Wired Responsiveness: Bulk Servo Wire in High-Performance Model Trains
Nov 01,2023
The term waterproof cable primarily refers to a cable that prevents water from entering its internal structure. This is achieved by incorporating waterproof features in the sheath of the cable, using specific structures and materials with waterproof capabilities.
For single-core cables, a semi-conductive water-blocking tape is wrapped around the insulation shield, followed by regular water-blocking tape, and then an outer sheath is extruded. To ensure proper contact with the metal shield, only a single layer of conductive water-blocking tape is wrapped outside the insulation shield. Depending on the waterproof performance requirements, the filling can be either ordinary or water-blocking. The inner lining and outer sheath materials are the same as those described for single-core cables.
An aluminum-plastic composite tape layer can be longitudinally wrapped inside the outer sheath or inner lining as a waterproof layer.
HDPE outer sheath can be directly extruded onto the cable exterior. For XLPE insulated cables rated 110kV and above, metal sheaths are used to meet waterproof requirements. Metal sheaths are completely impermeable and provide excellent radial water-blocking performance. Types of metal sheaths include hot-pressed aluminum jackets, hot-pressed lead jackets, welded corrugated aluminum jackets, welded corrugated steel jackets, and cold-drawn metal jackets.
Generally, there are two types: longitudinal water-blocking and radial water-blocking. Longitudinal water-blocking commonly uses water-blocking yarn, water-blocking powder, and water-blocking tape. The mechanism involves materials that expand upon contact with water, preventing further water ingress along the cable. Radial water-blocking is primarily achieved through extruded HDPE non-metallic sheaths or hot-pressed, welded, cold-drawn metal sheaths.
Environment Preparation
Ensure the installation environment is dry and dust-free; avoid operating in damp or dusty conditions.
The installation location should be away from high temperatures, oil, and chemical corrosive substances.
Wire Stripping
Use specialized wire stripping tools to remove the cable's outer sheath, avoiding damage to the conductor or shield.
Strip length should conform to the joint specifications (usually 10-20mm).
Cleaning and Moisture Protection
Wipe the cable ends and joint interior with alcohol or cleaner to ensure they are free of oil, moisture, or impurities.
You can apply waterproof sealant (such as silicone rubber) to the conductor surface to enhance sealing.
Connection and Fixing
Follow the joint instruction manual to securely crimp or weld the cable conductors and joint terminals, ensuring good contact.
Wrap the interface with waterproof tape (such as self-fusing tape, PVC tape), layer by layer from inside to out, covering all exposed parts.
Enhanced Sealing
Insert heat shrink tubing or waterproof joint boxes over the tape, then heat to shrink them tightly together.
If using liquid sealant, wait for it to fully cure before powering on.
Testing and Verification
After installation, test the conductivity and insulation resistance with a multimeter to ensure there are no short circuits or leaks.
A short water immersion test (not applicable to outdoor joints) can be conducted to check for water leaks.
Protection Level Matching
Select joints with appropriate protection level (IP65/IP67/IP68) according to the use case, avoiding environments with prolonged immersion or high-pressure water jets.
Regular Inspection and Maintenance
Regularly check the joints for aging, cracking, or loosening, and replace damaged components promptly.
Clear away water or debris around the joints to keep them dry.
Avoid Mechanical Stress
Ensure the cable joints are not excessively bent, stretched, or compressed. Protective sleeves or brackets can be added for fixation.
Temperature Control
Avoid using in extreme temperatures (e.g., below -40°C or above 100°C) to prevent material degradation.
Correct Stripping and Resealing
If repairs are needed, completely remove the original sealing layer, clean and reseal according to the steps, and do not reuse old tape directly.
Water Ingress: Check if the sealing layer is damaged, rewrap the tape or replace the joint.
Poor Contact: Ensure the terminal crimping is firm; reconnect if necessary.
Reduced Insulation: Test with an insulation tester, and if the issue is severe, replace the joint.
As a professional waterproof cable suppliers, HOLLY provides high-quality waterproof cables. Our factory uses advanced sealing technology to effectively prevent moisture, dust, and corrosive substances from entering, ensuring long-term stable operation under harsh conditions such as outdoor, industrial, and marine environments. Whether it's waterproof rating, durability, or anti-aging performance, HOLLY's cables can meet all your needs, helping ensure the successful operation of your projects.