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Tectonic

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Selecting the right cable

« on: February 20, , 10:40:54 pm » I'm designing a device to probe water temperature of a lake at different depths. The initial design will have two temperature sensors at the end of the wire as well as a bit of weight. The measurements will be done with a microcontroller displayed on a small LCD screen.

I'm looking to select the right cable for my application. The criteria are:

• Low cost (trying to keep it under $1.5/ft)
• 4 conductors
• Good flexibility (I want the wire to be straight when unrolling it. I want minimal weight required to keep it straight and not coiling when it's lowered into the water.)
• Temperature range from 5C to 35C
• Keep the wire's diameter at a minimum

I'm looking for recommendations on jacket material, insulation material (if needed), and stranding. I've done some research and it appears silicone-rubber would be ideal but the price for it is ~$6-8/ft. There's plenty of alternatives but mere descriptions aren't enough to go by. Once I get an idea of what is a good choice I'll go ahead and get some samples.

dwpatter53

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Re: Selecting the right cable

« Reply #1 on: March 01, , 11:12:32 pm » What type of sensor? and what will the voltage and current be?

I would go as small a AWG as possible.

24 or 28 AWG 4 cond stranded should work.

CAT 5E 24/4PR RISER 100 Feet GRAY is cheap, $20. in Canada.
Dave P.Eng. BScEE
Super Control Engineer retired

calexanian

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Re: Selecting the right cable

« Reply #2 on: March 02, , 03:18:37 am » I would think any four conductor would work. I would not go below 22 AWG as soldering becomes difficult. A fishing weight at the end sould keel it nice and straight. If you can get neoprene jacketing it will be more pliable and not hold kinks. PVC should be avoided because it holds kinks and gets stiff at low temperatures. bundling 4 silicone or Teflon conductors would be good as well. I would encapsulate the sensors in a sharpie cap filled with epoxy or something of the like at the end to keep the water out and fouling your measurement. Charles Alexanian
Alex-Tronix Control Systems

dom0

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Re: Selecting the right cable

« Reply #3 on: March 02, , 07:30:53 am » Soft PVC would work (for a few years. Microphone cable comes to mind. Soft PVC, light, thin conductors, many configurations available, cheap.), but you probably want cable with a rubber or silicone jacket, which tend not to lie flat. ,

made2hack

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Re: Selecting the right cable

« Reply #4 on: March 02, , 10:21:32 am » LAN / ethernet cable. It's AWG 24, usually solid copper conductor. If you want some extra shielding, buy FTP/s-FTP type that has some more shielding on it. Cheap as in the $1 - $2 / meter. Also, it's 4 Pairs, or 8 wires. So it gives you some redundancy.

dexters_lab

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Re: Selecting the right cable

« Reply #5 on: March 02, , 12:53:01 pm » CAT5 or other PVC cable would turn very rigid in cold water

i would head over to the Chinese sites like aliexpress or alibaba and look for silicone cable that would be used on headphones or in other audio applications where you have multicore cable.

ajb

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Re: Selecting the right cable

« Reply #6 on: March 02, , 02:04:00 pm » I can't think of many high-volume applications that require four conductor cabling.  You might have more luck if you can find a way to get away with only three conductors (might need a small MCU at the sensor end to multiplex the data from the two sensors onto a UART stream or something?), as that could allow you to use much more widely available commodity 3-wire audio cable and similar. 

You'll need to pay special attention to sealing the sensor end, especially if you go with a silicone jacket, to which a lot of sealants won't stick very well.  It may be best if you can somehow incorporate a gland at the sensor end. « Last Edit: March 02, , 02:06:39 pm by ajb »

dom0

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Re: Selecting the right cable

« Reply #7 on: March 02, , 02:48:58 pm » 2x2 / 4x (+ shield) microphone cables are pretty much standard. Telco cables with 2x2 are common, too, but normal PVC cable isn't a good match for this (see above). ,

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What is PVC Insulated Cable?

