High Durability Cables

Quick Reference Guide

Table of Contents
Physical

Stainless Steel Braid............... 10

PVC Coated Armor.................. 12

Washdown

Ecolab Resistant...................... 14

Stainless Steel Nut IP69K....... 16

Temperature

Fiberglass................................. 18

Thermoplast............................. 20

Welding

Silicone Cable.......................... 22

Molded Silicone Tube.............. 23

PTFE......................................... 26

2
 Application Performance

Stainless steel nut IP69K

Stainless steel braid

PVC coated armor

Ecolab resistant

Silicone cable

Silicone tube
Thermoplast
Fiberglass

PTFE
Resistance to:
Thermal Shock
Hot/cold surroundings
Abrasion
UV
Ozone
Flame retardant
Water
Fuels
Acids
Bases
Mig welding
Tig welding
Weld resistance

Key
Excellent
Good
Poor

3
High Durability Cables
Every manufacturer has challenges, but typically one of the
most frustrating problems is when a connector or a cable
causes downtime. Cable failures can be difficult to diagnose
due to their installation or finding the exact failure. They can
cause extended downtime due to trying to replace long cable
runs through cable trays and rafters. Sometimes cable failures
just cause short repetitive downtime and constant replacement.
Downtime can be caused by a variety of situations:
Physical
n Constant contact with loading components causes
physical failure
n Buildup of excess material can physically tear the
connector apart

Washdown
n Cleaning chemicals can eat through standard materials
n High pressure washdown can destroy components

4
Temperature
n Extreme swings in temperature age materials prematurely
n Constant high-temperatures can melt standard materials

Weld Slag
n Hot weld sparks burn, melt and destroy cables
and connectors
n Buildup of damage over time can cause shorts
and failures

5
Make-up of the head

PTFE coated nut to prevent

debris from sticking Easy connect nut

Specific material
design for slag
resistance and a
higher temperature
range

Jackets over molded into the

body to prevent fraying or ingress

6
Sacrificial Cables

Sacrificial Cordset Solution: Used in extremely rugged

applications to reduce cordset replacement downtime.

Cordsets do not last forever, but it is an accessory that is

important for operations. To help save money, time and work,
implementing a “sacrificial cable” concept for any cable under
2 meters can help in situations where cables are placed in
unforgiving environments.

A sacrificial cable does not have to be a specialty cable, with

a custom jacket; it could just be a 1 meter PVC cable that will
get changed out often. The idea is that by placing a sacrificial
cable in a problematic area and connecting to a longer length
cable, this will allow maintenance to have a shorter down
time changing out failures, less maintenance expense since
shorter cables are less expensive as the longer lengths, and
there is less travel for the cable around a cell.

A sacrificial cable can save money by reducing the amount

of downtime by exchanging a shorter cable compared to a
longer cable.

7
Downtime Reduction

The High Durability cables were made to withstand liquid,

weld slag, abrasion and crushing with the redesign from
everything to the nut, body and cable. A PVC cable can
be placed in an environment with harsh conditions, but
the cordset will be eaten up by the environment in a short
amount of time and it could be difficult to remove the cable
from a sensor if material prevents the nut to disconnect.

The High Durability cable is more

than just a cable, it is engineered to
last longer, and have less buildup of
material. This means, it reduces the
number of times the machine goes
down due to a cable. A standard
cable will get the job done for the
moment, and it’s easy to pull one off
the shelf, but how many times does
it take before breaking this cycle and
changing to something that will last?

These cables were designed based on feedback from

customers, then tested and retested by customers. One such
customer was replacing a cable weekly in a weld cell, due
to weld slag build-up. They liked and installed the fiberglass
cable which lasted more than a year in this installation, that’s
a 500% improvement for that installation.

8
Cost Savings

It comes down to the bottom line. Products today need to

be produced faster with a lower cost association. With any
startup, the cost is high. Specialty cables have a higher
startup cost compared to a standard cable. The cost savings
come from the longevity of the cable, and reduced amount of
downtime from cable failure.

The type of cable jackets determines the life of a cable.

