What are water-resistant cables and their importances?

Water-resistant cables or water-blocking cables are specially designed to withstand challenges related to moisture, ensuring reliability and efficiency in conditions where standard electrical cables might fail. Applications exposed to water are often harsh and can affect cable performance, so these specialized water-resistant cables are manufactured to endure various external factors and maintain functionality at different depths. These cables are designed to prevent water from penetrating and damaging the cable's insulation, ensuring the cable operates effectively and durably in wet conditions.

There are two main ways water or moisture can infiltrate electrical cables:

• Radial ingress: Water or moisture enters the cable through gaps in the sheath or protective layers, or through any breach in the cables. Once water gets inside the cables, it travels longitudinally within the cables.
• Longitudinal ingress: Water penetrates the cable through improperly constructed joints or terminations, inefficient end caps, especially when joint pits are flooded. This may occur during installation, maintenance, or when the cable is placed near high-moisture areas.

2.1 Applications of water-resistant cables

Water-resistant cables are essential for environments with a risk of exposure to moisture, such as:

• Food processing plants, where frequent cleaning and sterilization with hot steam are required.
• Outdoor applications like solar power systems, which are regularly exposed to rain and harsh environmental conditions. In particular, water-resistant cables are an indispensable component of floating solar power systems, which are becoming increasingly popular.
• Marine and offshore applications with harsh conditions, such as on ships, oil rigs, or port facilities.
• Underground applications, such as in infrastructure projects, where cables are buried.

2.2 Water-resistant cables ensure high durability

Water-resistant cables, depending on their AD level, can withstand and ensure durability for various applications. This is especially useful for applications like floating photovoltaic systems or installations in areas prone to flooding, heavy rainfall, or high humidity, without concerns about electrical cable failures. This durability provides long-lasting performance, minimizing the need for frequent replacements or repairs.

Water contact with cables can pose serious risks, including corrosion of components and potential system failures. When moisture, whether from the air or direct contact, interacts with metal parts such as electrical conductors, it can cause rust. This corrosion not only weakens the system’s integrity but also increases the likelihood of failures.

2.5 Water-resistant cables ensure compliance with industry standards

Water-resistant cables are manufactured to meet stringent international standards for safety and performance. This ensures they are suitable for use in a wide range of solar energy systems, from small residential setups to large solar farms. Using cables that comply with these standards helps solar installers and operators meet regulatory requirements and guarantees long-term reliability for their systems.

In an electrical system, it is crucial not only for each individual component to withstand the effects of moisture and water, but also for the connection points to be waterproof. These connection points are where electrical current or data transfers from one component to another, making them critical areas within the system. In all cases, the contact points within electrical connectors must remain dry, as moisture can lead to dangerous short circuits. Therefore, waterproof connectors must also be capable of preventing water ingress.

The IP (Ingress Protection) rating is a standard that helps users easily select appropriate waterproof connectors for their applications. Connectors with high IP ratings provide protection against dust, immersion in water, and high-pressure water jets. Different IP protection levels are defined based on operational conditions related to exposure to dust, short-term or long-term immersion in liquids, and contact with high-temperature water or steam.

5.2 HELUPOWER® AQUATIC-750-BLUE water-resistant cables

HELPOWER AQUATIC-750-BLUE cables are designed to operate at a voltage of 450/750 V while maintaining excellent performance even when used in underwater environments. With a protective sheath made from a special cross-linked compound, this cable is durable in potable water, seawater, and chlorinated water environments at depths of up to 600 meters.

A notable feature of the HELPOWER AQUATIC-750-BLUE cables is that they have been approved according to the KTW BWGL standard, which evaluates plastic and organic materials in contact with drinking water. This ensures hygienic safety for the cable and is further supported by the W270 approval from the German Gas and Water Association. Additionally, the cables meet the necessary drinking water standards in Italy and Poland through certifications DM 174 and PZH.

With its long coastline, many Vietnamese companies have leveraged this advantage to develop projects near the sea. Due to the specific environmental conditions of these installations, the cables used must meet two basic requirements:

• Resistant to saltwater corrosion, ensuring they withstand the high salinity of the marine environment.
• Stable signal transmission in underwater installation environments.

This was the challenge faced by one of our customers at HELUKABEL Vietnam for their Sun Signature Show project. To address the customer’s concerns for this project, we recommended and supplied the HELUPOWER AQUATIC-750-BLUE water-resistant cable. This cable resolved two major issues for the project:

• It performed well in water, ensuring the signal transmission remained stable and accurate.
• The cable was designed to withstand seawater salinity levels up to 3.5%, while the actual salinity level at the project site was only 3.2%.

>>Find out more: Sun Signature Show