The Importance of Choosing the Right Power Cable

Power cables are used for transmitting electrical energy. They can be installed as permanent wiring inside buildings, buried in the ground or run overhead.

These cables are generally made of factory insulated wires arranged in unison and protected by a flexible metallic sheath. The armor provides mechanical protection for the electric parts conductors and also makes the cable bendable.

Insulation

The insulation is the non-conductive covering that separates current from other parts of the cable. This helps to protect the wire from harsh environments and ensures that it functions properly.

The type of material that is used to insulate a wire depends on the targeted application. It can be made from plastic, rubber or fluoropolymers.

Insulation is important for electrical cables because it keeps the wire from getting too hot or melting. It also prevents it from accessing the surrounding environment and causing damage to other components.

High-voltage cables, for example, are insulated with polymers such as cross-linked polyethylene (XLPE) and polypropylene. This insulation withstands temperatures up to 80degC and resists cracking, cut-through and soldering.

Similarly, coaxial and low capacitance cables often use PE as their primary insulation material. It carries excellent electric qualities and is resistant to cracking, cut-through, solvents, and soldering. This wire insulation is usually available in densities ranging from -65degC to 80degC.

Conductors

Whether it is a consumer power cable or a wire harness for a piece of capital equipment, a lot of design and engineering goes into each type of conductor used.

The most common conductors are copper and aluminum. Both are efficient at conducting electricity.

Steel may also be used as a conductor. This is typically in situations where exceptional mechanical strength is required, though it does not conduct electricity as efficiently.

Copper and aluminum conductors can be coated with tinned or silver to improve their performance, especially in flex applications. Silver-coating increases conductivity and widens its operating temperature range.

Connectors

A power connector completes an electrical circuit by joining an electronic device to its power source. This can include a plug used with a wall outlet, connections between an electronic device and a large external battery or generator, or a connection between an electrical device and a computer's motherboard.

A wide range of connectors are available to meet different application needs and performance requirements. Common examples include lugs, crimps, set screws, and split-bolt types. Other methods, such as ring or spade terminal lugs, are available for terminating individual wires without physically joining them to the other ends.

Many connectors also have housings designed with locking mechanisms to prevent inadvertent disconnection, allowing for better environmental sealing. These locking mechanisms may be levers, jackscrews, screw-in shells, or toggle systems.

Length

Generally speaking, it is difficult to overemphasize the importance of choosing the right power cord for the job. For example, the right cord can save you money and a headache down the road, not to mention help your system perform at peak levels. A good power cord can also save a great deal of time, especially when installing or uninstalling your equipment. It is worth taking the time to pick out the best power cord for your application and test it out before hand. The most important thing to consider is the power cord's length and wattage rating, which will equate to cost savings down the road. Lastly, you may want to consider the temperature of the power cord when making your purchase decision. A power cord that is too warm or too cold can cause damage to the cable and damage your expensive gear.