, and can resist instantaneous overvoltage interference in industrial sites.

-Insulation resistance: The minimum insulation resistance between conductors and between conductors and shielding layers is ≥ 5000M Ω· km, ensuring stable insulation performance of the cable, avoiding leakage problems caused by insulation aging or moisture, and ensuring safe system operation.

-Working capacitance: maximum value ≤ 5.6nF/100m. A lower working capacitance can reduce capacitive losses during signal transmission, improve signal transmission speed, and ensure the transmission quality of high-frequency digital signals or rapidly changing analog signals.

-Transmission characteristics: Within the frequency range of 4-500MHz, the maximum phase delay is ≤ 536ns/100m, and the maximum delay difference is ≤ 45ns/100m. The extremely low delay difference ensures the synchronization of multi-channel signal transmission and avoids system control logic confusion caused by signal transmission delay differences, which is crucial for DSC systems that require multi parameter collaborative control.

2. Mechanical properties

-Minimum bending radius: ≥ 100mm (static laying), ensuring that the cable will not damage the insulation layer and shielding layer even when in the minimum bending radius state during the laying process, ensuring stable cable performance.

-Tensile performance: Short term maximum tensile force ≤ 1000N, long-term working tensile force ≤ 300N, able to withstand slight tensile stress during laying, avoiding conductor breakage or insulation layer damage.

-Flattening performance: The maximum short-term flattening pressure is ≤ 1000N, and the long-term working flattening pressure is ≤ 300N. It can resist slight squeezing in industrial sites and avoid damage to the internal structure of cables.

Applicable scenarios and compatible devices

1. Core applicable scenarios

KS2-5 * A cable is mainly used for signal transmission links within the Yokogawa DSC system, with typical application scenarios including:

-The transmission of analog signals (such as temperature, pressure, flow, and other sensor signals) between the signal conditioner and the DSC host.

-The transmission of digital signals (such as switch signals and control command signals) between the signal conditioner and the I/O module.

-Short distance signal interconnection between 40-40 pin interface devices in DSC systems such as Yokogawa Centum VP and CS1000.

-Suitable for scenarios that require high-precision process control, such as industrial automation production lines, petrochemical equipment, power generators, and biopharmaceutical fermentation tanks.

2. List of compatible devices

This cable is a specialized supporting cable for Yokogawa, and its compatibility has been rigorously verified. The main compatible devices include:

-Yokogawa JUXTA D series signal conditioners (such as models D-30, D-50, etc.).

-The FCS (Field Control Station) host unit of the Yokogawa Centum VP DSC system.

-I/O module and expansion unit of Yokogawa CS1000 DSC system.

-Other Yokogawa industrial automation equipment with a 40-40 pin interface (style code matching needs to be confirmed).

Usage environment and installation requirements

1. Environmental parameters

-Working temperature range: -20 ℃~70 ℃, can adapt to the temperature environment of most industrial sites, including outdoor installation in cold regions and indoor installation in high-temperature workshops.

-Storage and transportation temperature range: -50 ℃~70 ℃, ensuring that the material properties of the cable will not deteriorate due to low or high temperature during transportation and storage.

-Relative humidity: ≤ 95% (no condensation), can work stably in humid industrial environments, avoiding insulation performance degradation caused by humidity.

-Altitude: ≤ 2000m, can be used normally within the altitude range of conventional industrial plants.

2. Installation and laying requirements

-Laying method: Supports cable tray laying, conduit laying, and cable trench laying, avoiding direct laying on the ground or contact with sharp objects to prevent sheath damage.

-Distance from power cables: A distance of ≥ 30cm should be maintained between power cables of 380V and above to avoid strong electromagnetic interference caused by power cables affecting signal transmission; If cross laying is necessary, a vertical cross method should be used to reduce interference coupling.

-Shielding layer grounding: The shielding layer should adopt a single ended grounding method with a grounding resistance of ≤ 4 Ω. It is recommended to ground it at the end close to the DSC host or I/O module to ensure maximum shielding effect.

-Terminal processing: Cable terminals should use Yokogawa specific connectors to avoid poor contact or signal leakage caused by self crimping; When installing the joint, ensure that it is securely fastened to prevent looseness and contact resistance.

-Bending requirements: During the laying process, the bending radius of the cable shall not be less than 100mm, and excessive bending or folding is strictly prohibited to avoid damaging the conductor and shielding layer.

Maintenance and service life

1. Key points of daily maintenance

-Regularly inspect the appearance of the cable and check whether the outer sheath is damaged, aged, cracked, etc. If any problems are found, they should be replaced in a timely manner.

-Regularly check the connection of the joints to ensure that they are not loose or corroded by oxidation. If necessary, apply antioxidants.

-Regularly check the insulation resistance and shielding continuity of the cable. If the insulation resistance is below 5000M Ω· km or the shielding layer breaks, it should be immediately stopped and replaced.

-Avoid prolonged exposure of cables to tension, compression, or direct sunlight to reduce material fatigue and performance degradation.

2. Service life

Under the premise of meeting the usage environment and installation requirements, the normal service life of the cable is ≥ 10 years. If the usage environment is harsh (such as long-term high temperature, high humidity, strong corrosion, strong interference), the service life may be shortened. It is recommended to regularly evaluate and replace according to the actual situation.

Selection suggestions and precautions

1. Selection suggestions

-Determine the cable length based on the equipment spacing, and it is recommended to reserve a margin of 1-2 meters on the actual required length for easy laying and later maintenance.

-If applied to explosive hazardous areas, intrinsically safe cables with the suffix "/NL" should be selected to ensure compliance with explosion-proof grade requirements.

-If the device interface is not of the 40-40 pin specification, KS2 series cables should be avoided and other corresponding series of dedicated cables from Yokogawa can be selected.

-If the transmitted signal is a high-frequency digital signal or long-distance transmission (over 20 meters), consult Yokogawa technical personnel to confirm the applicability of the cable model.

2. Precautions

-This cable is a specialized cable for Yokogawa. It is recommended to purchase it from legitimate channels and avoid using counterfeit and inferior products to ensure the stability of the DSC system operation.

-During the process of cable laying and installation, industrial cable installation specifications should be strictly followed to avoid signal transmission failures or safety hazards caused by unauthorized operations.

-If it is necessary to cut and re crimp the cable joints, Yokogawa specialized tools and joint accessories should be used, and operated by professional technicians to ensure the quality of the joints.

-During the use of cables, if there are problems such as signal distortion or system false alarms, the connection and shielding layer grounding of the cable should be checked first to eliminate cable faults.