Flexible electric cable

Did you know that there are different types of wiring in your house? Among other things, we distinguish electrical cables according to whether they have rigid or flexible core cables. Read here when which types are used and what you should consider when selecting flexible cables.

How are flexible lines constructed?

The conductive core of a flexible cable does not consist of a solid (monolithic) wire, but of many little wires twisted together. These little wires form an insulated core, the so-called stranded wire. Depending on the purpose of the product, several of these cores can be bundled together in a further sheath to form a cable. The most important selection criteria for such a product are:

  • the number of insulated cores within the sheathing of a cable (this can be several dozen)
  • the color and positioning of the cores within the sheathing of a cable (see twisted pair cable)
  • the cross-section of the respective cores
  • the type and structure of the insulation and sheathing

 

The number and cross-section of the cores determine the total power of the current that can be safely conducted. This is one of the most important features of a cable and is specified by the manufacturer at regular intervals on the outer insulation. We recommend using quality products from well-known manufacturers. Tolerances can occur with cheap no-name items, which usually have an adverse effect on the cross-section and thus impair the performance of the line. There are also differences in the shape of the wires or lines. Most often we encounter the round shape, but in some variants the outer shape can also be flat, for example. This affects the outer diameter and the possible uses.

The type and structure of the insulation and sheathing

Insulation appropriate for the application is the primary safety feature of an electrical cable. Their main task is:

  • Protect people from contact with a live core
  • to protect the cable from mechanical damage
  • to ensure a correct current flow without interference from the outside
  • to shield the environment from the influences of the line

 

In a line, each core is separately insulated. This prevents contact between the electrical conductors in the cores and offers protection against mechanical damage. Another outer sheath holds all the components of the cable together and also protects the inner insulation from drying out, high humidity and other influences. Depending on the location and purpose of a line, different materials are used for the insulation. These should correspond to the expected mechanical, chemical and thermal influences. The UV radiation of the sun must also be taken into account. The following materials are therefore used most frequently in the area of classic household electrics:

  • PVC – inexpensive, flexible, low-wear, non-flammable and resistant to various chemical compounds, not suitable for high and very low temperatures
  • Rubber - particularly flexible, suitable for medium to difficult operating conditions, resistant to low temperatures
  • PE - resistant to chemical compounds, pressure and low temperatures
  • Silicone – particularly reliable at high temperatures up to around 200 °C, low mechanical strength
  • PUR – high oil resistance and abrasion resistant

 

immission and emission

Current-carrying cables generate magnetic fields. The immission protection protects the data flowing through the wire from external electromagnetic influences. The emission protection prevents the emission of electromagnetic interference signals through the line.


The outer casing can consist of additional elements:

  • Shielding made of metal foil or metal mesh as a barrier against immission and emission. These mainly include fault currents, radio waves, EM fields or radiation, which affect the transmission of signals in data lines.
  • Armor as maximum line protection against mechanical damage.
  • Cover made of (impregnated) cotton or silk to protect against mechanical damage, rot or for decorative purposes.

 

Source: eibabo®, various flexible cablesImage: Various flexible lines

What is the difference between flexible lines and rigid lines?

Cables with rigid conductors are used for fixed installation in domestic installations. Cables with flexible conductors are used where you want to connect mobile consumers. Mobile consumers are, for example, floor lamps, coffee machines, radios or hair dryers. But why is that?

Advantages and disadvantages of flexible, multi-core cables:

  • high elasticity and flexibility
  • small power losses
  • high quality circuit
  • reliability
  • poor performance on HF networks
  • high price

 

In particular, the higher price and the more complex production of connections (e.g. due to the necessary cable lugs) stand in the way of the use of flexible cables for all areas of electrical installation. In comparison, solid conductors have the following advantages and disadvantages in these points:

  • inexpensive
  • Use in HF networks
  • easier installation
  • easy connection
  • high rigidity, not very flexible, difficult handling

 

You save money with solid conductors in fixed installation. However, the handling of rigid cables is too cumbersome for daily mobile use on electrical devices, extensions or distributors.

Pliability of flexible lines

The number of cores and the diameter of the wires in a core determine the flexibility of the core of a cable. The standard DIN EN 60228 (VDE 0295) describes four classes of conductors: solid (i.e. single-core solid conductors), stranded, finely stranded and extra finely stranded. The thinner the wires, the easier it is to bend the line.

