Essential Cable Installation Tips for Cable Carriers: Avoid Failures & Extend Service Life

Proper installation of cables inside a cable carrier system is critical for maximizing performance and preventing premature wear or failure. Follow these best practices to ensure safe, efficient, and long-lasting cable operation.

1. Unspool Cables Correctly

Always unspool cables by allowing the spool to roll naturally. Never pull cables from the flange or uncoil them from the top. Improper unspooling creates unnecessary mechanical stress that can shorten cable life.

2. Inspect Cable Jacket Materials

Certain jacket materials can stick together, causing abrasion during movement. Always verify:

• That your cables are designed for use inside cable carriers.
• That the jacket materials are compatible with other cables or hoses in the carrier.
• Interior separation can help prevent wear from jacket-to-jacket contact.

3. Cut to Proper Length and Lay Cables Inside the Carrier

Cables should be cut to the appropriate length and laid directly into the cable carrier. This ensures:

• Proper connection at both ends
• Adequate strain relief
• Reduced risk of cable twisting, especially when pre-assembled with connectors
• Avoid forcing or twisting cables into position; gentle placement is key.

4. Allow Free Movement Within the Carrier

Each cable should have enough room to move freely during carrier operation. This helps:

• Minimize abrasion
• Reduce stress during motion
• Maximize cable service life

5. Maintain the Neutral Axis at Maximum Bend Radius

Cables must rest within the neutral axis of the cable carrier, especially when the carrier operates at its maximum bend radius. This positioning prevents tensile strain and reduces the chance of failure during repeated motion cycles.

6. Use Separators for Cables with Different Diameters

Installing cables or hoses of varying diameters? Use interior separators or shelving to prevent tangling. Follow these rules:

• If the combined diameters (D1 + D2) > 1.2 × the inner height of the cable carrier, separation is not required.
• If (D1 + D2) ≤ inner height, use vertical separators or a horizontal shelf to prevent abrasion and jacket material degradation.
• More resilient jackets can wear down softer ones over time.

7. Apply Proper Strain Relief

Always use strain relief on both ends of the cable. This can include:

• Mounting brackets
• Tie wrap plates
• Other secure cable restraint methods
• Strain relief ensures the cable’s length stays fixed inside the carrier during operation. In some cases, strain relief is only needed at the moving end.