August 2020

Wire and Cable for

Industrial Environments
 Table of Contents

01. Introduction Page 4

02. Basic Concepts Page 4

¡¡ Types of Cable Shielding

¡¡ Types of Shielded Cable
¡¡ Conductor Size
¡¡ Conductor Stranding
¡¡ Conductor Materials & Types of Cable

03. Requirements Page 11

¡¡ Mechanical Requirements
¡¡ Environmental Requirements
¡¡ Electrical Requirements

04. Industrial Cabling Page 12

¡¡ Different Types of Industrial Cables

05. Tech Tips Page 14

¡¡ Cable Ratings
¡¡ Hand Stripping PTFE Insulated Wire
¡¡ Ensuring Sufficient Cable Shielding
¡¡ Applying Heat Shrink Tubing
¡¡ VFD Cable Installation Considerations
¡¡ Avoiding Cable Stresses
¡¡ Power over Ethernet (PoE) Cable Considerations

06. Parts List Page 16

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 Wire and Cable for Industrial Environments

While wireless technology maybe the innovation of the moment, not all products and applications are
appropriate for wireless due to physical obstructions, obstacles, noise, and other environmental factors.
The Industrial Internet of Things (IIoT) relies heavily on cables to transfer data, commands, and power
between industrial machines, and between the factory floor, IT, and the Cloud. Industrial environments
and their design requirements highlight the need for rugged, durable, and high-performance cabling.
This eBook serves as an introduction to wire and cable specifically designed for industrial environments.

element14 is a Community of over 700,000 makers, professional engineers, electronics enthusiasts, and
everyone in between. Since our beginnings in 2009, we have provided a place to discuss electronics, get
help with your designs and projects, show off your skills by building a new prototype, and much more.
We also offer online learning courses such as our Essentials series, video tutorials from element14
presents, and electronics competitions with our Design Challenges.

element14 Community Team

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 Wire and Cable for
Industrial Environments
CHAPTER 1 Introduction

Wireless technology is the innovation of the moment, with substantial investments being poured into wireless
devices, components, and product development. But not all products and applications are appropriate for
wireless, due to physical obstructions, obstacles, noise, and other environmental factors. The Industrial Internet
of Things (IIoT) relies heavily on cables to transfer data, commands, and power between industrial machines,
and between the factory floor, IT, and the Cloud. Industrial environments and their design requirements highlight
the need for rugged, durable, and high-performance cabling. This eBook serves as an introduction to cabling
specifically designed for industrial environments.

CHAPTER 2 Basic Concepts

What is cable, and what are its types?

A cable is an assemblage of one or multiple thick, strong ropes

created from wires twisted together. Cables carry electric current
and are constructed with a conductor, insulation, shielding, and
an outer jacket.

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While there are many different types of wire and cable, the two main categories of wire and cable for industrial
environments that we will consider in this e-book are:

Unshielded Twisted Pair Cable (UTP)

An Unshielded Twisted Pair cable (UTP) is a 100-

ohm copper cable consisting of between 2 to 1,800
unshielded twisted pairs enclosed by an outer jacket.
The absence of a metallic shield makes the cable small
in diameter but vulnerable to electrical interference.

Shielded Twisted Pair (STP) Cable

A shielded cable is made of one or multiple insulated wires collectively enclosed by an aluminum Mylar foil
or woven braid shielding. The shielding bars the cable from external radio and power frequency interference,
allowing smooth signal transmission.

TYPES OF CABLE SHIELDING

A shield is an electrically conductive material enclosing a cable or a wire. The shield’s primary function is to limit
any signal trying to escape from the wire or cable. It also inhibits external signals or interference from flowing
into the wire or cable.

Foil Shield: Foil shields use a thin layer of aluminum, typically attached to a carrier like polyester, to add strength
and ruggedness. They offer 100% coverage of the conductors.

Braid Shield: A braid is a woven mesh of bare

or tinned copper wires. These shields, however,
offer partial coverage. The braids, depending
on the tightness of the weave, generally provide
anywhere between 70% and 95% coverage.

Combination Foil & Braid: Combines both foil

and braid shields to protect the cable.

Armor: Armors are metallic outer coverings that

protect the cable from mechanical or physical
damage. The difference between shielding
and armor is that shielding is used as noise
protection, while armor is used for physical
protection. Armor is a bonded aluminum and
steel tape that can act as a shield.

