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The proper installation of a cable is key to maximizing service life and performance, and simple, easy-to-follow guidelines can make the difference between thousands and millions of cycles of service life. That's why these seven quick rules for proper cable installation could maximize the service life of the cables in your next application.

Before installation, many professionals and cable manufacturers will claim that it is necessary to allow for at least 24 hours for cables to be “relaxed” or “shaken out.” Relaxation time is a luxury these days – most engineers are faced with increasingly tight deadlines, reduced resources and a multitude of different responsibilities. We relax to de-stress from hectic work and family lives. Likewise, many manufacturers recommend cables to be relaxed for installation to release stress from storage on a spool or reel before installation.

To allow for more relaxation time for the engineers and installation team, the igus® cable experts agree that a Chainflex® cable should be cut to the desired length and installed directly into a cable carrier. Our 25 years of experience in cable manufacturing and installation allows us the confidence to say that if properly designed, it is not necessary to waste time laying or hanging cables before their installation. Instead, use the following guide to ensure the performance of your cables quickly and easily.

1. Unspool Cables Properly

Always allow spools to roll while unspooling cables. Do not pull cables from the flange or uncoil from the top of the spool. This can cause unnecessary stress to cables.

2. Check the Jacket Materials of Different Cables

In some instances, different jacket materials can stick together and cause abrasion. Check to see if your cables’ jacket materials are intended for use inside a cable carrier or for use with corresponding jacket materials. Abrasion of jacket materials can sometimes be prevented with interior separation.

3. Cut to the Proper Length, and Lay Directly Inside the Cable Carrier

Ensure each cable is long enough for proper connection and strain-relief (see guideline 7). Laying cables is the preferred method for placing inside a cable carrier, especially cables that have already been harnessed with connectors. Cables can also be carefully pulled into the proper positioning in the cable carrier if necessary. Avoid any twisting of the cable while placing into the carrier.

4. Ensure Every Cable Has Room to Move Freely During Movement of the Cable Carrier

Be sure each cable has plenty of room to move while in operation. This will maximize the service life, and reduce risk of abrasion and other common cable failures.

For more information on common failures, read "6 Common Cable Failure Modes" [PDF].

Source: igus5. Take the Time to Be Sure that Cables Rest in the Neutral Axis of the Cable Carrier

This is especially important while operating at the carrier’s maximum bend radius. When the carrier is bent, there should be no tensile forces exerted on the cable.

6. If Cables or Hoses of Varying Diameters are Being Installed, Utilize Interior Shelving or Separators

This will prevent tangling. There are two easy cable distribution rules to follow to see if interior separation is needed. The first states that If the diameters of the cables, D1+D2 are greater than 1.2 x the inner height of the cable carrier, no separation between the two cables/hoses is necessary. If the diameters of cables D1+D2 is less than or equal to the inner height of the cable carrier, use vertical separators or horizontal shelf to prevent crossover and abrasion. If the outer jacket of cables or hoses have different coefficients of friction and rub against one another, the harder, more resilient material will gradually wear down the softer jacket, leading to failure.

7. Use Strain Relief at Both Ends of the Cables

There are a number of strain relief options, including mounting brackets, tie wrap plates, etc. Proper strain relief keeps the length of cable inside the carrier fixed at all times. In certain cases, strain relief may only be necessary at the moving end of the cable carrier.

To learn more about Chainflex continuous-flex cables, visit www.igus.com/chainflex. For questions about your individual application, contact igus cable experts directly via email at chainflex@igus.com or by phone at 800-521-2747.

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