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A Practical Guide To Cable Selection: Literature Number: SNLA164
A Practical Guide To Cable Selection: Literature Number: SNLA164
National Semiconductor
Application Note 916
David Hess
John Goldie
October 1993
1.0 INTRODUCTION
This application note provides an overview of the various
considerations necessary for selecting suitable copper multiconductor or twisted pair cables for use with standard interface devices. It is important that a cable is well matched to
the application; as well as, that the various cable selection
trade-offs are considered for a cost effective system design.
Cable types, constructions, and characteristics are covered
and then related to the various device requirements.
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with only one conductor (the shield serving the dual purpose
of signal return path and signal containment). In a similar
sense, a two conductor multiconductor cable, since it is
twisted, is equivalent to a single twisted pair cable.
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AN011937
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TABLE 1. Conductors Solid Stranded Tinned and Bare from 30 AWG to 20 AWG vs Diameter DCR Weight, etc.
AWG
Stranding
Diameter
D. C. Resistance @20C
Weight
Tin Coated
inches
mm
lbs./kft.
kg/km
ohms/kft.
ohms/km
ohms/kft.
ohms/km
40
solid
0.0031
0.079
0.0291
0.0433
1158
3799
1080
3540
38
solid
0.0040
0.102
0.0484
0.0720
696
2283
648
2130
36
solid
0.0050
0.127
0.0757
0.113
445
1461
415
1360
34
solid
0.0063
0.160
0.120
0.179
281
920
261
857
32
solid
0.0080
0.203
0.194
0.289
174
571
162
532
32
7/40
0.010
0.254
0.21
0.31
176
577
164
539
30
solid
0.0100
0.254
0.30
0.45
113
371
104
340
30
7/38
0.012
0.305
0.35
0.52
106
348
92.6
303
28
solid
0.0126
0.320
0.48
0.72
70.8
232
65.3
214
28
7/36
0.015
0.381
0.55
0.82
67.5
221
59.3
194
26
solid
0.0159
0.404
0.77
1.14
44.5
146
41.0
135
26
7/34
0.019
0.483
0.87
1.29
42.5
139
37.3
122
24
solid
0.0201
0.511
1.22
1.82
27.2
89.2
25.7
84.2
24
7/32
0.024
0.610
1.38
2.05
25.7
84.2
23.1
75.9
22
solid
0.0253
0.643
1.94
2.89
16.7
54.8
16.2
53.2
22
7/30
0.031
0.787
2.19
3.26
16.6
54.4
14.8
48.6
20
solid
0.0320
0.813
3.10
4.61
10.5
34.4
10.1
33.2
20
7/28
0.038
0.965
3.49
5.19
10.3
33.8
9.33
30.6
INSULATIONS
In addition to providing basic insulating properties, the plastics used to coat the conductors have various signal altering
characteristics. The two properties of insulating plastics that
affect transmission are the dielectric constant and the dissi-
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pation factor. The dielectric constant is a function of the velocity at which energy travels through the dielectric (another
name for insulation). The dissipation factor is a function of
the rate at which energy is absorbed by the dielectric. Reducing either of these factors results in better signal transmission performance.
The plastic most commonly used for conductor insulation is
polyvinylchloride (PVC). Its dielectric properties are good
but, generally not good enough for any data communication
application more demanding than basic low speed ( < 100
kbps), short distance ( < 50 m) links. PVC is normally used for
power, control, instrumentation, and audio cables; applications that operate at relatively low frequencies. High performance serial data cables normally use a polyolefin insulation; either polyethylene or polypropylene, because their
dielectric properties are far superior to PVC. Even though a
data signal may be operating at a fairly low data rate the signal may be made up of pulses with fast rise times. The rise
time of the pulse determines the frequency range covered by
the signal. Typical data signals have power spectrums well
into the 1 MHz to 10 MHz range. The polyolefins dielectric
constants and dissipation factors are low compared to PVCs
and, unlike PVC, remain low well into the microwave region
of the spectrum.
There is no great disadvantage to using polyolefins compared to PVC. The cost, at most, is only marginally higher.
Some cable design precautions must be taken to meet flammability regulations. Polyolefins are far more flammable than
PVC, but this can be overcome with a flame retardant outer
cable jacket. As will be seen later, polyolefin insulation is essential for good performance with shielded cables.
The only exception to the choice of polyolefin insulation is
the case of plenum cables used in premises wiring applications. Fluorinated ethylene/propylene copolymer (FEP),
SHIELDS
One problem that arises with long distances is a transmission
lines
susceptibility
to
interfering
signals.
Electro-magnetic interference (EMI) is basically unavoidable
and a long transmission line is very susceptible. Long wires
make good antennas.
Most of the serial interface standards do not require shielding, although provisions are made for shields within the standard connectors and recommendations for grounding. The
standards basically avoid the subject of shielding as one
which is outside of their scopes. On the other hand, the primary caution given in the distance and data rate guidelines
is that outside interference is not taken into consideration.
Shielding can greatly reduce or eliminate the possibility that
the system will fail after you have followed all the other
guidelines. Regardless of the effects interference may have
directly on the serial interface, shielded cable may be required due to the overall systems susceptibility or emissions
passed through the enclosure via an interface port. Shielding
should be considered for all but very short low speed data
circuits; above 10 meters or 100 kbps.
Shields are additional conductors added to cables and are
designed to isolate electro-magnetic fields surrounding conductors or pairs within the shield from those outside of the
shield. Shields may be placed over individual conductors,
twisted pairs, or may be placed over the entire bundle of
cable elements or in both locations. Multiple shields within a
cable may be electrically isolated from each other with additional insulating layers.