Environments with caustic agents, UV rays, weld slag or
other surrounding factors, shorten the lives of the jacket
in numerous ways. For
example, buildup of debris
can pull cables out of the
connector or cleaning
agents can eat through the
jacket material. High Durability cable jackets are made for
different situations to help prevent cable failure and keep
production moving.

One of the difficulties with cables is when debris would

encompass the nut and its counterpart. If the sensor/cable
fails, the cable cannot be disconnected due to buildup
of material preventing the nut to turn. Then there are two
components that have to be discarded instead of the part
that failed. Balluff High Durability cables have PTFE coated
nuts to prevent debris from sticking and easy disconnect.

We talked to customers, we listened to their feedback

and we redesigned the entire cable to withstand different
situations.

9
 Physical
Abrasion
Stainless Steel Braid

Type Stainless Steel Braid

Jacket Temperature -25…80 °C
Operational Temperature Fixed -50…80 °C
Operational Temperature Moving -25…80 °C
Voltage Rating 250 V
Amperage 4A
M12 Double-Ended
M12 Female St - M12 Male St, 4 wire BCC W415-W414-3A-304-MW8434-_ _ _
M12 Female Rt - M12 Male St, 4 wire BCC W425-W414-3A-304-MW8434-_ _ _
7/8" Double-Ended
7/8" Female St - 7/8" Male St, 4 wire BCC B314-B314-30-304-MW8434-_ _ _
7/8" Female Rt - 7/8" Male St, 4 wire BCC B324-B314-30-304-MW8434-_ _ _

Double-ended
Standard Lengths Available:
003 = 0.3 m
006 = 0.6 m
010 = 1 m
020 = 2 m

10
n Durable jacket made up of 1.4404 Stainless Steel braid
with cable jacket of PUR welding spark cable.
n 5 million bending cycles

Protects against:

n Rubbing against objects

n Moving debris
n Cable is resistant against thermal shock, UV, ozone,
and oxygen.

Ideal for:

Physical
Stainless Steel Braid Abrasion
11
 Physical
Crush
PVC Coated Armor

Type PVC Coated Steel Armor

Jacket Temperature
Operational Temperature Fixed
Operational Temperature Moving
Voltage Rating
Amperage
Single-Ended
M12 Female, 4-wire, St
7/8” Female, 4-wire, St
M12 Double-Ended
M12 Female St - M12 Male St, 4 wire
7/8" Double-Ended
7/8" Female St - 7/8" Male St, 4 wire
-40…105 °C
-40…105 °C
300 V
4A
BCC M415-0000-1A-003-MX04T2-_ _ _
BCC A314-0000-10-072-MX04W6-_ _ _
BCC M415-M414-3A-304-MX04T2-_ _ _
BCC A314-A314-30-346-MX04W6-_ _ _

Single-ended Double-ended
Standard Lengths Available: Standard Lengths Available:
010 = 1 m 006 = 0.6 m
020 = 2 m 010 = 1 m
050 = 5 m 020 = 2 m
100 = 10 m 050 = 5 m
100 = 10 m

12
n Jacket: PVC coated Stainless Steel armor
n PVC coating provides extra chemical and fluid resistance
n Temperature: -40°C…105°C
n Flexible conduit

Protects against:
n Contact with loaded component
n Simple crushing and compaction
n Knocking around
n Material build up physically tears components apart

Ideal for:

