Spiral cables & junction boxes for industrial doors – flexible connection & safe control
Coiled cables and junction boxes are essential components in the security technology of modern gate systems. They reliably connect moving parts such as closing edge safety devices, optosensors, and light barriers to the gate control system. Without them, secure signal transmission for moving gate leaves would be impossible. In this 10,000-word technical article, we explain everything about the design, technology, standards, installation, maintenance, and purchasing advice for coiled cables and junction boxes – and why tested systems from Tormeister24 are the best choice.
Why spiral cables and junction boxes are important
Door systems are constantly moving. For safety devices such as closing edge safety devices, optosensors, or light barriers to function reliably, their signals must be transmitted smoothly to the control system, even while the door is moving. Coiled cables take care of this task: They are flexible, durable, and specially designed to withstand constant movement without cable breakage. Junction boxes also ensure a secure, protected connection between the cable and the control system.
Spiral cable in detail
Coiled cables consist of flexible, twisted wires laid in a spiral. This makes them extremely flexible and protects them from mechanical overload. Advantages include:
- High flexibility: ideal for constantly moving gates.
- Durability: no cable breakage during regular use.
- Safety: stable signal transmission even at high frequencies.
They are mainly used in industrial doors, where hundreds of cycles are carried out every day.
Junction boxes for industrial doors
Junction boxes are the fixed interfaces between coiled cables and the control system. They serve as secure transfer points for electrical signals. Key features include:
- Protection class: IP54, IP65 or IP67 – depending on the environment.
- Robust construction: withstands dust, moisture and temperature fluctuations.
- Easy maintenance: quick cable replacement possible.
Advantages of spiral cables & junction boxes
- Maximum flexibility: no cable damage during movement.
- Reliable signal transmission: important for security systems.
- Standards compliant: meets EN 12453 & DGUV regulations.
- Easy installation: standardized connections & sets.
Areas of application
Spiral cables and junction boxes are used in many areas:
- Sectional doors: signal transmission for closing edge safety devices.
- Roller shutters: securing moving door leaves.
- High-speed doors: High-frequency operation requires flexible cables.
- Loading ramps: connection of sensors and controls.
- Industrial doors: wherever reliable security is a must.
Technology & Standards
The use of spiral cables and junction boxes is subject to various regulations:
- EN 12453: Safety of power-operated doors and gates.
- EN 60204: electrical safety of machinery.
- DGUV regulations: annual inspection requirement in Germany.
This ensures that signal transmission functions reliably even under continuous load.
Integration into gate controls
Coiled cables connect security systems directly to gate controls:
- Marantec industrial controls: e.g. CS 320, CBX series.
- Hörmann, Novoferm, ITW: standardized compatibility.
- High-Line, Select-Line, Pro-Line: compatible sets available.
Installation & Assembly
The assembly takes place in several steps:
- Attach the spiral cable to the gate leaf.
- Lead cable ends through junction box.
- Connect the box to the control unit and seal it.
- Perform functional test (check signal transmission).
Maintenance & Operation
Regular maintenance is necessary for safe operation:
- Visual inspection for cable breakage or wear.
- Check the junction box for moisture or corrosion.
- Test of signal transmission as part of the DGUV test.
- Immediate replacement required in case of defect.
Spiral cables & junction boxes at Tormeister24
In the Tormeister24 range you will find:
- Spiral cables in various lengths and designs.
- Junction boxes with industrial protection classes.
- Combination sets for quick retrofitting.
- Original spare parts & accessories for industrial doors.
Buying advice – which system is right for you?
The choice depends on several factors:
- Length: choose according to the gate size.
- Protection class: IP65/IP67 for dusty or humid environments.
- Compatibility: check with existing control.
- Area of application: sectional door, roller door or high-speed door.
Future of signal transmission in gate systems
The development is moving towards smart systems:
- Hybrid cable with data and power transmission.
- IoT sensors for remote monitoring.
- Wireless alternatives with redundant security.
Conclusion – small components, big impact
Coiled cables and junction boxes are inconspicuous yet essential components for secure industrial doors. They ensure stable signal transmission, prevent damage, and are required by standards. With tested models from Tormeister24 , you get maximum security, durability, and compatibility with all common control systems.