Dielectric
Dissipation
Volume
Dielectric
Gravity
Constant
Factor
Resistivity
Strength
ohm-cm
Volts/Mil
PVC (Standard)
1.251.38
46
0.060.10
1011
800900
Good
20 to 80
PVC (Premium)
1.38
35
0.0800.085
1012
800900
Good
55 to 105
Polyethylene
0.92
2.27
0.0002
Poor
60 to 80
0.90
2.24
0.0003
> 1016
> 1016
1200
Polypropylene
850
Poor
60 to 80
Cellular
0.50
1.5
0.0002
500
Poor
60 to 80
1.30
2.5
0.0015
> 1016
1000
Fair
60 to 80
2.15
2.1
0.0007
> 1018
1200
Excellent
70 to 200
Cellular FEP
1.2
1.4
0.0007
500
Good
70 to 200
Insulation Type
TempFlammability
erature
Range C
Polyethylene
Flame
Retardant
Polyethylene
(or 260)
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The ideal shield is a seamless metallic tube as with the aluminum tubing utilized by the CATV industry on semi-rigid co-
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Jackets
The most common cable jacket material is PVC, which has
good environmental resistance and can be compounded to
have good cold temperature flexibility and meet a range of
flammability requirements.
polypropylene, can be 15 to 2 mils thick. Thicknesses are selected by trading off flexibility with shielding effectiveness
and signal attenuation in cases where the shield provides
signal return path. Effective overlap of the tape is important
for reliable performance. Uninsulated drain wires are normally of the same construction as the cables conductors,
but must be tinned to permit direct contact with the aluminum.
Flammability Requirements
Equipment cables are generally required to meet some level
of vertical flames test. The National Electrical Code (NEC)
sets standards for the flammability ratings of cables to be installed in buildings. Cables must pass the vertical cable tray
flame test to be suitable for general purpose locations. This
is the same test generally required for industrial environments. Two special locations are identified by the NEC; riser
and plenum, each having respectively greater degrees of
flammability requirements. Plenum cable can be used in plenums, risers or general purpose locations, riser cable can
only be used in risers and general purpose locations, and
general purpose cables are restricted from risers and plenums. In the case of plenum cables, Polyvinylidene Fluoride
(PVDF) copolymer, available as Kynar , jackets may be
used for their low smoke and flame producing characteristics.
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TABLE 3. Applications
Application
Multiconductor
Number of
or Twisted
Conductors
Pair
AWG
or Pairs
Shielding
Transmission
Requirements
Characteristics
Specified
Specified
EIA/TIA-232-E
Section 2
Multiconductor
3 to 25
none
specified
none required
provisions included
TIA/EIA-422-B
Twisted Pair
not specified
none
specified
guidelines
use 24
none specified
none specified,
90150 impedance
recommended,
guidelines use
100 impedance,
66% max. voltage
drop
TIA/EIA-423-B
Multiconductor
(Twisted Pair
Better)
not specified
none
specified
guidelines
use 24
none specified
none specified,
guidelines use
100 impedance,
66% max.voltage drop
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Application
Multiconductor
Number of
or Twisted
Conductors
Pair
AWG
or Pairs
Shielding
Transmission
Requirements
Characteristics
Specified
Specified
EIA-485
Twisted Pair
not specified
none
specified
none specified
EIA/TIA-562
Multiconductor
not specified
none
specified
none specified
none specified
TIA/EIA-612
HSSI
Twisted Pair
not specified
(companion spec
TIA/EIA-613
requires 25)
none
specified 28
recommended
shield required
110 impedance
4.5 dB max. total
attenuation @50 MHz
79 ns max. total delay
2.0 ns/m max. total
skew
X3T9.2 SCSI I
Multiconductor
or Twisted Pair
50 conductor (flat)
25 pair (round)
28 AWG
required for
external
100 impedance
X3T9.2 SCSI II
Twisted Pair
A Cable: 25
B, P, Q
Cables: 34L
Cable: 55
28 or 30
AWG
required for
external
90132 nominal
impedance
(122 typical),
0.095 dB/m max.
attenuation
@ 5 MHz
0.20 ns/m max. skew
Twisted Pair
P or Q Cables: 34
30 minimum
required for
external
Multiconductor
flat or Twisted
Pair round
50 conductor (flat)
25 pair (round)
26 or 28
AWG
120 impedance
0.095 dB/m max.
attenuation @5 MHz
5.4 ns/m max. delay
0.49 ns/m max. skew
X3T9.3 HIPPI
Twisted Pair
25
28 AWG
two shields
required
108 impedance
0.28 dB/m max.
attenuation @50
MHz0.13 ns/m max.
skew
6.0 SUMMARY
The range of cable types and basic options available for data
communications applications is limited, making the basic
cable design selection reasonably easy. The scope of the
basic selection criteria is covered by the choices, flat or
round, multiconductor or twisted pairs, and shielded or
non-shielded. Basic attributes of the application; distance,
environment, and flexibility requirements determine the basic cable type selected. Cable construction details, conductor size, stranding and coating, insulation type, shield options, and jacket types are determined by more specific
application considerations; connector type, signal speeds,
emissions and susceptibility, work and abuse, flammability,
life expectancy and cost. Every cable has inherent electrical
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Author Biography:
David Hess, V.P. Technology, Berk-Tek, Inc., 132 White Oak
Road, New Holland, Pennsylvania 17757, has worked for 17
years in product engineering and product development in the
fields of copper and optical fiber data communication cables,
participates in various data communications standards committees in TIA/EIA and ANSI X3T9, holds a B.S. degree in
Mathematics from Pennsylvania State University and is a
member of IEEE.
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