Control cabinets act as the central nervous system of an industrial automation system, and are used to safely and reliably house high-value components such as drives, instrumentation and PLCs. The selection of halogen-free cables for these panels is an intelligent choice because it results in less toxic smoke and corrosive gases in case of a fire incident, thereby improving the safety of the fire. With more than 15 years in the industrial cable manufacturing sector, Hulk Electric can assist engineers and panel builders in choosing the right products that fit their high safety requirements, enhance the performance of the cabinets, and ensure long-lasting use.
From safety and layout suggestions to careful selection of cables, this guide offers hands-on, experience-based guidance on incorporating halogen-free cables into control cabinet design to minimize risk, product compliance and overall system reliability.
Why Use Halogen-Free Cables Inside Control Cabinets?
Control cabinets are frequently placed next to operators in industrial installations or in enclosures where fire safety has a direct impact on the protection of personnel and equipment. Traditional PVC cables can emit toxic hydrochloric acid and thick, dense smoke upon heat or fire, which can harm sensitive electronic equipment and hinder evacuation or fire fight.
The cables with halogen-free compounds, for instance cross-linked polyethylene, TPE or silicone-based compounds, are also called LSZH (Low Smoke Zero Halogen) cables or HFFR (Halogen-Free Flame Retardant) cables because they emit much less corrosive gas and smoke. This makes them particularly suitable for control cabinets, where even if there was a slight problem with the electrical equipment, a secondary malfunction could cause damage to costly equipment.
Safety Benefits in Control Cabinets – Fire, Smoke and Corrosion
Fire Safety Inside the Panel
Halogen-free cables are designed to be flame resistant and self extinguishing. The material of the wire’s sheathing resists the spread of flames on the wire, a vital factor in a control cabinet where there is a limited area and a high density of wiring. This helps to limit problems and preserve surrounding automation equipment.
Smoke and Toxic Gas Reduction Around Electronics
These cables do not produce the amounts of toxic and corrosive byproducts that are emitted by cables that contain halogens. This minimizes the possibility of corrosion issues on terminal blocks, circuit boards and communication interfaces that often occur in facilities that employ standard cables. This feature allows for compliance with fire safety codes in enclosed process areas/process buildings and contributes towards increased plant resiliency in high occupancy buildings.
Layout Best Practices for Control Cabinets Using Halogen-Free Cables
Wire Routing, Bend Radius and Length
Accurate cable measurement avoids excessive slack, creating clutter, and too tight runs which may not meet minimum bend radii requirements. The flexibility of halogen-free cables, depending on their construction, may be slightly different, always follow the manufacturer’s instructions to avoid stress on conductors or insulation.
Run cables in cable ducts or trunking and keep power and signal wires clear of each other to minimize EMI.
Separation of Power, Control and Communication
It is still necessary to have good segregation. Shielded halogen-free types (e.g. HSLH-JZ) for high-EMI environments for reliable signal integrity. This type of layout also makes it easier to maintain and troubleshoot.
Panel Cable Types and Flexibility
Use multi-stranded flexible panel wires capable of bending around corners and small vibration that are found in most industrial applications, which are also halogen free. Hulk has control cables that are halogen free and are designed to be excellent for routing, yet have mechanical strength.
Cable Selection in Halogen-Free Control Cabinets
Wire Size, Cross-Section and Current Capacity
Size is important. Undersized conductors overheat and oversized conductors waste space and money. Use load currents, voltage drop on distance and ambient temperatures within the cabinet to calculate. Use reference standard ampacity charts and consider grouping and installation method.
Material Choice – When to Prefer Halogen-Free
Use LSZH sheaths in cabinets installed in public buildings, hospitals, data centers or enclosed industrial areas. Hulk provides halogen-free single-core H07Z-K style panel wires to 90°C and multi-core control cables fully RoHS, REACH and CE compliant. Our silicone high temperature grades offer enhanced thermal resistance for more demanding applications.
Standards and Compliance
Provide cables that comply with IEC, VDE, CE and local CPR standards. Record of LSZH compliance in the specifications eliminates unwanted substitutions at time of procurement.
Practical Design Workflow for Plant Engineers
- Evaluate environment — Identify if there is a higher fire risk in the cabinet location (public areas, high risk areas).
- Identify loads and circuits — Specify power, control and data loads; make shielding decisions.
- Choose the right cables for your application that are appropriate for halogen-free — Match cross-section, flexibility, temperature rating and certifications.
- Design the routing — Make routing, bend radii, and separation for neat and serviceable as efficient as possible.
- Specify and document — Communicate and record — Clearly communicate and record halogen-free requirements in drawings and purchase orders.
This workflow helps reach safer and more reliable control panels, while reducing the total ownership cost.
At Hulk Electric (Dongguan) Co., Ltd., the factory is equipped with modern production lines, which produce the cables with the highest quality, specializing in manufacturing industrial automation and control cabinets. Global certifications, full testing and quick customization provide OEMs and system integrators around the world the newest solutions for compliance and performance.
Tell us about your cabinet and we will help you choose or design the perfect cables that are halogen-free to suit your project.
