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Product

industrial data rf cable seriesIEC 61196-7 · Air-Dielectric Feeder50 Ω · 93–95% VoP · High CW Power7/8" HCA78 · 1-5/8" HCA158

HELIFLEX HCA78-50JM / HCA158-50JM High-Power RF Feeder Cable50 Ω 7/8" & 1-5/8" air-dielectric corrugated copper high-power RF feeder (93–95 % VoP)

50 Ω air-dielectric corrugated copper high-power RF broadcast feeder cable (HCA78-50 / HCA158-50) per IEC 61196-4 with a copper tube inner conductor, helical PE spacer (91–96 % VoP), corrugated copper outer conductor (> 120 dB shielding), and PE/LSZH jacket.

Low-EMC design
EMC screen
Outdoor & humid
Ozone, UV & moisture
Order designation
HELIFLEX HCA78-50JM
Outer Ø ≈
28.00 mm
Wall thickness
1.50 mm
Total weight ≈
560.0 kg/km
Min. bend R (fixed)
150 mm
All sizes (8)
Request a quoteDatasheetWhatsApp
Engineering reply in 2 business hoursCut-to-length export drumsEN 10204 3.1 certificate per drum
Impedance
50 Ω ± 1 Ω
Air-dielectric broadcast feeder
Velocity (VoP)
93 % – 95 %
71.5 pF/m (7/8") · 70.0 pF/m (1-5/8")
Attenuation
1.95 dB/100m
HCA158 @ 800 MHz (3.55 dB HCA78)
Avg RF power
Up to 32 kW
HCA158 CW @ 100 MHz FM band
Dielectric
Helical PE + Air
Low-loss helical spacer in dry air
Outer conductor
Corrugated Cu
Helically corrugated solid copper

Typical values for this cable type, based on IEC 61196-7 / EIA RS-225 (Air-Dielectric Corrugated Copper High-Power RF Feeder) — confirmed in the datasheet and quotation for your order.

Application fit

Is HELIFLEX HCA78-50JM / HCA158-50JM right for your machine?

Specify HELIFLEX HCA78-50JM and HCA158-50JM for high-power FM/DAB radio, UHF digital television (DVB-T2/ATSC 3.0), HF/VHF defense transmitters, and particle-accelerator RF feeds.

Fixed installation

Suitable

Air dielectric with helical PE centering spline achieves 93–95 % VoP and handles tens of kilowatts of continuous RF power.

VFD inverter to AC motor screened feeder

Suitable

Corrugated solid copper outer tube provides ≥ 120 dB RF shielding and high lightning surge capacity on broadcast masts.

Immersion & wet locations

With conditions

Requires dry-air or nitrogen pressurization (20–50 kPa) with gas-tight EIA flange or 7-16/4.3-10 connectors.

Motorised monospiral reel

Not suitable

Large-diameter corrugated copper broadcast transmission line is strictly for fixed tower and transmitter hall installations.

Use CELLFLEX LCF12-50J
Typical machinesFM / DAB+ & Digital TV Broadcast TowersHigh-Power HF / VHF Defense RadarParticle Accelerator & Synchrotron RFPlasma Heating & Industrial RF GeneratorsCoastal & Air-Traffic Control Transmitters

Construction

Layer by layer

Air-dielectric high-power feeder: hollow copper inner tube, low-loss helical PE spacer in pressurized dry air, helically corrugated solid copper outer tube, and UV PE jacket.

1234
Schematic, not to scale — generated from the layer data
#LayerMaterial & reference
1Solid / corrugated copper tube inner conductorHigh-conductivity oxygen-free copper tube (Ø 9.0 mm on HCA78; corrugated Ø 17.6 mm on HCA158)Maximises RF surface area and thermal dissipation under multi-kilowatt CW power
2Air dielectric with helical PE centering splineContinuous precision-extruded low-loss polyethylene helix in dry air / nitrogen (93–95 % VoP)Eliminates bulk dielectric heating and achieves ultra-low attenuation (70.0–71.5 pF/m)
3Helically corrugated solid copper outer conductorContinuously welded and helically corrugated high-purity copper tube (Ø 25.0 mm / Ø 46.4 mm)100 % RF shielding (≥ 120 dB), gas-tight pressure boundary, and tower flex capability
4UV-stabilized polyethylene (J) or FRNC (B) sheathCarbon-black UV-resistant polyethylene ('JM', Ø 28.0 mm / Ø 50.3 mm) or halogen-free FRNCProtects the copper pressure tube against corrosion, tower ice, and UV exposure

HCA78-50JM (7/8-Inch · Ø 28.0 mm)

93 % VoP, 3.85 GHz max frequency, 9.8 kW avg power @ 100 MHz, 3.55 dB/100m @ 800 MHz

HCA158-50JM (1-5/8-Inch · Ø 50.3 mm)

95 % VoP, 2.70 GHz max frequency, 32.0 kW avg power @ 100 MHz, 1.95 dB/100m @ 800 MHz

Technical data

Ratings & operating limits

Typical values: Typical values for this cable type, based on IEC 61196-7 / EIA RS-225 (Air-Dielectric Corrugated Copper High-Power RF Feeder). Values for your order are confirmed in the datasheet and quotation.