 


TIP

Single-wire and multi-wire cables have different levels of flexibility. During operation, these should not be bent too much so that the core is not damaged.


 

The rule of thumb for solid conductors is: The minimum bending radius should not be less than four to five times the diameter of the cable including the sheath. A line with an outer diameter of 11 mm should therefore not be bent below a radius of about 50 mm. Flexible cables are more flexible than solid cables. Their bending radius should not be less than three times the cable diameter.

What is a stranded twisted pair?

Information systems have become an integral part of life today. Telecommunications, the global Internet and television are part of our everyday lives. One of the most important components of such networks is the twisted pair line. This is a line consisting of four or eight copper wires. The cores of the twisted pair cables are offered as solid or in the form of stranded wires. The special thing about it is that the wires are twisted together in pairs. A shield increases the protection of the line against electromagnetic interference. Twisted pair cables are primarily intended for the transmission of digital information in Ethernet networks. twisted pair lines. The area of application is not only private houses and apartment buildings, but also commercial offices and industrial companies as well as public facilities such as schools and hospitals.

What is the significance of the core colors in flexible cables?

If you look at a typical flexible power supply cable, you will see strands of different colors in it. In Germany these are typically black, brown, blue, gray and green-yellow. In order to be able to use the individual wires correctly, you should know the meaning of the color coding. This is important so that other people can rely on the correct assignment of the colors during repairs, checks or changes. Installers derive the function of individual wires from this. Instructions are printed on the sheathing, which provide information about the number of wires and their diameter. The following rules apply to the colors of the wires in Germany and the EU: The basic colors are brown, blue and green-yellow. There are also the extended basic colors black and grey. Alternative colors are white, orange, red and purple.

Notice

Depending on the manufacturer, country and type of cable, there are major deviations in the colors of the core insulation. Please use the standard applicable in your country.


The following applies to Germany and large parts of Europe: the brown wire is phase 'L1' and is always used as the current-carrying line to the device. The blue wire is the 'N' neutral and carries the power back to the source. The green-yellow wire is intended for grounding. This is called the protective conductor 'PE'. The extended basic colors black and gray are used when it is a three-phase AC installation. The black wire represents phase 'L2', the gray wire represents phase 'L3'. The alternative colors of white, orange, red and purple are intended to complement certain installations.

Which cross-section do I have to pay attention to with flexible cables?

Flexible cables with stranded copper for normal household use start with a standard cross-section of 0.5 mm². The dimensions 0.75 mm², 1.5 mm² and 2.5 mm² are widespread. The cross-section you need depends on numerous conditions. These include:

  • the type of current (direct current, alternating current)
  • the level of the operating voltage
  • the amperage
  • the length of the line
  • the type of transfer
  • the voltage drop
  • the phase angle

 

These parameters result in a formula that can be used to calculate a cable cross-section. Due to the many variables, for safety reasons we do not give any general recommendations for the use of certain cross-sections at this point.

Simply browse through our large eibabo® range. Here you will find flexible PVC hose lines, silicone lines, rubber lines or PUR lines at particularly reasonable prices.

 

eibabo - technology store

 

Catalogue content:


In this eibabo® catalogue Cables > Power cable < 1 kV, for moving application you will find items from the following product groups:

Item overview:

  • Control cable
  • Control line
  • Data cable
  • Data line
  • Device connection cable
  • External line
  • Fuse box
  • High voltage cable
  • House connection cable
  • Insulating tube
  • Line jumper
  • Machine control line
  • Measurement line
  • Measuring system
  • Medium voltage cable
  • Overvoltage protection
  • Power cable
  • Power control line
  • Power line
  • Rubber cable
  • Rubber hose line
  • Servo line
  • Silicone cable
  • Silicone line
  • Supply cable
  • Trailing cable
  • Trunk cable ring
  • Voltage tap


from the following manufacturers:

Manufacturer overview catalogue Flexible electric cable:

  • Bachmann
  • Barthelme
  • Comelit Group
  • Diverse
  • Eaton
  • Elspro
  • Faber Kabel
  • Glen
  • Hager
  • Harting
  • Helukabel
  • Igus
  • Lappkabel
  • Leoni Studer
  • Lütze
  • Murrelektronik
  • Phoenix
  • Pilz
  • Scharnberger+Has.
  • Walther
  • Warema
  • Weidmüller
  • Wieland


 
Did you know that there are different types of wiring in your house? Among other things, we distinguish electrical cables according to whether they have rigid or flexible core cables. Read here... read more »
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Flexible lines - A small guide

Did you know that there are different types of wiring in your house? Among other things, we distinguish electrical cables according to whether they have rigid or flexible core cables. Read here when which types are used and what you should consider when selecting flexible cables.

