Flexible Power Cables Overview

09.12.24 ● 2 minutes

Flexible Cable, also known as, 'continuous-flex' is a type of cable that provides increased flexibility and durability for applications that require difficult cable placement or motion.

They are specifically engineered to withstand the tight bending radius and physical stress of moving applications.

Flex cables are be used by most of your portable electric gadgets and light pendants.

The permanent wiring that goes through the walls/ceilings between the fixture and the power source is known as "cable," whereas the wire used to connect portable items such as lights to a wall socket is known as "flex" or "flex cable."

Applications

Below are some of the applications in which flexible cables are used:

Drag chain application
Repetitive bending and torsion stress
Machine tools
Data processing equipment
Robotics
Assembly lines
Automation networking
Microprocessors
Computer interconnects

Flex Power Colours

Flexible flat power cables have curved edges and include 2-4 cores. Flex (flexible cable) is circular and has 2-3 cores. The separated copper wires within the cable/flex are known as cores.

Each core (excluding the earth core in cables) is insulated with a color-coded PVC insulation that protects and enables for simple identification.

The cores are then coated in a final layer of PVC insulation known as a sheath, which is often grey or white.

Brown – live
Black – neutral

Is Flexible Power Cable Suitable for Outside Use?

The same principles apply to flexible cables as they do to any other type of electrical wire.

A cable must be weather resistant to be regarded suitable for outdoor use.

In general, weather resistance comprises resistance to the following elements:

Ambient temperature.
Ultraviolet radiation.
Ozone.
Water.

Even though many flex-type cables are outdoor-rated, certain flex cables cannot tolerate exterior extremes such as UV radiation.

How Long Can You Run Flex Power Cable?

There are a few aspects that should be considered when running a flexible power cables. The maximum length should not exceed:

12m – for flexes with 1.25mm2 conductors
15m – for flexes with 1.5mm2 conductors
25m – for flexes with 2.5mm2 conductors

However, if the extension lead is plugged into a residual current device (RCD) protected socket then 25 metres is still considered safe, but if there is no RCD the maximum length should not be more than 10 metres. That is because the most used flexes are 0.75mm or 1mm2.

What is the Difference between Armoured Cable and Flexible Power Cable?

When carrying data or conducting power in adverse conditions, it is critical to safeguard your cables to ensure safe and reliable operation. The most suitable cable for such conditions is the armoured cabling – it is mostly utilised in industrial applications, such as cable trays and raceways.Armoured CableArmoured cables have a metal sheath that serves as the initial layer of protection. It is often composed of interlocking or continuous aluminium or stainless steel, although it can also be coated in smooth or corrugated metal tape. The majority of this type of cables are also fire resistant.DifferencesMaterialArmoured cabling has a metal wrap, usually made from stainless steel or aluminium, that is the first line of defence. The wrapping is interlocked or continuous. The armour protects the internal wires from moisture generated by hot weather, increased washdown, and cleaning solutions. Electrical wires are designed to be exceptionally flexible and long-lasting. This type of wire can be flexed, stretched, and twisted as much as you like without causing harm. It is often commonly braided, or foil wrapped as opposed to armoured cabling. ApplicationArmoured cabling: Cable jacketing materials can shield the cables from harsh chemicals, oils, and sunlight. Flexible cabling: For placing complicated constructions, a flexible wire is perfect. Even in the harshest environments, flexible cables assure high-quality performance. It would be advantageous to use a flexible cable wire in applications that need extreme bending and a wide range of motion. Area of ApplicationArmoured: industrial applications – open locations such as electrical wires in factories, and carriers & raceways Flexible power: any application that requires constant bending FlexibilityAs the name suggests, flexible power cables are extremely flexible. Although many cables are flexible, it is important to remember that not all of them fall into the flex-type cable category. For more detailed information, check out our overview of flexible power cables.