TPE-S Wires

0,35 mm² to 2,50 mm²

Handling, Labelling, Storage and

Processing Recommendations

Handling, Labelling, Storage and

Processing Recommendations

The responsibility for further processing, handling and warehousing of the cables is NOT under the cable producer scope.
It´s responsibility of the user to select the appropriate cable for each application, as well as the appropriate process.
(Printed by TERESA MONJARAS on 7/26/2019 4:12:40 PM valid for 7/26/2019)
This document is exclusively reserved to Coficab and its partners. COFICAB Portugal Uncontrolled Copy
It cannot be distributed, quoted, or copied partially or completely to be distributed without the prior written permission of Coficab.
 Reference :10.42.01.01
TPE-S Wires Issue Date :08.03.2000
0,35 mm² to 2,50 mm² Updating Date :01.01.2019/12
Page :1/12

Index

1. EXAMPLE OF TPE WIRES: .................................................................................................................................................... 2

2. PACKING AND LABELLING .................................................................................................................................................. 2

2.1 PRODUCTION AND EXPEDITION LABELS: EXAMPLES AND PLACEMENT.............................................................................................. 3

2.2 STANDARD PACKING QUANTITIES ............................................................................................................................................. 4

3. TRANSPORT AND UNLOADING ........................................................................................................................................... 5

3.1 FOR SHORT DISTANCE: ............................................................................................................................................................ 5

3.2 FOR LONG DISTANCE: .............................................................................................................................................................. 5

4. STORAGE ............................................................................................................................................................................ 6

4.1 CONDITIONS ......................................................................................................................................................................... 6

4.2 SHELF LIFE OF THE WIRE........................................................................................................................................................... 6

5. CUTTING PROCESS ............................................................................................................................................................. 7

5.1 FEEDING SYSTEM/ UNWINDING: .............................................................................................................................................. 7

5.2 WIRE STRAIGHTENING: ........................................................................................................................................................... 9
5.3 BLADES RECOMMENDATIONS: ................................................................................................................................................ 10
5.4 PARAMETERS OF SPEED, ACCELERATION AND DECELERATION FOR THIS TYPE OF WIRE: ..................................................................... 11

6. TWISTING ......................................................................................................................................................................... 11

7. PACKING RETURN ............................................................................................................................................................ 12

7.1 DISASSEMBLY AND PACKING .................................................................................................................................................. 12

ISSUED BY CHECKED BY APROVED BY

Corporate Quality - Technical Corporate Process Control & Corporate Logistics Systems Corporate R&D Innovation
Corporate QEHS Manager
Support Monitoring Manager Manager Manager

Edgar Rodrigues Ciprian Tarsala Goncalo Monteiro Rosa Santos Mircea Mihit
(Printed by TERESA MONJARAS on 7/26/2019 4:12:40 PM valid for 7/26/2019)
ODR: 10.3055 COFICAB Portugal Uncontrolled Copy
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 Reference :10.42.01.01
TPE-S Wires Issue Date :08.03.2000
0,35 mm² to 2,50 mm² Updating Date :01.01.2019/12
Page :2/12

1. Example of TPE wires:

Fig. 1: Example of TPE wire

2. Packing and Labelling

Coficab is using EUROPALLETS 1,2m x 0,8m that accomplish “ISPM 15” standard, holding maximum 06 spool (Fig.2) at the same
time and no more than one level can be placed in top of other (Fig.3).

Figure
Image Description
Number

NPS
1
(400x400)

Fig. 2: Pallet with 6 NPS Fig. 3: Two levels packaging

Pallet
2 1200x800
mm

Table 1: Example of type of packaging

The NPS (Niehoff Packaging System) is the main packaging used for cross sections
0,35 mm² to 2,50 mm² and the average weight of one NPS is around 65 Kg. The
total pallet weight is around 400Kg.

Fig. 4: Pallet conditioning with plastic film

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TPE-S Wires Issue Date :08.03.2000
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2.1 Production and Expedition Labels: Examples and Placement

Table 2: Examples of Production and Expedition Label, for different products

NB: The weight indicated on the label is just approximate average weight, merely indicative, used for customs purposes.

