Specialised Cables

Based on installation distance and current specifications, choosing a right size for the solar panel’s DC cable is critical. The sizing chart contains wire sizes from 1.5 square millimeters (19 Amps) for small scale residential applications up to 240 square millimeters (520 Amps) for commercial use; typical wire sizes would be 4 square millimeters (42 Amps), 6 square millimeters (52 Amps), 10 sqmm (76 Amps) or 16 sqmm (95 Amps), depending on the number of panels and their capability.

The price of DC solar cables will depend on the size of the conductors, the type of insulation used, and how many cables are ordered. The actual pricing will be affected by the cross-sectional area of the conductors, which can range from 1.5 to 240 sq.mm, the specifications used to build each conductor (e.g., tinned copper, LSZH/XLPO insulation), and other standards that must meet BS EN 50618: 2014. You can also contact Tempsens for competitive quotations based on the unique specifications of your solar photovoltaic cable.

Lead wire provides connectivity between instrumentation(thermistors, resistors) and electrical components(LED, heaters) in places such as control panels, chemical plants, laboratories, and industrial heating systems that require specialized insulation and high temperature resistances for their use.

No. The lead wire is a connecting wire used in industries insulated with materials like PVC, PTFE polymers etc.

A lead wire’s longevity is affected by many things: operating temperature, conditions of the environment, and the insulator used. Under rated operating conditions, the PVC insulated lead wires from Tempsens will generally last for 15 to 20 years, whereas PTFE and FEP insulated lead wires may very well exceed 25 to 30 years of lifespan.

Lead Wire is frequently referred to as Hookup wiring, Connection Wiring or Conductor Wiring. Depending on the settings of various temperature measuring applications, the lead wire may be identified as Extension Wire or Compensation Cable.

The lead wire price is determined by the conductor size, insulation material, and specifications. The quality of lead wires offered by Tempsens is of the highest standard at prices that are competitive with the marketplace, and their quotation for each type of lead wire will be provided upon request.

Low voltage cables are used up to and including a maximum value of 1.1kV (1100 volts). LV cables made by Tempsens are designed specifically to operate within a maximum voltage rating of LV for applications such as industrial and commercial users of electricity that need dependable power transfer without exceeding the design criteria for medium voltage equipment.

LV (Low Voltage) cables operate at voltages of 1.1kV and below, and are generally used to wire buildings and supply electricity. MV (Medium Voltage) cables operate at voltages between 1kV and 35kV, and are typically used in distribution systems of electric utilities. HV (High Voltage) cables operate at voltages greater than 35kV, and are used for the transmission of electricity over long distances; they require specific insulation and design for improved performance under varying degrees of electrical stress.

A low-voltage power cable is composed of copper or tin plated copper (from 0.50 mm² to 300 mm²) as electrolytic grade conductors, core insulation made from either PVC, XLPE, or LSZH materials, a screen of either aluminium foil or mesh braid coverings used on the shielded variants, both the inner & outer sheaths protect the core from environmental damage; also available G.I. armour (metal-woven covering) for additional mechanical and impact resistance for difficult installations.

The various types that Tempsens uses include PVC (Polyvinyl Chloride) for standard installations, XLPE (Cross-Linked Polyethylene) to withstand higher heat exposure (up to 90°C), HR PVC (Heat Resistant PVC), LSZH (Low Smoke and Zero Halogen) polymers for fire safety, FR PVC and FRLS PVC, which are flame retardant, along with PE (Polyethylene) or XLPO are used for some extreme applications that comply with IS & IEC Standards.

When High Temperature Cables are used in the UAE they usually operate in an ambient temperature range of -40C to +90C but the conductor operating temperature can be as high as 1200C. Because of this very high operating temperature they will be used in not only very high ambient temperatures but also the extreme temperatures that are associated with the industrial processing of products from desert sand.

