4-Core 2.5mm² PUR Shielded Cable

Hard-wired for the conditions that shut down ordinary cables.

Standard PVC-sheathed control cables fail predictably in high-flex automation cells, outdoor freeze-thaw cycles, and areas washed down with aggressive cleaning agents. The failure mode is almost always the same — jacket embrittlement, insulation cracking, then intermittent signal loss that takes hours to trace. A 4-Core 2.5mm² PUR Shielded Cable eliminates that failure chain. The polyurethane jacket resists abrasion, mineral oils, hydrolysis, and UV degradation long after PVC would have hardened and split. For plants where unplanned downtime directly erodes margin, this is not a premium option. It is the lowest-cost choice measured over the equipment lifecycle.

Why This Cable Outlasts Standard Control Lines

[Hard Data] 2.5mm² Stranded Bare Copper (Class 5/IEC 60228)
Flexible fine-wire stranding keeps conductor resistance low and bend radius tight. For the engineer specifying cable trays that snake through confined machine frames, this means the cable routes cleanly without fighting you. For the finance team, it means no premature conductor fatigue in the middle of a production year.

[Signal Integrity] Braided Tinned Copper Shield (≥85% Optical Coverage)
High coverage braid forms a Faraday cage that blocks VFD noise, contactor spikes, and adjacent power cable crosstalk. Low-voltage analog signals — 4-20mA sensor loops, encoder feedback, RTD inputs — arrive at the PLC clean and unfiltered. No need to oversample or apply heavy digital smoothing to mask noise picked up along the run. You read the actual process value, not an averaged approximation.

[Jacket Chemistry] Polyether-Based PUR, Halogen-Free
Polyether PUR resists microbial attack and hydrolytic degradation in high-humidity environments where polyester-based compounds turn gummy. It shrugs off contact with SAE 10W30 hydraulic oil, water-glycol coolants, and diesel fuel splash. For food and beverage plants, the halogen-free formulation means no corrosive acid gas release if a short-circuit occurs inside the processing hall. Cleanup stays contained, compliance is simpler.

[Mechanical Endurance] Min. Bend Radius: 5x Outer Diameter (Flexing) / 7.5x (Fixed)
Repeated motion over drag chains and cable carriers eventually work-hardens copper and fatigues insulation. At 5x OD for moving applications, this cable exceeds the 7.5–10x typical of commodity PVC types. Less internal stress accumulation per cycle translates directly into longer replacement intervals. Maintenance teams spend fewer hours swapping cable and more time on predictive tasks that actually add value.

[Supply Chain] Made to Your Length, Terminated or Bulk
Standard reels from distribution don’t always match the machine builder’s reality. You end up paying for 50 metres when the run is 42 — and storing the scrap or writing it off. We cut to exact metre length from a continuous inventory of copper and compound, pre-connectorise with overmolded M12/M8/RJ45 ends if the BOM calls for it, and ship with a unique batch number linked to raw material traceability certificates. One supplier, one charge code, zero leftover coil ends cluttering stores.

Technical Specifications

Where This Cable Runs — and What It Solves

• Machine Tool and CNC Wiring. Cutting fluid, hot chips, and continuous flex inside drag chains punish PVC cable within months. The PUR jacket withstands coolant immersion without swelling. The screened cores keep spindle encoder signals clear even when the VFD ramps current. Less chatter in the finish pass, fewer surface finish rejects.
• Food and Beverage Processing Lines. Daily washdown with hot water and foam detergents destroys standard jacket materials. Halogen-free PUR survives the chemical exposure and does not contribute toxic smoke in the unlikely event of a fire inside the production zone. Plant EH&S sign-off is faster.
• Renewable Energy and Outdoor Installations. Solar tracking controllers, wind turbine pitch control boxes, and biogas plant sensors sit in full sun and freezing rain for a decade. The UV-stabilised jacket does not chalk or crack. The tinned copper braid resists oxidation in high-humidity terminal boxes where bare copper would turn black and high-resistance.
• Intralogistics and Automated Warehouses. Shuttles and transfer cars on constant acceleration/deceleration cycles twist and flex the cable continuously. Tight bend radius and flexible stranding reduce stress on the conductor bundle. Predictable replacement cycles replace emergency call-outs during peak fulfillment windows.
• Water Treatment and Chemical Dosing Skids. H₂S ambient gas, chlorine vapour, and ferric chloride drips embrittle ordinary jackets within a year. PUR chemically outperforms PVC and even many TPE compounds in these conditions. Signal screen stops pH and ORP sensor readings drifting due to pump VSD noise picked up on the 4-20mA loop.

Compliance & Testing

• ✅ IEC 60228 (Class 5 flexible copper conductor)
• ✅ IEC 60332-1-2 (Flame propagation resistance)
• ✅ CE Marking under the Low Voltage Directive 2014/35/EU
• ✅ RoHS 3 (Directive 2015/863/EU) — compliant materials throughout
• ✅ Halogen-free per IEC 60754-1/2
• ✅ Oil resistance testing per IEC 60811-404 (mineral oil, 7 days immersion)
• ✅ UV resistance validated via xenon arc accelerated weathering (ISO 4892-2 methodology)
• ✅ ISO 9001:2015 manufacturing facility — process traceability from copper rod to finished drum

FAQ

Your datasheet lists both PVC and PP core insulation. Which one do I actually get for my application?

It depends on the operating temperature at the conductor and the soldering condition at the termination. PVC insulation is standard, rated for conductor temperatures up to 70°C, and strips easily with mechanical tooling. PP (Polypropylene) insulation runs cooler at higher frequencies and withstands soldering iron dwell times better, making it the default choice if you terminate with hand-soldered connectors rather than crimp ferrules. When you submit an RFQ, specify termination method and operating current. We match the insulation grade to the actual thermal load rather than shipping a one-size-fits-most construction that compromises somewhere.

What is the real difference between the >85% optical coverage braid you specify and the 65–70% coverage I see on cheaper cables?

Optical coverage directly sets the surface transfer impedance — how easily external electromagnetic energy couples onto the signal pair. At 65% coverage, gaps in the braid act as slot antennas at higher frequencies, letting VFD carrier-frequency noise leak through onto encoder signals or analog inputs. At ≥85%, the window for that leakage shrinks significantly. For digital encoders pulsing at >100 kHz, the difference is the difference between a clean eye pattern and sporadic position faults that trigger a machine E-stop with no obvious root cause in the fault log.

We operate in an ATEX Zone 2 environment. Can you supply this cable with the required documentation?

The 4-Core 2.5mm² construction using PP insulation and anti-static PUR jacket can be manufactured to satisfy the low-fire-hazard and electrostatic discharge constraints of ATEX/IECEx Zone 2 and Zone 22. We do not just hand you a generic IECEx component certificate and walk away. We supply the full GA drawings, cable construction data sheet with capacitance and inductance per metre, and a declaration of conformity that your notified body can use to assemble the technical file for the complete apparatus. Lead a structured inquiry with the zone classification, gas/dust group, and T-class, and our compliance engineer will match a tested construction variant to the hazard level.

Engineering Review Kit

One cable construction does not fit every control panel, drag chain, or outdoor junction box. We ship a no-cost sample kit containing a 300mm section of the 4-Core 2.5mm² PUR Shielded Cable, the full material datasheet, and the test reports available for the batch.

Request your kit, specify your voltage class and insulation preference, and receive the exact documentation set your approvals team requires before a PO is raised.