Category 5 cable is a twisted pair high signal integrity cable type often referred to as Cat5 . Most cables are unshielded, relying on the twisted pair design for noise rejection, and some are shielded. Category 5 has been superseded by the Category 5e specification structured cabling for computer networks such as Ethernet, and is also used to carry many other signals such as basic voice services, token ring, and ATM (at up to 155 Mbit/s, over short distances).
Usage and wiring methods
Category 5
The specification for category 5 cable was defined in ANSI/TIA/EIA-568-A, with clarification in TSB-95. These documents specified performance characteristics and test requirements for frequencies of up to 100 MHz.
Category 5 cable includes twisted pairs in a single cable jacket. This use of balanced lines helps preserve a high signal-to-noise ratio despite interference from both external sources and other pairs (this latter form of interference is called crosstalk). It is most commonly used for 100 Mbit/s networks, such as 100BASE-TX Ethernet, although IEEE 802.3ab defines standards for 1000BASE-T – Gigabit Ethernet over category 5 cable. Cat 5 cable typically has three twists per inch of each twisted pair of 24 gauge (AWG) copper wires within the cables.
Category 5e
Cat 5e cable is an enhanced version of Cat 5 that adds specifications for far end crosstalk. It was formally defined in 2001 as the TIA/EIA-568-B standard, which no longer recognizes the original Cat 5 specification. Although 1000BASE-T was designed for use with Cat 5 cable, the tighter specifications associated with Cat 5e cable and connectors make it an excellent choice for use with 1000BASE-T. Despite the stricter performance specifications, Cat 5e cable does not enable longer cable distances for Ethernet networks: cables are still limited to a maximum of 100 m (328 ft) in length (normal practice is to limit fixed ("horizontal") cables to 90 m to allow for up to 5 m of patch cable at each end, this comes to a total of the previous mentioned 100 m maximum). Cat 5e cable performance characteristics and test methods are defined in TIA/EIA-568-B.2-2001.
How It's Made
Copper Rod Breakdown The first step in low voltage cable production is copper rod breakdown. Copper is sent to the factory in 5,000lb coils. These copper coils are continuously drawn through diamond dies that drastically reduce the diameter of the copper to 10 or 12 gauge. Lubrication is used during this process to reduce the amount of friction and heat on the copper cable. Once completed, the copper is stacked in vertical coils, called Stem Packs. These stem packs are then transferred to another drawing operation that further reduces the gauge of the copper. During this stage, the copper is also charged with an electrical current. This anneals the copper, which is a softening process. Once annealed and cooled off, the copper runs through a laser measurement system, to verify it is within manufacturing specifications.
Copper Insulation Process The copper insulation process is continually monitored and controlled up to +/- .0001". Once the copper is insulated, it runs through a water cooling trough, allowing the wire jacket to properly harden.
Copper Twisting Twisting helps reduce crosstalk between the individual pairs of wire. Some Cat6 premise cables include a center spline, or wire separator, to further reduce crosstalk and increase performance. Copper twisting is accomplished by running each individual wire through multiple faceplates. This helps control pair position. Once twisted, we have what's called a Cable Unit.
Jacketing The cable unit then goes through the jacketing process. This step varies, depending on the type of cable being manufactured. OSP cable typically uses a black polyethylene or UV rated Polyvinyl chloride (PVC). For Cat3, Cat5e and Cat6 Premise cable, varying grades of PVC are used, depending on flame safety rating requirements. This steps starts off with molten plastic being extruded at high pressure and formed around the moving cable core. Shielding, ripcords, armoring and water blocking compound may also be applied at this step. Cables that require dual shielding or double armor will need to repeat this process. Once completed, the cable passed through a long cooling bath, then through a laser micrometer to verify the final diameter.
Printing Printing is done just before the cable is put in it's final packaging. For OSP cable, a hot foil printing process is used, that leaves an indented print in the cable jacket. For Premise cable, a high speed ink jet printer is used. Some cable manufacturers print footage marking from 1000-0ft, making it very easy to determine how much cable you have left in the box, or measuring out cable runs. Other manufacturers use a 6 digit footage mark, making the process a little harder.
Coiling The completed cable is then wound onto a reel or coil. the coiling process requires very precise tension controls to ensure the cable won't tangle when being pulled out of the box.
Final Testing Once the cable is printed and coiled, it goes through one last set of tests. The manufacturer will test it against a large set of mechanical and electrical performance specifications. Once tested, the cable is ready for shipment.
Low-end cable problem
The Communications Cable and Connectivity Association, Inc. (CCCA) cautioned that many low-end communications cable products could present a significant fire risk. In response to concerns from the industry, the CCCA commissioned an independent laboratory to analyze whether nine randomly selected low end samples of these products met U.S. minimum requirements for performance and safety. Test results showed that none of the samples fully met all of the minimum requirements and eight of the nine samples failed to meet the National Fire Protection Association (NFPA) minimum code requirements for low flame spread and/or smoke safety requirements for installation in commercial buildings, schools and multi-tenant residences. Many of the samples failed the flame spread and smoke tests catastrophically. Because of the seriousness of these safety concerns, the CCCA plans to work in cooperation with the major leading independent telecommunications industry testing agencies to establish a new product certification program. Although details of the proposed program have not yet been established, a key component will be independent laboratory testing of structured cabling products that have been procured from point–of-sale locations..
Copper-clad aluminum
The American market had also been flooded with copper clad cable imported mostly from China and falsely presented in the market as being a 100% copper Cat 5e cable. With less copper involved in the manufacturing process, the cost to the consumer is lower, yet the consumer is not getting a true 100% copper Cat 5e cable.
Installation of copper clad aluminum Cat 5e wire has also been proven — by low-voltage contractors in the Southern California market, where this cable first arrived — to have poor test results and often not passing the Category 5e transmission standard. Since copper conducts electricity better than aluminum, signal strength has also been proven to be very weak over long runs using this substandard cable.
Additionally, some manufacturers have also falsely represented their Cat 5e cable conductors as being 24 AWG. In actuality, a 26 AWG conductor is being sold and is hard to detect unless further examination beneath the sheath of the conductor is performed. A 26 AWG Cat 5e cable will not make proper contact on Cat 5e jack modules as most jack modules require 22 or 24 AWG per the specification and qualified connectors.
The United States Federal Government will not accept bids from China for Cat 5e cable due to China being absent from the Trade Agreements Act of 1979. In general, a product is only "TAA compliant" if it is made in the United States or a "Designated Country".
The Cat 5e “350 MHz” debacle
The 350 MHz term started a couple of years before the arrival of Category 6 cable by the Belden Electronics Division and promised better performance. Although the performance of this new 350 MHz cable was slightly better it was an easy way to sell the consumer on future proofing their needs while charging around 15% more and leading to a higher margin on the 350 MHz cable than the standard 5e cable. Soon after many other manufactures also offered a 350 MHz cable and followed the trend of an easy way to add to a higher margin. Some low-end cable manufacturers have the term “tested to 350 MHz” printed on the jacket as a way to appear to the consumer that they are receiving a better quality of 5e cable, but the cable was only “tested to 350 MHz” and no promise of a performance guarantee is ever mentioned.
As the 350 cable and term gained momentum, many manufacturers began offering a 400 MHz 5e cable, a 550 MHz 5e cable, and so on. This led to the consumer and communications contractor assuming and leaving them confused that the higher a MHz rating meant for a better performing cable. The arrival of the Category 6 cable standard which specified a delivered performance at 250&#
Category 5 cable - Wikipedia, the free encyclopedia
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