Electrical

Characteristic impedance
50 Ω ± 1 Ω
Velocity of propagation
93 % (HCA78, 71.5 pF/m) · 95 % (HCA158, 70.0 pF/m)
Max. operating frequency
3.85 GHz (HCA78) · 2.70 GHz (HCA158)
Attenuation @ 100 / 800 MHz
1.19 / 3.55 dB/100m (7/8") · 0.65 / 1.95 dB/100m (1-5/8")
Peak RF power rating
90 kW (HCA78) · 310 kW (HCA158)
Avg power @ 100 / 800 MHz
9.8 / 3.3 kW (HCA78) · 32.0 / 10.8 kW (HCA158)

Thermal

Operating temperature range
-55 °C to +85 °C
Max. inner conductor temp.
+115 °C under continuous CW broadcast load
Recommended gas pressure
20 to 50 kPa (3 to 7 psi) dry air or N2

Mechanical

Inner / outer Cu diameter
9.0 / 25.0 mm (HCA78) · 17.6 / 46.4 mm (HCA158)
Overall jacket diameter
28.0 mm (7/8") · 50.3 mm (1-5/8")
Min. bending radius (single/rep)
150 / 250 mm (HCA78) · 300 / 550 mm (HCA158)

Resistance

Screening attenuation
≥ 120 dB (solid welded corrugated copper)
UV & weather resistance
ISO 4892-2 carbon-black PE outdoor sheath
Passive intermodulation (PIM3)
≤ -163 dBc (solid Cu-to-Cu EIA flange)

Reference standards

Feeder standard
IEC 61196-7 / EIA RS-225
Flange interfaces
7/8" EIA, 1-5/8" EIA, 7-16 DIN, 4.3-10
RoHS & REACH
RoHS 3 & REACH SVHC compliant

Identification

Sheath colour
Black (RAL 9005) with metric length marks
Jacket marking
TEBAOFLEX HELIFLEX HCA78-50JM / HCA158-50JM 50 OHM AIR FEEDER
Customs tariff (HS)
8544.20

Sizes

8 standard configurations (HELIFLEX HCA78-50JM / HCA158-50JM)

Engineering dimensions, impedance, propagation velocity, and electrical ratings for HELIFLEX HCA78-50JM / HCA158-50JM per IEC 61196-7 / EIA RS-225 (Air-Dielectric Corrugated Copper High-Power RF Feeder).

Dimensions & weights
Order designationImpedance / sizeConductor & dielectricWall ≈
mm		Outer Ø ≈
mm		Metal
kg/km		Weight ≈
kg/km		Min. bend R
fixed mm		Enquiry
Standard HELIFLEX HCA78-50JM / HCA158-50JM configurations
HELIFLEX HCA58-50J5/8" · 50 Ω AirCu Ø 6.5 + Helical PE1.2520.20230.0340.0110
HELIFLEX HCA78-50JM7/8" · 50 Ω Air (PE)Cu Tube Ø 9.0 + Helical PE1.5028.00390.0560.0150
HELIFLEX HCA78-50BM7/8" · 50 Ω Air (LSZH)Cu Tube Ø 9.0 + Helical PE1.5528.10390.0595.0150
HELIFLEX HCA118-50J1-1/8" · 50 Ω AirCu Tube Ø 12.1 + Helical PE1.6036.00540.0790.0210
HELIFLEX HCA158-50JM1-5/8" · 50 Ω Air (PE)Corrugated Cu Ø 17.6 + Air1.9550.30980.01,380.0300
HELIFLEX HCA158-50BM1-5/8" · 50 Ω Air (LSZH)Corrugated Cu Ø 17.6 + Air2.0050.40980.01,450.0300
HELIFLEX HCA214-50J2-1/4" · 50 Ω AirCorrugated Cu Ø 24.0 + Air2.2067.501,480.02,080.0420
HELIFLEX HCA300-50J3" · 50 Ω AirCorrugated Cu Ø 33.5 + Air2.5088.002,320.03,250.0600
  • Typical values for this cable type; dimensions and weights for your order are confirmed in the quotation.
  • Outer diameters and weights are nominal engineering values for HELIFLEX HCA78-50JM / HCA158-50JM subject to standard manufacturing tolerances per IEC 61196-7 / EIA RS-225 (Air-Dielectric Corrugated Copper High-Power RF Feeder).