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 Wire and Cable for Industrial Environments
TYPES OF SHIELDED CABLE

Numerous acronyms describe shielded cables, and many find synonymous use, as listed in the table below:

F/UTP(FTP) An overall foil shield (F) with unscreened twisted pairs (UTP). This cable is similar to a
standard UTP cable, with foil added underneath the main cable jacket. F/UTP cables are
standard in 10GBaseT applications.
S/UTP An overall braid screen (S) with unscreened twisted pairs (UTP) and occasionally referred to
as an STP cable. The S/UTP finds use in low-frequency applications that need cable flexibility
and secure connections.
SF/UTP Both an overall braid screen (S) and foil shield (F) with unscreened twisted pairs (UTP). An
SF/UTP cable constructed with an overall braided screen effectively prevents EMI from
entering or exiting the cable.
S/FTP An overall braid screen (S) with foil screened twisted pairs (FTP). The “shield” underneath the
jacket is a braid, and its foil barrier encloses each pair.
F/FTP An overall foil shield (F) with foil screened twisted pairs (FTP). Similar to F/UTP cables, these
shielded cables are commonly used in 10GBaseT applications.
U/FTP No overall shielding or braid (U) with foil screened twisted pairs (FTP). This type of shielded
cable is commonly used in 10GBaseT applications.
U/UTP No overall shielding or braid (U) with unscreened twisted pairs (UTP). This cable is fully
unshielded and frequently referred to as UTP cable.

CONDUCTOR STRANDING

Various stranding formations are used in the wire and cable industry. These are similar to conductor materials. It
is crucial to understand the properties of each conductor stranding arrangement before you select the best for
your application. There are two types of conductor stranding in cables as below:

Solid Type Conductor

A solid type conductor is made of one metal piece. It is mechanically robust but nearly inflexible. It is inexpensive
when compared to a Stranded type conductor. This type of cable is used where a conductor is exposed to a
harsh environment. It finds use in direct burial and other related applications.

Conductors - Table 1: Solid Copper Wire, American Wire Gage

Gage (AWG) Nominal OD Nominal Circular Nominal Weight Nominal Resistance @

Inches mm MIL Area (Lbs. per 1000 Ft.) 68°F(Ω/1000 Ft.)
10 .1019 2.60 10380.0 31.43 .9989
11 .0907 2.30 8234.0 24.92 1.260
12 .0808 2.05 6530.0 19.77 1.588
13 .0720 1.83 5178.0 15.68 2.003
14 .0641 1.63 4107.0 12.43 2.525
15 .0571 1.45 3260.0 9.858 3.184
16 .0508 1.29 2583.0 7.818 4.016
17 .0453 1.15 2050.0 6.200 5.064

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 Wire and Cable for Industrial Environments
Table 1: Solid Copper Wire, American Wire Gage - (continued)

Gage (AWG) Nominal OD Nominal Circular Nominal Weight Nominal Resistance @

Inches mm MIL Area (Lbs. per 1000 Ft.) 68°F(Ω/1000 Ft.)

18 .0403 1.02 1620.0 4.917 6.385

19 .0359 .912 1200.0 3.899 8.051
20 .0320 .813 1020.0 3.092 10.15
21 .0285 .724 812.1 2.452 12.80
22 .0253 .643 640.4 1.945 16.14
23 .0226 .574 511.5 1.542 20.36
24 .0201 .511 404.0 1.223 25.67
25 .0179 .455 320.4 .9699 32.37
26 .0159 .404 253.0 .7692 40.81
27 .0142 .361 201.5 .6100 51.47
28 .0126 .320 159.8 .4837 64.90
29 .0113 .287 126.7 .3836 81.83
30 .0100 .254 100.5 .3042 103.2
31 .0089 .226 79.7 .2413 130.1
32 .0080 .203 63.21 .1913 164.1
33 .0071 .180 50.13 .1517 206.9
34 .0063 .160 39.75 .1203 260.9
35 .0056 .142 31.52 .09542 331.0
36 .0050 .127 25.00 .07568 414.8
37 .0045 .114 19.83 .0613 512.1
38 .0040 .102 15.72 .04759 648.6
39 .0035 .089 12.20 .03774 847.8
40 .0031 .079 9.61 .02993 1080.0

Stranded Type Conductor

A stranded type conductor is made of several metal threads. It is more flexible compared to a solid type
conductor, but a little more expensive than a solid type conductor.

The different types of stranded conductors are Bunched, Concentric, and Rope stranding.

Conductors - Table 2: Stranded Copper Wire, American Wire Gage

Gage Stranding Min. Average Approximate ASTM Min. Min. Weight Max Resistance*
(AWG) (Nom. OD of Strand OD Circular MIL (Lbs./1000 @ 68°F (Ω/1000
AWG)
Inches mm Area Ft.) Ft.)
36 7x44 .0019 .006 .152 25 .076 414.8
34 7x42 .0024 .0075 .191 39.7 .121 260.9
32 7x40 .0030 .0093 .236 64 .195 164.1
32 19x44 .0018 .010 .254 64 .195 164.1
30w 7x38 .0038 .012 .305 100 .304 112.0
30 19x42 .0023 .012 .305 100 .304 112.0