Physical
PVC Coated Armor Crush

13

ECOLAB Resistant
Type
Configuration
Operational Temperature
Voltage Rating
Amperage
M8 Single-Ended
M8 Female, 3-wire, Rt
M8 Female, 4-wire, Rt
M12 Single-Ended
M12 Female, 4-wire, St
M12 Female, 4-wire, Rt
M12 Female, 5-wire, St
M12 Female, 5-wire, Rt
M12 Female, 5-wire, St, Braided Shield
M12 Female, 5-wire, Rt, Braided Shield
M12 Female, 8-wire, St, Braided Shield
M12 Double-Ended
M12 Female St - M12 Male St, 4-wire
M12 Female Rt - M12 Male St, 4-wire
Standard Lengths Available:
100 = 10 m
200 = 20 m
250 = 25 m
Washdown
Caustics
ECOLAB tested, H2O2 resistant
Stainless Nut, PUR Cable
-25...80 °C
60 V (M8 3-wire), 30 V (M8 4-wire),
250 V (M12)
4A
BCC S323-0000-10-001-PX8334-_ _ _-C002
BCC S324-0000-10-003-PX8434-_ _ _-C002
BCC S415-0000-10-003-PX8434-_ _ _-C002
BCC S425-0000-10-003-PX8434-_ _ _-C002
BCC S415-0000-10-017-PX8534-_ _ _-C002
BCC S425-0000-10-017-PX8534-_ _ _-C002
BCC S415-0000-10-017-PS8534-_ _ _-C002
BCC S425-0000-10-017-PS8534-_ _ _-C002
BCC S418-0000-10-069-PS8834-_ _ _-C002
BCC S415-S414-3A-304-PX8434-_ _ _-C002
BCC S425-S414-3A-304-PX8434-_ _ _-C002
14
n Survived 28 days without swelling, brittleness, discoloring
n 1.4404 Stainless steel nut
n Bending cycles: >2 million

Protects against:

n Caustic washdown areas

n Water, fuel, oil, acid, and bases

Ideal for:

Washdown
ECOLAB Resistant Caustics

15
 Washdown
High Pressure
Stainless Steel Nut

Type IP69K Rated, 1.4404 Stainless

Configuration Stainless Nut
Operational Temperature -5...105 °C (PVC)
Voltage Rating 60 V (M8 3-wire), 30 V (M8 4-wire),
250 V (M12)
Amperage 4A
M8 Single-Ended
M8 Female, 3-wire, Rt BCC S323-0000-10-001-VX43T2-_ _ _
M8 Female, 4-wire, Rt BCC S324-0000-10-003-VX44T2-_ _ _
M12 Single-Ended
M12 Female, 4-wire, St BCC S415-0000-1A-003-_ _ _ _ _ _-_ _ _
M12 Female, 4-wire, Rt​ BCC S425-0000-1A-003-_ _ _ _ _ _-_ _ _
M12 Double-Ended
M12 Female St - M12 Male St, 4-wire BCC S415-S414-3A-304-_ _ _ _ _ _-_ _ _
M12 Female Rt - M12 Male St, 4-wire BCC S425-S414-3A-304-_ _ _ _ _ _-_ _ _
M12 Female St - M12 Male Rt, 4-wire BCC S415-S424-3A-304-_ _ _ _ _ _-_ _ _
M12 Female Rt - M12 Male Rt, 4-wire BCC S425-S424-3A-304-_ _ _ _ _ _-_ _ _

Jacket Materials:
Yellow PVC = VX44T2
Grey PVC = VX8434
Black PUR = PX0434
Standard Lengths Available:
020 = 2 m
050 = 5 m
100 = 10 m

16
n 1.4404 Stainless steel nut
n Available in Yellow, Grey or PUR Black
n Bending cycles: >2 million
n IP69K rated
n Temperature (fixed) -40°C…105°C

Protects against:

n High pressure washdown

n Water, fuel, UV, ozone

Ideal for:

Washdown
Stainless Steel Nut High Pressure

17
 Temperature
High Temperature
Fiberglass

Type Fiberglass Jacket Cable

Jacket Temperature -60...400 °C
Operational Temperature Fixed -50...80 °C
Operational Temperature Moving -25...80 °C
Voltage Rating 250 V
Amperage 4A
M12 Single-Ended
M12 Female, 4-wire, St BCC W415-0000-1A-003-FW9434-_ _ _
M12 Female, 4-wire, Rt BCC W425-0000-1A-003-FW9434-_ _ _
M8 - M12 Double-Ended
M8 Female St - M12 Male St, 3 wire BCC W313-W413-3E-300-FW9334-_ _ _
M12 Double-Ended
M12 Female St - M12 Male St, 4 wire BCC W415-W414-3A-304-FW9434-_ _ _
M12 Female Rt - M12 Male St, 4 wire BCC W425-W414-3A-304-FW9434-_ _ _
M12 Splitters
M12 Male St - 2 x M12 Female St BCC W414-W415-W415-U2045-_ _ _
M12 Male St - 2 x M12 Female Rt BCC W414-W425-W425-U2045-_ _ _

