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LV Control Cables
Low Voltage Control Cables, designed for low voltage industrial applications, are a particular type of electrical conductors designed to transmit control signals and power. Rated for voltage levels of 1.1 kV or lower, these cables typically provide communication between control panels and instruments in the field. Electrolytic grade copper conductors and PVC, XLPE, LSZH and flame retardant materials enable the manufacturing of our Low Voltage Control Cables, all of which are built for industrial use and will provide reliable signals and power.
Our low voltage control cables can be manufactured single core or multi-core cables as small as 0.50 sq. mm to 300 sq. mm, for a variety of control and automation applications. All of our cables are built in accordance with international standards including IS1554, IS 7098, IEC60227 and IEC60502-1 specifically to withstand the extremes of temperature, mechanical stress and electromagnetic interference conditions that are found in modern industrial facilities.
About LV Control Cables
Types of LV Control Cables
Tempsens makes various kinds of LV control cable to meet specific application needs:
- Unarmoured Control Cables: Either single- or multi-core cables with PVC, XLPE or LSZH insulation for general-purpose control applications in a protected environment.
- Armoured Control Cables: Either G.I. round wire or flat strip armoured cables (in accordance with IS 3975) to provide mechanical protection against physical damage and rodent interference.
- Screened Control Cables: Individually or overall screened with an aluminium foil with a drain wire, suitable for instrumentation circuits susceptible to electromagnetic noise.
- Flame Retardant Control Cables: FR PVC and FRLS PVC insulated cables which fulfill fire safety requirements for high-risk installation sites.
- LSZH Control Cables: Low smoke zero halogen polymer insulation to minimise toxic gas emission during a fire, which is critical for enclosed areas.
- Flexible Control Cables: A multi-strand conductor construction particularly able to withstand continuous flexing in moving machinery or robotics.
Specifications of LV Control Cables
| Construction | Multi Core |
| Voltage Grade | Up to 1.1 KV |
| Conductor | Electrolytic Grade Bare Copper/ Tinned Copper |
| Conductor Size | 0.50, 0.75, 1.0, 1.5, 2.5 Sq. mm |
| Conductor Stranding | Solid or Multi Strand |
| Core Insulation | PVC, HR PVC, PE, XLPE, LSZH Polymer, FR PVC, FRLS PVC, XLPO etc. |
| Screening | Aluminum Foil type/Mesh Braided type |
| Inner/Outer Sheath | PVC, HR PVC, PE, LSZH Polymer, FR PVC, FRLS PVC, PUR, XLPO etc. |
| Armoring | G.I. Round Wire / Flat Strip Armouring(As per IS 3975 : 99) |
| Standards | As per IS 694, IS 1554, IS 7098, IEC 60227, IEC 60502-1, IEC 60332 |
Key Features of LV Control Cables
Tempsens LV Control Cables are designed and manufactured based on engineered design characteristics providing excellent performance:
- Conductor: Ranges from 0.50 to 300 sq. mm in size and constructed of either bare electrolytic grade copper or tinned copper to achieve batch maximum current carrying capacity.
- Rated Voltage: Continuous working voltage rating of up to 1.1 kV with superior dielectric strength.
- Insulation: PVC, HR PVC, PE, XLPE, LSZH, FR PVC, FRLS PVC, PUR, and XLPO materials and constructions meeting temperature ratings and fire rated requirements.
- Mechanical Integrity: Optional G.I. armouring and G.I. braiding to protect against crush, impact and tensile load.
- EMI/RFI Shielding: Pre-installed aluminum foil or mesh braided screen with coverage of 70%-95% allowing for greatest shielding effect for electromagnetic compatibility (EMC).
- Conforms: Made according to standards in the industry such as IS 1554, IS 7098, IEC 60227, IEC 60502-1, IEC 60332.
- Flexibility: Multi-strand construction that allows the cable to be installed in cable trays, into conduits, and to bend at tight radii.
- Environmental Protection. Outer sheath compounds that resist UV radiation, moisture, oils, and industrial chemicals.
Applications of LV Control Cables
The LV Control Cables from Tempsens fulfil vital roles in various industrial applications, including:
- Process Automation: Transfer of signals between PLCs, DCS and SCADA networks within the chemical, refinery, and pharmaceutical industries.
- Power Generation: Providing control circuit wiring in thermal, hydro, and renewable energy facilities for switchgear and protection systems.
- Manufacturing: the transfer of signals between machine control systems, conveyors, and robotic assembly lines that all rely on repeatable operations.
- Building Management: the transfer of signals for all of the HVAC controls, lighting automations, and fire alarm systems in commercial buildings.
- Oil & Gas: the transfer of signals on offshore platforms, pipelines, and in petrochemical plants that are subject to extreme temperature and environmental conditions for instrumentation and control wiring.
- Water Treatment: the transfer of signals for pump controls, valve actuation, and for control and monitoring applications in water and wastewater applications.
- Mining Operations: Heavy duty control and applications on extraction equipment, ventilation, and material transport are also prevalent.
- Transportation: Railway signaling and control, metro systems, and ground support equipment in airports.
Why Choose Tempsens for LV Control Cables?
- 35 Years of Expertise in thermal, and cable solutions.
- ISO-certified manufacturing with rigorous testing as per international standards ensuring consistent product reliability.
- Technical Support: Expert engineering assistance for cable selection, sizing calculations, and installation recommendations.
- Global presence in 75 countries.
FAQ
Frequently Asked Questions
Find answers to frequently asked questions related to LV Control Cables.
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.