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 Wire and Cable for Industrial Environments
Table 2: Stranded Copper Wire, American Wire Gage - (continued)

Gage Stranding Min. Average Approximate ASTM Min. Min. Weight Max Resistance*
(AWG) (Nom. AWG) OD of Strand OD Circular MIL (Lbs./1000 @ 68°F (Ω/1000
Inches mm Area Ft.) Ft.)
28w 7x36 .0048 .015 .381 159 .484 70.7
28w 19x40 .0029 .016 .406 159 .484 70.7
27 7x35 .0054 .017 .432 202 .614 55.6
26w 7x34 .0060 .019 .483 253 .770 44.4
26 10x36 .0050 .021 .533 253 .770 44.4
26w 19x38 .0036 .020 .508 253 .770 44.4
24w 7x32 .0076 .024 .610 404 1.229 27.7
24 10x34 .0064 .024 .610 404 1.229 27.7
24w 19x36 .0046 .024 .610 404 1.229 27.7
24w 42x40 .0031 .023 .584 404 1.229 27.7
22w 7x30 .0096 .030 .762 640 1.947 17.5
22w 19x34 .0058 .031 .787 640 1.947 17.5
22 26x36 .0050 .030 .762 640 1.947 17.5
20w 7x28 .0126 .038 .965 1020 3.103 10.9
20 10x30 .0101 .037 .940 1020 3.103 10.9
20w 19x32 .0073 .037 .940 1020 3.103 10.9
20 26x34 .0063 .036 .914 1020 3.103 10.9
20w 42x36 .0049 .038 .965 1020 3.103 10.9
18w 7x26 .0152 .048 1.22 1620 4.93 6.92
18 16x30 .0101 .047 1.19 1620 4.93 6.92
18w 19x30 .0092 .049 1.24 1620 4.93 6.92
18w 42x34 .0062 .047 1.19 1620 4.93 6.92
18w 65x36 .0050 .047 1.19 1620 4.93 6.92
16w 7x24 .0192 .060 1.52 2580 7.85 4.35
16w 19x29 .0117 .058 1.47 2580 7.85 4.35
16 26x30 .0100 .059 1.50 2580 7.85 4.35
16w 65x34 .0063 .059 1.50 2580 7.85 4.35
16 105x36 .0050 .059 1.50 2580 7.85 4.35
14w 7x22 .0242 .076 1.93 4110 12.50 2.73
14w 19x26 .0147 .071 1.80 4110 12.50 2.73
14w 42x30 .0099 .075 1.91 4110 12.50 2.73
14 105x34 .0063 .075 1.91 4110 12.50 2.73
12w 7x20 .0305 .096 2.44 6530 19.86 1.71
12w 19x25 .0185 .093 2.36 6530 19.86 1.71
12w 65x30 .0100 .095 2.41 6530 19.86 1.71
12 165x34 .0063 .095 2.41 6530 19.86 1.71
10 37x26 .0167 .115 2.92 10380 31.58 1.08
10 65x28 .0126 .120 3.05 10380 31.58 1.08
10 105x30 .0099 .118 3.00 10380 31.58 1.08

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 Wire and Cable for Industrial Environments
C O N D U C T O R M AT E R I A L S & T Y P E S O F C A B L E

A conductor can be defined as an un-insulated wire designed to carry an electrical current. Several types of
conductor materials are used in the wire and cable industry, with copper and aluminum being the most popular.
Different types of copper are used to make conductors, as listed in the below table:

Coppers Uses and Characteristics

Heavy Tinned Copper Used for high-frequency induction heaters

Over Coated Copper Less flexible than tinned copper, often used in hand
soldering situations
Top Coated Copper Less flexible than tinned copper, but more cost-
effective than over coated copper
Perfused (Prebond) Copper Specifically requested material, restricted to sizes 26
to 16 AWG
Silver Coated Copper Able to operate continuously at temperatures as high
as 200˚C, used in high-frequency applications.
High Strength Copper Alloy (HSCA) Used typically in the Aerospace industry, it offers
higher flex life.
Nickel Coated Copper Less expensive than silver-coated copper, this material
can withstand prolonged operating temperatures from
200˚C to 260˚C
Copper Covered Steel Usually found in coaxial cables. The steel strand in
coaxial cables provides “messenger” abilities

Aluminum conductors are similar to copper. usually transmit a radio frequency signal (RF). The
However, they are used in specific applications like center conductor and the outer conductor, or shield,
service entrance cables. The equivalent gauge size are configured in such a way that they form concentric
of an aluminum conductor to carry equal levels of cylinders with a common axis (hence coaxial). The
currents as in a copper conductor is two sizes larger. characteristic impedance ranges from 35-185 ohms
with Common values of 50 and 75 ohms.
Ampacity
There are multiple types of coaxial cable, including
Ampacity is the maximum amount of electric current flexible, semi-rigid, triaxial, and dual coaxial.
that the product can safely carry. The primary
importance of ampacity is that it is often the main
driver for determining the conductor AWG required for
a given application.

