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A Guide to Cables and Wire - RS Components

09 Jun.,2025

A Guide to Cables and Wire - RS Components

Different types of cables are used in various applications, each selected based on their specific properties and capabilities.

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Let's explore the uses of some common cable types:

Power cables: These cables transport electrical power from one point to another. They are commonly used in residential, commercial, and industrial settings to supply electricity to buildings, machinery, and appliances
Data cables: Also known as communication cables, these cables transmit data signals between devices. They are widely used in computer networks, telecommunications systems, and audio/video applications
Coaxial cables: Coaxial cables transmit high-frequency signals with low loss. They are commonly used in TV systems, CCTV installations, and high-speed internet connections
Ethernet cables: These cables connect devices in local area networks (LANs) to facilitate data transfer. Ethernet cables are widely used in homes, offices, and data centres
HDMI cables: HDMI (High-Definition Multimedia Interface) cables transmit high-quality audio and video signals between devices. They are commonly used in home theatre systems, gaming consoles, and multimedia devices
USB cables: USB (Universal Serial Bus) cables are used for connecting devices like smartphones, tablets, printers, and cameras to computers or power sources. They facilitate data transfer and device charging

These are just a few examples of the wide range of cable applications. Depending on the specific requirements of a project or application, different types of cable should be used to ensure optimal performance and reliability.

In the UK, there are specific cable regulations in place to ensure the safety, reliability, and performance of different types of cables used in various applications. These regulations outline the naming and coding system for cables, and British standards for design and manufacturing.

The naming and coding system for cables provides a standardised way to identify and categorise different types of cables. It assists users, engineers, and installers in quickly recognising a cable’s purpose and characteristics based on its name or code. This system includes abbreviations and codes representing specific features such as the conductor material, insulation type, voltage rating, and more.

British standards play a crucial role in ensuring cable quality and safety. These standards define the requirements that cables must meet to be considered compliant. They cover aspects such as fire performance, mechanical strength, chemical resistance, and environmental factors. Adhering to British standards is essential to guarantee cable suitability and reliability for their intended applications.

British Standards: PVC insulated cables to BS are designed for the internal cabling of electrical and electronic equipment and are also used for wiring within instrumentation and control panels. BS EN compliant wire is of a tinned annealed copper construction suited for use as rewireable fuse links, shorting links, etc
DEF STAN: Cables designed to meet the requirements of DEF STAN 61-12 Part 29/1 are used typically in high-demand applications found in military, avionics, aerospace, nuclear, and medical environments
Harmonised: Compliant with European Harmonised Standards H05V-K and H07V-K, harmonised cables are colour-coded PVC sheathed cables with a single-stranded untinned copper core. Harmonised cable is widely used in lighting, wiring installation work within control and distribution panels, conduits, and channels. First introduced in , the harmonised colour code differentiates between conductors in single and three-phase circuits
MIL SPEC: Cables designed to military specifications and compliant with MIL-W-/13 are single-cored with PVC or PTFE insulation. Specially designed for harsh environments, they are used in aerospace and similar industries where a high degree of tolerance to chemicals and radiation may be required. They can be used in high-temperature and high-frequency applications. MIL SPEC cable lends itself to both soldered and wire wrap work and should be used when challenging conditions demand strong durability
UL Standard: These cables meet UL (Underwriters Laboratories) testing classification. This is a category of cables and wire that has been tested independently to conform to requirements for use in a variety of applications, including general-purpose wiring circuits, control circuits, and internal appliance wiring. Cables manufactured to UL Standards have single-stranded cores and are available in a variety of colours with four sheath constructions. A wide range of cables and wires meet UL standards and it is UL’s evaluation of the product that determines its area of use

When dealing with cables, safety should always be the priority. Cables are integral components of various electrical systems, and understanding their safety features, potential hazards, and safe usage methods is crucial to preventing accidents and ensuring equipment longevity.

Cables come with a range of safety features to protect users and equipment. Some common safety features include insulation, shielding, and grounding. Insulation reduces the risk of electric shock by covering the conductive parts of the cable with non-conductive material. Shielding minimises electromagnetic interference, ensuring cable performance is not affected by external factors. Grounding provides a safe path for electrical energy to dissipate, reducing the risk of electrical faults.

Despite these safety features, cables can still pose potential hazards if not used correctly. Some hazards include tripping over loose cables, overloading cables with excessive current, or using damaged cables. To avoid these hazards, it's important to keep cables properly organised and secured, ensuring they are not left in walkways or areas where they can be damaged. Additionally, it's crucial to follow the manufacturer's guidelines for current ratings to prevent overloading. Regularly inspecting cables for damage, such as frayed insulation or exposed wires, is also essential for safe use.

Here are some general tips for using cables safely:

Always use cables appropriate for the intended purpose and environment
Avoid bending cables excessively, as this can damage internal conductors
Do not pull cables from their connectors to disconnect them; instead, grasp the connector firmly and disconnect it
When unplugging cables, hold the connector firmly and pull straight out

By following these safety guidelines, you can ensure safe and efficient cable use in your electrical systems.

Cable screening is a necessity in many wiring applications. Screening protects a conductor from external interference or EMI, prevents radiation from the cable itself, and minimises cross-talk between conductors.

Various degrees of screening are used according to cable type and application. From unshielded power or control cable used in areas not prone to interference, e.g. within a metal control cabinet, to foil or braided shielded cable for areas of high EMI or electrical interference.

