The problem with CCA, CCS and CCC Cable and why to avoid.

CCA, CCS, CCC Cable vs Pure Copper Cabling

Data cables can look very similar to the naked eye. They are sometimes made in different colours and supplied in different boxes, but the specification is more important than the look or style of the cable. In essence, what is inside the cable matters. For example, can you tell the difference between a CCC cable and a pure copper cable?

The biggest reason is that sub-standard cables do not comply with European or British standards.

 

Pure Copper Data Cables

Pure copper conductors should be the standard for data cabling. This is the construction method used by all industry data-cabling manufacturers.

This construction will be used throughout all categories, such as Cat5e, Cat6, Cat6a and Cat7.

The cores within the cables will all be constructed from one solid piece of copper. In summary, there is no separate core and cladding

 

Cheaper and Lower Lower-Grade Data Cables

The alternatives to pure copper data cables are generally cheaper (due to the lower grade of materials in the cable) and lack performance.

There are three main alternatives to be aware of.

1. CCA Cable
2. CCS Cable
3. CCC Cable

These cables have their applications and suitability. However, when passed off as an alternative to pure copper cables, the result is a lower-grade cable and performance.

 

What is a CCA Cable?

 

A copper-clad aluminium cable is a type of data cable in which the aluminium conductor carries the electrical current. In the case of data transmission, "The Signal" is made of aluminium. This central core is then coated with a thin layer of copper.

 

A data cable with this design combines

1. The conductivity of copper
2. The lighter weight of aluminium
3. The lower cost of aluminium

CCA cables are commonly used in various applications, such as

• Telecommunications
• Networking
• Automotive wiring.

 

However, CCA cables have some limitations compared to pure copper cables, particularly in terms of conductivity and durability.

When conductivity and durability are diminished, we have lower-grade performance and a greater risk of failure. This results in poor transmission, poor signal quality and potential data loss

The longer the data cable link, the closer to the 100m link limit, the greater the possibility of poor performance.

CCA Cables are also not suitable for PoE (Power over Ethernet) as the conductors can overheat and lose signal power, resulting in the equipment powered remotely failing.

The Approved Cables Initiative explores the key issues with CCA cables here

What is a CCS Cable?

Copper-clad steel cables are similar to CCA cables.

Both cables are constructed with a central core and wrapped with copper. CCS cable is made of a steel central conductor, which is then coated with a layer of copper.

By having a steel central conductor and copper coating, we have

1. The strength and durability of steel
2. The conductivity of copper.

This results in the cable being heavier and less flexible. The plus side is the cable has increased strength from the steel central core.

CCS cables are often used in applications where strength and cost-effectiveness are important considerations, such as

• Telecommunications
• Power distribution
• RF (Radio Frequency)

 

These cables are sometimes chosen where mechanical strength is crucial. This is because the steel core provides excellent tensile strength. The copper coating then ensures good electrical conductivity.

The downside is that CCS cables may have higher electrical resistance than pure copper cables. This higher resistance could affect their performance, damaging applications requiring high conductivity or low signal loss.

 

What is a CCC Cable?

A Copper-Clad Copper or CCC cable consists of a core made of copper that is then coated with another layer of copper.

Therefore, we have a third cable with a separate central core and cladding.

However, with CCA (Copper-Clad Aluminium) or CCS (Copper-Clad Steel) cables, the core material differs from the cladding material. By contrast, a CCC cable uses the same material for the core and the cladding.

A CCC cable is sometimes chosen for applications where the primary goal is to enhance the durability and conductivity of the cable. In essence, it is trying to achieve the same as pure copper cables at a cheaper cost.

The aim of using copper for both the core and the cladding is to

1. Ensure electrical conductivity
2. Maintaining high mechanical strength
3. Corrosion resistance.

These cables are commonly used in electrical and telecommunications applications where reliable performance and longevity are essential.