Coaxial Cable

A Coaxial cable is made of two conductors (center

and outer conductor) separated by a dielectric, and
overall covered with an outer jacket. Coaxial cables

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 Wire and Cable for Industrial Environments
Flex vs. Flexible Cable offices to the corrosive industrial environment, and
many service failures followed. It soon became
Any pliable, easily bendable cable can be termed a apparent that the Total Cost of Ownership (TCO) can
flexible cable. In contrast, a flex or flexing cable is be minimized by choosing the correct industrial-grade
designed for a certain amount of flex life cycles during cable. This is important, as these cables form the
an application’s runtime, such as a pick and place sinew of Ethernet network infrastructure.
device. Flexible cables find use in applications where
easy routing is desired, and the cable should not move Industrial-grade Ethernet cable is compulsory
in any flexing motion. in traditional process control and manufacturing
operations, power generation plants, and wind and
solar farms. Extreme operating temperatures, contact
with chemicals and/or water, and UV exposure makes
consistent signal transmission a challenge. Uptime
ensures reliable network and productivity. Conversely,
downtime means lower production and crippling
maintenance costs. Industries dependent on control
data communications and automation need control
during the relay of signals between machinery, devices,
and control systems.

Robotics Cable The infrastructure must also endure several external

factors like electromagnetic interference (EMI),
Cables and wires are the literal lifelines of any robot. mechanical hazards, power or voltage fluctuations,
Cables are vital for power and for sending control or mechanical vibration. Safety is paramount for both
signals and data to and from robotic applications. people and processes.
When choosing a cable for your robotics application,
it’s essential to understand the physical forces that will Industrial grade cables must maintain signal integrity in
act on your cable and the overall system. The three the face of numerous factory hazards.
different types of force are:

¡¡ Static—push and pull motions or gravitational

influence (vertically hanging cable)

¡¡ Dynamic—subtle forces from acceleration and

deceleration

¡¡ Static & Dynamic—systems inclusive of both forces.

Once you understand the physical requirements

your system needs to withstand, you can go about
determining your cable needs based on flexing
characteristics like Simple Flexing, Continuous Flexing,
Guided Flexing, and Torsion Flexing.

Industrial-Grade vs. Office Grade Ethernet Cable

Ethernet, once associated with the office, has now

become common in industrial environments. This
migration, unfortunately, included transference of
existing commercial cable from climate-controlled

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 Wire and Cable for Industrial Environments

CHAPTER 3 Requirements

The IIoT is dependent on cables to transfer data, commands, and power between industrial machines, and
between the factory floors. Shop floor connectivity, however, needs careful attention to cable choice and routing
due to physical, environmental, and electrical hazards. A total of three requirements, electrical, mechanical, and
environmental, are generally considered. Let’s discuss these requirements in this section.

MECHANICAL REQUIREMENTS UV resistance: Jacketing materials may lose some of

their physical properties when exposed to UV radiation
(sunlight) unless they are specifically designed to be
The mechanical property is defined as a characteristic UV resistant or UV stable.
that indicates certain behaviors of a material when
a specific force is applied. The typical mechanical RoHS: Abbreviation for Restriction of Certain
requirements in the wire & cable industry are: Hazardous Substances. RoHS became law in July
2006 and forbids any products from entering the
Abrasion Resistance: Ability of the material to resist EU that contain lead (Pb), hexavalent chromium
surface wear
(Cr+6), cadmium (Cd), other heavy metals, as well as
Cut-Through Resistance: Ability of the material to Deca-BDE, PBB or PBDE (chemicals used as flame
withstand mechanical pressure without separation retardants in compounds).

Elongation: The increase in length as the material is WEEE: Abbreviation for Waste Electrical & Electronic
placed under tension Equipment. WEEE falls under Directive 2002/96/EC,
and it became law around June 2004. It makes the
Flex Life: Ability of the cable to withstand repeated
flexing without damage manufacturer responsible for the disposal of products
that have reached end-of-life status.
Tensile Strength: Pulling strength needed to break a
given material ELECTRICAL REQUIREMENTS

E N V I R O N M E N TA L
When choosing a wire or cable, the electrical needs
REQUIREMENTS
for the application must be factored in. Conductor
properties like ampacity, capacitance, inductance,
The most frequently used and popular environmental impedance, resistance, Velocity of Propagation, and
requirements in wire and cable are: voltage must be taken into consideration.

