A Guide to Choosing Industrial Ethernet Cables: From Harsh Environments to Network Protocols

Avoid wasting time and money on downtime due to improper Ethernet cable selection in your industrial Ethernet environment. When considering the network design of your factory, you need to account for the environment in which the cable will operate. Proper Ethernet cable selection plays a key role in cutting downtime due to loss of communication, factory stoppage, or damage control to repair a cable.

Selecting the right Industrial Ethernet Cables, PROFINET cables, and M12 connectors will stabilize the network communications and keep the factory running without expensive repairs and unnecessary non-productive time or lengthy troubleshooting.

Whatever protocol you are working with, if the Ethernet cable and connectors are properly selected, it will stabilize the network communications, reduce downtime costs, and limit repair issues.

Take the proper time to ensure you have selected the right cable for your environment and application/protocol to maximize your reliance on the system performing as intended.

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1. Stop Guessing: Why Office Ethernet Cables Fail in Industrial Settings and What You Need Instead

There is a great difference between Industrial Ethernet cables and office Ethernet cables for factory utilization. Factory floors present different conditions than an office would.

Office cables are made with PVC jackets, while industrial cables are made of tougher jackets such as PUR or TPE that are oil-resistant, chemical-resistant, abrasion-resistant, and extreme heat-resistant. The jacket is a significant reason why industrial cables are generally much more durable and longer-lasting than office cables in extreme conditions.

The shielding is also an important element. An industrial Ethernet cable will have better shielding for electromagnetic interference (EMI), with the EMI shielding elements being foil, braid, or dual shields.

Office cables generally do not have such robust shielding, and therefore are susceptible to all kinds of noise in an industrial environment that could affect communication.

Mechanical stress also represents another distinct difference. An industrial Ethernet cable can withstand bending, vibration, and shock when being subjected to machines moving around.

An office cable is not made for this type of mechanical stress, and it will deteriorate and fail in those conditions much quicker than an industrial cable.

In an industrial environment, using an office-grade Ethernet cable could result in severe consequences such as failed networks, lost revenue due to not being able to connect to your network or machine, and increased maintenance costs due to office-grade Ethernet cable failures and replacements.

Industrial-grade Ethernet cables are built to withstand factory floor environments with their rugged construction, EMI shielding, and the materials used to build these cables are suited for extreme conditions. These Industrial-grade Ethernet cables will provide reliability in performance and efficiency without downtime.

2. Don’t Get It Wrong: How to Accurately Assess Your Industrial Environment to Choose the Best Ethernet Cable

Choosing an Industrial Ethernet Cable takes some thought process and consideration of the environment where the cables will be installed. Industrial environments have different characteristics: dry indoor environments, wet environments, dusty environments, oily environments, chemical environments, high vibration environments, outdoor environments, or buried environments.

Each environment has a different impact on the cable's performance and longevity.

• For dry indoor environments, cables with standard PUR jackets will provide good protection, flexibility, and durability.
• For wet environments or locations with moisture, dry dust, or grease, look for cables that meet high ingress protection standards with robust materials such as thermoplastic elastomer (TPE).
• For oily environments or locations where chemicals can be found, you want a cable constructed from a polyurethane (PUR) or comparable jacket that provides excellent hydrocarbon and chemical resistance. If you don’t, the PVC jacket will deteriorate quickly, leading to failure points in the network.
• High vibration areas require cables designed with some armor or reinforcement to withstand constant flexing and mechanical stresses. Flexible cables with high tensile strength built in are less likely to break from mechanical stresses near machinery that moves frequently and requires high durability cables.
• For outdoor applications, direct burial installations, or locations where cables will be exposed to outdoor weather elements for long periods, cables with UV-resistant, waterproof jackets, and a type of stiffening or mechanical protection would be prudent.

All the above-mentioned jacket materials and construction should suit the conditions. Ignoring any condition discussed leads to a shorter lifespan for the cable, which results in costly downtime for production and lost revenue.

3. Match Your Protocol: PROFINET, Ethernet/IP, and More: What Your Cable Must Support

Industrial Ethernet protocols such as PROFINET and Ethernet/IP document the characteristics of cables used to assure reliable operation.

The number of conductors used is one of the more important characteristics, as PROFINET uses 4 or 8 conductor cables, depending on the application.

Most modern PROFINET devices and systems are designed for an 8-conductor shielded cable; the use of an 8-conductor shielded cable is also typical in Ethernet/IP applications to accommodate the various signals required to support Ethernet/IP communication.

Shielding is important to both protocols as it addresses electrical interference (EMI) consistent in industrial settings.

