Industrial Cable Assemblies factory

How to select industrial cable for low-temperature environments​

Industrial cables operating in low-temperature environments—such as polar industrial sites, freezing warehouses, low-temperature manufacturing equipment, or outdoor applications in cold regions—face unique challenges: material brittleness, insulation failure, reduced mechanical strength, and even electrical performance degradation. Choosing the right cable is critical to ensuring operational reliability, avoiding unplanned downtime, and minimizing maintenance costs. Below is a practical, step-by-step guide to selecting industrial cables for low-temperature conditions.​

1. Prioritize Core Material Selection​

The performance of industrial cables in low temperatures is largely determined by their conductor, insulation, and jacket materials. Each component must be selected based on the specific temperature range of the application (typically -15°C to -60°C for low-temperature scenarios, or lower for extreme conditions).​

Conductors​

• Copper conductors (preferred): Annealed copper conductors offer stable electrical conductivity and higher mechanical toughness in low temperatures compared to aluminum. Aluminum conductors are prone to increased brittleness and resistance at low temperatures, making them unsuitable for applications requiring frequent bending or vibration.​

• Strand structure: For applications involving movement (e.g., robotic arms in cold warehouses), choose finely stranded copper conductors. Fine stranding reduces stress on the conductor during bending, preventing breakage in frigid conditions.​

Insulation Materials​

Insulation must resist hardening, cracking, and dielectric breakdown at low temperatures. Common options include:​

• Polyethylene (PE): Suitable for -40°C to 80°C. PE maintains flexibility and low dielectric loss in moderate low temperatures, making it ideal for general industrial use (e.g., power supply in freezing storage).​

• Cross-linked polyethylene (XLPE): Offers improved thermal stability and resistance to aging compared to standard PE, with a low-temperature range of -40°C to 90°C. It is preferred for cables requiring long-term reliability (e.g., underground cables in cold regions).​

• Fluoropolymers (PTFE/FEP): Designed for extreme low temperatures (-60°C to 200°C). PTFE and FEP retain flexibility and dielectric strength even in polar or cryogenic environments (e.g., aerospace or liquefied natural gas (LNG) equipment). However, they are higher in cost and best reserved for critical applications.​

• Avoid PVC: Polyvinyl chloride (PVC) becomes brittle below -15°C and is prone to cracking, making it unsuitable for low-temperature use.​

Jacket Materials​

The jacket protects the cable from physical damage, moisture, and chemicals. Low-temperature-compatible jackets include:​

• Polyurethane (PU): Excels in -30°C to 80°C, with excellent abrasion resistance and flexibility. It is ideal for mobile cables (e.g., cables for forklifts in cold warehouses).​

• Chloroprene rubber (neoprene): Withstands -30°C to 90°C and offers good resistance to oil and ozone, suitable for outdoor low-temperature applications (e.g., construction equipment in winter).​

• Fluoropolymer jackets: Paired with PTFE/FEP insulation, they provide extreme low-temperature protection (-60°C) and chemical resistance (e.g., cables in LNG processing plants).​

2. Evaluate Mechanical Performance​

Low temperatures cause materials to lose flexibility, increasing the risk of cable damage during installation or operation. Key mechanical properties to verify include:​

Low-Temperature Flexibility​

• Ensure the cable meets international standards such as IEC 60811-504, which requires cables to withstand repeated bending at the minimum application temperature (e.g., -40°C) without insulation cracking.​

• Check the “minimum bending radius”: In low temperatures, the bending radius should be 1.5–2 times larger than the 常温 (room-temperature) radius. For example, a cable with a 10mm diameter may require a 60mm radius at -40°C (vs. 40mm at 25°C).​

Low-Temperature Impact Resistance​

• Cables should pass impact tests per IEC 60811-506: A weighted hammer is dropped on the cable at the minimum operating temperature, and the jacket/insulation must not crack or expose the conductor.​

Tear Resistance​

• Materials like PU or XLPE offer higher tear resistance in low temperatures than rigid plastics. Avoid cables with thin or brittle jackets, as they are prone to tearing during installation.​

3. Verify Electrical Performance Stability​

Low temperatures can alter a cable’s electrical properties, leading to issues like increased resistance or insulation failure. Focus on these parameters:​

Conductor DC Resistance​

• The resistance of copper conductors increases slightly at low temperatures, but it must stay within the limits of standards like IEC 60228. Excessive resistance can cause overheating (even in cold environments) and voltage drops, affecting equipment performance.​

Insulation Resistance​

• Insulation resistance (measured via megohmmeter) should remain above 100 MΩ at the minimum operating temperature. A sharp drop in resistance indicates insulation degradation, which may lead to 漏电 (leakage current) or short circuits.​

Voltage Withstand Capacity​

• Test the cable’s ability to withstand rated voltage at low temperatures (e.g., 1kV AC for 1 minute per IEC 60060). Insulation that fails this test at low temperatures is unsafe for use.​

4. Assess Environmental Compatibility​

Low-temperature environments often involve additional stressors; the cable must withstand these to avoid premature failure:​

• Moisture/Condensation: Freezing warehouses or outdoor cold applications may expose cables to condensation. Choose jackets with water resistance (e.g., PE or PU) to prevent water ingress and insulation freezing.​

• Chemicals: Cables in cold manufacturing (e.g., food processing with low-temperature cleaners) need chemical resistance. Fluoropolymer jackets resist most solvents and cleaners at low temperatures.​

• Vibration: Equipment like cold-region pumps or conveyors generates vibration. Finely stranded conductors and flexible jackets (e.g., neoprene) absorb vibration, preventing conductor breakage.​

5. Follow Installation Best Practices​

Even the right cable will fail if installed incorrectly in low temperatures:​

• Pre-Installation Storage: Store cables at temperatures above their minimum operating limit (e.g., -20°C for a -40°C-rated cable) to avoid pre-mature brittleness.​

• Avoid Forceful Bending: Use tools to maintain the required bending radius; never twist or kink the cable, as this can crack insulation.​

• Secure with Flexible Clamps: Use plastic or rubber clamps (not metal) to fix cables. Metal clamps can compress and damage brittle jackets at low temperatures.​

Choose Reliable Cables for Low-Temperature Success​

Selecting industrial cables for low temperatures requires balancing material performance, mechanical strength, and environmental resilience. By focusing on these key factors, you can ensure long-term cable reliability and avoid costly downtime.​

For businesses seeking high-quality low-temperature industrial cables, FRS factory delivers tailored solutions that meet the strictest performance standards. FRS cables feature annealed copper conductors for stable conductivity, a range of insulation/jacket options (XLPE, PTFE, PU) to suit -15°C to -60°C environments, and pass IEC low-temperature flexibility and impact tests. Whether for freezing warehouses, cold-region infrastructure, or cryogenic equipment, FRS cables are engineered for durability and reliability—backed by rigorous quality control and customizable designs to fit your specific application needs. Trust FRS to keep your low-temperature operations running smoothly.