PTFE, FEP, silicone, and fiberglass-insulated cables are the best options for high-temperature applications in refineries, petrochemical plants, and floating facilities by using oil, chemicals, and flame-resistant materials for high-temperature applications above 260° Celsius.

The conductor materials for high temperature cables are selected from among annealed bare copper, tinned copper, silver plated copper, nickel plated copper, pure nickel, and NPC 27% alloy based on the temperature and performance of the application.

Operating temperature, voltage grade, conductor size, environmental factors, chemical exposure, degree of flexibility required and relevant standards must all be taken into consideration when selecting a high temperature cable. Refer to the manufacturer’s specifications for assistance in making the best selection.

Heat resistant cables should be chosen based on maximum operating temperature, voltage requirement, conductor size based on current load and environmental exposure (chemicals).

A heat-resistant cable can endure continuous high-temperature service (between 200°C - 800°C) whereas Fire Resistant Cables keep circuit integrity during a fire at "normal" temperatures.

Tempsens cables are designed for continuous use and have a service life of more than 20+ years when installed correctly and within the rated parameters provided by IS 8130.

There are several types of insulation used, and each type will determine how flexible (or stiff) the cable is. For example, Silicone and FEP insulations are very flexible, whereas fiberglass and ceramic fiber insulation provide average flexibility based on the application's needs.

Yes, instrument signal cables constructed using armoured construction and high corrosion resistance at rated voltages along with Marine Insulation materials designed specifically for use in an offshore environment, as the exposure of these cables to harsh environments such as saltwater is ongoing.

Industries in the UAE that utilise Instrumentation Signal Cables include Oil and Gas Refineries, Petrochemical Plants, Power Plants, Building Automation Systems, Water Treatment Facilities and as well as Manufacturing Units used in many applications where a reliable means of process control or monitoring is required.

Instrument signal cables use bare copper conductors or tinned copper conductors that have cross section areas of between 0.50 square millimetres to 2.50 square millimetres. These conductor materials and sizes give optimal conductivity and reasoning for flexibility for use in a wide range of signal transmission requirements within an Arc welding and industrial instrumentation application.

Typical RTD cabling is made of copper conductors with insulation made from materials that vary based on operating temperature (e.g., PVC is used for most applications up to 105°C, PTFE or FEP cable for temperatures up to 260°C, and insulated with fiberglass for severe environments up to 600°C).

Triad cable for RTD applications has three cores twisted together, minimizing electromagnetic interference and maintaining balanced electrical characteristics between the three-wire configuration. This is necessary to balance lead wire resistance for measurement accuracy.

The RTD cable length limitation can be different depending on the wire size used, and the wiring configuration for the measurement circuit. Typically, the maximum distance for a standard installation would be around 300 meters when utilizing 20 – 22 AWG conductors in 3-wire configuration. For a 4-wire RTD connection the distance can be increased to 600 meters with no loss of accuracy.

FEP cable insulation has great chemical resistance, has a continuous operating range from -65°C to +200°C, retains excellent dielectric properties throughout its operating range, and is far more moisture resistant than standard polymer insulations.

FEP insulated cable provides almost identical chemical and thermal resistance properties of a PTFE insulated cable but is easier to process when extruded with conventional processes providing a more consistent wall thickness while also having enhanced mechanical properties at a much lower cost.

FEP cable can be installed as continuous operating at -65°C to +200°C, with the possibility for short excursions to 260°C. FEP cable is suitable for most industrial RTD applications – with the exception of the highest furnace and combustion monitoring applications.

PVC insulated cable will operate reliably from -40°C to +105°C for standard formulations of PVC insulated cable. For heat-resistant PVC compounds, the continuous operating temperature can be extended to 120°C for short durations. This temperature range is suitable for most ambient and moderate temperature RTD installations.

XLPE is cross-linked polyethylene insulated cables which provide greater temperature capability (up to 150°C continuous) than PVC insulated options and greatly improve aging resistance, but PVC insulated will be more cost-effective as a general use under temperature of 105°C.