Single-ended Double-ended
Standard Lengths Available: Standard Lengths Available:
006 = 0.6 m 003 = 0.3 m
010 = 1 m 006 = 0.6 m
020 = 2 m 010 = 1 m
015 = 1.5 m
Splitter 020 = 2 m
Standard Lengths Available:
003 = 0.3 m
006 = 0.6 m

18
n Non-silicone, Halogen Free
n Jacket: Fiberglass
n Cable jacket: PUR welding spark durable
n Jacket temperature: -60°C…400°C
n Cable temperature (moving): -25°C…80°C
n Air gap insulation and non-flammable

Protects against:

n High Temperature

Ideal for:

Temperature
Fiberglass High Temperature

19
 Temperature
Standard Automation
Thermoplast

Type
Operational Temperature Fixed
Operational Temperature Moving
Voltage Rating
Amperage
M12 Single-Ended
M12 Female, 4-wire, St
M12 Female, 4-wire, Rt
M8 - M12 Double-Ended
M8 Female St - M12 Male St, 3 wire
M12 Double-Ended
M12 Female St - M12 Male St, 4 wire BCC W415-W414-3A-304-BW8434-_ _ _
M12 Female Rt - M12 Male St, 4 wire
M12 Splitters
M12 Male St - 2 x M12 Female St
M12 Male St - 2 x M12 Female Rt
Thermoplast
-50...130 °C
-40…125 °C
250 V
4A
BCC W415-0000-1A-003-BW8434-_ _ _
BCC W425-0000-1A-003-BW8434-_ _ _
BCC W313-W413-3E-300-BW8334-_ _ _
BCC W425-W414-3A-304-BW8434-_ _ _
BCC W414-W415-W415-U2044-_ _ _
BCC W414-W425-W425-U2044-_ _ _

Single-ended Double-ended
Standard Lengths Available: Standard Lengths Available:
006 = 0.6 m 003 = 0.3 m
010 = 1 m 006 = 0.6 m
020 = 2 m 010 = 1 m
015 = 1.5 m
Splitter
020 = 2 m
Standard Lengths Available:
003 = 0.3 m
006 = 0.6 m

20
 n Higher temperature than standard cable
n Excellent aging in hot and cold surroundings
n Temperature: -50 ... 130°C

Protects against:
n UV, ozone, and oxygen
n Notch resistant
n Thermal shock resistant

Ideal for:

Temperature
Thermoplast Standard Automation
21
 Weld Slag
Silicone
Silicone Cable

Type Silicone Cable

Operational Temperature Fixed
Operational Temperature Moving
Voltage Rating
Amperage
M12 Single-Ended
M12 Female, 4-wire, St
M12 Female, 4-wire, Rt
M8 Double-Ended
M8 Female St - M8 Male St, 4 wire
M8 Female St - M12 Male St, 3 wire
M8 Female St - M12 Male St, 4 wire
M12 Double-Ended
M12 Female St - M12 Male St, 4 wire
M12 Female Rt - M12 Male St, 4 wire
M12 Splitters
M12 Male St - 2 x M12 Female St
M12 Male St - 2 x M12 Female, Rt
-40...200 °C
-25...200 °C
250 V
4A
BCC W415-0000-1A-003-SW0434-_ _ _
BCC W425-0000-1A-003-SW0434-_ _ _
BCC W314-W314-30-304-SW0434-_ _ _
BCC W313-W413-3E-300-SW0334-_ _ _
BCC W314-W414-3E-304-SW0434-_ _ _
BCC W415-W414-3A-304-SW0434-_ _ _
BCC W425-W415-3A-304-SW0434-_ _ _
BCC W414-W415-W415-U2046-_ _ _
BCC W414-W425-W425-U2046-_ _ _

