By Eileen Harvey
Flexible control cables are integral components in a variety of applications, serving to power machinery, transmit signals and facilitate smooth operational processes in both industrial and commercial settings. These cables are engineered for flexibility, allowing for easy maneuvering and installation in tight spaces. However, a common concern is whether these cables can be utilized outdoors, given the various environmental factors involved.
The good news is that TKD flexible control cables can indeed be used outdoors, but it is essential to ensure that they are specifically designed and rated for such conditions. Outdoor-rated cables are constructed with materials that can withstand exposure to ultraviolet (UV) light, as well as moisture and temperature fluctuations, making them suitable for prolonged use in external environments.
When considering outdoor applications for flexible control cables, take into account the specific challenges they will face. Cables that are not explicitly designed for outdoor use can suffer from accelerated wear and tear due to harsh weather, leading to potential failures in power transmission or signal integrity. Factors such as UV degradation can cause insulation to break down over time, while exposure to water can lead to short circuits and other electrical issues. Additionally, outdoor cables must be robust enough to handle mechanical stress, such as those caused by movement, abrasion or impacts from environmental elements.
Understanding Flexible Control Cable Specifications
When using flexible control cables outdoors, it is essential to ensure that the cable meets specific outdoor usage standards. Not all cables are engineered for direct exposure to sunlight, rain or harsh environments.
There are five key factors to consider. First is UV resistance; outdoor cables must have jackets resistant to sunlight to prevent cracking or brittleness. Second is temperature range; cables should operate effectively in wide temperature fluctuations. A third factor is moisture resistance; jackets should be water-resistant or rated for wet conditions.
A fourth key factor is abrasion resistance, which means protection against physical damage in outdoor installations. A fifth factor is standards compliance; look for UL, CSA or IEC certifications indicating suitability for outdoor applications.
Key Considerations for Outdoor Use
Let’s look at five considerations:
1. UV Resistance: Most standard PVC-insulated control cables degrade under prolonged sun exposure. UV radiation causes the insulation to crack, leading to short circuits or conductor exposure. For outdoor use, cables must be UV-stabilized or installed in protective conduits.
2. Moisture Protection: Rain, snow and condensation pose risks to non-shielded or poorly insulated cables. If the insulation absorbs water, it can cause insulation resistance failure. A shielded or PUR-jacketed cable (like theKaweflex 6210 series) provides better protection against outdoor humidity.
3. Temperature Fluctuations: Outdoor environments may expose cables to freezing winters or scorching summers. PVC jackets stiffen in cold weather, while excessive heat can soften insulation. Choosing a cable rated for a wide temperature range is crucial.
4. Mechanical Stress: If the cable runs along an outdoor drag chain, crane or robot, both flex-life and environmental resistance matter. For these cases, flexible drag chain cables like theKaweflex 6110 12-Conductor 16 AWG are engineered to withstand repetitive bending.
5. Chemical Resistance: Outdoor environments may involve oils, fuels or corrosive chemicals. Polyurethane (PUR) jacketing is usually more chemical-resistant than PVC.
Outdoor-Safe Cable Options
While standard indoor flexible cables should be avoided outdoors unless protected, some models are designed for tougher conditions. Kaweflex 6210 Shielded Cables provide enhanced jacket protection and shielding against electromagnetic interference (EMI). One example is4-Conductor 18 AWG Shielded.
Another product line made for tough conditions is the Kaweflex 6110 Series. Its flexible PVC cables are suitable for indoor and limited outdoor use when installed in conduit or protected areas. An example is 7-Conductor 16 AWG.
Benefits of Outdoor-Grade Control Cables
Cables designed for outdoor conditions come with five big benefits. First is weather resistance; with UV-stabilized jackets and moisture-resistant insulation, these cables withstand rain, sunlight and temperature extremes. A second benefit is longevity; outdoor-rated control cables typically have a longer lifespan, reducing replacement costs. Outdoor control cables also bring safety assurance; proper insulation minimizes risks of short circuits, electrical fires and downtime.
A fourth benefit of these cables is enhanced flexibility; even in low temperatures, high-quality outdoor cables remain flexible for easy routing. A fifth benefit is reduced maintenance; high-durability jackets prevent wear and tear, lowering maintenance frequency.
Installation Guidelines for Outdoor Cables
Even the best cables can fail if installed improperly, so following key guidelines is essential for durability and performance. Installers should avoid sharp bends, excessive tension and areas where cables may be exposed to mechanical damage. Protective enclosures provide an added layer of defense against both physical and environmental stress, while weatherproof connectors and junction boxes help prevent water ingress. Unless a cable is specifically designed for direct burial, it should not be placed directly in the soil but instead routed through conduits or chosen in armored versions. Because temperature changes cause expansion and contraction, it is also important to avoid pulling cables too tightly.
Maintenance Tips for Outdoor Cables
Outdoor installations are exposed to constant stress, so regular maintenance is key to extending service life. We offer five tips.
First, inspect outdoor cables regularly, looking for cracks, discoloration or fraying in cable jackets. Second, check connections, ensuring connectors and junctions remain sealed and corrosion-free. Third, clean your cables, removing dirt, debris or vegetation that may trap moisture.
A fourth tip is to replace damaged sections promptly, because minor wear can escalate into major failures if ignored. Fifth, document and monitor, keeping a log of inspections and maintenance for better planning.
Recommendations
For general outdoor use, select shielded TKD Kaweflex 6210 cables with proper UV and moisture resistance. For protected outdoor areas (inside conduit or trays), the TKD Kaweflex 6110 series can be sufficient. For heavy-duty outdoor machinery, opt for PUR-jacketed shielded cables where available.
Flexible control cables can be used outdoors, but only if the right type is chosen. Factors like UV resistance, moisture protection, temperature range and shielding determine long-term performance.
For outdoor reliability, consider the Kaweflex 6210 shielded seriesor use the 6110 series with added protection (like conduits). Investing in the right cable upfront prevents costly replacements and downtime.