Shielded cables, which can be FTP (foil), STP (braid), or S/FTP (foil + braid), are needed to maintain the integrity of the signals. In environments where machinery and power devices are used, unshielded cables or devices introduce the risk of communication problems.

Color codes or markings on cables follow either manufacturer processes or guidelines for protocols to confirm proper installation and troubleshooting.

While cables can also be labeled with either PROFINET or Ethernet/IP, PROFINET cables have a unique type and color of sheath. In contrast, Ethernet/IP cables are designed to the general standards for Ethernet cables that cover a larger range.

Using the wrong type will invariably cause communication problems and possibly a failure of the network, including loss of communication, delayed communication, or no communication whatsoever.

For example, if the cable does not have sufficient shielding, or pairs of conductors are not correctly mapped, PROFINET will not communicate in real time, and Ethernet/IP will certainly not communicate.

A practical cable protocol matrix:

PROFINET:

• Conductor Pairs: 4 or 8
• Shielding: FTP (foil), STP (braid), or S/FTP (foil + braid)
• Standard Connectors: Shielded RJ45
• Notes: 8-pair cable preferred for futureproofing

Ethernet/IP:

• Conductor Pairs: 8
• Shielding: FTP or STP
• Standard Connectors: Shielded RJ45 or M12
• Notes: Supports full Ethernet signaling

Choosing cables meeting these specs guarantees seamless operation and stability in demanding industrial systems.

4. Master EMI Shielding: Shielding Types in Industrial Ethernet Cables That Protect Your Network

Electromagnetic interference (EMI) typically disrupts data signals on industrial networks. The heavy machinery and power devices used in an industrial setting generate electrical noise, which can affect the data signals moving through the data cables.

Using an appropriate industrial Ethernet cable with the correct shielding restores the integrity of your network's data communications.

The types of shielding for data cables can vary from the least to the most shielding materials:

• Unshielded Twisted Pair (UTP) data cables only contain twisted pairs, and no extra shielding material. UTP is simply insufficient in proximity to typical sources of industrial EMI interference.
• Foil Shielded Twisted Pair (FTP) cables wrap the pairs with a thin aluminum foil. FTP provides moderate shielding and may be a better data cable option in areas where there is EMI interference, such as on general manufacturing floors.
• Shielded Twisted Pair (STP) cables offer additional shielding, with a braided metal mesh that helps block a higher level of interference. STP cables can be the appropriate cable in proximity to interference, such as near motors, drives, and robotic arms.
• The highest level of shielding is found in Screened Foiled Twisted Pair (S/FTP) cables. S/FTP cables have foil shielding on the individual pairs plus another braided metal shield overall. This type of shield helps minimize the EMI modulation and significant crosstalk if present, in the center of a massive industrial EMI zone.

Which choice of shielded cable to use depends on how close the cable is to an EMI interference source. If the cable is in proximity to a large motor or power conduits, STP or S/FTP may make more sense to minimize the EMI influence.

If the cable is in an area with lower noise, FTP can provide a balance of flexibility and some protection.

Solid shielded data cables for industrial Ethernet will significantly reduce internal data errors, which can reduce maintenance and provide a reliable industrial Ethernet network for the long term.

5. Conquer Distance and Signal Integrity: Long-Run Industrial Ethernet Cable Solutions That Work

There are physical limitations that call for Industrial Ethernet cable lengths of around 100 meters. As distances increase, signals degrade due to attenuation and interference. This causes errors and/or an unstable signal.

Fiber optic cables are the perfect solution for longer distances. Fiber provides distances beyond 2000 meters, as opposed to copper, while having immunity to EMI and being able to provide higher bandwidth. It is even better for backbone or inter-building connections.

When the use of copper is necessary, there are options available in the form of industrial Ethernet switches or repeaters to regenerate the signal every 90-100 meters, which extends the use of copper and maximizes the use of distance, especially when it comes to longer runs of 150 meters or more.

From a planning standpoint, most network designers are able to develop routes for cables and possibly even strategically place devices, ensuring the integrity of signals, while also properly using more expensive cables at longer distances, and preventing downtime due to poorer signal quality or loss of signal.

These terms, such as industrial Ethernet length, signal integrity, and industrial Ethernet design, help provide a robust long-distance communication solution.

6. Choose the Right Connector: Why M12 Connectors Outperform RJ45 in Industrial Ethernet Networks

In comparison to M8 and RJ45 connectors, M12 connectors are far superior for both environmental protection and durability in industrial Ethernet applications.

M12 connectors are designed and tested to account for proper IP67 to IP69K ratings, so they can resist dust and moisture ingress, vibration, and extreme temperatures.

While RJ45 connectors are common and familiar for use in office networks, they do not offer the robustness suitable for usage in factory floors or outdoor sites.