Fiberglass insulated cable provides excellent abuse resistance with its woven glass fiber construction. Fiberglass insulated cables can provide resistance to mechanical stress, flexing, and contact with surfaces that would have damaged polymer insulations. This feature allows it to be used for furnace applications and in industrial environments with extreme temperature applications.

The selection of an MI heating cable depends on many parameters, which include the operating temperature, required heat output, available voltage, compatibility with the sheath material, and hazardous area classification. Tempsens’ engineers will analyse these parameters and help you choose the best specifications.

Use of an infrared thermometer to inspect the cable condition and occasional insulation resistance testing is usually adequate for MI heating cable because of the robust design and sealed construction.

Your MI cable will be installed directly on the surface using recommended mounting methods, covered with thermal insulation, and terminated using the special termination kits connecting the MI cable to the power supplies requiring temperature controls.

MC Cable is polymer-insulated and allows for electrical distribution; MI cable is a mineral-insulated heating cable, allowing installation in extreme temperature environments.

MI cables can withstand extreme temperatures, up to 1000°C; the cable is completely moisture proof, has better mechanical strength, has a small outer diameter, which allows for better heat distribution, and can be utilised in hazardous locations.

Fire-retardant cables resist initial ignition and slow the spread of flames. Fire-resistant cables are designed to stay functional for limited time periods during a fire event. Fire survival cables are designed to ensure full circuit integrity at temperatures exceeding 750°C for 30-180 minutes, thereby keeping essential emergency safety systems operational throughout and subsequent to varying emergency fire events.

Installation must account for minimum bending radius (6-8 times cable diameter), use of fire resistant/cable retention fixings, adequate segregation away from other cables, fire rated terminations with cable duration rating, and qualified installation per BS 7671 regulation in order not to compromise fire survival integrity.

Temperature limits depend on sheath material: SS316L/Inconel 600 to 800°C, SS446 to 1150°C, Pt10%Rh to 1300°C.

Resistance is maintained above 100 MΩ with high-purity MgO (≥99.4%) owing to its compressed crystalline structure as warranted by ASTM E839 testing.

Yes, bend radius must be a minimum of 2x the diameter; exposed ends must be resealed against moisture ingress immediately.

Metal sheathing provides mechanical protection and seals from environmental influences; MgO insulation electrically separates the conductors.

Yes, all thermocouple cables are provided with certificates with EMF values tested in accordance with ANSI MC 96.1; IEC 584-2; and ASTM E230.

MIMS cables should be stored in dry environments and factory end seals should remain intact, if a cut ends occurs then resealed immediately to protect hygroscopic MgO from moisture penetration.

LV cables are used in voltages up to a given limit of 1.1 kV; they send control signals or power to operate equipment. HV (high voltage) cables will operate at voltages above a given limit (generally above 1 kV but typically in the 11 kV-132 kV range or above), and are used to move bulk/power with increased insulation thickness and dielectric strength requirements.

LV cables generally work with identifiers from voltages of 50V to 1100V (1.1 kV); specifically, Tempsens control cables are built for a continuous rating of 1100 V as determined by the IEC 60502-1 and IS 1554 standards.

Choosing LV cable size requires calculations of the load current (using I = P/V), applying derating factors based on ambient temperature and installation method, identifying a permissible voltage drop (as a percent of the system voltage) that meets the voltage drop limits (which in practice means, it’s usually limited to below 3-5%). It’s also necessary to check a cable’s ability to withstand short circuit events, reference IEC 60228 conductor standards.

The minimum distance between HV and LV cables is commonly specified to be greater than 300 mm for unscreened cables or greater than 150 mm with a physical barrier present. All individual installations must ensure those minimum separations (or applicable separation distances) conform to local electrical codes as well as IEEE and IEC segregation guidelines to minimize interference concerns, and any overall safety concerns. 

