Introduction: Why High-Flex Drag Chain Cables Matter in South Africa

South Africa’s industrial landscape is changing fast. From Johannesburg to Rustenburg, from Durban’s manufacturing zones to the coal belt of Mpumalanga, factories and mines are becoming more automated, more mobile, and more dependent on continuous, high-performance machinery.

Robotic arms in Gauteng’s automotive sector, high-speed CNC machines in engineering workshops, and mobile screening plants in open-cast mines all rely on one thing that is often ignored—high-flex drag chain cables that deliver safe, stable power under millions of bending cycles.

And this is where the HIFLEX PZ-FD 0.6/1kV cable stands out.

Its polyurethane (PUR) outer sheath is built specifically for extreme mechanical abuse:

• aggressive bending

• constant vibration

• exposure to hydraulic oils

• harsh South African sun

• abrasive mine dust

• freezing winter nights in the Free State

As South African industries push for greater uptime, fewer breakdowns, and longer maintenance intervals, high-flex cables like HIFLEX PZ-FD have quietly become the backbone of efficient, reliable operations.

What Exactly Is the HIFLEX PZ-FD 0.6/1kV Cable?

The HIFLEX PZ-FD is a high-flexibility drag chain power cable, designed specifically for continuous movement applications. Unlike traditional PVC or rubber-sheathed power cables, this cable is engineered to survive:

• dynamic bending

• repetitive chain movement

• sudden acceleration

• harsh abrasion

• chemical exposure

• outdoor weathering

The voltage rating 0.6/1kV (600/1000V) makes it suitable for most South African industrial power circuits, especially servo motors, DNC motors, robots, mobile equipment and dynamic plant systems.

Compared with PVC flexible cables, HIFLEX PZ-FD offers:

Cable Structure — A Deep Technical Breakdown

To understand why the HIFLEX PZ-FD cable performs so well, let’s break it down layer by layer—just like an engineer would.

Conductor

The conductor is made of:

• extra-fine, multi-strand bare copper

• Class 6, complying with:

  • VDE 0295

  • IEC 60228

  • BS 6360

Why Class 6 matters:
Class 6 conductors use extremely fine copper strands—much finer than Class 5 or normal flexible cables. This gives the cable:

• Ultra-high flexibility

• Resistance to fatigue during continuous movement

• Improved vibration tolerance

• Stable conductivity even under bending stress

This is crucial for drag chain cables where the conductor bends millions of times.

Insulation — TPE (Thermoplastic Elastomer)

TPE is used instead of PVC or rubber because it provides:

• High-temperature stability

• Excellent elasticity

• Improved resistance to tearing

• Consistent electrical performance during bending

Each core is identified using:

• Black insulation

• Continuous white number printing

• Yellow-green protective earth conductor (for 3 cores or more)

This makes wiring easy in South African maintenance workshops.

Stranding / Cabling Design

The cable uses:

• Optimised stranding pitch

• Short lay lengths for higher movement capability

• Reduced internal stress during flexing

• Lower electromagnetic interference—ideal for servo and DNC motors

This careful design greatly extends cable life under continuous motion.

Wrapping Layer

A non-woven fabric tape surrounds the cores:

• Allows smooth movement inside the drag chain

• Reduces friction

• Makes stripping fast and clean

• Helps absorb micro-movements caused by vibration

Outer Sheath — Special Silver-Grey PUR (RAL 7001)

The PUR outer jacket is what makes the HIFLEX PZ-FD cable a true heavy-duty performer.

Key PUR Sheath Characteristics

• Halogen-free

• Flame retardant (IEC 60332-1)

• Highly tear-resistant

• Superior abrasion resistance

• Outstanding oil and hydraulic fluid resistance

• UV, ozone and weather resistant

• Hydrolysis-proof

• Resistant to acids and alkalis

This makes the cable suitable for:

• outdoor installations

• coastal conditions

• underground mines

• steel mills

• mobile equipment

• dusty, hot, or oily environments

No PVC cable can deliver this combination of properties.

Technical Specifications — Engineer-Level Details

Below is an engineering breakdown of the HIFLEX PZ-FD 0.6/1kV cable performance characteristics.

Electrical Characteristics

• Rated voltage: 600/1000V

• Test voltage: 4000V

• Insulation resistance: ≥20 MΩ·km at 20°C

This ensures stable power delivery for servo motors and dynamic systems.

Mechanical Characteristics

Minimum bending radius:

• Fixed installation: 10 × outer diameter

• Continuous movement: 7.5 × outer diameter

This tight radius capability makes it ideal for confined drag chain channels.

Temperature Range

• Dynamic use: –30°C to +80°C

• Fixed installation: –50°C to +90°C

This is perfect for the outdoor Highveld, Western Cape coastal regions, and cold underground mines.

Environmental Resistance

• Radiation resistance up to 80 × 10⁶ cJ/kg

• Hydrolysis-proof

• UV and ozone resistant

• Resistant to acids, alkalis, oils, and coolants

This makes it suitable for:

• platinum mines

• steel factories

• chemical plants

• coastal ports

Standards Compliance

The cable complies with:

• DIN VDE 0293

• DIN VDE 0295

• DIN VDE 0250

• DIN VDE 0281

• Flame retardancy: IEC 60332-1

These are commonly used in South Africa, especially for imported machinery.