Although M8 connectors can be used in less harsh environments because they are compact, they do not provide the robustness M12 connectors do, especially with cable stress.

M12 connectors come with different coding configurations: A, B, D, X, which denote that the connectors are designed for the appropriate data rate and protocol.

• A-coding supports basic Ethernet capabilities and Fieldbus usage for dry environments.
• D-coding provides waterproof options but does not have all the benefits of X-coding.
• X-coding connectors support use for Gigabit Ethernet cabling with added shielding.

Making the right choice for an M12 connector for your industrial Ethernet cable will provide a stable, secure physical connection that is designed to withstand physical and electrical stressors.

Making the right choice in connectors also reduces the risk of faults in your network, ultimately protecting uptime and functions in complex industrial environments.

7. Exclusive Case Study: How a Leading Manufacturer Slashed Network Downtime by 90% with Smart Industrial Ethernet Cable Choices

A large automotive company was plagued with network reliability issues due to the failure of “standard” cables entering oily and dynamic environments.

The constant breakdowns and downtime were detrimental to production, resulting in significant and ongoing costs.

The engineering team installed high-flexibility, PUR-jacketed, Industrial Ethernet cables. This particular cable is well-known for its outstanding resistance to oil and excellent flexibility.

The standard cables previously installed obviously could not perform in greasy and moving applications.

To further mitigate the breakdowns, a robust M12 connector was utilized, which provided a tight seal and the ability to withstand vibrations.

To justify the cables, side-by-side comparisons demonstrating the degree of failure and estimating the return on investment were required for management approval.

They would need to demonstrate how the cables wore in certain instances, which could create installation issues from the bending/cut radius. With M12 connectors, it would require careful consideration of cable installation and routing to relieve stress on the connectors for maintenance purposes.

The installation achieved a 90% reduction in network downtime, leading to upwards of $500,000 in annual maintenance and productivity loss.

Additionally, overall production efficiency was improved by approximately 15%, demonstrating how both the physics of the environment the Industrial Ethernet Cable was being utilized in, and the cable design for that environment, can offer tremendous operational value.

8. Exclusive Quick Reference: Cat5e vs Cat6 vs Cat6A vs Single Pair Ethernet (SPE): What Industrial Users Must Know

The following comparison of industrial Ethernet cables discusses important parameters that impact their performance and longevity.

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Cat5e:

• Bandwidth: 100 MHz
• Max Speed: 1 Gbps
• Max Length: 100 meters
• Shielding: None / UTP
• Vibration Resistance: Low
• Oil/Chemical Resistance: Low
• Approximate Cost: Low
• Typical Use Case: Basic networks

Cat6:

• Bandwidth: 250 MHz
• Max Speed: 10 Gbps (up to 55 meters)
• Max Length: 100 meters
• Shielding: UTP / FTP
• Vibration Resistance: Medium
• Oil/Chemical Resistance: Medium
• Approximate Cost: Medium
• Typical Use Case: Moderate industrial use

Cat6A:

• Bandwidth: 500 MHz
• Max Speed: 10 Gbps (up to 100 meters)
• Max Length: 100 meters
• Shielding: S/FTP
• Vibration Resistance: High
• Oil/Chemical Resistance: High
• Approximate Cost: High
• Typical Use Case: High-performance industrial

Single Pair Ethernet (SPE):

• Bandwidth: Varies (10-100 MHz)
• Max Speed: Up to 1 Gbps
• Max Length: 1000+ meters
• Shielding: Varies
• Vibration Resistance: Medium
• Oil/Chemical Resistance: Medium to High
• Approximate Cost: Low to Medium
• Typical Use Case: IIoT, sensor networks

SPE is an exciting potential option for future-proofing your network and simplifying wiring in IIoT applications, while the old-fashioned cable can cater to other high-bandwidth use cases.

Final Golden Rules: The Top 3 Tips for Installing and Maintaining Industrial Ethernet Cables

Proper installation and maintenance support a reliable network and help to eliminate interruptions.

1. Do not exceed the cable's minimum bend radius to avoid putting stress on the cable and degrading the signal while in use. Sharp bends create weak points that could eventually fail.
2. Separate your power cable by at least 15 cm (6 inches) from the Ethernet cable. This distance helps to reduce electromagnetic interference and prevents data corruption.
3. Connectors should be secured well, but should also be regularly inspected for looseness or corrosion. Bad connections hinder signal quality and have a tendency to drop in and out.

If you follow the three golden rules of good practice, you will significantly help with network stability in distressing situations.

Please share the information and continue to explore industrial Ethernet cable options that are available and that meet your needs.