Introduction

In South Africa, the industrial landscape is evolving rapidly. From the automotive assembly plants in Gauteng and KwaZulu-Natal to the sprawling platinum and gold processing facilities in Limpopo and North West Province, there is an increasing demand for flexible, reliable, and high-performance control cabling solutions. Modern automation, robotics, and mobile machinery rely heavily on drag chain cable systems that are subjected to continuous bending, torsion, and mechanical stress.

Traditional PVC or standard control cables fail prematurely under these demanding conditions, leading to unexpected downtime, high maintenance costs, and safety risks. This is where HIFLEX Z-FD ultra-flexible drag chain cables stand out. Designed for continuous motion applications, these cables combine electrical performance, mechanical resilience, and flame-retardant safety to meet South Africa’s industrial requirements.

With an operating voltage of 300/500 V, compliance with IEC 60332-1 flame-retardant standards, and the ability to handle frequent bending in drag chains, HIFLEX Z-FD cables are engineered to reduce maintenance downtime and enhance operational reliability. This article dives deep into the technical specifications, structure, applications, and real-world performance of HIFLEX Z-FD cables in South Africa, providing engineers and industry professionals with a complete reference.

Technical Specifications of HIFLEX Z-FD

Electrical Ratings

HIFLEX Z-FD cables are designed for industrial control applications that require stable and reliable electrical performance:

• Operating voltage (Uo/U): 300/500 V – suitable for a wide range of automation and control systems.

• Test voltage: 2000 V – ensures robust insulation under stress conditions.

• Insulation resistance at 20°C: ≥ 20 MΩ × km – high resistance minimizes leakage current, ensuring signal integrity in sensitive control applications.

These electrical characteristics are particularly critical in South African plants, where voltage fluctuations and intermittent power supply are common challenges.

Mechanical & Installation Parameters

HIFLEX Z-FD is engineered for flexibility and durability in drag chain applications:

• Minimum bending radius:

  • Moving installation: 7.5 × cable outer diameter

  • Fixed installation: 4 × cable outer diameter

• Operating temperature range:

  • Moving installation: –5°C to +80°C

  • Fixed installation: –40°C to +80°C

• Radiation resistance: ≤ 80 × 10⁶ cJ/kg – suitable for environments with moderate exposure to industrial radiation or high-energy processes.

The wide temperature tolerance ensures that these cables can function reliably in South African factories exposed to both cold storage areas and high-temperature manufacturing zones.

Flame-Retardant Performance

Safety in industrial applications is paramount. HIFLEX Z-FD cables comply with IEC 60332-1, ensuring that in case of fire, the cable sheath will resist ignition and prevent flame propagation. This is especially important in South African industries where PVC insulation is common and where regulatory inspections for fire safety are stringent.

Cable Structure – What Makes HIFLEX Z-FD So Flexible?

The remarkable flexibility and durability of HIFLEX Z-FD cables stem from their carefully engineered structure.

Conductor Design

• Ultra-fine stranded bare copper: IEC 60228 Class 6 / VDE 0295 Class 6

• Benefits: High flexibility, excellent resistance to vibration, and long service life in continuous bending applications.

• Ideal for dynamic applications like robotic arms, gantries, and conveyor drag chains in South African industries.

The use of ultra-fine strands allows the cable to handle thousands of bending cycles without micro-cracks in the conductor, a common issue in standard Class 5 cables.

Core Insulation

• Special PVC insulation provides robust electrical isolation while maintaining flexibility.

• Black core with continuous white numbering ensures clear identification during installation and maintenance.

• Yellow-green earth conductor (included for 3 cores or more) ensures safety compliance.

For South African factories, clear color coding reduces human error during maintenance and speeds up troubleshooting in complex control circuits.

Cable Assembly

• Short lay-length stranding optimizes torsion and bending performance.

• Non-woven fabric wrapping minimizes internal friction, enabling smooth movement inside drag chains.

• Enhanced abrasion resistance ensures longevity even in high-wear applications.

Outer Sheath

• Special PVC outer sheath in silver-grey (RAL 7001)

• Offers resistance to oils, chemicals, and mechanical wear

• Smooth surface improves sliding in cable carriers and reduces drag, critical for high-speed automation systems.

Size Range, Weight & Dimensional Overview

HIFLEX Z-FD cables are available in a wide variety of core counts and cross-sectional areas:

• Core counts: 2 to 60

• Cross-sectional areas: 0.5 mm² to 16 mm² (and higher for larger control systems)

• Weights and diameters: Range to suit both compact drag chains and large industrial applications

Selection depends on the specific control or power requirements:

• 2–4 cores: Suitable for simple sensor wiring and single-axis actuator control.

• 5–12 cores: Ideal for PLC connections, encoder feedback, and moderate complexity machinery.

• 14–60 cores: Used in complex systems requiring multiple control signals, power lines, or combined control + communication circuits.

In South African manufacturing plants, careful selection ensures that the cable fits the drag chain without excessive stress while providing reliable power and signal transmission.

