Introduction to BUFLEX-M Polyurethane Cable
The BUFLEX-M cable is a premium-grade polyurethane (PUR) flexible control cable engineered for demanding industrial environments where mechanical stress, oil exposure, and repeated flexing are constant challenges. As part of TEBAOFLEX’s specialized cable portfolio, BUFLEX-M combines advanced polymer chemistry with precision conductor design to deliver exceptional performance in automation systems, robotic applications, and continuous flexing installations.
Unlike standard PVC or rubber cables that degrade under harsh industrial conditions, the BUFLEX-M polyurethane cable utilizes a specially formulated PUR outer sheath that provides superior abrasion resistance, oil resistance, and mechanical strength. This makes it the ideal choice for industrial automation applications where cable reliability directly impacts production uptime and equipment safety.
Whether you are specifying cables for a new manufacturing line, replacing worn-out power chains, or upgrading your facility’s control infrastructure, understanding the complete technical specifications of BUFLEX-M will help you make an informed decision. This comprehensive datasheet guide covers every aspect of the cable’s construction, electrical properties, and performance characteristics.
BUFLEX-M Cable Construction and Materials
Conductor Design
The BUFLEX-M features finely stranded bare copper conductors compliant with IEC 60228 Class 5 standards. The high strand count provides exceptional flexibility, allowing the cable to bend and flex repeatedly without conductor fatigue or breakage. Each conductor is precision-insulated with a special PVC compound rated for 70°C continuous operation, ensuring reliable electrical isolation even under thermal stress.
For applications requiring enhanced corrosion resistance, BUFLEX-M is also available with tinned copper conductors. Tinned conductors provide superior solderability and oxidation resistance, making them particularly suitable for marine environments, chemical processing facilities, and outdoor installations where moisture and corrosive agents are present.
Insulation System
Each core conductor is insulated with a high-quality PVC (polyvinyl chloride) compound. The insulation thickness is carefully controlled to meet the voltage rating requirements while maintaining flexibility. The insulation is color-coded according to DIN 47100 standards, with numbered cores for easy identification during installation and maintenance.
Shielding Options
BUFLEX-M is available in both unshielded and shielded configurations:
- Unshielded (BUFLEX-M-UC): Standard configuration for general control applications where electromagnetic interference is not a concern.
- Shielded (BUFLEX-M-CYC): Features a tinned copper braid shield with coverage exceeding 85%, providing excellent protection against EMI/RFI in environments with high electrical noise. The shield is applied helically over the cable core with an aluminum-polyester tape for enhanced shielding effectiveness.
Outer Sheath
The hallmark of the BUFLEX-M is its polyurethane (PUR) outer sheath. This specially formulated compound delivers:
- Abrasion resistance: Up to 5 times greater than PVC and 2 times greater than rubber compounds
- Oil and chemical resistance: Resistant to mineral oils, greases, and common industrial chemicals
- Tear resistance: High tensile strength prevents mechanical damage during installation and operation
- Weather resistance: UV-stable formulation suitable for both indoor and outdoor use
- Temperature flexibility: Remains flexible at low temperatures down to -40°C
The sheath is available in orange (RAL 2003) for high-visibility safety applications, as well as black for standard industrial use. The smooth surface finish facilitates cleaning and reduces dirt accumulation in hygiene-sensitive environments.
BUFLEX-M cable construction cross-section: conductor, insulation, shielding, and PUR sheath layers
BUFLEX-M polyurethane control cables installed in industrial automation cabinet applications
Complete Technical Specifications Table
The following comprehensive specification table provides all technical parameters needed for proper cable selection and system design:
| Parameter | Specification |
|---|---|
| Product Name | BUFLEX-M Polyurethane Flexible Control Cable |
| Conductor Material | Bare or tinned copper, finely stranded (IEC 60228 Class 5) |
| Conductor Size Range | 0.14 mm² to 240 mm² (AWG 26 to AWG 4/0) |
| Core Configuration | 2 to 60 cores (unshielded); 2 to 24 cores (shielded) |
| Insulation | PVC compound, TI2 (IEC 60172), rated 70°C |
| Shielding | Tinned copper braid (≥85% coverage) + aluminum-polyester tape |
| Outer Sheath | Polyurethane (PUR), EM 103 / PU compound |
| Sheath Color | Orange (RAL 2003) or Black (RAL 9005) |
| Voltage Rating | 300/500 V (control); 450/750 V (power) |
| Test Voltage | 2000 V AC (1 minute) |
| Temperature Range | Fixed: -40°C to +80°C; Flexing: -5°C to +70°C |
| Minimum Bend Radius | Fixed: 4×D; Flexing: 7.5×D (D = cable outer diameter) |
| Flex Life Rating | ≥3 million cycles at 7.5×D bend radius |
| Tensile Strength | ≥25 N/mm² (sheath); ≥15 N/mm² (insulation) |
| Oil Resistance | Resistant to mineral oil per IEC 60811-2-1 |
| Flame Retardancy | IEC 60332-1-2; self-extinguishing |
| Halogen Content | Available in halogen-free (LSZH) version upon request |
| Certifications | CE, RoHS, REACH; UL/CSA available upon request |
Electrical Properties
Voltage Rating and Insulation
The BUFLEX-M is rated for 300/500V applications in its control cable configuration, making it suitable for instrument, control, and signal transmission circuits. For power transmission applications, the cable is rated at 450/750V, accommodating higher voltage power distribution within machinery and industrial equipment.
