How do you properly strip and terminate PVC Jacketed Control Cable without damaging the insulation
2026-04-29
Properly preparing PVC Jacketed Control Cable for termination is a precision task. Incorrect stripping or termination leads to signal failure, short circuits, or hazardous equipment downtime. At DAYA, we engineer cables for reliability, but even the best cable performs poorly if handled incorrectly. This guide follows industry best practices to help you achieve flawless terminations every time.
The Right Tools for the Job
Using standard electrician’s tools often damages the soft insulation beneath the PVC jacket. Below are the recommended tools and their functions.
| Tool Type | Purpose | Why It Matters |
|---|---|---|
| Multi-layer stripper | Removes outer PVC jacket | Prevents nicking conductor insulation |
| Cable jacket slitter | Longitudinal jacket cutting | Controls cut depth precisely |
| Torque screwdriver | Tightening terminal screws | Avoids crushing the conductor |
| Heat shrink tubing | Insulating terminated ends | Adds strain relief and protection |
Step-by-Step Stripping Process
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Measure and mark – Determine the required strip length (typically 1.5–2 inches for the jacket, and 0.25–0.5 inches for individual conductors).
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Score the outer jacket – Use a DAYA-recommended ring cutter, applying light pressure just enough to cut the PVC jacket without touching the inner insulation.
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Remove the jacket – Grip the cable firmly, twist the scored section to break the PVC, then slide the jacket off. Inspect the conductors under bright light. Any visible nick means the cable should be re-stripped.
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Strip individual conductors – Switch to a smaller gauge hole on your stripper. Align the wire and strip insulation cleanly. The remaining insulation should not slide or show copper.
Termination Best Practices for PVC Jacketed Control Cable
| Step | Action | Common Mistake |
|---|---|---|
| 1 | Insert conductor fully into terminal block | Leaving loose strands outside |
| 2 | Tighten screw to specified torque (e.g., 4.5 lb-in) | Over-tightening that flattens wire |
| 3 | Pull gently on wire to verify grip | Skipping the pull test |
| 4 | Apply identification markers | No labeling, causing future errors |
PVC Jacketed Control Cable FAQ – Common Questions from Engineers
Q1: Can I reuse a PVC Jacketed Control Cable that has a slightly nicked conductor from poor stripping?
A: No. Even a minor nick creates a weak point where vibration or thermal cycling will cause the conductor to break over time. It also increases local resistance and heat. DAYA recommends cutting the cable back to a damage-free section and re-stripping. Never rely on electrical tape to repair a nicked conductor in control circuits.
Q2: How do I know if my stripping tool has cut too deep into the PVC Jacketed Control Cable?
A: Bend the stripped area gently. If a ring-shaped crack or white stretch mark appears on the inner conductor insulation, the PVC jacket cut was too deep. Also, if you see copper shine through any insulation gap, discard that section. A properly stripped cable shows smooth, uniform insulation with no tool marks.
Q3: Does the operating temperature of PVC Jacketed Control Cable affect the stripping technique?
A: Yes. At low temperatures (below -10°C / 14°F), PVC becomes stiffer and more prone to cracking during stripping. Warm the cable gently to room temperature before working. At high temperatures (above 60°C / 140°F), the jacket softens and may stretch rather than cut cleanly. In such conditions, use a fresh, sharp blade and reduce cutting pressure by 30%.
Ensuring Long-Term Reliability
After termination, always perform a continuity test and insulation resistance test. DAYA’s PVC Jacketed Control Cable is designed for industrial environments, but correct termination is your final quality checkpoint. Use ferrules on stranded wires and maintain a service loop to allow re-termination if needed.
Contact Us
For technical datasheets, custom lengths, or selection support for your next control system project, contact us at DAYA directly. Our engineers are ready to help you specify the exact PVC Jacketed Control Cable for your application. Visit our website or email our support team today.