How are flexible lines constructed?

The conductive core of a flexible cable does not consist of a solid (monolithic) wire, but of many little wires twisted together. These little wires form an insulated core, the so-called stranded wire. Depending on the purpose of the product, several of these cores can be bundled together in a further sheath to form a cable. The most important selection criteria for such a product are:

  • the number of insulated cores within the sheathing of a cable (this can be several dozen)
  • the color and positioning of the cores within the sheathing of a cable (see twisted pair cable)
  • the cross-section of the respective cores
  • the type and structure of the insulation and sheathing

 

The number and cross-section of the cores determine the total power of the current that can be safely conducted. This is one of the most important features of a cable and is specified by the manufacturer at regular intervals on the outer insulation. We recommend using quality products from well-known manufacturers. Tolerances can occur with cheap no-name items, which usually have an adverse effect on the cross-section and thus impair the performance of the line. There are also differences in the shape of the wires or lines. Most often we encounter the round shape, but in some variants the outer shape can also be flat, for example. This affects the outer diameter and the possible uses.

The type and structure of the insulation and sheathing

Insulation appropriate for the application is the primary safety feature of an electrical cable. Their main task is:

  • Protect people from contact with a live core
  • to protect the cable from mechanical damage
  • to ensure a correct current flow without interference from the outside
  • to shield the environment from the influences of the line

 

In a line, each core is separately insulated. This prevents contact between the electrical conductors in the cores and offers protection against mechanical damage. Another outer sheath holds all the components of the cable together and also protects the inner insulation from drying out, high humidity and other influences. Depending on the location and purpose of a line, different materials are used for the insulation. These should correspond to the expected mechanical, chemical and thermal influences. The UV radiation of the sun must also be taken into account. The following materials are therefore used most frequently in the area of classic household electrics:

  • PVC – inexpensive, flexible, low-wear, non-flammable and resistant to various chemical compounds, not suitable for high and very low temperatures
  • Rubber - particularly flexible, suitable for medium to difficult operating conditions, resistant to low temperatures
  • PE - resistant to chemical compounds, pressure and low temperatures
  • Silicone – particularly reliable at high temperatures up to around 200 °C, low mechanical strength
  • PUR – high oil resistance and abrasion resistant

 

immission and emission

Current-carrying cables generate magnetic fields. The immission protection protects the data flowing through the wire from external electromagnetic influences. The emission protection prevents the emission of electromagnetic interference signals through the line.


The outer casing can consist of additional elements:

  • Shielding made of metal foil or metal mesh as a barrier against immission and emission. These mainly include fault currents, radio waves, EM fields or radiation, which affect the transmission of signals in data lines.
  • Armor as maximum line protection against mechanical damage.
  • Cover made of (impregnated) cotton or silk to protect against mechanical damage, rot or for decorative purposes.

 

Source: eibabo®, various flexible cablesImage: Various flexible lines

What is the difference between flexible lines and rigid lines?

Cables with rigid conductors are used for fixed installation in domestic installations. Cables with flexible conductors are used where you want to connect mobile consumers. Mobile consumers are, for example, floor lamps, coffee machines, radios or hair dryers. But why is that?

Advantages and disadvantages of flexible, multi-core cables:

  • high elasticity and flexibility
  • small power losses
  • high quality circuit
  • reliability
  • poor performance on HF networks
  • high price

 

In particular, the higher price and the more complex production of connections (e.g. due to the necessary cable lugs) stand in the way of the use of flexible cables for all areas of electrical installation. In comparison, solid conductors have the following advantages and disadvantages in these points:

  • inexpensive
  • Use in HF networks
  • easier installation
  • easy connection
  • high rigidity, not very flexible, difficult handling

 

You save money with solid conductors in fixed installation. However, the handling of rigid cables is too cumbersome for daily mobile use on electrical devices, extensions or distributors.

Pliability of flexible lines

The number of cores and the diameter of the wires in a core determine the flexibility of the core of a cable. The standard DIN EN 60228 (VDE 0295) describes four classes of conductors: solid (i.e. single-core solid conductors), stranded, finely stranded and extra finely stranded. The thinner the wires, the easier it is to bend the line.