Quality & approvals

Testing & inspection

Routine tests on every production length, sample and type tests per batch — documented on an EN 10204 3.1 inspection certificate.

  1. ConductorClass 5 stranding
  2. Spark test100 % in-line
  3. Lay-upCores, earth, fillers
  4. SheathingInner, braid / screen, outer
  5. Electrical testsAC voltage, resistance
  6. DimensionsOD, wall thickness
  7. Inspection documents & dispatchDrum & dispatch
Testing & inspectionTest value / referenceFrequency
Routine tests
Characteristic impedance, return loss (VSWR) & TDR sweep100 % frequency-domain return loss and TDR impedance verification per IEC 61196-7 / EIA RS-225 (Air-Dielectric Corrugated Copper High-Power RF Feeder)Every manufactured length
Dielectric spark & high-voltage withstand test100 % in-line spark and AC/DC dielectric withstand per IEC 61196-7 / EIA RS-225 (Air-Dielectric Corrugated Copper High-Power RF Feeder)Every spool or drum length
Sample tests
Insertion loss (attenuation), velocity & capacitance checkAttenuation (dB/100m), VoP (%), and capacitance within IEC 61196-7 / EIA RS-225 (Air-Dielectric Corrugated Copper High-Power RF Feeder) limitsPer production batch
Screening attenuation, transfer impedance & environmental qualificationQualified to IEC 61196-7 / EIA RS-225 (Air-Dielectric Corrugated Copper High-Power RF Feeder) EMC shielding, thermal, and flame/fluid criteriaType qualification

Inspection certificate

Issued with every drum, listing the routine test results for that length.

Product approvals

IEC 61196-7 / EIA RS-225 (Air-Dielectric Corrugated Copper High-Power RF Feeder)CE (2014/35/EU) & RoHS 3 (2015/863/EU) CompliantREACH SVHC Compliance Verified

Company certificates

ISO 9001ISO 14001ISO 45001VDE marks approvalUL / cULCE · LVD / EMC

Marking & supply

Ordering & delivery

Sheath marking

TEBAOFLEX HELIFLEX HCA78-50JM 7/8" 50 OHM AIR-DIELECTRIC HIGH-POWER FEEDER
Delivery form
Export wooden drums, flange reels or precision coils
Standard lengths
100 m · 305 m · 500 m · 1000 m (or custom cut lengths)
MOQ
100 m (stock sizes) · 300–500 m (custom build)
Lead time
2–4 weeks ex-works
Incoterms
EXW, FOB, CIF, DAP

Technical documents

Downloads

PDFHELIFLEX HCA78-50JM / HCA158-50JM High-Power RF Feeder Cable – technical datasheet8 sizes · construction, technical data, approvalsXLSXHELIFLEX HCA78-50JM / HCA158-50JM spec data (Excel)All 8 sizes with dimensions and data, for your BOM or quotation
Revision
2026-10-20
Updated
2026-10-20

FAQ

Questions engineers ask first

Not covered here? Send your drawing — an engineer replies within 2 business hours.

Why use air-dielectric HELIFLEX HCA78 / HCA158 instead of foam-dielectric CELLFLEX?
Foam polyethylene begins to soften above +85 °C to +100 °C inner-conductor temperature and has higher dielectric loss at multi-kilowatt CW power. HELIFLEX uses dry air/nitrogen with a minimal helical PE centering spline (93–95 % VoP), supporting 2× to 3× higher average CW transmitter power and lower attenuation on tall FM/TV broadcast towers.
Does HELIFLEX require dry-air or nitrogen pressurization?
Yes. Because the dielectric volume is open air between helical spacer turns, HELIFLEX lines are connected to an automatic dry-air dehydrator or nitrogen manifold at 20–50 kPa (3–7 psi) with gas-barrier EIA flange or 7-16 DIN connectors to prevent moisture condensation.
Why is the inner conductor of HCA158-50JM also corrugated?
On 1-5/8-inch and larger feeders, a smooth Ø 17.6 mm copper inner tube would buckle during reel coiling and tower bending; corrugating both the inner and outer copper tubes preserves concentricity at a 300 mm bend radius while allowing continuous drum delivery without rigid 6 m elbows.
What broadcast bands are served by HCA78-50JM and HCA158-50JM?
Both cables cover HF shortwave, VHF Band II FM radio (87.5–108 MHz), VHF Band III DAB+ (174–240 MHz), UHF DVB-T2/ATSC 3.0 television (470–862 MHz), and L-band radar up to 2.7 GHz (HCA158) or 3.85 GHz (HCA78).

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01Selected sizes

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03Message for our engineers

HELIFLEX HCA78-50JM / HCA158-50JM High-Power RF Feeder Cable

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Reel & motion:
- Reel type: 
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- Exposure (outdoor, water, oil, abrasion): 
- Destination country: 
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