Insulation is a nonconductive material within a cable's construction. Insulation is also commonly called a dielectric when discussing radio frequency cables. The longevity and effectiveness of a wire depends on the type of insulation that is used. Dielectric and insulation materials preserve the material integrity of the wire by protecting the wire against environmental hazards and threats such as water, heat, chemicals, or physical damange. Wire insulation also resists electrical leakage, which prevents the wire&#;s electrical current from coming into contact with other wires and cables that are nearby.
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There are many different kinds of wire and cable insulation materials available and performance varies depending on the use case. The three main insulation materials are Plastic, Rubber, and Fluoropolymer. The following is a list of wire and cable insulation materials with information on the typical uses, advantages, and disadvantages for each option. Insulation for both wires and cables are essentially the same. Wire insulation is insulating a single conductor; which is the definition of a wire. When referencing cables, cable insulation is referring to a cable made of multiple (wire) conductors. Cable insulation can refer to the insulation type surrounding each wire, or the insulation of the cable as a whole. The type of insulation and level of insulation required for your cable to perform at its best will depend on the specific applications use case.
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Polyvinyl Chlroride, or PVC, is a relatively inexpensive and easy-to-use wire & cable insulation material with the potential to be used in a diverse array applications. PVC insulation has a recommended operating temperature ranging from -55° Celsius to +105° Celsius and is resistant to flame, moisture, and abrasion. PVC wire insulation can also endure exposure to gasoline, ozone, acids, solvents, and other industrial chemicals. PVC is a common wire insulation material for medical and food-related purposes due to PVC material being odorless, tasteless, and nontoxic. Wire and cable with PVC insulation is suitable for both heavy- and thin-wall applications. However, PCV insulation displays high attenuation and capacitance loss, meaning there is some performance loss when compared to other insulation materials that could be used in an electrical system. PVC insulation also shows below-average flexibility when used in retractile cord applications, and should also not be used in environments where wire flexibilty and extended flex life would be required at low temperatures
Semi-Rigid PVC (SR-PVC) is mainly used as primary insulation and is very abrasion-resistant. SR-PVC insulation also had heat, water, acid, and alkali resistance, along with being flame-retardant. For 30-16 gauge wire, a 10-mil. wall meets the UL-style UL (80 degrees Celsius, 300 volts).
Plenum Polyvinyl Chloride (Plenum PVC) insulation is suitable for use in plenum spaces -- building spaces behind dropped ceilings or raised floors left open to allow for air circulation. Standard PVC is considered a non-plenum insulation option because it does not exhibit the qualities necessary for safe usage in plenum areas. To be plenum-rated, the insulation must meet more-stringent fire safety regulations.
Polyethylene (PE) Insulation is mostly used in coaxial and low-capacitance cables because of its exemplary electric qualities. It is often used in high performance applications because it is affordable and can be foamed to reduce the dielectric constant to 1.50. This makes polyethylene a popular insulation option for cables requiring high-speed transmission. Wire and cable with polyethlene insulation can be used in operating temperatures ranging from -65° Celsius to +80° Celsius. All PE insulation is stiff, hard, and inflexible at all densities. PE insulation is also flammable. Additives can be used to make PE insulation flame-retardant, but doing this will sacrifice the dielectric constant and increase power loss.
Polyproylene insulation (PP) is very similar to polyethylene (PE) insulation, but has a wider temperature range of -30° Celsius to +105° Celsius. PP insulation is commonly used primarily for thin-wall primary insulations and can be foamed to improve its electrical properties.
Polyurethane (PUR) insulation is known for its extreme toughness, flexibility, and flex life; even in low temperatures. It also has excellent ratings for chemical, water, and abrasion resistance. PUR insulation works well in retractile cord applications and is a popular option for salt-spray and low-temperature military purposes. However, polyurethane is a flammable material. PUR insulation can be made flame-retardant with additives, but doing this sacrifices some insulation strength and affects the surface finish. Although polyurethane is generally very durable, it has poor electrical properties, making PUR more commonly used for wire and cable jacketing rather than as an insulation material.
Chlorinated Polyethylene (CPE) insulation has very good heat, oil, and weather resistance and commonly serves as a lower-cost, more environmentally friendly alternative to chlorosulfonated polyethylene (Hypalon / CSPE) insulation. CPE insulation also has reliable performance when exposed to fire and flame; making CPE insulation a favorable alternative to PVC insulation. Chlorinated polyethylene insulation is commonly found in power and control cables, as well as industrial power plant applications.
Nylon is usually extruded over softer insulation compounds. It serves as a tough jacket, exhibiting strong abrasion, cut-through, and chemical resistance, especially in thin-wall applications. Nylon is also extremely flexible. One disadvantage of nylon is its absorption of moisture. This degrades some of its electrical properties.