Size & Weight Overview

The HIFLEX PZ-FD range covers everything from 2×0.5 mm² to 4G120 mm².
This includes:

• control cores

• power cores

• servo motor supply sizes

Engineers typically choose:

• 0.5–1.5 mm² for auxiliary and control circuits

• 2.5–16 mm² for servo motors

• 25–120 mm² for heavy-duty machinery

Key Features That Matter in South Africa

The cable’s design solves real problems that South African industries face daily.

Superior Abrasion, Tear & Oil Resistance

South Africa’s mines, steel plants and heavy workshops are full of:

• hydraulic oil

• lubricants

• cutting fluid

• abrasive dust (especially quartz dust)

PUR performs exceptionally well here.

High Flex Life for Automation

The cable is engineered for millions of bending cycles, perfect for:

• automotive robot arms

• servo-driven axes

• CNC machines

• packaging robots

• mobile gantry systems

Plants in Gauteng rely on this performance to avoid downtime.

Weather & UV Resistance for Outdoor Machinery

South African sunlight is brutal—UV levels are among the highest in the world.

The PUR sheath resists:

• harsh UV radiation

• humidity in KZN

• salt air in the Western Cape

• blowing dust in North West and Limpopo

Reliable Performance in Harsh Environments

Typical local applications include:

• crusher plants near Rustenburg

• mobile screening systems in Mpumalanga

• sheet coil conveyors in steel mills

• outdoor cranes at Durban port

Application Scenarios Across South Africa

Mining: Gold, Platinum & Coal

Used in drag chain systems for:

• shuttle cars

• continuous miners

• pump stations

• drilling rigs

Benefits:

• survives abrasive dust

• resists hydraulic oils

• flexible in cold underground conditions

• keeps maintenance downtime low

Steel Production & Foundries

Ideal for:

• robotic welders

• rolling mills

• casting equipment

• high-temperature automation

The oil resistance is particularly important in steelworks.

Automotive Manufacturing in Gauteng

Car factories depend heavily on:

• servo motors

• drag chain robotics

• high-speed moving equipment

The HIFLEX PZ-FD prevents:

• jacket cracking

• insulation fatigue

• servo motor errors due to poor power delivery

Outdoor Mechanical Equipment

Suitable for:

• agricultural machinery

• mobile conveyors

• water pumping systems

• cranes and gantries

Machine Tools & Industrial Robotics

Compatible with CNC machines, laser cutters, plasma cutters, and milling machines.

Case Study — Real-World Performance in Rustenburg Platinum Mine

Location: Rustenburg, North West Province
Application: Drag chain cable on conveyor maintenance robot
Problem: PVC-sheathed flexible cable was failing every 6 weeks

Issues observed:

• Outer sheath cracking

• Oil absorption swelling

• Severe abrasion inside drag chain

Solution: Replace with HIFLEX PZ-FD 0.6/1kV PUR drag chain cable

Results:

• Cable life increased from 6 weeks → 14 months

• Maintenance downtime reduced significantly

• Workers no longer replaced cables during every shutdown

• Mine safety improved

• Cable paid for itself within 8 weeks

The improved performance came from:

• PUR tear resistance

• hydrolysis resistance

• Class 6 copper flexibility

• anti-abrasion design

This case study is a perfect example of why industrial engineers across South Africa trust the HIFLEX PZ-FD cable.

How to Choose the Right HIFLEX PZ-FD Cable Size

Key factors include:

✔ Motor current

✔ Voltage drop
✔ Drag chain length
✔ Ambient temperature
✔ Expected bending cycles
✔ Physical space inside drag chain

Expert tip:

• 2.5–6mm² are typical for servo motor supply

• 0.5–1.5mm² for control circuits

• 25mm²+ for heavy mobile machinery

Installation Guidelines for South African Conditions

To maximise cable life:

• Maintain correct bending radius

• Avoid twisting inside drag chain

• Keep cables away from sharp steel edges

• Use PUR-compatible clamps

• Do not force cables through small chain links

For mining environments:

• Keep cables away from sharp quartz dust

• Inspect for jacket damage weekly

• Ensure compliance with mine electrical codes

Frequently Asked Questions (FAQ)

Q1: Is HIFLEX PZ-FD suitable for outdoor installations in South Africa?

Yes. It is fully UV, ozone and weather resistant.

Q2: Can this cable be used in mines?

Absolutely. Its mechanical strength and oil resistance are ideal for mining machinery.

Q3: What is the advantage of PUR over PVC?

PUR is tougher, more flexible, oil-resistant, tear-resistant, and more durable outdoors.

Q4: Is it suitable for continuous bending cycles?

Yes — it is designed for millions of cycles.

Q5: Is the cable halogen-free and flame retardant?

Yes. It meets IEC 60332-1.

Q6: Can it be used with servo motors?

Yes — it provides stable power delivery for servo and DNC motors.

Conclusion

The HIFLEX PZ-FD 0.6/1kV cable has become one of South Africa’s most trusted high-flex drag chain cables for a reason. Its combination of:

• Class 6 ultra-flexible copper

• TPE insulation

• high-strength PUR sheath

• outstanding oil, abrasion and UV resistance

• millions of bending cycles

• safe flame-retardant design

makes it a true workhorse in mines, factories, steel plants, outdoor machinery, robotics and automotive production.

If your machinery demands reliability, uptime and safe dynamic movement, then choosing HIFLEX PZ-FD 0.6/1kV is not just a technical decision — it’s a smart business investment.