Hybrid Copper & OF Cables

Are you also tasked with ensuring optimal network performance while addressing challenges like limited bandwidth, signal integrity, and the operational complexities of power and data delivery? Hybrid Copper & Opand optical (OF) Cables are engineered to overcome these challenges. They offer a sophisticated solution integrating power transmission and high-speed data transfer in a single, streamlined system. 

Conductor Material

High-conductivity annealed electrolytic copper (99.99% pure). 

Insulation Material

Cross-linked polyethylene (XLPE) or Polyvinyl chloride (PVC), UV-cured acrylate coating. 

Voltage Rating

Up to 600V AC or DC, depending on application. 

Temperature Range

Operational temperature range: -40°C to +90°C. 

Fire Resistance

Flame retardant to IEC 60332-3, with low smoke zero halogen (LSZH) insulation options available. 

Product Description

High-bandwidth, low-latency communication is a top priority in today’s data-driven environments. Hybrid cables integrate single-mode or multi-mode optical fibers that offer unlimited bandwidth and high data transmission rates up to several terabits per second (Tbps). The optical fibers are optimized for long-distance transmission without signal degradation, utilizing advanced wave-division multiplexing (WDM) technologies to ensure minimal crosstalk and enhanced signal integrity. 

Water Resistance

IP68 rated, fully water-blocked with gel-filled cores and moisture-resistant sheathing. 

UV Resistance

UV-stabilized outer sheath, compliant with ISO 4892-2 for UV resistance. 

Cross-sectional Area

Copper conductors available from 1.5mm² to 400mm². Optical fibers with core sizes ranging from 9µm (single-mode) to 50µm (multi-mode). 

Sheath Material

UV-resistant Polyethylene (PE) or LSZH sheath for high environmental and mechanical protection. 

Armoring

Galvanized steel wire armor (SWA) or aluminum armor for enhanced mechanical protection in industrial environments. 

Current-Carrying Capacity

Copper conductors rated for up to 400A, depending on conductor size, installation conditions, and ambient temperature. 

Flexibility

Highly flexible construction, meeting bending radius specifications of 10x outer diameter 

Cable Size

Optical fiber cores from 2 to 144 fibers. 

Outer Diameter

Ranges from 10mm to 60mm, depending on power and fiber configuration, conductor size, and armoring options. 

Mechanical Protection

Withstands tensile forces up to 2000N and impact resistance per IEC 60794 

Standards Compliance

Complies with IEC 60793, IEC 60794 (for optical fiber), IEC 60502-1 (power cables), and ISO/IEC 11801  

Technical Advantages

Managing separate power and data infrastructure can lead to installation complexities, particularly in industrial applications where space is limited. Our hybrid cables combine high-conductivity copper conductors for power (up to 600V) with optical fibers for high-speed data transmission. This reduces cable footprint and allows for simultaneous power and data transmission along a single physical path, which is ideal for powering remote network devices (e.g., PoE systems) or sensors in industrial automation. 

Copper cables typically exhibit significant attenuation beyond 100 meters, making them impractical for long-distance data transfer without repeaters or signal amplifiers. In contrast, the optical fiber component in hybrid cables supports data transmission over distances exceeding 100 kilometers without needing external signal boosters. This is achieved through optimized glass core designs, low-loss fiber coatings, and advanced optical modulation techniques such as Quadrature Amplitude Modulation (QAM). 

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Industry Applications

Healthcare

Facilitates data transfer and power for Healthcare imaging devices, patient monitoring systems, and telemedicine equipment in hospitals. 

Data Centers

Supports high-density connectivity and power distribution for Data Centers, servers, storage systems, and network switches in data processing environments. 

Smart grid

Integrates power and real-time data communication for Smart grid energy distribution and monitoring across electrical substations. 

Railway Signaling

Transmits high-bandwidth control signals while powering trackside equipment in Railway Signaling systems. 

Defense & Military

Supports secure data and power transfer in Defense & Military tactical communication systems, unmanned vehicles, and battlefield sensors. 

Military Applications

Ensures Military Applications secure communication and data transfer in harsh environments and critical operations. 

High Flexibility and Environmental Resistance

Hybrid cables are engineered for durability and resilience in harsh environments. The copper conductors are insulated with high-dielectric materials to prevent power loss. At the same time, the optical fibers are reinforced with aramid yarns and UV-resistant sheaths, providing excellent tensile strength and flexibility. These cables are also shielded against electromagnetic interference (EMI) and radio frequency interference (RFI), making them suitable for industrial, military, or outdoor deployment. 

Having Doubts? Our FAQ

Check all our Frequently Asked Question

What is the purpose of using hybrid copper and optical fiber in a single cable?

Hybrid copper and optical fiber cables combine the strengths of both technologies. The copper conductors are used for power transmission, while the optical fibers handle high-speed data transfer. This allows the same cable to provide both electrical power and high-bandwidth data communication, making it ideal for applications like surveillance systems, telecom infrastructure, and smart buildings. 

How does the power transmission capacity of copper affect the performance of hybrid cables?

The power transmission capability of copper in hybrid cables depends on the gauge of the copper wires used. Larger copper conductors allow more current flow, supporting higher power levels. This is critical for powering devices like cameras or sensors while maintaining the integrity of data transmission through the optical fiber. 

How does the presence of copper in a hybrid cable impact its signal loss compared to pure optical fiber cables?

In hybrid cables, the optical fiber portion remains unaffected by copper’s presence in signal transmission. Optical fibers operate using light signals and are immune to electromagnetic interference (EMI), which can affect copper. However, signal loss in the copper conductors can occur over long distances, especially if high-frequency signals are transmitted. 

What are the challenges of integrating copper and optical fiber in harsh environmental conditions?

Hybrid cables face unique challenges in harsh environments. While optical fibers are resistant to moisture and electromagnetic interference, copper is more susceptible to corrosion and voltage drops in extreme conditions. Therefore, hybrid cables are often manufactured with ruggedized jackets and protective layers to ensure reliability in industrial or outdoor applications. 

How do hybrid copper and optical fiber cables simplify installations in complex systems?

Hybrid cables reduce the need for separate wiring systems by combining power and data transmission in one cable. This simplifies installation, minimizes cable clutter, and reduces labor and material costs. This is especially beneficial in large-scale projects like smart city networks or industrial automation, where power and data are required at multiple endpoints. 

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LOCATIONS

Global Sales Office

818, Preakness lane, Coppell, Texas, USA – 75019

Registered Office

23, 6th West Street, Balaji Nagar, Kattur,  Pappakuruchi, Tiruchirappalli-620019, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

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Hybrid Copper & OF Cables

Need reliable wires and cables for your next project? Get in touch with us today, and we’ll help you find exactly what you need!

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