In many applications, Thermoplastic Rubber (TPR) insulation is used to replace true thermoset rubber. TPR has improved colorability, higher processing speeds, and a wider usable temperature range. TPR also displays excellent heat, weather, and age resistance without curing. Thermoplastic rubber insulation is not cut-through resistant, but can be utilized in applications where other properties of rubber are preferred.
Neoprene (Polychloroprene) insulation is a synthetic thermoset rubber that must be vulcanized to obtain its desired qualities. Neoprene exhibits supreme abrasion, cut-through, oil, and solvent resistance. Neoprene is also known for its long service life, wide temperature range, and usability. It is remarkably flame retardant and self-extinguishing. Neoprene is especially desirable for hand-held cord sets and is often used in Military applications.
Styrene-Butadiene Rubber (SBR) Insulation is a thermoset compound with qualities similar to neoprene. SBR insulation has a temperature range of -55° Celsius to +90° Celsius and is primarily used in Mil-C- cables.
Silicone insulation is extremely heat-resistant, flame-retardant, and can be used in operating temperatures up to +180° Celsius. Silicone is moderately abrasion-resistant and extremely flexible. Other benefits of silicone insulation include a long storage life and good bonding properties; two features which are commonly required for many electrical applications.
Fiberglass is the most widely used glass insulation and can be used continuously in operating temperatures up to +482° Celsius. Although fiberglass is resistant to moisture and chemicals, it only has average abrasion-resistance. Common applications of fiberglass include heat treating, glass and ceramic kilns, foundries, and extensive applications in aluminum processing.
Ethylene Propylene Rubber (EPR) insulation is known for its excellent thermal characteristics and electrical properties, allowing a smaller cross-sectional area for the same load-carrying capacity of other cables. It is commonly used in high-voltage cables. EPR insulation is heat, oxidation, weathering, water, acid, alcohol, and alkali-resistant, and is commonly used in high-voltage cables. The flexibility of EPR insulation also makes it appropriate for temporary installations and applications in the mining industry. Although EPR is very flexible, it is also a relatively soft material, and may require more care during installation to avoid damage. Ethylene Proplyene Rubber insulation has an operating temperature range from -50° Celsius to +160° Celsius like other common insulation materials, but EPR is also not as tear-resistant as other insulation options.
Rubber insulation generally refers to both natural rubber and SBR compounds, each available in a variety of formulas for use in a wide range of applications. Because formulas vary, so do the operating temperature ranges and some other basic characteristics. While rubber insulation has poor oil and ozone resistance, it exhibits good low-temperature flexibility and electrical properties, as well as water, alcohol, and abrasion resistance.
Chlorosulfonated Polyethylene (CSPE) insulation works well in low-voltage applications. CSPE insulation is known for its ability to perform in a wide temperature range, as well as its resistance to chemicals and UV rays. CSPE insulation can be commonly found in appliance wire, lead wire, coil leads, transformer leads, and motor lead wire. Chlorosulfonated Polyethylene is also referred to as Hypalon, a registered trademark of Dupont.
Propylene Diene Monomer (EPDM) insulation is a synthetic rubber insulation that displays outstanding heat, ozone, weather, and abrasion resistance. EPDM insulation also exhibits excellent electrical properties. Further benefits of EPDM insulation include excellent flexibility at both high and low temperatures, ranging from -55° Celsius to +150° Celsius, as well as having a good dielectric strength. Propylene Diene Monomer is commonly used as a replacement material for silicone rubber in some applications.
Rubber Neoprene CSPE EPDM Silicone Oxidation Resistance F G E E E Heat Resistance F G E E O Oil Resistance P G G P F-G Low-Temperature Flexibility G F-G F G-E O Ozone Resistance P G E E O Weather (Sun Resistance) F G E E O Abrasion Resistance E G-E G G P Electrical Properties G P G E G Flame Resistance P G G P F-G Nuclear Radiation Resistance F F-G E G E Water Resistance G E E G-E E Acid Resistance F-G G E G-E F-G Alkali Resistance F-G G E G-E F-G Alcohol Resistance G F G P G Aliphatic Hydrocarbons Resistance P G F P P-F Aromatic Hydrocarbons Resistance P P-F F F P Halogenated Hydrocarbons Resistance P P P-F P P-G P = POOR F = FAIR G = GOOD E = EXCELLENT O = OUTSTANDINGPerfluoroalkoxy (PFA) insulation has different operating temperature ratings depending on the cables' construction, ranging from -65° Celsius to +250° Celsius. PFA insulation also has a very low dissipation factor, making it an electrically efficient option. Although PFA can be processed in long lengths, it is also an expensive material and does not exhibit thermoset qualities, limiting the use of PFA insulation to select application.
