Several different data cables floating in front of a digital graphic

Copper-based data cabling Reliable data transmission with proven technology

In many fields of application, whether infrastructure, buildings, or industry, the focus is on process automation. More devices are being integrated into networks all the time. Cabling is becoming more and more complex due to increasing data volumes and growing transmission speeds. Copper-based data cabling has proven its worth for decades.

Increasing data rates and transmission speeds present ever greater challenges for transmission technology and thus also for transmission cables and the connected connectors. Future-proof developments and products are required. Otherwise, reliable data transmission is not possible. In home applications, the problems that occur are usually tolerable. However, faulty transmissions in industrial applications can lead to high costs. Due to their good physical and mechanical properties, copper cables ensure reliable connections for data transmission.

Advantages

  • Cost-optimized data transmission based on years of experience
  • Reliable protection against data theft: no data tapping possible via the cable
  • Standardized interfaces such as RJ45, USB, HDMI, coaxial, and D-SUB connectors as well as circular connectors in M8 and M12 format
  • Optimum electrical properties with solid copper conductors
  • High level of expertise through development and in-house production
Copper-based data connectors with cables fanned out next to each other

Copper conductors in application

Why copper conductors? – Copper cables use different technologies to transmit current and voltage for the device supply with power and data. Copper has optimal properties for the transmission of electrical energy. Alternative materials such as aluminum are also sometimes used in inexpensive conductors, but they offer a much lower level of performance – around two thirds of the electrical conductivity in the case of aluminum.

A wide range of copper cables are available on the market, which means that the optimum cable with connectors is available for almost every application with a specific protocol. D-SUB connectors for the VGA connection of monitors to a PC are just one example. In industry, on the other hand, the PROFINET protocol is widely used. This is often transmitted via RJ45 connectors in two-pair or four-pair twisted pair cables.

The development of the technology is already very advanced, yet further innovations are available on the market. A good example is Single Pair Ethernet, the transmission of Ethernet protocols via just one pair of wires. For this new technology, brand-new cables and connectors are being designed, which will then be standardized. This promotes the standardization of interfaces.

Copper-based data cables in RJ45, Single Pair Ethernet, and M8 format

How are copper-based data cables constructed?

A distinction is generally made between two types of copper-based data cables:

  • Coaxial cables, where one conductor is centrally routed within the cable.

  • Stranded cables, in which several conductors are routed in one cable and are twisted together. They are either twisted around a central filler element – as is the case with many four-pos. cables – or the wires of one pair are twisted together and the wire pairs are then twisted together – as is the case with many eight-pos. cables. The latter type is called twisted pair (TP).

There are also other combinations of these basic constructions, as in the case of cables that support the hybrid transmission of data and power, for example.

The structure of a coaxial copper cable

Internal structure of a coaxial L cable
Internal structure of a coaxial L cable
Internal structure of a coaxial L cable
Internal structure of a coaxial L cable

The cable sheath on coaxial cables protects the internal elements of the cable from external influences. In order to improve mechanical or thermal properties and resistance levels, this sheath is usually made from plastic materials mixed with additives. For example, it is thus possible to make cables suitable for outdoor use and to achieve resistance to moisture and sunlight.

The inner conductor can be solid or made up of thin wires. In both cases, the cable is referred to as a flexible cable.

Many flexible coaxial cables feature shielding with tightly braided metal litz wires. To achieve better shielding properties, a metal or metal-coated plastic foil can also be used in addition. In contrast, there are cables with a solid outer conductor. These rigid cables are called semirigid cables.

The dielectric is the insulation material between the inner and outer conductors. This can consist of solid plastic, as well as plastic discs or, as in most cases, a plastic foam, e.g., polyethylene.

Internal structure of a coaxial L cable

When it comes to transmission, an important parameter is the attenuation of the signal by the transmission medium. Since this attenuation depends on the transmission frequency, it is specified in different frequencies – typical frequencies are, for example, 2.4 GHz or 5.8 GHz for WLAN. Cables with an impedance of 50 Ω or 75 Ω are widely used. Only cables and other components with the same impedance should be used together. Mixing may result in mismatching. This causes unwanted reflections.