[Guide] Electrical Cable & Wire Selection for Industrial Use - Simcona

Choosing the right industrial cables and wires is a major factor in optimizing electrical product design. While advanced technology and intricate layouts are important, the quality of the materials themselves can significantly impact performance.

With a vast array of options available, browsing a manufacturer’s e-store can be overwhelming. This cable selection guide offers valuable insights to help simplify your decision-making and find the best fit for your needs.

8 Cable Selection Guidelines

Following these eight electrical wire/cable guidelines will help you meet your unique requirements, down to the smallest detail:

Mechanical durability
Electrical performance
Flexibility
Heat, flame, & cold resistance
Corrosion resistance
Processability
Price
Availability

1. Mechanical Durability

Several elements of a wire assembly influence its strength, starting with its size and protective layers.

The gauge of an industrial cable refers to its thickness. Today’s customers are demanding smaller and smaller designs, which makes the physical side of cable performance a little harder to manage. A thinner cable is easier to sever or smash but there are ways to add protection:

Jacketing/
Insulation to Try

Armoring to Try

Conductor to Try

Filler
to Try

Crush resistance

Polyethylene, Neoprene, nylon, thermoplastic rubber

Steel

Cut-through resistance

Nylon, TPE,
fluoropolymers, XLPE

Steel

Tongda Product Page

Nickel-plated

Polyimide tape

Avoid jacketing and insulation with weak mechanical properties if your cables are at risk of being stepped on, run over, or cut. Materials to stay away from include:

PVC
Thermoplastic rubber (for cut-through resistance)
Paper (for filler)

2. Length

In a “normal” situation (no chemical fire, unexpected submerging, etc.), there are two main factors in a cable’s electrical performance: length and shielding.

Size requirements are different from at home, where “How long?” might be your only question. For the factory floor, there are entire electric cable guides dedicated to sizing best practices.

Gauge matters too, as thicker cables generally have lower resistance and can handle higher electrical loads across longer distances. Consider the current requirements of your application and select a gauge that can safely carry it without overheating or losing voltage.

Length is still important too, but for more than just physical spacing of its connection points. A cable’s signal decreases as it travels, making excessively long cables a poor fit for applications that need low losses.

Oversized cable is also a waste of money, so only buy what you need. That said, if your assembly might change in location or expand in function later, include some slack and perhaps a service loop.

Shielding, meanwhile, is a feature dedicated specifically to preserving a cable’s ability to carry current.

Electromagnetic interference (EMI) is the enemy of electrical cabling, as it causes cross-talk (noise) and signal degradation. Shielding is a conductive layer that minimizes EMI by acting as a barrier. It may prove a more cost-effective design, as it helps you run farther with less cable before the signal degrades.

Take note of your project’s end-use location and whether nearby objects will play nicely with each other. If you’ve got 20 induction heating machines or automated conveyors in one room, dialing in a specific frequency will be challenging due to cable cross-talk. If you’re spec’ing cables for traffic signals, there’s no need for shielding because only air will surround them.

3. Flexibility

Your needs in this department are highly dependent on the cable’s intended use.

Benefits of a flexible industrial cable include:

Fits in tighter spaces
Less likely to snap
Easier to use

Consider the flexibility requirements of your equipment, because not all connections need to or should be flexible.

A flexible cable would make sense for a robotic arm that rotates all day. A semi-rigid cable is easy to configure to your desired shape while maintaining its set, making it useful in metal-bending operations. A rigid cable is usually the top performer in high-power applications, like computer setups. They also cost less (usually), so it may be worth going that route if cable flexibility is irrelevant to your project.

A cable’s shielding (if any) is the biggest factor in its flexibility, with spiral shields the most flexible. Jacketing and insulation materials matter too, with thermoset and rubber types offering the most flexibility. Last and probably least important is the conductor type, of which stranded conductors are the most flexible.

Certain cables contain filler materials to improve flexibility:

Cotton
Aramid fiber
Paper (note this is flexible, but has a short flex life)

4. Heat, Flame, & Cold Resistance

Some types of electrical wires and cables can endure high heat, some thrive in freezing temperatures, and a few excel at both. Meanwhile, some cables are popular because they don’t emit toxins while burning, while others are popular because they’re not flammable to begin with.

Choose cables with temperature ratings and fire reactivity appropriate for your application.

High temperatures – A poorly rated cable will turn to mush, causing mechanical issues, conductor overheating, and insulation breakdown.
Flames – UL rates cables for circuit integrity during a fire, as well as any smoke, toxic fumes, or corrosives produced when burning.
Cold temperatures – Certain materials become brittle, lose flexibility, or otherwise degrade.

Cable jacketing and wire insulation choices are the #1 factor of success or failure relative to heat and cold:

Hazard Good Examples Bad Examples

Heat
????️

Silicone, fiberglass, PVDF,
FEP (Teflon), PFA

PVC, Neoprene, SBR

Flame
????

Thermoset materials, CEP (thermoplastic), FEP (Teflon), (PVDF), silicone

Polyethylene, PVC

Cold
❄️

Thermoplastic elastomer (Santoprene),
PTFE, EPR, PFA, silicone

PVC, polyurethane, polyethylene, rubber

“Highly resistant” is a relative term, so consult with your cable and wire distributor to best balance needs with budget. What’s “highly resistant” in an indoor appliance may not suffice for a military submarine.

Are you interested in learning more about PVC Insulated Cables? Contact us today to secure an expert consultation!

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