Polytetrafluoroethylene (PTFE) insulation is a thermoplastic material that has an operating temperature range of -73° Celsius to +204° Celsius. PTFE insulation is extremely flexible, as well as resistant to water, oil, chemicals, and heat. The mechanical properties of PTFE are low compared to other fluoropolymer materials.
Fluorinated Ethylene Propylene (FEP) insulation is mostly used because of its processing characteristics and wide range of application uses. FEP insulation is also highly flame-resistant. Improved data transmission can also be achieved when FEP is foamed. Pricing and processing are also being improved. Fluorinated Ethylene Propylene insulation is commonly used in plenum cable and military applications.
Ethylene Tetrafluoroethylene (ETFE) and Ethylenechlorotrifluoroethylene (ECTFE) are stronger insulation materials and more flexible than PFA or FEP insulation. ETFE and ECTFE insulation can also become thermoset through irradiation. Foaming ECTFE and ETFE improves data transmission and reduces weight. However, ETFE and ECTFE lack many of the electrical advantages that FEP insulation provides.
Polyvinylidene Fluoride (PVDF) is a flexible, lightweight, and thermally stable insulation material. PVDF insulation is also resistant to chemicals, heat, weather, abrasion, and fire. PVDF is a relatively low-cost insulation option, so it is used in a wide range of industries and applications. Polyvinylidene Fluoride is often found in cables that need to meet the UL standard 910 Plenum Cable Flame Test, which labels cables as suitable for use in a building&#;s space for air circulation. PVDF is also commonly called Kynar, a registered trademark of Arkema Inc.
Thermoplastic elastomers (TPE) consist of a mix of polymers, typically plastic and rubber, to combine the benefits of each material into one insulating product. TPE can be molded, extruded, and reused like plastic materials while still maintaining the flexibility and stretch of rubber. Thermoplastic elastomers are commonly used in applications where conventional elastomers cannot provide the necessary range of physical properties. TPE insulation is now being more and more commonly used in household appliances and automotive applications. Disadvantages of TPE insulation include poor chemical and heat resistance, low thermal stability, and an overall higher cost when compared to other types of insulation.
FEP ETFE PTFE PVDF ECTFE TPE Oxidation Resistance O E O O O E Heat Resistance O E O O O E Oil Resistance O E E-O E O G Low-Temperature Flexibility O E O F O E Ozone Resistance E E O E E E Weather (Sun Resistance) O E O E-O O E Abrasion Resistance E E O E E F-G Electrical Properties E E E G-E E E Flame Resistance O G E E E-O F-G Nuclear Radiation Resistance P-G E P E E G Water Resistance E E E E E G-E Acid Resistance E E E G-E E G Alkali Resistance E E E E E G-E Alcohol Resistance E E E E E G Aliphatic Hydrocarbons Resistance E E E E E P Aromatic Hydrocarbons Resistance E E E G-E E P Halogenated Hydrocarbonic Resistance E E E G E - Underground Burial E E E E E P P = POOR F = FAIR G = GOOD E = EXCELLENT O = OUTSTANDINGWhen it&#;s time to make an investment that will impact long-term business continuity, uptime, and effectiveness, you want to make sure you get it right. There&#;s little room for error or guesswork.
Like with many important product purchases, when it comes to purchasing multi-conductor cables, the trick is to find the right balance between cost and performance.
By learning as much as you can about these cables before you make a purchasing decision, you&#;ll avoid the hassle of discovering too late (likely during installation) that the solution you chose wasn&#;t the best option after all. This discovery can lead to rework and overspending, as well as system failure and unplanned downtime.
Not all multi-conductor cables are created equal. The decisions you make shouldn&#;t be based solely on price &#; your application and environment need to be considered, too. They&#;ll help you determine the type of cable construction and material you need for the results you want.
From small electronic components to factory automation applications, multi-conductor cables can be found all over. They safely transmit signals and electrical power over one cable to control applications.
To do this, multi-conductor cables bring several insulated conductors together inside a jacket. You may hear the term &#;multipair cable&#; as well, which refers to a type of multi-conductor cable designed to guard against electromagnetic interference and crosstalk by twisting insulated conductors into pairs before they&#;re placed inside a jacket.
You&#;ll find multi-conductor cables in:
Because they&#;re used in so many applications &#; serving as control cables, VFD cables, robotics cables, and much more &#; multi-conductor cables are one of the most common types of cable around. They play a critical role in our daily connected communications.