Outgassing: The percentage of gas released during Industrial hazards are absent in a typical commercial
material combustion is defined as outgassing. environment; office spaces and server rooms have
Outgassing of by-products is potentially harmful, HVAC systems that keep cables away from dust,
causing damage to sensitive electronic equipment temperature extremes, UV radiation, and moisture.
such as semiconductors. Both humidity and temperature levels are kept
constant. The selected cable must fit the application.
Temperature: When selecting a cable, one must
The table (Figure 3) on the following page compares
consider both the high and low end temperatures that
the two cable types based on standard tests.
the cable will endure in its working environment.

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 Wire and Cable for Industrial Environments
Testing Requirements: Commercial vs Industrial Cable for Chapter 3

Test Summary of Test Results: Commercial Cable Results: Industrial

Cable
Abrasion Cables stretched across abrasive drum, Failure after 25 cycles (jacket Conductors remained
the moved back and forth cyclically broke, conductors visible) protected (armored
jacket)
Cold Bend Cable cooled to temperature, then Became brittle with visible No visible damage
(UL 444) wound around 3” bar while under cracks
tension; tested at -80˚C, -60˚C, & -40˚C
Cold Impact Drop weight down tube: 2.7 joules Failure at -20˚C Failure at -70˚C
(UL 444) impact energy. Progressively lower with appropriate
temperature temperature jacket
Crushing Apply 2” x 2” plate to cable segment: Failure at 400lbs Failure at 2,250lbs
increase force while monitoring (armored cable)
performance
Cut-through Lower chisel point onto cable with Failure at 92lbs applied force Failure at 1048lbs
(CSA C22.2) increasing force until conductors applied force
shortened
High Expose cable to +60˚C over time, Increased attenuation at Continued to support
Temperature performance tested vs. ambient (20˚C) +60˚C would not support a a run distance of 100
run distance of 100 metters meters ar +60˚C
Oil Resistance Immersion in oil for 60 days, +125˚C Showed signs of deterioration No signs of
(UL 1277) in tensile properties and deterioration
elongation observed
UV Exposure Fluorescent light exposure for 720 Discoloration, precursor to No damage
(ASTM G154) hours degradation
Water Sixth-month test, periodic testing Increasing attenuation and Slight attenuation,
Immersion degradation exceeded Cat 5e
specs after 6 months

Figure 3: When subjected to identical tests, industrial-grade cables offer better performance (Source: Belden)

CHAPTER 4 Industrial Cabling

Industrial cables are compatible with most industrial applications from the factory floor to process controls.
Cables, in industrial environs, frequently transmit signals or power while enduring demanding situations.
Industrial cables, depending on usage, must be protected from EMI and RFI. A certain kind of cable can be ideal
for a particular application.

DIFFERENT TYPES OF What is High Flex Cable? conditions. These cables are able
to tolerate continuous flexing and
INDUSTRIAL CABLES High flexible (High Flex) cables can even surpass 10 million flex
are manufactured for rigorous cycles. They are often found in
performance and maximal flexing automation applications.

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 Wire and Cable for Industrial Environments
Benefits of High Flex / Highly Critical Factors in Cable with multiple layers (generally
Flexible / Ultra-Flexible Cable Selection more than 12 conductors) increase
such risks. Insulation materials
A custom-designed Galaxy high flex ¡¡ Conductors and Current:
should not mutually attach within
cable and wire offers exceptional As specified by motor and drive
the cable, but must support the
manufacturer
performance, better reliability, and conductor’s stranded individual
extended cable life. The sturdy ¡¡ Shielding: Higher shielding wires. High-pressure-extruded
build of High Flex Round Cables grades are necessary if EM TPE or PVC are suitable. Here, the
offers reliable environmental and interference is present cable’s outer jacket failed, exposing
mechanical protection in such those conductors to wear and may
¡¡ Turns per Inch: A maximum of
chaotic environments. The results eventually lead to failure.
four turns per inch can be used to
is significantly reduced downtime, limit the chances of coupling
less maintenance, and less overall Variables-Speed Drives (VSD)
cost over the equipment life cycle. ¡¡ Insulation: The suitable type of
insulation and its thickness depend Any motor winding insulation using
Superior Oil and Chemical on the working voltages VSDs will suffer higher voltage
Resistance in a Rugged Cable for stresses due to transmission lines
Stationary Applications Servomotor-driven machines and rapid voltage pulse effects in
are miniaturized to cut costs. An connecting cables. Motors may
Oil can wreck the life and increasingly condensed space need better windings if higher
performance of electrical cables. means greater difficulty in snaking voltages get used. A few VSDs
Introduced as a coolant and as a several cables through them. The may produce harmonics that are
lubricant, it may cause molecular addition of more cables increases filtered out to ease magnetic noise,
damage on the jacketing and cable the chances of flexing, leading decrease motor vibration, and
insulation polymers. If ignored, to failures. The problem is that prevent them from re-entry into
there can be cable failures, many servomotors regulate speed, the system. These are primarily
replacement, and downtime costs. functioning like variable-frequency done within the VSD unit. Variable-
When it comes to oil resistance, not drives (VFDs), though with added frequency drive (VFD) cables
all wire and cable insulations are functions and controls for torque are the high standard in reliable
the same. Insulating compounds and position commands. Hybrid and high-performance cables.
can be made to contain plasticizers servo cables thus should carry Their explicitly articulated cross-
in particular amounts, which signals through regions prone to linked polyethylene insulation
provides resistance to fatigue and crosstalk and EMI from the servo offers superior corona resistance,
promotes flexibility. Compounds drive’s noisy power conduction, an superb low-temperature properties,
exposed to coolant processing identical issue plaguing VFDs. and low capacitance ideal for
and lubricating oils are designed to longer runs. A symmetrical design
either mop up the oil or diffuse the Tough PVC Cable for Continuous
positions the ground wires in
plasticizer from that compound. Flex Control Applications
the conductors’ interstices for
Continuous-flex cables last longer a uniform conductor-to-ground
Servo Power and Control
and work better than conventional capacitance and impedance.
Reliable drives and motors need cables in automated machinery
Cat 5e—Industrial Ethernet
the correct cable, and choosing for control, coaxial, servo,
Data and Bus-Seamless
the right one helps to achieve and power, data, bus, fiber-optic, and
Communication for Industrial
maintain the desired performance. position feedback applications. An
Environments
improperly constructed cable may
lead to failures like corkscrewing Moving Ethernet from an office
and jacket rupture. Flexible cables environment into the industrial