Internal structure of a coaxial L cable

A typical application for coaxial cables is the connection of a transmitter or receiver to an antenna, e.g., in LTE, WLAN, 5G, and campus networks.

The structure of a twisted pair copper cable

Eight-pos. SF/FPT twisted pair cable with four wire pairs
Eight-pos. SF/FPT twisted pair cable with four wire pairs
Eight-pos. SF/FPT twisted pair cable with four wire pairs
Eight-pos. SF/FPT twisted pair cable with four wire pairs
Eight-pos. SF/FPT twisted pair cable with four wire pairs
Eight-pos. SF/FPT twisted pair cable with four wire pairs

Copper-based data cables usually have an outer sheath, which protects the internal elements of the cable from external influences. This sheath is usually made from plastic material such as polyurethane (PUR), polyvinyl chloride (PVC), or polyethylene (PE). In order to improve mechanical or thermal properties and resistance levels, these materials are usually mixed with additives.

Eight-pos. SF/FPT twisted pair cable with four wire pairs

Under the cable sheath, copper-based data cables usually have an electrical shield that protects against external influences. Two different shielding concepts are typically used: A braided shield comprising tightly meshed metal litz wires (screened = S) and a shielding foil made from metal or metal-coated plastic (foiled = F). The overall shielding of the cable is thus indicated by S, F, or SF.

Eight-pos. SF/FPT twisted pair cable with four wire pairs

It is not just the overall cable, but also the individual wire pairs that can be shielded from the other wire pairs by their own shielding with a shielding foil (foiled twisted pair = FTP).

Eight-pos. SF/FPT twisted pair cable with four wire pairs

In twisted pair cables, two wires are twisted together and the wire pairs are then twisted together.

Eight-pos. SF/FPT twisted pair cable with four wire pairs

The individual wires of a copper-based data cable consist of plastic insulation and the copper core. This differs depending on the intended use. In installation cables it is a solid copper core. In flexible cables, this core is made up of 7 litz wires, or 19 litz wires in the case of highly flexible cables. American Wire Gauge (AWG) is the unit of measurement used to specify the cross-section of the single-core wires. AWG 22 is very common for four-pos. cables and AWG 26 is very common for eight-pos. cables.

Copper cables with various measuring devices in a high-voltage test

What is the performance of copper cables?

The performance of a copper-based data cable as a raw cable is indicated by the transmission category. To explain the differences between the categories and the test methods, it is also worth taking a look at the Ethernet protocol here.

Raw cables are defined by their own standards. These standards also specify test methods as well as electrical limit values for the parameters to be tested. The return loss is an example of one of the parameters to be tested. This value measures the signal reflected by the cable at the transmitter end. However, the limit values that must be observed differ greatly depending on whether a raw cable, a cable assembled with connectors (patch cable measurement – permanent link test – ISO 11801), or an entire transmission path (channel test – ISO 11801) is being measured.

Test engineer with a copper-based cable and measurement setup

At this point, the assembled cable must meet the strict values, as it represents just one part of a transmission path. Limit values for transmission paths are accordingly less strict, so parts that are weaker as a result of aging or other effects can be compensated. In order to minimize the influences of the measuring device, the first and the last connection are hidden during channel measurement. If a patch cable is measured with a channel test for the transmission path, this measurement thus has no informative value, since the two connectors of the cable are hidden.

Which measurement method is used can be determined by looking at the data sheet and the transmission properties of a patch cable. Cables with a channel test must be specified with the transmission class, whereas cables with a permanent link test must be specified with the transmission category. Unfortunately, this cannot always be verified by testing the cables, so caution is advised when selecting the right cable.