Fig. 5: Examples of correct and incorrect Label Placement

The label must be fixed to ensure that it will remain in the spool till the end of the use, the plastic bag may be fixed on the spool.

NB: It is forbidden to stick the labels inside the spool because we cannot assure the correct clean after returning the spool.

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TPE-S Wires Issue Date :08.03.2000
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2.2 Standard Packing Quantities

Standard Packing Quantity

Section per Spool (*) (m) Minimum Quant. Maximum Nb of cuts
(mm²) between cuts (m) per Spool (**)
NPS 400 x 400
0,35 14000 800 2
0,50 10000 800 2
0,75 8500 800 2
1,00 7000 500 2
1,50 5000 500 2
2,50 3200 250 2
Table 3: Standard Packing Quantity / Spool

(*) other type of packing can be used/ produced after commercial conditions or direct customer agreement.
(**) 1 cut means that the spool has 2 lengths.

The table above shows the standard Packaging Units used and the maximum number of cuts that the spools can have.

1st - The minimum length per package is 70% of the standard packing quantity (denominated as incomplete spools). Can be sent
at each delivery around 15% of incomplete spools.

2nd – In line measurement device has a measurement accuracy (maximum permissible errors) of ±0,5% (E.g.: Spool with a label
from 17000mts could be in reality 16915mts or 17085mts)

3rd – Standard packing quantity + 10m is considered complete spool.

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TPE-S Wires Issue Date :08.03.2000
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3. Transport and Unloading

3.1 For short distance:
For short distance transport and/or in good roads, with no risk of damage for the products, shipment can be made without
additional reinforcements or simply applying plastic film around the cargo.

3.2 For long distance:

For long-distance transport and/or overseas shipments, other types of reinforcement are recommended, such as corner
protections, plastic ribbons, plastic film or others, when applicable. The pallets shall be protected, to avoid damages in the
packaging and the wire during the transportation.

For Spools/ Reels handling: a suitable device or load carrier must be used with the necessary caution, to avoid any type of
damage of the wire.

Fig. 6: Appropriated Handling tools

Fig. 7: Incorrect Handling

NB:

▪ If it is necessary to remove the plastic film wrapped in the pallet or other protections, it is important to use adequate
tools to not damage the wire.

▪ For environmental reasons, all non-reusable packing materials shall be treated according to the local laws of the
receiving country.

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TPE-S Wires Issue Date :08.03.2000
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4. Storage
4.1 Conditions

The recommended temperature for storage is 10 ºC <T< 30 ºC, and relative humidity of 45 – 75% (indicative value).

Recommend storage for cross sections until 0.50mm², at a maximum of 3 levels in racks, starting from the ground.

Our Products cannot be stored under direct sunlight.

If the storage conditions are not assured, some failures may occur, such as:

• The wire loses mechanical properties and the insulation can “break” once its “plastic properties” are inhibited.

• Humidity may cause conductor oxidation.

• UV exposure will cause wire color degradation and insulation mechanical properties damage.

4.2 Shelf life of the wire

COFICAB wire has 2 years of shelf life.

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TPE-S Wires Issue Date :08.03.2000
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5. Cutting Process
5.1 Feeding System/ Unwinding:

The proper un-winding of the wire is very important to avoid any wire damage or blocking. The un-winding system must be
adjusted to the type of wire/cable. The wire/cable must be free during the un-winding process, together with side protection, in
order to avoid getting damage or create some spiral loop effects. The best position of the spool is the closest possible and
aligned with the machine.

Fig. 8: Protection for NPS 400 Fig. 9: Spool Alignment with machine Fig. 10: Ideal position of the spool

The distance from the end (edge) of the spool and the first porcelain (ceramic) must be less than the total height of the spool,
or, less than the perimeter in the smallest place of the spool [*].

Must be unwinding on the center of the spools like the pictures below:

Fig. 11: Unwinding the wire

NB:

▪ For proper use, in some cases it must be placed in suitable unwinding equipment, which allows free movement of the
wire and avoids any obstacle (whip effect).

▪ Before process the wire, it must be conditioned at ambient temperature (18ºC to 25ºC) at least 24h.

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Fig. 12: Unwinding the wire

Returning of spool with wire:

After using the required quantity of the wire in the cutting machine, the wire must be very well
tightened and fixed on the upper end flange of the spool.