Double-ended Single-ended
Standard Lengths Available: Standard Lengths Available:
003 = 0.3 m 006 = 0.6 m
006 = 0.6 m 010 = 1 m
010 = 1 m 020 = 2 m
015 = 1.5 m 050 = 5 m
020 = 2 m
050 = 5 m Splitter
Standard Lengths Available:
003 = 0.3 m
006 = 0.6 m
22
Type Molded silicone tube
Jacket Temperature -60…180 °C
Operational Temperature Fixed -50…80 °C
Operational Temperature Moving -25…80 °C
Voltage Rating 250 V
Amperage 4A
M12 Single-Ended
M12 Female, 4-wire, St BCC W415-0000-1A-003-NW0434-_ _ _
M12 Female, 4-wire, Rt BCC W425-0000-1A-003-NW0434-_ _ _
M12 Double-Ended
M12 Female St - M12 Male St, 4 wire BCC W415-W414-3A-304-NW0434-_ _ _
M12 Female Rt - M12 Male St, 4 wire BCC W425-W414-3A-304-NW0434-_ _ _

Double-ended
Standard Lengths Available:
003 = 0.3 m
006 = 0.6 m
010 = 1 m
015 = 1.5 m
020 = 2 m

Single-ended
Standard Lengths Available:
006 = 0.6 m
010 = 1 m
020 = 2 m

Weld Slag
Molded Silicone Tube Silicone

23
 Weld Slag

Silicone Cable and Tube

n Cable jacket: Silicone

n Silicone cable temperature (moving): -25°C…200°C
n Silicone tube temperature: -60°C…180°C

Protects against:
n Resistance against thermal shock
n Aging in hot and cold surroundings
n Resistance against humidity and carbon hydride
n Resistance against crop and abrasion
n Advanced mechanical burden

Ideal for:

24
Weld Accessories

Weld Repel ® Wrap

BAM0183 1" wide x 12 ft Clear wrap
BAM0182 2" wide x 36 ft Clear wrap

Weld Repel ® Area Protection

BAM0179 3 ft x custom length in ft
BAM017A 3 ft x 3 ft sheet

Weld Repel ® Jacket M8 M12

BAM017E Clear tubing, 1/4" dia. x 50 ft (15 m)
BAM017H Clear tubing, 3/8" dia. x 50 ft (15 m) SE
BAM017L Clear tubing, 1/2" dia. x 50 ft (15 m) DE SE
BAM017N Clear tubing, 5/8" dia. x 50 ft (15 m) DE
BAM017R Clear tubing, 3/4" dia. x 50 ft (15 m)
BAM017U Clear tubing, 1.5" dia. x 25 ft (15 m)
BAM017Z Clear tubing, 2" dia. x 25 ft (15 m)

SE = Single ended
DE = Double ended

WELD Jacket
BAM PT-XA-002-095-2-30 3/8" ID, Silicone & Fiberglass, 100 ft Roll
BAM PT-XA-002-127-2-30 1/2" ID, Silicone & Fiberglass, 100 ft Roll
BAM PT-XA-002-190-2-30 3/4" ID, Silicone & Fiberglass, 100 ft Roll

Weld Slag

25
 Weld Slag
Silicone Free
PTFE

Type PTFE (FEP)

Operational Temperature Fixed
Operational Temperature Moving
Voltage Rating
Amperage
M12 Single-Ended
M12 Female, 4-wire, St
M12 Female, 4-wire, Rt
M8 Double-Ended
M8 Female St - M12 Male St, 3 wire
M12 Double-Ended
M12 Female St - M12 Male St, 4 wire
M12 Female Rt - M12 Male St, 4 wire
M12 Splitters
M12 Male St - 2 x M12 Female St
M12 Male St - 2 x M12 Female, Rt
-65...200 °C
-65...200 °C
250 V
4A
BCC W415-0000-1A-003-TW0434-_ _ _
BCC W425-0000-1A-003-TW0434-_ _ _
BCC W313-W413-3E-300-TW0334-_ _ _
BCC W415-W414-3A-304-TW0434-_ _ _
BCC W425-W414-3A-304-TW0434-_ _ _
BCC W414-W415-W415-U2048-_ _ _
BCC W414-W425-W425-U2048-_ _ _

