YOKOGAWA KS9-5 * A signal cable

YOKOGAWA KS9-5 * A signal cable

Product Overview

YOKOGAWA KS9-5 * A is a specialized signal transmission cable developed by Yokogawa Electric for industrial automation control systems in Japan. It belongs to the Yokogawa KS9 series signal cable product line. The core positioning of this cable is to meet the stable transmission requirements of multi-channel and high-precision signals in mid to high end industrial control scenarios, especially suitable for signal interconnection between control system core equipment in complex electromagnetic environments. Based on Yokogawa Electric's profound technical accumulation in the field of industrial measurement and control, the KS9-5 * A cable has been optimized for anti-interference ability, environmental adaptability, and mechanical reliability, and can be matched with mainstream distributed control systems (DSC) and PLC systems such as Yokogawa Centum VP and CS3000. It is widely used in high-end industrial scenarios such as petrochemicals, power energy, metallurgy and building materials that require strict control accuracy and system stability.

Core Structure and Material Characteristics

The KS9-5 * A cable adopts a multi-layer composite shielding structure design, consisting of conductor, insulation layer, sub shielding layer (optional), total shielding layer, and outer sheath from inside to outside. The materials of each layer have been strictly selected and process optimized, taking into account signal transmission quality, mechanical protection performance, and service life:

1. Conductor layer

Made by twisting multiple strands of ultra-fine oxygen free copper wire, the copper material has a purity of ≥ 99.99%, extremely low conductivity loss, and excellent mechanical flexibility. The multi strand twisting process adopts precise pitch design, which not only improves the bending performance of the cable (easy to lay and install in narrow spaces), but also reduces the risk of conductor fracture during the bending process; The nominal cross-section of the conductor is impedance matched to ensure compatibility with the transmission characteristics of industrial control signals (4-20mA analog signals, high-frequency digital signals), reducing signal reflection and attenuation.

2. Insulation layer

High density polyethylene (HDPE) is used as the core insulation material, which has the characteristics of stable dielectric constant and extremely low dielectric loss. It can effectively isolate signal crosstalk between adjacent conductors and ensure the integrity of multi-channel signal parallel transmission. The insulation layer is formed through precision extrusion technology, with a thickness uniformity tolerance controlled within ± 0.05mm. It tightly wraps around the outside of the conductor to form an independent insulation core, avoiding the imbalance of electric field distribution caused by uneven insulation layer thickness, and further improving the voltage resistance and insulation reliability of the cable.

3. Shielding layer

Adopting a double-layer composite shielding structure of "separate shielding+total shielding" (presumably based on the high-end model characteristics of the KS series): the inner layer is an independent tinned copper wire braided separate shielding for each pair of wire cores, with a braiding density of ≥ 90%, which can effectively suppress crosstalk between wire cores; The outer layer is a longitudinal package of aluminum-plastic composite tape and a total shielding of tinned copper wire weaving, with a weaving density of ≥ 95%, which can strongly resist external high-frequency electromagnetic interference (EMI), low-frequency magnetic field interference, and electrostatic interference. The double-layer shielding structure forms a fully enclosed electromagnetic protection barrier, which can attenuate external interference signals by more than 95%, ensuring stable transmission of weak control signals in strong interference industrial environments such as frequency converters and high-power motors. The shielding layer adopts a single ended grounding design to form a complete shielding circuit, avoiding the shielding layer itself from becoming an interference source.

4. Outer sheath

Using low smoke halogen-free flame-retardant polyvinyl chloride (PVC) or cross-linked polyethylene (XLPE) as the outer sheath material (specific material matching with style code), it has excellent flame retardant performance, oil resistance, aging resistance, and mechanical wear resistance. The surface of the sheath has been smoothed to resist mechanical friction, oil contamination, and slight acid-base mist corrosion in industrial sites; The low smoke and halogen-free characteristics ensure that cables do not release toxic and harmful gases or large amounts of smoke in fire scenarios, improving the safety of personnel evacuation and equipment protection, and complying with industrial cable fire protection standards such as GB/T 19666-2019.

Key performance parameters

The various performance parameters of KS9-5 * A cable have passed the strict factory testing of Yokogawa Electric, complying with enterprise standards and international industrial cable standards such as IEC 60228 and IEC 60502. The core parameters are as follows (test environment: 20 ℃ room temperature):

1. Electrical performance

-Single conductor DC resistance: maximum value ≤ 9.8 Ω/100m, ensuring that energy loss during signal transmission is at an extremely low level and avoiding excessive attenuation of weak signals 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 signal pair, reducing differential signal distortion caused by resistance differences, and adapting to high-precision analog 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 excellent insulation withstand voltage capability 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 during long-term use, avoiding leakage risks caused by insulation aging or moisture, and ensuring safe system operation.