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 Wire and Cable for Industrial Environments
world is complex. The office jacket. These bigger cables are not to the requirements mentioned
environment offers its cabling only inflexible but also inconvenient above. They are typically used in
system a relatively safe operating when it comes to installation small offices, gaming consoles, and
environment, whereas industrial compared to the standard COTS computer networks. Cables in this
applications are often subject to cable with identical construction. category are enhanced versions of
hazardous environments. A few Yet another disadvantage of such the CAT5 cable and are designed
cable manufacturers, to satisfy a cable is that the COTS cable to be backward compatible and
Industrial Ethernet needs, have restricts the temperature rating. minimize crosstalk. They can thus
introduced purported “Industrial interact with older data and dated
Ethernet” cables. These are The CAT5e Industrial Ethernet systems. CAT5e cable can support
commercial off-the-shelf (COTS) cables available in stranded or solid 1000 megabytes per second
Ethernet cable enclosed by an extra options provide a complete solution running network.

CHAPTER 5 Tech Tips

The steady rise in the number of automation devices connected via cables significantly complicates wire
management needs spanning a plant, forcing manufacturers to vary their methods when it comes to planning,
design, and installation of network infrastructure. An absence of a cohesive network management strategy
will cause customers to suffer longer repair times, unplanned downtime, unreliable performance, inefficient
maintenance in harsh industrial applications, and interoperability loss.

The basics of cable management are explained in the following content.

C A B L E R AT I N G S

The maximum continuous current rating for a cable is To use the current capacity chart, first determine
limited by conductor size, the number of conductors conductor size, temperature rating, and the number of
contained within the cable, the maximum temperature conductors from the applicable product description for
rating of the cable, and environmental conditions such the cable of interest.
as ambient temperature and airflow.

Current Ratings
No. of Conductors* Factor
1 1.6
2 to 3 1.0
4 to 5 0.8
6 to 15 0.7
16 to 30 0.5
*Do not count shields unless used as conductor.

Next, find the current value on the chart for the proper
temperature rating and conductor size. To calculate
the maximum current rating/conductor, multiply the
chart value by the appropriate conductor factor.