Double-ended Single-ended
Standard Lengths Available: Standard Lengths Available:
003 = 0.3 m 003 = 0.3 m
006 = 0.6 m 006 = 0.6 m
010 = 1 m 010 = 1 m
015 = 1.5 m 015 = 1.5 m
020 = 2 m 020 = 2 m
050 = 5 m 050 = 5 m

Splitter
Standard Lengths Available:
003 = 0.3 m
006 = 0.6 m
26
n Low smoke generation
n Excellent dielectric properties
n Low friction
n Temperature : -65°C…200°C Silicone
Free

Protects against:
n Highly flame retardant
n Resistance against water, fuel, oil, acid and bases

Ideal for:

Weld Slag
PTFE Silicone Free

27
 Services

Weld Cell Process Improvement

n Expert analysis of all problematic
sensor “hotspots”
n Timely and tailored
recommendations for weld cell
process improvements
n Provide “roadmap” towards
reducing unplanned downtime
n Train and educate employees to make premature sensor
failures in welding a thing of the past

Superior Service
n 24 hour on-call service
n Complete in-house technical
support
n Comprehensive product
selection, cross reference, and
application assistance
n Fast, friendly, experienced service – guaranteed!
n Managed inventory in 4 locations across North America
n Same day shipping – in by 2:00 p.m. EST, out the same
day!

Training
n Standard training is off-the-shelf,
containing all the modules.
n Custom training allows you to
create your own training.
n Our training has hands-on
exercises at the end of each
lesson to measure the lesson‘s learning objectives.
n Our courses include job aids – booklets that you can use on
the job – to help you accomplish tasks with the technology.
28
Helpful Tools
Rulers and sizes

100
Size M8 M8 M8 M8
Gender Female Female Male Male
Poles 3-wire 4-wire 3-wire 4-wire
Wire Code DC DC DC DC

90
1

1 BR BR BR BR
2 WH WH
3 BU BU BU BU

80
4 BK BK BK BK

70
2

60
Size M12 M12 M12 M12
Gender Male Male Female Female
Poles 4-wire 4-wire + PE 4-wire 4-wire + PE 50
Wire Code DC DC DC DC
1 BR BR BR BR
2 WH WH WH WH
40
3

3 BU BU BU BU
4 BK BK BK BK
5 GN/YE GN/YE
30
20

Size 7/8" 7/8" 7/8" 7/8"

4

Gender Female Female Male Male

10

Poles 4-wire 4-wire 4-wire 4-wire

Wire Code US AC DC US AC DC
1 BK BN BK BN
0

2 WH WH WH WH
3 RD BU RD BU
4 GN BK GN BK
29
5
 Systems and Services

Industrial Networking and Connectivity

Industrial Identification

Object Detection

Linear Position Sensing and Measurement

Fluid Sensors

Accessories

Mexico
USA Canada Balluff de México SA de CV
Balluff Inc. Balluff Canada, Inc. Anillo Vial II Fray Junípero Serra
8125 Holton Drive 2840 Argentia Road, Unit #2 No. 4416
Florence, KY 41042 Mississauga, Ontario L5N 8G4 Colonia La Vista Residencial.
Phone: (859) 727-2200 Phone: (905) 816-1494 Querétaro, Qro. CP76232
Toll-free: 1-800-543-8390 Toll-free: 1-800-927-9654 Phone: (++52 442) 212-4882
Fax: (859) 727-4823 Fax: (905) 816-1411 Fax: (++52 442) 214-0536
E-Mail: balluff@balluff.com E-Mail: balluff.canada@balluff.ca E-Mail: balluff.mexico@balluff.com

Doc. No. 910906/Mat. No. 236068 EN

L13; Product specifications, availability,
and pricing are subject to change without notice.