Traveling Cable For Elevator: Everything You Need to Know About Flat Elevator Cables
In elevator systems, the traveling cable that provides energy and signal transmission between the car and the control panel is one of the most critical components in continuous motion. Especially in high-rise buildings and narrow hoistway spaces, flat elevator cables are preferred over traditional round cables. So, what makes these cables so special? In this article, we will examine the structure, types, technical specifications, and selection criteria of flat elevator cables in detail.
What Is a Flat Elevator Cable?
A flat elevator cable is a type of traveling cable produced by covering multi-strand copper conductors with a special PVC or halogen-free insulation material and then combining them with a flat outer sheath. Its biggest difference from round cables is that its cross-section is elliptical or rectangular. This geometric structure gives the cable a much more efficient movement capability in the elevator hoistway.
While round cables create uneven stress on the cores as they bend in the hoistway, in flat cables the bending stress is distributed more homogeneously among the cores; this allows the cable to withstand millions of bending cycles. Additionally, the flat structure takes up less space in narrow hoistways and almost eliminates the risk of the cable twisting around itself.
Why Are Flat Cables Preferred?
We can list the prominent advantages of flat elevator cables as follows:
Superior performance in narrow spaces: The flat cross-section takes up less space in the hoistway and increases the free suspension length of the cable.
Low bending radius: Compared to round cables, it can bend at a much smaller radius; this minimizes the cable's friction against the hoistway walls.
Lightweight: Especially in models with CCA (copper-clad aluminum) conductors, weight is reduced by up to 30-40%; this reduces the static load on the elevator motor and suspension system.
Long lifespan: Thanks to fine multi-strand copper conductors (Class 5/6) and a special PVC compound, the cable is resistant to millions of bending cycles.
Common Flat Elevator Cable Types
Elevator traveling cables are produced in different types depending on the application and environmental conditions. The most common standards and types are as follows:
H05VVH6-F
This is a flat elevator cable with PVC insulation and PVC sheath, with a rated voltage of 300/500 V. It is manufactured in accordance with the EN 50214 standard; it is used as a control and command cable in moving systems such as elevators, cranes, escalators, and conveyor systems. Its maximum operating temperature is +70 °C.
H05VVD3H6-F
This is a flat elevator cable developed for long travel distances and high buildings, reinforced with two steel wire ropes. Thanks to the steel support members, the cable's elongation under its own weight is prevented; it provides safe operation up to a free suspension length of 150 meters and a travel speed of 10 m/s.
TVVB and Its Variants
The TVVB series consists of flat elevator cables with PVC insulation and PVC sheath. They can be produced in cross-sections of 0.75 mm² and 1 mm², with 18 to 60 cores. The sub-types of this family are as follows:
| Type | Feature |
|---|---|
| TVVB | Standard flat cable |
| TVVBP | Contains shielded pairs |
| TVVBG | Steel wire rope reinforced |
| TVVBPG | Both shielded and steel wire rope reinforced |
All of these types are used at a rated voltage of 300/500 V and an operating temperature of up to 70 °C.
Technical Specifications and Standards
Flat elevator cables are manufactured in strict compliance with international standards. The most common reference standard is EN 50214. This standard covers the construction, requirements, and particular test methods for flat, flexible PVC or halogen-free insulated and sheathed cables with a rated voltage of Uo/U 300/500 V and, for cross-sections above 1 mm², Uo/U 450/750 V, intended for use in passenger and goods lifts (elevators) .
The technical data of a typical flat elevator cable is as follows:
Conductor: Fine multi-strand electrolytic annealed copper (IEC 60228 / VDE 0295 Class 5)
Insulation: PVC (TI2) or halogen-free thermoplastic compound
Sheath: PVC (TM2) or halogen-free thermoplastic compound
Rated Voltage: 300/500 V (in some models 450/750 V)
Test Voltage: 2 kV
Maximum Operating Temperature: +70 °C
Maximum Short-Circuit Temperature: +160 °C (max. 5 sec)
Flame Test: IEC 60332-1-2
For example, MKS Kablo's 05ZZD3H6-F 24G1 model is 73.7 mm wide and 4.1 mm thick; its maximum free suspension length is 210 meters, maximum travel height is approximately 370 meters, and maximum travel speed is 10 m/s . Its dynamic minimum bending radius is 150 mm, and its static minimum bending radius is 42 mm .
Steel Wire Rope Support: Why Is It Essential for High-Rise Buildings?
In high-rise buildings, the weight of the elevator traveling cable itself can cause the cable to break or sag significantly. To solve this problem, steel wire rope reinforced flat cables have been developed. In the construction of these cables, in addition to the copper conductors, there are two steel wire ropes (for example, with a 7×7×0.20 mm construction and Ø1.8 mm diameter) . The steel wire ropes carry the weight of the cable and eliminate the mechanical stress on the copper conductors. Thus, the cable can operate safely at free suspension lengths of up to 150 meters and travel speeds of up to 10 m/s.
Shielding and Data Transmission
Modern elevator systems require not only energy but also high-speed data (CCTV, network connection, sensor signals) transmission. To meet this need, shielded flat elevator cables are produced. Types such as TVVBP and TVVBPG provide protection against electromagnetic interference thanks to the shielding of data pairs with Al/PET foil . In more advanced solutions, CAT6 network cables and even fiber optic elements can be integrated into the flat cable structure.
Things to Consider When Selecting a Flat Elevator Cable
Choosing the right cable is of vital importance for the reliability and long life of the elevator. When making a selection, you should consider the following criteria:
Building height and free suspension length: In hoistways over 35 meters, cable types with steel wire rope support (ST or G) should definitely be preferred.
Travel speed: In high-speed elevators (4 m/s and above), cables with high dynamic bending radius and mechanical strength should be selected.
Number of cores and cross-section: The number of cores and conductor cross-section required for control, lighting, communication, and safety circuits must be calculated correctly.
Environmental conditions: In humid, oily, or corrosive environments, the chemical resistance of the sheath material should be questioned.
Fire safety: Especially in enclosed and high-rise buildings, halogen-free (LSZH) or flame-retardant (FR) sheath options should be evaluated.
Certificates: The cable's compliance with the EN 50214 standard and relevant test reports must be checked.
Installation and Maintenance Tips
The performance of a flat elevator cable is directly related to correct installation and regular maintenance. During installation, the cable should be released to form a natural loop, not be over-tensioned, and be kept away from sharp edges. Cable clamps should not be too tight, as this prevents crushing of the cores. During periodic maintenance, the sheath surface should be checked for cracks, abrasion, or discoloration; in steel wire rope models, the tension and breakage status of the ropes should be reviewed.
For unsupported flat cable installations, the cable is attached with hanging devices at the hoistway midpoint and at the bottom of the car. The maximum hanging length for unsupported cable is 46 m (150 ft) according to EN standards . For supported flat cable, the steel support members are attached with hanging devices at the hoistway top and at the bottom of the car .
Conclusion
Flat elevator cables are the invisible heroes of modern elevator systems. With their superior movement capability in narrow hoistway spaces, long-lasting construction, and steel wire rope reinforced options suitable for high-rise buildings, they increase both safety and efficiency. Choosing the right type and technical specification of cable directly affects the performance and passenger comfort of your elevator. By clearly determining the needs of your project and choosing products that comply with international standards such as EN 50214, you will ensure trouble-free operation for many years.
