How to choose the right JZ-500 control cable: PVC, PUR, HMH, COLD, BLACK, or ORANGE?
Although they are all JZ-500 300/500V control cables, the versions with gray PVC, black PVC, orange PVC, COLD version, PUR, or halogen-free (HMH) jackets are suitable for very different environments. Choosing the wrong version can lead to premature aging of the cable jacket in sunlight, cracking caused by oil, or failure to meet the project’s fire safety requirements. This article will help you select the right JZ-500 type in just a few steps.
Article content:
1. What is the JZ-500 control cable?
The JZ-500 is a line of flexible control and connection cables from HELU, with a rated voltage of 300/500 V and a fine-stranded copper conductor in accordance with DIN VDE 0295 Class 5. The cable does not have a shield and is intended for applications involving moderate mechanical stress and free movement: machine tools, assembly lines, conveyor belts, and electrical enclosures.
If you want to find out why the JZ-500 is so widely used, check out the article “ 7 key advantages of the JZ-500 control cable .”
2. Distinguishing between the JZ-500 and OZ-500 control cables
The JZ-500 and OZ-500 have the same construction; the only difference is in the grounding core:
- The JZ-500 has green-and-yellow protective conductors (GN-YE). The "G" in the part number, for example, JZ-500 4G1.5, indicates 4 conductors, one of which is a ground conductor with a cross-sectional area of 1.5 mm².
- The OZ-500 does not have a protective conductor. The "x" designation, for example, OZ-500 4x1.5, indicates 4 signal conductors with a cross-sectional area of 1.5 mm².
The cores are black with white numbers printed on them, which facilitates quick connections and minimizes errors when wiring electrical panels.
3. Comparison of the 6 versions of the JZ-500 control cable
| Version | Outer sheath | Flexible temperature | Bending radius (× outer diameter) | Outdoors | Number of cores | Cross-sectional area (mm²) | Strengths | Data sheet |
| JZ-500 | Gray PVC | -15 to +80°C | 7.5 | No | 2–100 | 0.5–185 | The widest, most economical product line | 10001 |
| JZ-500-BLACK | Black PVC | -15 to +80°C | 7.5 | Yes (UV-resistant) | 2–34 | 0.5–35 | Resistant to UV radiation and weather | 10340 |
| JZ-500 PUR | Gray PUR | -15 to +80°C | 7.5 | Yes | 2–42 | 0.5–16 | Resistant to oil, abrasion, hydrolysis, and microorganisms | 23314 |
| JZ-500 HMH | Halogen-free polymer, gray | -25 to +70°C | 12.5 | 2–65 | 0.5–120 | Halogen-free, low smoke when burning | 11201 | |
| JZ-500 COLD / OZ-500 COLD | PVC is particularly flexible at low temperatures | -30 to +80°C | 7.5 | Yes | 2- 25 | 0.5–6 | Particularly flexible at low temperatures | 10750 |
| JZ-500-ORANGE / OZ-500-ORANGE | Orange PVC | -15 to +80°C | 7.5 | No | 2 - 5 | 1–2.5 | Label the exempt electrical circuits, especially the interlocked circuits. | 10537 |
When permanently installed, all six versions can withstand temperatures ranging from -40°C (HMH up to +70°C; the other versions up to +80°C), with a minimum bend radius of 4 times the outer diameter.
4. Tips for selecting the appropriate JZ-500 control cable for different installation environment
Refer to the following guidelines to select the appropriate type of control cable:
- Factories, electrical cabinets, and indoor machine tools → JZ-500 (gray PVC): This is an economical choice that offers the widest range of conductor counts and cross-sectional areas, but it is not intended for outdoor use.
- Outdoor equipment, UV-resistant → JZ-500-BLACK: Black UV-resistant PVC housing compliant with DIN EN ISO 4892-2 and weather-resistant.
- The circuit remains energized even after the main circuit breaker has been tripped → JZ-500-ORANGE: The orange PVC jacket (RAL 2003) allows for immediate identification of circuits powered from an external source that remain energized even after the panel’s main switch has been turned off. This helps maintenance technicians minimize the risk of electric shock.
- Cold storage, freezing warehouses, frozen food processing plants → JZ-500 COLD: The special black PVC casing remains flexible when bent at -30°C, whereas the standard version can only be bent at -15°C.
- Steel mills, steel rolling mills, machine tools with high oil exposure → JZ-500 PUR: PUR coating resistant to oil, UV, ozone, hydrolysis, and microorganisms; excellent resistance to abrasion, cutting, and tearing.
- Buildings, data centers, high-occupancy areas, HVAC systems → JZ-500 HMH: Halogen-free in accordance with DIN VDE 0482-754-1, flame-retardant, and produces minimal smoke when burning, reducing the risk of toxic gases and equipment corrosion.
5. Guide to select the appropriate number of cores and cross-sectional area for JZ-500 cable
To select the correct number of conductors and cross-sectional area for JZ-500 cable from among the many versions and within the relatively wide range of cross-sectional areas, please note the following information:
- Count the number of signals to be transmitted (sensors, valves, limit switches, etc.), and add a spare channel for maintenance or future expansion.
- Determine whether a ground conductor is required: If yes → select control cable type JZ (G); if no → select type OZ (x).
- Select the cross-sectional area based on the current carrying capacity , line length, and allowable voltage drop. Control signals typically use a smaller cross-sectional area; the power supply for the motor requires specific calculations.
- Compare this with the range for the selected version in the table above. For example, if 50 outdoor cores are required, neither BLACK (maximum 34 cores) nor PUR (maximum 42 cores) will meet the requirement; you will need to split them into two strands or consult with a HELU engineer.
6. Some notes on installing JZ-500 cable
When installing JZ-500 cables, keep the following factors in mind:
- Bending radius: at least 7.5 × the outer diameter when the cable is in motion (HMH is 12.5 ×), 4 × when installed in a fixed position.
- Not intended for continuous-motion drag chains: The JZ-500 is designed for free movement and moderate stress. For cable chain applications, use a specialized cable series.
- High-interference environments (inverters, high-power motors): Since the JZ-500 cable series mentioned above does not have a shielding layer, consider using JZ-500 HMH-C / OZ-500 HMH-C shielded control cables or other shielded cable series from HELU.
- Cable glands: Use cable glands with a clamping band that matches the cable’s outer diameter to ensure the cabinet’s IP rating.
If you're still undecided between the JZ-500 and the higher-voltage cable series, check out our articles on JZ-600 control cables and control cable classifications .
7. FAQs
The standard grey PVC version is not suitable. Choose the JZ-500-BLACK or JZ-500 PUR for outdoor applications.
No. Even the BLACK version should not be buried directly or submerged in water.
The JZ-500 has a green-and-yellow ground wire, while the OZ-500 does not. All other specifications are the same.
When a project or developer requires halogen-free, low-smoke cables: public buildings, data centers, hospitals, tunnels.
The orange color is used to mark circuits that are still energized after the main circuit breaker has been tripped, helping maintenance personnel identify them more quickly and safely.
JZ-500 COLD. The cable remains flexible when bent at temperatures as low as -30°C. Standard PVC cables tend to stiffen and crack if bent at temperatures below -15°C.
You can quickly look up a product code using the Product Finder on shop.helu.com, or contact the HELU Vietnam engineering team for advice on selecting the version, number of cores, and cross-sectional area that best suit your project.