Finally, the focus should be on the approval of an RJ45 patch cable in the same way this is done at Phoenix Contact:

  1. Raw cable test 100 m followed by
  2. Assembly of 2-meter patch cables* with two RJ45 connectors
  3. Permanent link (not channel link) patch cable test followed by
  4. Approval of the connector and cable combination only upon successful completion of all tests
  • In Phoenix Contact’s experience, two meters represents the most critical length for patch cables in accordance with current standards.
Copper-based data connector being assembled with both hands for RJ45

Copper-based solutions for field cabling

Whether for use directly on your machine, in buildings, or even outdoors, the connection solutions are the perfect choice in any environment. Your application can benefit from these product features:

• Transmission speeds up to 10 Gbps
• Innovative hybrid cabling
• Solutions from IP20 to IP69K
• Spring, pierce, and IDC connection
• 360° shielding concepts

Copper-based data connectors for network and fieldbus connection

Copped-based solutions for device connection

Use high-performance connectors and cables designed for assembly on site in your device. Whether future-proof high-speed cabling with up to 10 Gbps or innovative hybrid cabling: Phoenix Contact offers you a comprehensive product range featuring various pin connector patterns for different transmission properties – from SPE, RJ45, HDMI, USB, coaxial connectors for printed circuit boards and M12 panel feed-throughs to D-SUB connectors.

• Transmission speeds up to 10 Gbps
• Innovative hybrid cabling
• Solutions from IP20 to IP69K
• Spring, pierce, and IDC connection
• 360° shielding concepts

Ideally suited for these industries

Copper conductors are also used in measurement, communications, and automation technology, data processing, and in controllers in machine building and systems manufacturing. They also come into play for server-to-switch and desktop-to-switch connections.

Ideally suited for these areas of application

Collaborative robot in product manufacturing with a woman in the background
Interior view of frequency converter with board-to-board connectors
Data connectors used in a control cabinet
Phoenix Contact employee with an iPad and robot in an industrial production line
Engineer with a tablet in a modern building
Installation of a surveillance camera on a mast
Collaborative robot in product manufacturing with a woman in the background

Special shielding concepts and torsion-resistant, optimally coordinated components are essential for the reliable operation of robots and conveying systems. Complex automation processes demand communication in many areas. For error-free data transmission, you can rely on the copper-based product range, qualified in accordance with various transmission standards. These include Ethernet APL, PROFINET, Ethernet CAT5, and EtherCAT P.

More about device connection
Interior view of frequency converter with board-to-board connectors

Copper cables are also used in conjunction with board-to-board connectors. These connectors provide shielded and unshielded solutions for signal and data transmission in the device in a confined space. Individual PCB orientations with various application-oriented designs, stack heights, and numbers of positions can be realized.

More about the board-to-board connectors
Data connectors used in a control cabinet

In the control cabinet, copper components provide cabling solutions for Ethernet and PROFINET applications – to suit your data transmission system.

More about the data connectors
Phoenix Contact employee with an iPad and robot in an industrial production line

Reliable connection solutions and consistent data transmission up to 10 Gbps (CAT6A): RJ45, USB, and HDMI patch cables as well as RJ45 connectors designed for assembly that do not need special tools are ideal for the special requirements in industrial cabling. The reliable operation of robots and conveyor systems hinges on special shielding concepts and torsion-resistant copper components.

More about industrial IP20 and IP6X cabling
Engineer with a tablet in a modern building

In smart buildings, different applications are networked in a distributed way. A smart building is only made possible by standardized device connections so that the individual building systems and their applications communicate fluidly with each other. Connectors and patch cables provide the basis for this.

More about device connections in building automation
Installation of a surveillance camera on a mast

High demands are placed on components used for outdoor data transmission, e.g., in fields such as telecommunications and renewable energy. Special connectors for outdoor applications can withstand demanding environmental conditions with extreme temperature variations, humidity, UV rays, and vibrations.

E-paper on data connectors
Copper-based data connectors at a glance
Would you like to browse through our copper-based range? – The e-paper on data connectors also provides an overview of the corresponding connections for you.
Open the e-paper
Different data connectors at a glance