Customer Q&A: What Are the 5 Toughest Questions About Armored Cable Glands That Keep Engineers Awake?

Armored cable installations fail when engineers can’t get straight answers to critical technical questions. Wrong choices lead to safety hazards and costly rework.

These 5 frequently asked armored cable gland questions cover earthing methods, size selection, installation torque, sealing performance, and certification requirements – answering them correctly prevents 90% of field failures.

Yesterday, David called me at 2 AM (his time) from a power plant in Germany. His team was stuck on an armored cable installation, and production couldn’t start until they got it right.

Table of Contents

• How Do I Properly Earth the Cable Armor Without Creating Ground Loops?
• Which Gland Size Do I Need for SWA Cables with Irregular Armor Profiles?
• What Torque Settings Prevent Armor Damage During Installation?
• Can Armored Cable Glands Maintain IP Rating with Damaged Cable Sheaths?
• Do I Need Special Certifications for Armored Glands in Hazardous Areas?

How Do I Properly Earth the Cable Armor Without Creating Ground Loops?

This question stumps even experienced engineers and causes 40% of armored cable installation problems.

Connect armor earthing through the cable gland body to the equipment chassis at one end only, using proper earthing washers and avoiding parallel earth paths that create dangerous ground loops¹.

The Ground Loop Nightmare

Last month, Hassan’s petrochemical plant experienced mysterious equipment failures. The culprit? Improper armor earthing creating 50-amp ground currents that fried sensitive electronics.

Common Earthing Mistakes:

• Both-end earthing: Creates ground loops and circulating currents
• No earthing washer: Poor electrical contact increases resistance
• Wrong gland material: Brass glands can’t provide reliable earthing
• Missing continuity: Painted surfaces block earth path

The Bepto Earthing Solution

Our armored cable glands feature integrated earthing systems:

Design Features:

1. Stainless steel construction: Excellent conductivity and corrosion resistance
2. Serrated earthing washers: Cut through paint for reliable contact
3. Spring-loaded contacts: Maintain pressure under vibration
4. Low-resistance path: <0.1 ohm from armor to gland body

Proper Installation Sequence:

1. Strip cable armor to correct length (25-30mm)
2. Install earthing washer against equipment surface
3. Tighten gland body to specified torque
4. Verify continuity with multimeter (<1 ohm)
5. Apply thread locker to prevent loosening

Real-World Earthing Guidelines

Application	Earthing Method	Key Considerations
Motor drives	Single-point at drive end	Prevents bearing currents2
Control panels	Equipment chassis only	Avoids noise in control circuits
Hazardous areas	Intrinsically safe barriers	Maintains safety integrity
Outdoor installations	Lightning protection integration	Surge protection coordination

“Your earthing system eliminated our ground loop problems completely,” David told me after the installation. “No more mysterious equipment failures.”

Which Gland Size Do I Need for SWA Cables with Irregular Armor Profiles?

Cable manufacturers’ tolerances create sizing nightmares that lead to expensive field modifications.

Measure the cable’s maximum outer diameter including armor irregularities, then select a gland with sealing range 2-3mm larger than your measurement to accommodate manufacturing tolerances.

The SWA Cable Sizing Challenge

Steel Wire Armored (SWA) cables³ aren’t perfectly round. The wire wrapping creates an irregular profile that varies by manufacturer and cable size.

Typical Variations I’ve Measured:

• 4-core 25mm²: 18.5-21.2mm outer diameter
• 3-core 70mm²: 24.8-27.1mm outer diameter  
• Single core 185mm²: 32.1-35.4mm outer diameter

Our Gland Sizing System

Step 1: Accurate Measurement

• Use calipers at multiple points along cable
• Measure including any protective tape
• Account for cable bend radius effects
• Document maximum dimension found

Step 2: Gland Selection Matrix

Cable OD Range	Recommended Gland Size	Sealing Range	Safety Margin
15-18mm	M20	10-18mm	2mm
18-22mm	M25	13-22mm	3mm
22-28mm	M32	18-28mm	4mm
28-35mm	M40	22-35mm	5mm

Step 3: Verification Process

• Test fit with actual cable sample
• Check sealing compression range
• Verify armor clamping effectiveness
• Confirm thread engagement length

Hassan’s Sizing Success Story

Hassan’s team was struggling with 50mm² SWA cables that measured anywhere from 26.8mm to 29.2mm. Standard M32 glands (22-28mm range) were too small for the largest cables.

Our Solution:

• Recommended M40 glands (22-35mm range)
• Provided sizing verification kit
• Included installation torque specifications
• Delivered technical support during installation

Result: Perfect fit for all cable variations, zero field modifications required 😉

What Torque Settings Prevent Armor Damage During Installation?

Over-tightening destroys cable armor, while under-tightening allows water ingress and poor earthing.

Apply 40-60 Nm torque for M32 armored glands, using a calibrated torque wrench⁴ and stopping immediately when the specified value is reached to prevent armor wire breakage.