Key Features & Performance Advantages

High Flexibility for Continuous Motion

HIFLEX Z-FD is designed to endure high-cycle bending without copper fatigue. In South African production lines, where machines operate 24/7, this flexibility ensures:

• Reduced maintenance downtime

• Continuous motion without interruption

• Longer service life compared to standard control cables

Medium Mechanical Stress Capability

The cable withstands moderate mechanical stress in moving applications such as:

• Robotic welders

• Gantry-mounted conveyors

• Material handling systems in mining and automotive plants

Stability in Harsh Environmental Conditions

HIFLEX Z-FD performs reliably under:

• Temperature fluctuations (–5°C to +80°C moving; –40°C to +80°C fixed)

• Dusty environments (common in South African mining and metal processing plants)

• Oil and chemical exposure (found in automotive, food processing, and manufacturing sectors)

Safety & Compliance

• Flame-retardant IEC 60332-1

• High insulation resistance

• Mechanically protected through optimized stranding and sheath materials

• Meets South African occupational safety standards and reduces fire hazards

Typical Applications in South Africa

Industrial Automation

• CNC machines

• Robotic arms

• Automated assembly systems in automotive plants (e.g., Gauteng, KwaZulu-Natal, Eastern Cape)

HIFLEX Z-FD ensures high reliability in continuous motion, preventing costly interruptions during production.

Material Handling & Warehousing

• Long-travel conveyors

• Gantry robots

• Packaging and palletising systems

In these applications, the cable must flex repeatedly, maintain signal integrity, and resist abrasion from moving parts.

Mining & Processing Plants

• Mobile control systems for crushers, screens, and conveyor maintenance robots

• Sensor and PLC wiring for drag-chain cable management

• Medium mechanical stress applications around moving platforms and heavy-duty machinery

South African Energy & Minerals Sector

• Platinum and gold processing facilities

• Controls on slurry pumps, feeders, and movable operator consoles

• Cables withstand dust, vibration, and harsh environmental conditions without performance degradation

South African Case Study – Real Operational Success

Case Study 1: Drag Chain Cable Failure at a Gauteng Automotive Plant

Background: Robotic welding lines suffered frequent cable breakage. Standard PVC cables lasted only 3–6 months due to bending fatigue.

Solution: Replacement with HIFLEX Z-FD 18G1.0.

Results:

• Service life extended 4×

• Reduced unplanned downtime

• Better performance under heat and oil contamination

• ROI: significant savings on maintenance and increased productivity

This demonstrates how HIFLEX Z-FD enhances reliability and lowers operational costs in South African manufacturing.

Case Study 2: Mining Application in Limpopo

Application: Maintenance robot for platinum conveyor system

Cable Used: HIFLEX Z-FD 7G1.5

Outcome: Withstood dust, vibration, and continuous movement better than standard PVC cables, extending service intervals and reducing maintenance effort.

Cable Selection Guide for South African Engineers

When selecting HIFLEX Z-FD cables, consider:

• Current load: Ensure conductor cross-section matches power requirements

• Core number: Based on control, sensors, and encoders

• Flexing cycle requirements: Moving or stationary applications

• Environmental factors: Temperature, UV, oil, chemicals, dust

Installation tips:

• Maintain recommended bending radius (7.5× OD moving, 4× OD fixed)

• Avoid sharp bends or clamping pressure points

• Use proper drag chain spacing to minimize wear

Correct selection and installation maximize cable life and performance.

Frequently Asked Questions (FAQ)

Q1: Is HIFLEX Z-FD suitable for continuous-flex applications?
Yes. It is engineered for drag chains and continuous motion environments.

Q2: Can it be used outdoors in South African weather?
The PVC sheath is weather-resistant. For prolonged UV exposure, additional protection or a UV-resistant version is recommended.

Q3: Which industries in South Africa prefer this cable?
Automotive manufacturing, mining machinery, logistics automation, metal processing, and food & beverage conveyor systems.

Q4: What’s the difference between Class 5 and Class 6 conductors?
Class 6 conductors offer higher flexibility and endurance for dynamic applications compared to Class 5.

Q5: Does it meet fire-safety requirements?
Yes, IEC 60332-1 flame-retardant compliant, suitable for industrial safety inspections.

Q6: How long can HIFLEX Z-FD last in a drag chain system?
Typically 3–5× longer than standard PVC control cables when installed correctly.

Q7: Can it be used with encoders or sensors?
Yes. Recommended core counts: 4–12 cores for sensors, 12–18 cores for complex control circuits.

Conclusion

HIFLEX Z-FD ultra-flexible drag chain control cables provide South African industries with:

• Exceptional durability under continuous motion and vibration

• Long service life that reduces downtime

• Safety and fire compliance

• Stability in harsh environmental conditions

• A cost-effective solution for automation, mining, and manufacturing applications

For engineers, plant managers, and procurement teams, HIFLEX Z-FD offers peace of mind, lower maintenance costs, and enhanced operational efficiency. From automotive plants in Gauteng to platinum processing facilities in Limpopo, HIFLEX Z-FD is proving to be an indispensable component of modern South African industry.