Electrical cables now come in many types and varieties for various applications and environments, from earth cables to high-voltage cables. However, when looking for those suited for industrial applications, deliberate selection is vital since they serve as the lifeline to any plant or facility. This is because industrial electrical cables come with more advanced features and have higher levels of engineering that further adds to the overwhelm when browsing your options. The cable selection guide below covers the most important factors to look for in industrial electric cables to ensure you make the right choice for your application.
1. Mechanical Durability
The main elements that influence the strength of a wire assembly are its protective layers and size. To know the thickness of a cable, look for its gauge specifications, as they refer to the same thing. Although cables with smaller designs are preferable since they are easier to work with, this thinness means the cables are more vulnerable to being severed or smashed. To better protect such thinner cables, consider opting for the following jacketing insulation materials:
For crush resistance:
- Neoprene
- Polyethylene
- Thermoplastic rubber
- Nylon
For cut-through resistance:
- XLPE
- TPE
- Nylon
- Fluoropolymers
If your cables are at risk of being cut, run over, or stepped on, steer clear of jacketing and insulation materials with weak mechanical properties, such as:
- PVC
- Paper (for filler)
- Thermoplastic rubber (for cut-through resistance)
2. Length
The two main factors that affect an industrial electrical cable’s performance are its length, gauge and shielding. Choosing the right length matters since signal degradation must be accounted for when the cables are intended for use cases that require low losses.
Meanwhile, gauge or thickness determines the cable’s resistance specifications and ability to handle higher electrical loads over long distances. As such, check your application requirements and choose the gauge that can safely carry the intended load without losing voltage or overheating.
3. Shielding
Shielding is a critical component designed to mitigate the effects of electromagnetic interference (mainly signal degradation and cross-talk/noise) by acting as a barrier around the cable. To learn what type of shielding your application needs, take note of its end-use location and check if nearby machinery and objects will interfere with each other.
4. Corrosion Resistance
In industrial environments, corrosion comes in many forms, including moisture, chemicals, and UV light. When sourcing corrosion-resistant cables, consider the following:
- Which corrosives are present in the application
- The intensity or concentration of said corrosives, and
- How long exposure may last
The cable’s coating plays a significant role in keeping the assembly safe and reliable for the long term. Below is an overview of the associated hazards of each corrosive element and the best solutions for them.
- Moisture
Moisture exposure brings hazards such as electrical failure, short-circuiting, reduced insulation integrity, and conductor corrosion. The ideal solutions for fending off moisture include XLPE, TPU, and polypropylene,
- Chemicals
Industrial chemicals are prone to causing corrosion that results in loss of electrical and mechanical properties. Materials like TPE, PTFE, and FEP can provide sufficient protection depending on the specific chemicals involved.
- UV
Long-term exposure to UV light leads to degradation and deterioration of insulation, insulation failure, brittleness and reduced electrical performance. The common anti-UV coatings used today include XLPE, TPE, and EPR.
5. Temperature Resistance
Certain types of electrical wiring can withstand high heat, others thrive in freezing temperatures, and a few can do both. On the other hand, some cables are popular not because of their temperature resistance but because they are toxin-free when burned or non-flammable. A cable’s wire insulation and cable jacketing material are what enable it to resist such temperatures.
As such, determine the fire reactivity and temperature ratings appropriate for your needs, which are categorised into:
- High temperatures: Poorly rated cables will easily turn to mush and cause insulation breakdown, mechanical issues, and conductor overheating. Some of the best materials that can withstand high heat include PFA, Teflon, fibreglass, and silicone.
- Flames: UL rates the circuit integrity of cables exposed to direct flames, as well as any toxic fumes, smoke, or corrosives it produces when burning. Thermoplastic, PVDF, Teflon, and silicone are great for use cases with fire hazards.
- Cold temperatures: To ensure cables do not lose flexibility, become brittle, or degrade, it is best to protect them with materials like thermoplastic elastomer, PFA, EPR, PTFE, and silicone.
Conclusion
There are now countless cable variations to choose from, even among those specific to a certain industry. When deciding which to source, it is best to focus on a few areas, namely how the specs will affect usability, robustness of the electrical signal protection, and environmental resistances. By prioritising the key factors above, you can be more confident that your cables and devices will work harmoniously for your application.
No matter what type of industrial cables you need, we at Cable Source are sure to have them on hand and ready to send them your way. As a one-stop cable distributor with years of industry experience, we can effectively meet the cable needs of various industries with our vast catalogue of products complemented by unparalleled logistic support. Explore our website today to learn more about high-quality products such as flexible control cables, marine cables, drum reeling cables, and many more.