How can you pinpoint the right multi-conductor cable for your application? First, consider your environment. Then, select a multi-conductor cable constructed for that setting. The four components that make up these cables &#; conductors, insulation, shielding, and jacketing &#; directly impact whether a cable will work in your plant or facility.
Before you make a purchasing decision, ask yourself these questions about your environment. Your answers will guide you to the right choice.
If high heat is a regular occurrence, then pay special attention to cable insulation and jacket materials.
In factories or mills &#; or even in applications where baking equipment, lighting, or heating elements are located nearby &#; high temperatures may impact cable performance.
To avoid overheating, melting, or other issues, select a multi-conductor cable with insulation and a jacket designed to withstand high-heat environments. Cable materials like TPE (thermoplastic elastomer) and silicone can protect against high temperatures, ensuring long life and protecting against damage from heat.
Always reference the cable&#;s maximum rated temperature (which is based largely on its materials of construction) and consider potential &#;over-temperature&#; conditions in your application. Also be aware that many cable designs will have more than one &#;maximum temperature&#; depending upon the application, for example a PVC-insulated multi-conductor cable could be rated to 221°F (105°C) in stationary use, but only to 194°F (90°C) for flexible, motion-based applications.
If so, then pay special attention to the cable&#;s jacketing. The right material will protect your cable from harsh liquids and chemicals.
Just because chemicals, oils, lubrication, and/or machinery coolant are common in factories and food and beverage environments doesn&#;t mean all multi-conductor cables are designed to withstand them. Their presence should factor into your cable selection.
To maintain flexibility, multi-conductor cables contain plasticizers inside their insulating compounds. If these plasticizers come into contact with harsh chemicals, oils, or lubrications through absorption, cable degradation, performance failure, and potential downtime can occur. Once this happens, it can&#;t be undone.
A few examples of possible damage from exposure to chemicals or oils include:
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Swelling
Melting
Discoloring
Cracking
In these environments, it&#;s important to select a cable with a jacket designed to withstand these liquids, such as one made of polyurethane (PUR). It resists oils and chemicals better than other jacketing materials, including the commonly used polyvinyl chloride, or PVC (although PVC also has the ability to resist oil and acid in certain environments).
Will it be installed across or near a rough surface? Will something rub up against it? If so, your cable needs a jacket that can withstand this abrasion.
In environments where abrasion exists, cables can fail when their jackets are too thin or soft to protect shielding and conductors inside. Look for heavy-duty PUR cable jackets, which resist cutting or wearing away from rubbing against rough surfaces. It will take a very high number of strokes to cause the cable&#;s insulation to fail if it&#;s jacketed in the right material.
If cables will be used in wet environments &#; or in locations with high humidity &#; then corrosion may be a concern. Selecting the right conductor material can improve performance in these conditions.
Bare copper conductors are suitable in most of today&#;s industrial sites and are suitable for use in ultrasonic welding applications, but tinned copper (covered in metal alloy) is better suited for wet, high-humidity applications and are very easy to solder. Both offer similar performance, but tinned copper conductors will last longer in production and process environments.
If so, then you&#;ll need a cable jacket with a low smoke zero halogen (LSZH) classification. This type of thermoset jacket is suitable for installation in places where fire possibilities exist.
Although fires can start nearly anywhere, some environmental conditions are favorable for potential fires: dust accumulation, flammable liquids and gases, welding or other hot work, overloaded electrical wiring, or even friction inside heavy machinery. Depending on the application and the applicable standards (UL in the United States, CSA in Canada, IEC in Europe, etc.), there are several levels of flame resistance.
In general, the strictest type of flame resistance is for plenum rated cable, followed by riser-rated cable. Both of these apply to critical applications where human beings work or reside such as permanent installation within buildings and dwellings. (see next question). Other common industrial types of flame ratings include FT4 and FT1 (CSA Vertical Tray Tests) and UL VW-1 (UL Vertical Flame Test).
Lastly, low smoke zero halogen (LSZH) cables utilize jacketing materials that are safer when exposed to fire; they don&#;t produce as much dense smoke or highly toxic gases like non-LSZH cables, such as those with PVC jackets. If a cable with an LSZH classification encounters fire, fewer toxic fumes and less smoke will be emitted as it melts, keeping people and equipment safer.
Are cables going into air-return (plenum) spaces? Below raised floors? If the installation involves a plenum or underfloor space, then the cable should be rated for that environment.
By selecting a cable rated for plenum spaces, you can rest easy knowing that the jacket and insulation materials allow safe operation with smoke and low-flame characteristics. Featuring high heat ratings and fire resistance, they can support technology such as signaling, sensors, security systems, HVAC equipment, and communications systems.