The CCC cable offers advantages compared to cables with different core and cladding materials in terms of

1. Signal integrity.
2. Durability
3. Overall transmission performance.

However, CCC cables still have an inferior cable construction compared to pure copper cables.

 

Problems associated with CCA & CCS Cables

The advantage of CCA (copper-clad aluminium) and CCS (copper-clad steel) cables is that they offer cost-effective alternatives to pure copper cables. However, they come with specific hazards and limitations that need to be considered:

1. Electrical performance
2. Compatibility issues
3. Corrosion
4. Mechanical Strength
5. Fire Safety
6. Heat Dissipation

Electrical Performance:

CCA and CCS cables generally have higher electrical resistance than pure copper cables.

Higher resistance equals

• Increased power losses,
• Voltage drop,
• Degraded signal quality,

 

These performance drops increase even more over long distances or in high-frequency applications.

 

Compatibility Issues

Some equipment and systems may not be compatible with CCA or CCS cables. This is due to their different electrical properties.

Most data cabling equipment is designed to work with pure copper cables and their transmission capabilities. Furthermore, it is important to understand how they all connect.

Therefore, an inferior cable can lead to compatibility issues, which in turn result in performance degradation.

 

Corrosion

Both aluminium and steel are more prone to corrosion compared to copper.

The copper coating on CCA and CCS cables indeed helps mitigate this risk to some extent.

However, exposure to the following can still lead to corrosion over time.

1. Moisture
2. Chemicals
3. Harsh environments

These possible corrosion exposures potentially compromise the cable's integrity and performance.

 

Mechanical Strength

CCS cables have a steel core, which provides excellent tensile strength. On the downside, it results in a heavier and less flexible cable.

CCA cables and their Aluminium cores provide less strength than pure copper cables.

This reduction in strength can make them more prone to damage during installation. This is especially so if subjected to excessive bending or when pulled.

 

Fire Safety

In many cases, CCA cables and other alternatives may not meet the same fire safety standards as pure copper cables.

Aluminium has different fire-resistant properties than copper, which can affect the overall fire safety of the installation.

 

Heat Dissipation

Aluminium and steel have different thermal conductivity properties compared to copper.

The different central core materials can affect the heat dissipation capabilities of CCA and CCS cables.

When heat cannot dissipate correctly, it leads to overheating issues, especially in high-power applications.

 

Examples of when we have come across these alternative cable types at NM Cabling

Our project and installation team have encountered these inferior alternative cables on many occasions in client properties. Below are a few examples of what we found and the problems they caused

1. Having to replace a client's total structured cabling system as every cable installed failed on a standard data cabling fluke test.
2. A box of data cable at an electrical wholesaler marked with "Do not use over 70m" – the industry standard maximum run for all data cables is 90m, so this cable was stating it was sub-standard already.
3. A client's phones were losing calls, with considerable delays and dropouts. The issue was that the CCA cables to the phones couldn't handle the required transmission.

How to ensure you have the correct cables proposed and installed

1. Request the specification sheet for the cable that your installer is to install.
2. Check or ask that it is pure copper cable.
3. If in double call the manufacturer on the specification sheet and check
4. Ensure you receive test results for all cables installed from an industry-approved data cabling tester such as those listed here – "Approved Data Cabling Testers”.
5. If cables are already installed, you can look at one of the copper cores and you can see if it's one single material or one central core wrapped in another.

 

Summary: CCA, CCS, CCC Cable vs Pure Copper Cabling

CCA and CCS cables may offer cost savings and perceived advantages in specific applications. However, as they are not to a set standard, you never know what you will get.

Be doubtful of cables that are much cheaper than other brands or are too good to be true.

Pure copper alternatives are often marketed as a cost-effective alternative to solid copper cables. However, their reduced cost comes with considerable downsides in terms of

1. Performance,
2. Safety
3. Compliance with Ethernet standards.

It is essential to consider their limitations and potential hazards carefully.

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