The Goldilocks Zone of Torque

Too little torque = water ingress and poor earthing
Too much torque = broken armor wires and damaged cables
Just right = reliable sealing and armor integrity

Torque Specifications by Gland Size:

Gland Size	Torque Range	Typical Application
M20	25-35 Nm	Small control cables
M25	30-45 Nm	Medium power cables
M32	40-60 Nm	Standard SWA cables
M40	50-75 Nm	Large power cables
M50	60-90 Nm	Heavy-duty applications

Installation Best Practices

Essential Tools:

• Calibrated torque wrench (±4% accuracy)
• Proper socket size (avoid adjustable wrenches)
• Thread cleaning brush
• Marine-grade thread sealant

Step-by-Step Process:

1. Prepare threads: Clean and apply sealant
2. Hand tighten: Until gland body contacts surface
3. Mark position: Note starting point with marker
4. Apply torque: Gradually increase to specification
5. Verify sealing: Check for proper compression
6. Document: Record torque values for maintenance

David’s Torque Disaster (And Recovery)

David’s maintenance team was using impact guns to install armored glands. Result: 30% of armor wires broken, multiple water ingress failures, and $150K in cable replacements.

Our Training Program Included:

• Proper torque wrench calibration procedures
• Hands-on installation practice
• Armor damage recognition training
• Quality control checklists

“Your torque training saved us from repeating that expensive mistake,” David admitted. “Now we get perfect installations every time.”

Can Armored Cable Glands Maintain IP Rating with Damaged Cable Sheaths?

Minor sheath damage during installation often leads to expensive cable replacement or compromised sealing.

Quality armored cable glands with dual-seal design can maintain IP68 rating even with minor outer sheath damage, using inner cable sealing and armor compression to prevent water ingress.

Understanding Sheath Damage Types

Acceptable Damage (Repairable):

• Surface scratches <1mm deep
• Minor cuts not penetrating armor
• Localized abrasion from handling
• Small nicks from cable pulling

Unacceptable Damage (Replace Cable):

• Cuts through armor wires
• Damage exposing inner conductors
• Crushed or deformed sections
• Chemical contamination of insulation

Our Dual-Seal Technology

Primary Sealing System:

• Compression seal on outer sheath
• Accommodates minor surface irregularities
• Maintains pressure under thermal cycling
• Self-adjusting design compensates for wear

Secondary Sealing System:

• Individual conductor sealing
• Armor wire compression chamber
• Redundant O-ring barriers
• Breathable membrane option available

Damage Assessment Protocol

Field Inspection Checklist:

• Measure damage depth with calipers
• Check armor wire integrity
• Verify conductor insulation condition
• Test insulation resistance (>1000 MΩ)
• Document damage with photos

Repair Decision Matrix:

Damage Type	Depth	Action Required
Surface scratch	<0.5mm	Proceed with installation
Minor cut	0.5-1.0mm	Use repair tape + gland
Deep cut	>1.0mm	Replace cable section
Armor damage	Any	Replace cable

Hassan recently had a cable with 0.8mm sheath damage from a sharp cable tray edge. Instead of replacing the entire 200-meter run, our dual-seal glands provided reliable IP68 protection, saving $25K in materials and labor.

Do I Need Special Certifications for Armored Glands in Hazardous Areas?

Mixing standard and explosion-proof requirements creates dangerous compliance gaps.

Armored cable glands in hazardous areas require both ATEX⁵/IECEx explosion-proof certification AND proper armor earthing certification to meet safety standards and prevent static electricity buildup.

The Certification Maze

Hazardous area armored glands must satisfy multiple standards simultaneously:

Explosion Protection Standards:

• ATEX: European Directive 2014/34/EU
• IECEx: International standard IEC 60079
• UL: North American safety standards
• CSA: Canadian safety certification

Armor-Specific Requirements:

• Earthing continuity: <0.1 ohm resistance
• Static dissipation: Prevents charge buildup
• Mechanical integrity: Armor clamping strength
• Environmental sealing: IP66/IP68 rating

Our Hazardous Area Portfolio

Available Certifications:

• ATEX Ex d IIC T6 (Zone 1 flameproof)
• ATEX Ex e II T6 (Zone 2 increased safety)
• IECEx Ex d IIC T6 (International)
• UL Class I Div 1 & 2 (North America)

Key Features:

• Integrated armor earthing system
• Flame path machining to ±0.05mm
• Temperature-rated materials
• Comprehensive test certificates

Compliance Documentation Package

What We Provide:

1. ATEX/IECEx certificates: Original certification documents
2. Installation instructions: Hazardous area specific procedures
3. Material certificates: Traceability for all components
4. Quality test reports: Factory acceptance testing
5. Maintenance guidelines: Inspection and service intervals

What You Must Maintain:

• Installation records with torque values
• Periodic inspection reports
• Earthing continuity test results
• Environmental condition monitoring
• Personnel training documentation

Hassan’s Compliance Success

Hassan’s refinery needed 200 armored glands for a Zone 1 area upgrade. The challenge: meeting both German TÜV requirements and local safety regulations.

Our Solution Package:

• ATEX Ex d certified armored glands
• German-language documentation
• On-site installation training
• Compliance verification testing
• 5-year certification maintenance program

“Your complete certification package passed the TÜV inspection without a single question,” Hassan reported. “The inspector was impressed with the documentation quality.”

The project completed on schedule with zero compliance issues, saving 6 months of potential delays 😉

Conclusion

These five tough questions cover the critical aspects of armored cable gland selection and installation that determine project success.

FAQs About Armored Cable Glands

1. Understand the causes of electrical ground loops and best practices for eliminating them in industrial systems. ↩

2. Learn how stray currents can be induced in motor shafts and the damage they cause to bearings. ↩

3. Explore the construction, standards, and applications of Steel Wire Armored (SWA) cables. ↩

4. Discover why regular calibration of torque wrenches is critical for safety and reliability in engineering applications. ↩

5. Access the official European Commission page for the ATEX Directive on equipment for potentially explosive atmospheres. ↩