Every environment experiences some amount of electrical noise (RFI or EMI), whether it&#;s from motors, lighting systems, wireless devices, two-way radios, or other cables. Very small amounts of interference are manageable, but noisy environments need shielded cables.
A shielded cable eliminates unwanted circuit noise through a metallic layer that prevents EMI and RFI from entering or emitting from the conductor. Without shielding, electrical noise may impact the cable&#;s performance, create crosstalk (interference), or impact the performance of equipment and electronics.
The type of cable shielding you select should be based on the type of electrical noise being generated in your environment. For example:
In certain applications, multipair cable &#; a specific type of multi-conductor cable &#; can also be used to defend against noise. Their construction (insulated conductors twisted into pairs before being placed inside a jacket) is effective at preventing noise, crosstalk, and interference.
If your plant utilizes moving technology, then cable flexibility is crucial. Flexibility is impacted by all four components of the cable: the conductor, insulation, shield, and jacket.
Flexibility can literally make or break the ability for a cable to be used in a certain situation. Many of today&#;s industrial environments call for cables that offer flexibility and a small bend radius to accommodate tight clearances, maximize space usage, and route around equipment or machinery. Forcing non-flexible cables into applications where tight bends or routing are required can generate crosstalk, interference, or cable damage.
If cables will be used in a fixed application (lay static a straight line), then flexibility isn&#;t usually necessary. A cable with a solid conductor will fit the bill (solid conductors tend to be stiff and inflexible). Remember, some flexibility may be necessary for routing, so make sure to take that into consideration.
If your application involves automation or movement (robots, moving gantries, etc.), however, then flexible cables will be needed to withstand bend. Look for cables with stranded conductors (multiple smaller strands grouped together) vs. one solid conductor.
Multi-conductor cables are available with different strand counts (the higher the strand count, the more flexible the cable). Determine upfront how much installation room is available &#; as well as what the cables will need to be installed around &#; and you&#;ll be able to accommodate the flexibility and bend radius requirements you need.
If you&#;re utilizing a shielded cable to control noise interference, some shield types are more flexible than others. While braid shields offer some flexibility, foil shields are even more flexible &#; but their ability to &#;flex&#; doesn&#;t last as long.
Insulation and jacketing material also impact flexibility, with some compounds having more than others. Silicone, for example, offers high levels of flexibility.
If cable glands will be used, then insulation and jacket materials matter to keep diameters as small and round as possible. If cable glands won&#;t be used, then the thickness or roundness of the cable may not be as important.
If a cable gland (cord grip) will be used to prevent accidental pullout, decrease potential stress or damage, relieve strain, or create a tight seal to prevent dust or moisture intrusion, then cable diameter &#; and the ability to maintain roundness and a consistent diameter (no swelling) &#; matters.
For example, cables with pressure-extruded jackets maintain roundness with a consistent diameter that eliminates convolutions. As a result, they create a better seal when used with cable glands or cord grips.
Are you in a hurry to get multi-conductor cables installed? Is there a deadline that needs to be met? If so, certain cable choices can be easier to handle and install than others.
If your project isn&#;t a rush job, then maybe speed isn&#;t a huge concern. But, if you&#;re on a tight timeline or have limited labor available, choosing the right multi-conductor cable can reduce installation time.
Consider tube extrusion cables, for example. They feature a tube jacket that&#;s faster and easier to strip as opposed to a pressure-extruded jacket. If you use automated cutting/stripping wire processing machines, this option can make the installation process go faster.
If you&#;re installing in tight spaces or small cable trays, then jacket and insulation thickness and weight can matter.
Based on the cable you select, its overall diameter (thickness) can make it more difficult to install in congested cable trays or narrow conduit. If space is at a premium in your installation environment, select a cable with minimal jacket thickness and smaller cable diameter. This will allow you to run more cable through your trays or conduit.
In other applications such as vehicles, moving industrial equipment and other use-cases the overall weight of a cable can matter. Different material formulations can factor into the overall weight per foot of the multi-conductor cable.
Cables with a novel jacket and insulation materials such as mPPE can reduce overall cable diameter by up to 50% while reducing weight up to 65% versus industry-standard PVC materials.
Want to learn more about choosing the right multi-conductor cable for your environment and finding the right balance between price and performance? Contact Lapp Tannehill and we'll be happy to help you find the right cable for your needs. Reach us at 800.633. or chat with us online.
Now that you know what to consider when selecting a multi-conductor cable, take a look through the multi-conductor cables that Lapp Tannehill offers. As a distributor, we have access to a variety of manufacturers to help you find what you need.
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