What are Armored Cables?

Meet the Connector: Armored Cables

Armored cables are versatile, self-contained conduit-wire systems that can be used in the most challenging applications. The armor is a metal sheath surrounding the cable.  It acts as a protective barrier against damage to the insulator and conductors and helps block electromagnetic interference in high- and low-current applications. Particularly in harsh environment applications, armored cables are designed to withstand abrasion, crushing, and contact with corrosive substances, as well as the ingress of dirt, water, and other liquids. Exposure to any of these can result in damage that puts the cables at risk of losing signal performance or even complete signal loss.

A variety of materials are available depending on the environment and conditions in which the cable assemblies will be used. Armoring is often used for cables in high-mechanical-stress environments, such as underwater or underground; in applications with a high chance of exposure to high-temperatures, chemicals, and other corrosive substances; and in applications where damage from digging or animals may occur. Armoring may consist of steel wires or steel tape that protects the cables from damage.

COAX Connectors provides a wide range of standard and bespoke armored RF cable assemblies to suit most environments and applications.

Design Notes

Standards: Armored cables meet various National Energy Code standards, including NEC 310, NEC 770, and NEC 725.

Material specifications:

SWA, steel wire armor 3 core cable is used for low and medium voltage.

AWA, aluminum wire armor prevents induced current in the armor.

The conductor is plain stranded copper or aluminum.

Insulation materials such as cross-linked polyethylene (XLPE) provide high temperature resistance and excellent dielectric strength.

Greene Tweed’s single-fiber FC-Fiber Protec and ST-Fiber Protec patch cords and pigtails feature a 900 μm buffered fiber surrounded by an armored stainless steel jacket. They withstand crush and pressure while maintaining flexibility and durability.

Physical properties:

Armored cables can be customized to meet specific requirements, ranging from shielded pairs to coaxial cables. The armor is an effective electrical shield for reducing electromagnetic interference (EMI) and enhancing signal integrity in sensitive applications. The current dictates what kind of shield to use. Aluminum is used in low-current applications.

Environmental properties:

SWA (steel) provides the best protection against physical damage and stress.

AWA (aluminum) is lighter with greater flexibility but offers less protection than steel.

Interlocked armored cable features a helically wound interlocking metal strip that provides a high degree of flexibility and resistance to physical stress.

Sealed or liquid-tight armored cable features a layer of waterproof material that provides ingress protection (IP).

Hydro Group, a Trexon company, has the in-house capability to armor multicore electrical, optical, and hybrid cables using galvanized steel or aluminum wire.

Electrical properties: Voltage ratings: 600/1000V, 6.35/11kV and 19/33kV

Also known as steel wire armored cables or SWA cable, aluminum wire armored cable or AWA cable, mains power cable, single core power cable, and multi-core booklet armored cable.

Markets

Industrial, Mil/Aero, Medical, Consumer, Energy

Applications

Power, instrumentation, and control applications; underground or underwater applications; manufacturing; construction; military and defense applications; medical equipment for diagnostics and treatment; consumer goods; power distribution and transmission for renewable energy; oil & gas and mining

Suppliers

COAX Connectors, Greene Tweed, Molex, Radiall, Smiths Interconnect, TE Connectivity, Times Microwave Systems, Trexon, Winchester Interconnect, Amphenol CIT

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