Fig. 13: Correct wire fixation

After use:

This will
automatically
generate a
bad winding.

Fig. 14: Winding problems if the wire fixation was not done properly.

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5.2 Wire Straightening:

Wire guiding and tightening is mandatory to ensure wire alignment through the cutting/crimping machine. However, proper
ceramic guides and clamping rollers MUST be used to avoid wire damage and quality issues on the wire after
cutting/crimping/twisting operations.

Choose the right diameter according to wire cross-section

Fig. 15: First wire guiding (ceramics and rollers)

Check rollers status Check the setting of roller’s

and settings pressure

Fig. 16: Rollers before cutting machine.

Fig. 17: Example of Correct and Incorrect Rollers Adjustment

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Through the cutting machine, the wire must be carried using an appropriate guide with tubes, ceramic or other, in order to
avoid any mechanical wire aggression that may damage the insulation.

Check the status

and the pressure
of the draw straps

Fig. 18: Drawing belts adjustments

5.3 Blades recommendations:

➢ TPE-S wires:
▪ Coficab recommends the use of “V-Form Blades” in cutting / stripping process.

NB: The user can select the adequate blade types according to the best wire quality obtained. In serial production the blade
types that MUST be used, must be according to the first homologation industrial tests.

➢ Type of Blades:

Check the status and

the opening distance of
the cutting/stripping
blades.

Fig. 19: V-Form Blade Fig. 20: Cutting / stripping blade adjustment

NB:

▪ Blades Must be frequently changed according to their wear.

▪ After cutting the wire, the extremities must be adequately protected to avoid oxidation before next operation.

▪ After cutting and crimping, the wire must be adequately protected to avoid any damage on the terminal.

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5.4 Parameters of Speed, Acceleration and Deceleration for this type of wire:

CROSS SECTION LENGTH SPEED ACCELERATION DECELERATION

[mm²] [mm] [%] [%] [%]
100- 1000 85 75 65
1001-2000 85 65 55
0,35 – 2,50 2001-3000 75 60 50
3001-4000 65 50 40
> 4001 SPECIAL HANDLING

Table 4: Parameters of Speed

NB: Coficab recommends some parameters to avoid any kind of mechanical aggression and fewer process issues. Deep analysis
is required to adapt the process to the wire (table 4).

6. Twisting

When twisting, the pair must be twisted in the same direction of the bunched strands.

For Coficab the twist MUST be left “S” (Anti-clock direction)

Fig. 21: Twisting way

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TPE-S Wires Issue Date :08.03.2000
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7. Packing Return
7.1 Disassembly and Packing

Empty spools must be disassembled by pressing the two securities breaks and remove the top flange.

To reduce the storage space, they can be stacked this way.

Total of 25 stacked cones per tower --->

<--- Total of 25 lids per tower

Total of 25 stacked cones per tower --->

Fig. 22: Correctly positioned Spools<--- Total of 25 lids per tower

Upper view: Front view:

Fig.23: Two pallets stacked containing: 150 cones + 150 lids (wrapped together with plastic film)

In case of return, the packaging as well as the pallets must be returned to Coficab clean, in proper conditions to reuse, carefully
packed to avoid damages.
During the time in which the packaging is under customer responsibility, it must be carefully treated and stored, protected from
weather conditions and direct sunlight, to avoid damages. If the packaging has any kind of damage, including damages caused by
weather conditions or sunlight exposition, it will not be accepted by Coficab.

All packing of COFICAB is identified with proper labels, indicating “COFICAB … PROPERTY”.

ISSUED BY CHECKED BY APROVED BY

Corporate Quality - Technical Corporate Process Control & Corporate Logistics Systems Corporate R&D Innovation
Corporate QEHS Manager
Support Monitoring Manager Manager Manager

Edgar Rodrigues Ciprian Tarsala Goncalo Monteiro Rosa Santos Mircea Mihit
(Printed by TERESA MONJARAS on 7/26/2019 4:12:40 PM valid for 7/26/2019)
ODR: 10.3055 COFICAB
Cancel and replace instruction refª: 10.42.01.01-11Portugal Uncontrolled Copy 10.30.07.02/01
www.coficab.com