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 Wire and Cable for Industrial Environments
HAND STRIPPING 1. Cable must have adequate components when they are used
shielding for the application’s in moisture, dust, and saturated
PTFE (TEFLON)
needs. Use braids or foil-braid chemical environments.
I N S U L AT E D W I R E
combinations for environments with
more noise. VFD CABLE
The hand stripping of PTFE (Teflon)
2. The cable must be suited to the I N S TA L L AT I O N
insulated wire is a notoriously
application. Cables that undergo C O N S I D E R AT I O N S
tough task. The same contrivances
repeated flexing generally use a
that make PTFE desirable in wire
spirally-wrapped shield rather than
insulation work against it when VFD cable installation is not the
a braid. Avoid foil-only shielding on
it is time to strip. The key is to same as terminating standard
flex cables since continuous flexing
have a precision blade that cuts cable. Follow these few simple
may tear the foil.
most of the way but not through guidelines to terminate your VFD
the insulation, and to have a 3. Ensure that the equipment cable for optimal system reliability:
mechanism for cantering the connected to the cable is properly
insulation in the blades. ¡¡ The shield and ground system
grounded. Use an earth ground
must be terminated directly at the
wherever possible.
The Micro-Strip tool has an motor and drive, avoiding breaks
interchangeable alignment guide to 4. Most connector designs allow for or intermediate cable cuts between
centre the wire in the blades and a full 360 degree termination of the them.
the interchangeable blades. This shield. Ensure that the connector
combination of interchangeable ¡¡ Do not terminate shields or
offers shielding effectiveness equal
parts enables a few critical actions. grounds in service disconnect, as
to that of the cable.
First, the alignment guides come such an action may create a noise
in different sizes to allow picking 5. Ground the cable at one end. loop.
the guide closest to the maximum This eliminates the potential for
¡¡ Ensure one continues to use
insulation OD. Second, the cutting noise inducing ground loops. A
VFD cable out to the motor and not
blades are available in a host of shielded system is only as good as
unshielded cable in the last few feet
precision sizes. This allows, albeit its weakest component.
after disconnect.
through a bit of a trial and error
process, one to use the optimum A P P LY I N G H E AT ¡¡ Avoid any intermediate
combination of the alignment guide
SHRINK TUBING termination of ground through
and cutting blades. A further
the use of an isolating cable
benefit is the replacement of blades
gland where the cable enters the
if they become damaged or worn. Heat shrink tubing is versatile, enclosure
guarding cables against weather,
ENSURE SUFFICIENT abrasion, and chemicals. It ¡¡ Ensure these grounds remain
CABLE SHIELDING is suitable for colour coding, sleeved to avoid any metal contact.
bundling, and strain relief. It is also
used as a strain relief for breakouts, ¡¡ Braid must not be cut at the
The shield’s primary function is to back end connector sealing, and termination point. Pull conductor
limit any signal trying to escape connector-to-cable transition. Heat through braid, leaving the latter
from the wire or cable, but it also shrink tubes provide insulation on intact. Combine braids with the
functions as a way to prevent wires, splices, wire or cable joints, bare grounds before terminating
external signals or interference from and in a terminal, and are used as together at each end.
flowing into the wire or cable. a protective element for bundling
cables or loose wires. They protect

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 Wire and Cable for Industrial Environments
AV O I D I N G C A B L E S T R E S S E S ¡¡ Storage/Handling/Transportation: Cables not
intended for external applications must be stored in
dry and indoor environments.
Installation can affect cable performance. Installed
cables get bent around corners, get pulled on, and
POWER OVER ETHERNET (POE)
may kink when coming off the reel. These installation
factors change the cable’s physical properties,
C A B L E C O N S I D E R AT I O N S
which consequently often degrade cables’ electrical
performance. Some considerations to avoid cable Power over Ethernet (PoE) technology permits network
stress during installation are: operators to offer electric power to multiple devices
via the same cable, which transmits data. PoE grants
¡¡ Bending stress: The cable’s internal bending
equipment a better level of mobility, scalability,
radius should be selected so that the cable remains
and flexibility. This is invaluable in the production
undamaged when bent.
environment. A few considerations to avoid common
¡¡ Current overload: The cables, along with their PoE pitfalls include:
attachments, can be damaged by short-circuits, or any
¡¡ Plug and jack quality and type
current overload.
¡¡ Containment/pathway type and cabling category
¡¡ Tension: Applied tension must not exceed
specifications, typically up to 1000 N maximum value ¡¡ Bundle sizes and ambient/environmental
for the tensile stress of the conductor population. temperature effects

¡¡ Compression: Cables must not be compressed to ¡¡ Check design with someone who is conversant with
any point where they become damaged. the standards

¡¡ Compatibility: Avoid hindering any cable heat ¡¡ Consider ‘Commscope’s Powered Fibre Cable
dissipation and electrical and mechanical influences System’ as a viable solution for those channel links
between neighboring circuits. beyond 100 meters in a campus environment

CHAPTER 6 Parts List

Many types of cables are available based on their applications. The designer must choose the correct one for the
use. A few of them are:

EcoGen™ EcoWire® Hook-Up Wire

EcoWire derives its advantage from its unique insulation, a modified polyphenylene ether (mPPE) thermoplastic.
mPPE-based insulation is non-halogenated and contains no heavy metal pigments, allowing it to help
manufacturers meet Waste Electrical and Electronic Equipment (WEEE) requirements.

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 Wire and Cable for Industrial Environments
Xtra-Guard® 2 Multiconductor Cable

Xtra-Guard® 2 oil and abrasion-resistant 300V foil

shielded multiconductor cable for use in industrial
applications where abrasion and mechanical abuse
is common. Xtra-Guard® 2 cable brings high
performance and reliability to the biggest challenges in
the harshest environments. Its specially formulated, rugged polyurethane jacket offers three times the tear and
abrasion resistance of ordinary PVC.

