Armored Cable: A Comprehensive Guide to Protection and Performance

Armored cable is a type of electrical cable designed to withstand demanding environments and provide superior protection from physical damage, electromagnetic interference (EMI), and environmental hazards. Its rugged construction makes it ideal for industrial, commercial, and outdoor applications where reliability and durability are paramount.

What is Armored Cable?

Armored cable is constructed with a layer of interlocking metal armor, typically made of steel or aluminum, wrapped around an insulated conductor. The armor serves as a protective barrier against physical impact, crushing, abrasion, and bending. Additionally, it provides grounding and shielding against EMI, which can disrupt electrical signals and cause equipment malfunctions.

Key Features and Benefits

Enhanced Durability: Armored cable's robust design withstands harsh conditions, making it suitable for both indoor and outdoor installations where traditional cables may fail. Its resistance to physical damage minimizes downtime and maintenance costs.

EMI Shielding: The metal armor acts as an effective EMI shield, preventing electromagnetic interference from entering or escaping the cable. This ensures reliable signal transmission and protects sensitive equipment from interference.

Grounding: The metal armor provides a continuous grounding path, reducing the risk of electrical shocks and faults due to stray currents. This safety feature is crucial in industrial environments and where personnel safety is a priority.

Environmental Protection: Armored cable's rugged construction offers protection against moisture, dust, chemicals, and extreme temperatures. It can withstand exposure to harsh weather conditions, making it ideal for outdoor applications, telecommunications, and marine environments.

Types of Armored Cable

Armored cable comes in various types, each designed for specific applications:

BX (Flexible Metal Conduit)

• Interlocking steel armor with a non-metallic covering
• Provides flexibility for bending and installation in tight spaces
• Suitable for residential and commercial wiring

MC (Metal Clad)

• Steel or aluminum armor over an insulated conductor
• Provides excellent EMI shielding and protection from physical damage
• Commonly used in industrial and commercial settings

AC (Armored Cable)

• Interlocking steel armor with an insulated conductor
• Offers high strength and protection from moisture and harsh environments
• Ideal for outdoor installations, telecommunications, and marine applications

Applications of Armored Cable

Armored cable finds applications in a wide range of industries and settings:

Industrial:

• Power distribution
• Machinery and equipment connections
• Control systems
• Heavy-duty electrical installations

Commercial:

• High-rise buildings
• Data centers
• Telecommunications
• Security and surveillance systems

Outdoor:

• Underground burial
• Pole-mounted wiring
• Street lighting
• Marine applications

Benefits of Using Armored Cable

• Increased Safety: Armored cable's protective armor reduces the risk of electrical accidents, fire hazards, and EMI-related malfunctions.
• Improved Reliability: The robust construction ensures reliable signal transmission and equipment performance, minimizing downtime and maintenance costs.
• Long-Term Durability: Armored cable's rugged design withstands demanding conditions, extending its service life and reducing replacement costs.
• Versatile Applications: Its ability to handle harsh environments and challenging electrical requirements makes armored cable suitable for a wide range of applications.
• Code Compliance: Armored cable meets industry standards and electrical codes, ensuring safety and compliance with regulations.

Installation and Maintenance

Proper installation and maintenance are crucial for the optimal performance of armored cable. Follow these guidelines:

Installation:

• Use appropriate connectors and terminations designed for armored cable.
• Secure the cable firmly using cable ties or clamps.
• Avoid sharp bends or kinks that can damage the armor.
• Ensure proper grounding to minimize electrical hazards.

Maintenance:

• Regularly inspect the cable for visible damage, corrosion, or loose connections.
• Clean the exterior of the cable using a mild detergent and water.
• Do not expose the cable to excessive sunlight or heat, which can degrade its insulation.
• If any damage is detected, consult a qualified electrician for repair or replacement.

Case Studies

Story 1: A manufacturing plant experienced frequent power outages due to electrical faults caused by EMI interference from nearby machinery. By installing armored cable on critical circuits, they eliminated EMI-related disruptions, improving production efficiency.

Story 2: A high-rise building's telecommunications system was prone to signal loss due to environmental hazards, such as lightning strikes and moisture ingress. The installation of armored cable provided reliable signal transmission, ensuring uninterrupted communication and data transfer.

Story 3: An outdoor lighting system installed in a coastal area suffered from corrosion and salt damage, leading to premature cable failures. By upgrading to armored cable with a corrosion-resistant armor, the lighting system's lifespan was extended, reducing maintenance costs.

What We Learn: These stories highlight the importance of using armored cable in demanding environments to ensure reliable performance, safety, and long-term durability.

Tips and Tricks

• Consider the specific environment and application when selecting the appropriate type of armored cable.
• Use a torque wrench to tighten connectors properly and prevent damage to the cable.
• Avoid using armored cable in areas with limited space or where frequent bending is required.
• Ensure that the armor is properly grounded using a grounding lug or other approved method.
• Keep armored cable away from sharp objects or abrasive surfaces that can compromise its integrity.

Common Mistakes to Avoid

• Failing to install the cable properly can result in poor performance, safety hazards, and premature failure.
• Over-tightening connectors can damage the cable or its insulation.
• Exposing armored cable to corrosive environments without proper protection can lead to premature deterioration.
• Using armored cable in applications where it is not necessary can increase costs and reduce efficiency.
• Neglecting regular inspection and maintenance can compromise the cable's safety and performance.

Pros and Cons of Armored Cable

Pros:

• Enhanced durability and protection
• EMI shielding
• Grounding
• Environmental protection
• Meets electrical codes and standards

Cons:

• Higher cost compared to non-armored cable
• Less flexible than other types of cable
• Can be heavier and more difficult to install

Conclusion

Armored cable is a robust and versatile solution for electrical installations in demanding environments where durability, safety, and EMI shielding are paramount. Its enhanced protection and long-term performance make it an ideal choice for industrial, commercial, and outdoor applications. By choosing the appropriate type of armored cable, following proper installation and maintenance guidelines, and avoiding common mistakes, you can ensure reliable performance and peace of mind.

Additional Resources

National Electrical Code (NEC) Article 330: Armored Cable

Underwriters Laboratories (UL) Standard 628: Armored Cable

Institute of Electrical and Electronics Engineers (IEEE) Standard 1202: Electrical Power Cable Performance Characteristics and Test Methods

Tables

Table 1: Types of Armored Cable

Table 2: Benefits of Armored Cable

Table 3: Common Mistakes to Avoid with Armored Cable