The insulation resistance exceeds 100 MΩ·km at 20°C, ensuring minimal leakage current and reliable signal transmission even in long cable runs. The high dielectric strength of the PVC insulation, rated at a minimum of 1500 V/mil, provides a robust safety margin against voltage transients and surges.
Capacitance and Inductance
For shielded configurations, the BUFLEX-M exhibits a mutual capacitance of approximately 100-150 pF/m and a characteristic impedance optimized for industrial signal transmission. These parameters are critical for high-speed data communication and pulse signal applications, where signal integrity must be maintained over extended distances.
Current Carrying Capacity
The ampacity of BUFLEX-M cables depends on installation method, ambient temperature, and number of loaded conductors. The following general guidelines apply for ambient temperature of 30°C:
| Cross-Section (mm²) | Current Rating (A) – 2 Cores | Current Rating (A) – 3-6 Cores |
|---|---|---|
| 0.5 | 5 | 4 |
| 0.75 | 8 | 6 |
| 1.0 | 12 | 10 |
| 1.5 | 18 | 14 |
| 2.5 | 26 | 20 |
| 4.0 | 35 | 28 |
| 6.0 | 47 | 36 |
These values should be derated according to the installation conditions. For precise ampacity calculations, refer to our engineering services and the IEC 60364-5-52 standard, or consult with our technical team for project-specific recommendations.
BUFLEX-M cable configuration and ampacity chart for common conductor sizes
Mechanical and Environmental Performance
Flexibility and Flex Life
One of the most critical performance metrics for flexible cables is flex life — the number of bending cycles a cable can withstand before failure. The BUFLEX-M’s PUR sheath and Class 5 stranded conductors work synergistically to deliver a flex life exceeding 3 million cycles at the rated minimum bend radius of 7.5×D.
This exceptional flex life makes BUFLEX-M ideal for:
- Continuous flexing in cable carriers and drag chains
- Torsional applications in robotic arms and rotating tables
- Linear motor applications with high acceleration/deceleration rates
- Pendulum and C-track installations with complex motion paths
Abrasion and Wear Resistance
The polyurethane sheath of BUFLEX-M exhibits exceptional resistance to mechanical wear. In comparative abrasion testing per DIN 53516, the PUR compound achieves wear values below 30 mm³, compared to 80-100 mm³ for standard PVC compounds. This superior abrasion resistance translates directly to extended service life in applications where cables are in contact with metal surfaces, guides, or abrasive environments.
Oil and Chemical Resistance
Industrial environments frequently expose cables to cutting fluids, hydraulic oils, greases, and cleaning agents. The BUFLEX-M’s PUR sheath provides excellent resistance to:
- Mineral oils and lubricants (per IEC 60811-2-1)
- Aliphatic hydrocarbons
- Greases and lubricating pastes
- Mild acids and alkalis
- Water-based coolants and cutting fluids
This chemical resistance ensures the cable maintains its mechanical and electrical integrity even in harsh manufacturing environments. For specific chemical resistance data, please contact our technical engineering team with your application details.
Compliance and Certification
BUFLEX-M cables are manufactured in compliance with international standards and carry the following certifications:
- CE Marking: Compliant with the Low Voltage Directive (LVD 2014/35/EU) and EMC Directive (2014/30/EU)
- RoHS Directive: Free from hazardous substances per Directive 2011/65/EU
- REACH Regulation: Compliant with EC 1907/2006 requirements
- IEC 60332-1-2: Flame retardant, self-extinguishing
- UL/CSA: Available with UL 758 and CSA C22.2 No. 49 approval upon request
Visit our certifications page to download certificates of conformity, test reports, and declaration documents. All TEBAOFLEX products undergo rigorous quality testing at every production stage, ensuring consistent performance and reliability.
Available Configurations
BUFLEX-M is available in multiple configurations to meet diverse application requirements:
| Model | Description | Core Range | Shielding |
|---|---|---|---|
| BUFLEX-M-UC | Unshielded control cable | 2-60 cores | None |
| BUFLEX-M-CYC | Shielded control cable | 2-24 cores | Copper braid + Al-poly tape |
| BUFLEX-M-HF | Halogen-free version | 2-40 cores | Optional |
| BUFLEX-M-TR | Torsional flex version | 4-24 cores | Optional |
Custom configurations, including hybrid designs combining power, signal, and data pairs within a single cable, are available upon request. Contact us through our inquiry form for custom specifications.
Product Detail and Ordering Information
For detailed product specifications, dimensional data, and ordering information, please visit the BUFLEX-M product detail page. Our comprehensive product database includes complete datasheets, installation drawings, and technical documentation for all standard configurations.
If you need assistance selecting the right BUFLEX-M configuration for your application, our experienced engineering team is ready to help. We provide personalized cable selection consultation, custom design services, and technical support throughout your project lifecycle.
Request a Quote or Technical Consultation
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Related Resources
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