Standard thermocouples have a 2-wire or (Positive and Negative Leg) configuration; the 3-wire adds the ground wire providing shielding and safety in electrically-noisy environments, but again, Thermocouples operate 2-wire inherently unlike the RTD style of temperature sensing.

Thermocouple cables can reach lengths of 300-500 meters depending on the gauge of wire and the electromagnetic interference (EMI) in the environment; anything beyond that, it is recommended to utilize signal amplifiers or signal transmitters to prevent noise related errors and to maintain an accurate measurement.

The temperature rating of the thermocouple cable varies based on insulation type.  PVC insulation can be rated in the range of -20°C to +105°C, while fiberglass braided cable can be continuous up to 400°C. Silicone rubber feeling can maintain -60 Celsius to +180 °C, while Teflon insulation can operate applications down to -200 Celsius to up to 260 Celsius.

Nickel alloy is defined as using pure nickel with stainless steel which includes chromium, copper or iron added for specific performance properties such as corrosion resistant or for high-temperature capability.

Nickel alloy has superior corrosion resistant and high-temperature capability compared to stainless steel, which is a requirement for extreme industrial conditions in the Gulf.

Through self-registering cables, constant wattage systems and mineral insulated cables that will maintain the required temperature.

Self-regulating (LTSRH, MTSRH, HTSRH series), constant wattage parallel (CWPHT), series resistance (CWSHT) and mineral insulated (MIHT) systems.

Maintains process temperatures, prevents freeze damage, promotes consistent product flow, compaction and protects equipment against extreme temperatures in the industrial process.

MI cable is a sheathed Thermocouple Cable, having an outer sheath of metal with Two to Eight Cores where positive and negative thermo elements run around Circular Pattern, embedded in MgO. Mineral Insulated Cables are suitable to high Mechanical, Chemical, and Electrical stability. Due to good Flexibility, Excellent mechanical strength, and pressure resistance, mineral insulated Thermocouples/RTD’s can be installed in complex installations.

Construction:

• One or more wire like conductors (cores) are embedded in a high insulation quality MgO(Magnesium Oxide) and pressed into a metal tube (sheath) made of oxidation and corrosion resistant material. The entire combination is then processed using suitable forming steps to obtain the final dimensions.

Compensating cable is made of alloys which are different from those of thermocouples but have the same output over a limited temperature range. Compensating cable is a connector between thermocouple and measuring instruments, these cables are less precise, but cheaper. They harness quite different relatively low cost alloy conductor materials, whose net thermocouple in question. The combination develops similar output as those of the thermocouple, but the operating temperature range has to be restricted to keep miss-match error acceptably small.

MI Cables cover up the wide area of applications. Important are listed below:

• In Chemical, Petrochemical and fertilizer industries, and as equipment in dairy, food processing, pharmaceutical industries, in hospitals, households as kitchenware, cryogenic vessels and as heat exchanger in air conditioning refrigeration, for machinery in paper, pulp and textile beverage sector.
• Architectural trims, Marine exteriors, chemical processing equipment, food processing equipment, petroleum refining equipment, photographic equipment.
• Nuclear power and reactor construction, chemical apparatus engineering, annealing furnaces, heat exchangers, crude oil industry, grease and soap industry, aircraft exhaust stacks and manifolds, pressure vessels, large mufflers for diesel engines, carburetors, expansion bellows, stack liners, fire walls etc.
• Power technology, recuperates, heat treatment kilns, vortex firing installations, waste incinerators, furnace construction, boilers and blast furnaces, PWR, Space Travel.

Extension cable uses wire of nominally the same conductor as the thermocouple itself, which thus inherently possess similar thermo power characteristics, and with no connection problems. Miss-match error arising from high connecting box temperature is likely to be relatively small. These cable are less costly then thermocouple wire, although not cheap, and are usually produced in a convenient form for carrying over long distance typically as flexible wiring or multi-core cables.They are recommended for best accuracy.