PVC insulated cable is consist of a conductor (typically copper or aluminum) surrounded by Polyvinyl Chloride (PVC) insulation.PVC insulated is an essential component of modern electrical and electronic systems. Distinguished by its insulation layer, this type of cable offers several advantages, including electrical isolation, fire resistance, chemical stability, and physical durability. PVC insulated flexible cable’s flexibility allows for easy installation in tight spaces and around corners, making it ideal for a wide range of indoor and outdoor applications. PVC cable insulation is the best choice for electrical installations due to its versatility and cost effectiveness.Whether you are working on a commercial project or setting up wiring in your home.PVC sheathed cables are the reliable option.Stay informed about the benefits of PVC cable for a successful electrical setup.

What is Insulated wire?

PVC insulated wire consists of a single core conductor wrapped in a PVC layer.The insulation layer isolates the conductor in pvc cable from the surrounding environment or conductors nearby.Ensure that current or electromagnetic waves and light waves can only propagate along the conductor and not affected by external interference.

Pvc wiring’s insulation enhances pvc wire’s mechanical strength without compromising flexibility, making it suitable for diverse applications from automotive wiring to household appliances. PVC insulated wires are available in various colors for easy identification during installation and maintenance. Additionally, pvc insulation cable can be customized with different grades of PVC to meet specific requirements such as higher temperature resistance or reduced flame propagation. PVC automotive wires are used in automobile circuit systems, and due to the safety and inherent characteristics of PVC, they occupy a huge share in the automotive field.

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Is 694 for pvc insulated cable?

Yes,IS 694 standard, which was developed by the Bureau of Indian Standards, is vital for maintaining the quality and safety of Polyvinyl Chloride (PVC) insulated cables utilized in residential, commercial, and industrial sectors. The standard provides detailed specifications for cable pvc, covering construction, testing protocols, and performance benchmarks, with a specific emphasis on cables rated up to volts. It underscores a commitment to electrical safety, make sure pvc insulation wire meets the stringent requirements for reliability and efficiency in power transmission and lighting applications.

Are PVC Insulated Cables Safe?

Safety is the top priority when dealing with electrical systems. PVC cable wires are generally regarded as safe due to their insulating properties which effectively protect against electrical shocks and short circuits. It’s important to be mindful that when exposed to fire, PVC electrical wire can emit toxic fumes. but we use LSZH Cable (Low smoke zero halogen) when we are in public spaces like big shopping malls or hospitals.

It is made of special materials with excellent flame-retardant properties, which can greatly reduce the production of harmful gases and smoke while also protecting human life. Meanwhile, proper safety protocols must be followed during installation and maintenance. On the other hand, we can also explore whether PVC cables can withstand high temperatures

Can PVC Insulated Cable Withstand High Temperatures?

PVC insulated cables have a limited ability to withstand high temperatures. The pvc wire insulation temperature rating is usually between 70°C and 90°C, but max temperature can be 105°C depends on the particular PVC materials and application.In places with higher temperatures, it is essential to use insulation materials that can withstand such conditions, like XLPE insulated cables or polytetrafluoroethylene（PTFE) materials. In addition, the PVC wire cable manufacturer’s specifications and guidelines must be consulted to ensure that the pvc insulated copper cable is suitable for the intended temperature range and environment. If cables are used beyond their rated temperature range, it could lead to the insulation heating up and potentially causing a fire. Now let’s find out more about his longevity

How Long do PVC Insulated Cables Last?

The lifespan of PVC cables can vary greatly depending on their usage conditions. Factors such as environmental conditions, mechanical stress, and temperature can affect their service life. For example, prolonged UV exposure may lead to aging and deterioration of the outer insulation layer and outer sheath of the cable, thus reducing the transmission performance and lifespan of the cable. Therefore, we can usually use weather-resistant special materials, such as UV-resistant wire insulation which can maintain stable physical and electrical properties under prolonged UV exposure. Under normal conditions, these cables can typically last for decades without significant performance degradation. Single-core PVC wires have a service life of 70 years, e.g. 2.5mm wire and 4mm wire, and PVC insulated power cables have a service life of up to 50 years. Regular inspection and maintenance can further extend the lifespan of the cable. Under normal circumstances, PVC insulated cables can typically be used for decades without significant performance degradation.

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