-Working capacitance: The maximum working capacitance between wire pairs is ≤ 5.8nF/100m. A lower working capacitance can reduce capacitive losses in signal transmission and improve the transmission rate and integrity of high-frequency digital signals (such as Ethernet control signals).

-Transmission characteristics: Within the frequency range of 4-500MHz, the maximum phase delay is ≤ 540ns/100m, and the maximum delay difference is ≤ 45ns/100m, ensuring the synchronization of multi-channel signal transmission and avoiding control system logic confusion caused by differences in transmission delay.

2. Mechanical properties

-Minimum bending radius: ≥ 120mm (static laying), ≥ 200mm (dynamic laying), ensuring that the cable will not damage the insulation layer and shielding layer even when in the minimum bending radius state during laying and use, ensuring stable performance.

-Tensile performance: Short term maximum tensile force ≤ 1200N, long-term working tensile force ≤ 350N, able to withstand slight tensile stress during laying, avoiding conductor breakage or insulation layer damage.

-Flattening performance: The maximum short-term flattening pressure is ≤ 1500N, and the long-term working flattening pressure is ≤ 400N. It can withstand slight squeezing impacts in industrial sites and protect the integrity of internal structures.

Applicable scenarios and compatible devices

1. Core applicable scenarios

KS9-5 * A cable is mainly used for high-precision signal transmission links within Yokogawa Industrial Control System, with typical application scenarios including:

-The transmission of analog signals (sensor signals such as temperature, pressure, flow rate, liquid level, etc.) between DSC/PLC systems and multi-channel signal conditioners.

-The transmission of high-frequency digital signals (control instructions, status feedback signals) between integrated I/O modules and system hosts.

-In DSC systems such as Yokogawa Centum VP and CS3000, multi-channel signal interconnection is achieved between high-density terminal boards and core control units.

-High precision process control scenarios for complex industrial environments such as petrochemical refining plants, large generator sets, metallurgical blast furnace control systems, and biopharmaceutical clean workshops.

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 multi-channel signal conditioner (such as D-100, D-200, etc.).

-The FCS (Field Control Station) host unit and I/O expansion module of the Yokogawa Centum VP DSC system.

-The core control module and high-density terminal block of Yokogawa CS3000 DSC system.

-Other industrial automation equipment with Yokogawa standard interfaces (need to confirm that the style code matches the interface specifications).

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 extreme temperatures 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.

-Special environmental taboos: Avoid direct installation in environments with large amounts of dust, conductive powder, oil mist, salt mist, or organic solvents. If necessary, protective sleeves must be provided.

2. Installation and laying requirements

-Laying method: Supports cable tray laying, conduit laying, and cable trench laying. It is strictly prohibited to lay directly on the ground or in contact with sharp objects to prevent damage to the protective sheath.

-Distance from power cables: A parallel distance of ≥ 30cm should be maintained with power cables of 380V and above; If cross laying is necessary, a vertical cross method should be used to reduce electromagnetic interference coupling.

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

-Terminal processing: Cable terminals must use Yokogawa specific connectors, and self crimping is strictly prohibited to avoid poor contact or signal leakage; When installing the joint, it should be tightened in place to prevent looseness and contact resistance.

-Bending requirements: During the laying process, the bending radius of the cable must not be less than the corresponding specifications (static ≥ 120mm, dynamic ≥ 200mm), and excessive bending or folding is strictly prohibited to avoid damaging the conductor and shielding layer.

-Installation spacing: The distance between the equipment cabinet wall, cable tray wall, and other external equipment should be ≥ 50mm to ensure good heat dissipation and facilitate later maintenance.

Maintenance and service life

1. Key points of daily maintenance

-Regular appearance inspection: Check the outer sheath of the cable monthly for any damage, aging, cracking, oil stains, etc., and promptly address or replace any problems found.

-Joint maintenance: Check the connection tightness and oxidation corrosion of terminal joints every quarter, and apply antioxidants if necessary to ensure reliable contact.

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

-Environmental protection: Avoid prolonged exposure of cables to direct sunlight, high temperature baking, or strong vibration environments 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 conduct a comprehensive performance evaluation every 5 years and replace it in advance if necessary.