Multiconductor Cable, EcoCable® Mini

EcoGen EcoCable Mini recyclable, halogen-free cable

has been developed by Alpha Wire lighter 300V cable.
It uses mPPE insulation and jacketing to provide
application advantages in a cable that is 32% smaller
and 44% lighter than standard PVC cable, combining better performance and minimal environmental impact.

FIT® Heat Shrink Tubing FIT 221 Series

The FIT-221-3/16 BK063 is a Heat-shrinkable Tubing with cross-linked

polyolefin construction. It has approximately 2:1 shrink ratio and
1500psi minimum tensile strength.

Multiconductor Cable, Xtra Guard® 4, Shielded Cable

The preferred outdoor cable for advanced high/

low-temperature performance, Xtra-Guard 4, has
an operating range from -50°C to +125°C, making
it suitable for a wide variety of applications and
environments, from mining and petrochemical process
controls to arctic pipeline operations.

EcoGen™ EcoFlex®, Unshielded, 2 Conductor, Multiconductor Cable

The EcoGen™ products contain no halogens,

phthalates, or heavy metals. The mPPE thermoplastic
insulation and jacketing can be easily recycled.
The 1.03 specific gravity of mPPE is 25% to 40%
lower than other insulation materials, such as PVC,
polyethylene, and cross-linked polyethylene. It is
suitable for use in NFPA 79 applications.

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 Wire and Cable for Industrial Environments

Multiconductor Cable, Series SF, Shielded, 4 Conductor, 8 AWG, 8.5 mm²,

100 ft, 30.5 m

A type of Servo Motor Cable. A type of Servo Motor

Cable. Alpha Wire’s Series SF cables are designed
specifically for servo motors and drives, and are a
good choice if you need increased flexibility for your
power servo applications.
Industrial Series SF Key features:

Power cable ¡¡ Sunlight resistant ¡¡ Thermoplastic elastomer jacket

¡¡ 4-conductor power cable, with or ¡¡ UL Oil Res I/II Designed specifically for
without brake pair connecting power between the
¡¡ Control cable
supply and servo motors, drives,
¡¡ 18 – 8 AWG
¡¡ 3 to 6 pairs for resolver and controllers, Series SF cables
¡¡ Thermoplastic elastomer jacket applications feature a flexible TPE jacket and
PVC/nylon insulation, making them
¡¡ SF Series offers increased ¡¡ 9 conductors for encoder
suitable for flexing applications that
flexibility applications
require continuous movement.
¡¡ UL Type TC-ER (600V) ¡¡ 20 AWG

¡¡ UL Type WTTC (1000V) ¡¡ Polyolefin insulation

FIT® Wire Management, Heat Shrink Tubing Kit,

FIT-221

The FIT-221-R MC213 is a Heat Shrink Kit. The general purpose

irradiated polyolefin heat shrinkable tubing in 6-inch cut pieces and
various colors and sizes.

Multiconductor Cable, Series V VFD, Per Ft, Shielded, 3 Conductor, 1 AWG;

V16000 BK199

Series V cables for variable-frequency drives (VFD)

set the standard in highperformance and reliable
connectivity. Their specially formulated cross-linked
polyethylene insulation provides superior corona
resistance, low capacitance for longer runs, and
excellent low-temperature properties. A symmetrical
design places the ground wires in the interstices
of the conductors for uniform conductor-to-ground
capacitance and impedance. Smaller gauge cable
feature a combination foil + braid shield to offer exceptional EMI/RFI protection in noisy environments. On larger

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 Wire and Cable for Industrial Environments
gauge cable, a double copper tape is used to provide the same noise-free operation. Series V VFD cables will
work with drives from all major manufacturers.

Multiconductor Cable, Shielded, 6 Conductor, 16 AWG, 1.23 mm², 1000 ft,

305 m

A type of Robotics Cable. Xtra-Guard® Flex - Wide

variety of flexing applications

¡¡ Long-lasting flex cables designed to provide ¡¡ Rounded geometry helps insure a liquid-tight
excellent performance in high-flex, high torsion, and installation per IP67 or NEMA 6
continuous-flex applications, such as motion control
and robotics ¡¡ Supra-Shield provides precise EMI interference
resistance for your specific application is easily
¡¡ Rated for up to 14 million flex life cycles (85000 achievable with the available standard flex, torsional
series), up to 6 Million flex life cycles (86000 series) flex, and continuous flex applications

¡¡ Available in a variety of configurations allowing ¡¡ Meets NFPA Standard 79 for industrial machinery*
exactly the right cable to be selected for the
application

Visit our Industrial Automation page to learn more about cables.

Sources for diagrams and charts are provided by Alpha Wire & Belden

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