 


TIP

Single-wire and multi-wire cables have different levels of flexibility. During operation, these should not be bent too much so that the core is not damaged.


 

The rule of thumb for solid conductors is: The minimum bending radius should not be less than four to five times the diameter of the cable including the sheath. A line with an outer diameter of 11 mm should therefore not be bent below a radius of about 50 mm. Flexible cables are more flexible than solid cables. Their bending radius should not be less than three times the cable diameter.

What is a stranded twisted pair?

Information systems have become an integral part of life today. Telecommunications, the global Internet and television are part of our everyday lives. One of the most important components of such networks is the twisted pair line. This is a line consisting of four or eight copper wires. The cores of the twisted pair cables are offered as solid or in the form of stranded wires. The special thing about it is that the wires are twisted together in pairs. A shield increases the protection of the line against electromagnetic interference. Twisted pair cables are primarily intended for the transmission of digital information in Ethernet networks. twisted pair lines. The area of application is not only private houses and apartment buildings, but also commercial offices and industrial companies as well as public facilities such as schools and hospitals.

What is the significance of the core colors in flexible cables?

If you look at a typical flexible power supply cable, you will see strands of different colors in it. In Germany these are typically black, brown, blue, gray and green-yellow. In order to be able to use the individual wires correctly, you should know the meaning of the color coding. This is important so that other people can rely on the correct assignment of the colors during repairs, checks or changes. Installers derive the function of individual wires from this. Instructions are printed on the sheathing, which provide information about the number of wires and their diameter. The following rules apply to the colors of the wires in Germany and the EU: The basic colors are brown, blue and green-yellow. There are also the extended basic colors black and grey. Alternative colors are white, orange, red and purple.

Notice

Depending on the manufacturer, country and type of cable, there are major deviations in the colors of the core insulation. Please use the standard applicable in your country.


The following applies to Germany and large parts of Europe: the brown wire is phase 'L1' and is always used as the current-carrying line to the device. The blue wire is the 'N' neutral and carries the power back to the source. The green-yellow wire is intended for grounding. This is called the protective conductor 'PE'. The extended basic colors black and gray are used when it is a three-phase AC installation. The black wire represents phase 'L2', the gray wire represents phase 'L3'. The alternative colors of white, orange, red and purple are intended to complement certain installations.

Which cross-section do I have to pay attention to with flexible cables?

Flexible cables with stranded copper for normal household use start with a standard cross-section of 0.5 mm². The dimensions 0.75 mm², 1.5 mm² and 2.5 mm² are widespread. The cross-section you need depends on numerous conditions. These include:

  • the type of current (direct current, alternating current)
  • the level of the operating voltage
  • the amperage
  • the length of the line
  • the type of transfer
  • the voltage drop
  • the phase angle

 

These parameters result in a formula that can be used to calculate a cable cross-section. Due to the many variables, for safety reasons we do not give any general recommendations for the use of certain cross-sections at this point.

Simply browse through our large eibabo® range. Here you will find flexible PVC hose lines, silicone lines, rubber lines or PUR lines at particularly reasonable prices.

 

eibabo - technology store

 

Catalogue content:


In this eibabo® catalogue Cables > Power cable < 1 kV, for moving application you will find items from the following product groups:

Item overview:

  • Control cable
  • Control line
  • Data cable
  • Data line
  • Device connection cable
  • External line
  • Fuse box
  • High voltage cable
  • House connection cable
  • Insulating tube
  • Line jumper
  • Machine control line
  • Measurement line
  • Measuring system
  • Medium voltage cable
  • Overvoltage protection
  • Power cable
  • Power control line
  • Power line
  • Rubber cable
  • Rubber hose line
  • Servo line
  • Silicone cable
  • Silicone line
  • Supply cable
  • Trailing cable
  • Trunk cable ring
  • Voltage tap


from the following manufacturers:

Manufacturer overview catalogue Flexible electric cable:

  • Bachmann
  • Barthelme
  • Comelit Group
  • Diverse
  • Eaton
  • Elspro
  • Faber Kabel
  • Glen
  • Hager
  • Harting
  • Helukabel
  • Igus
  • Lappkabel
  • Leoni Studer
  • Lütze
  • Murrelektronik
  • Phoenix
  • Pilz
  • Scharnberger+Has.
  • Walther
  • Warema
  • Weidmüller
  • Wieland
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