Control Cable

Material: Most control cables use copper or aluminum as the conductor material.

Copper: High conductivity, flexibility, and resistance to oxidation.

Aluminum: Lightweight, lower cost, but less conductive than copper.

Conductor Type: Can be solid or stranded.

Solid: One continuous piece of wire, used for short distances or stationary installations.

Stranded: Composed of multiple smaller wires, offering better flexibility for applications requiring movement or vibration resistance.

Material: Insulation materials prevent short circuits and electrical leakage.

PVC (Polyvinyl Chloride): Common for general-purpose cables, providing good electrical insulation and resistance to chemicals, oils, and abrasion.

XLPE (Cross-Linked Polyethylene): Offers higher temperature resistance and better mechanical properties than PVC.

Rubber: Often used in flexible control cables for outdoor or extreme environments.

LSZH (Low Smoke Zero Halogen): Non-toxic and emits low smoke, often used in public areas or confined spaces to minimize health risks during fire situations.

Voltage Rating: Insulation thickness and material are selected based on the required operating voltage. Common voltage ratings for control cables:

Low Voltage: Up to 750V (typically used in residential or small industrial installations).

Medium Voltage: Between 750V and 35kV (for larger industrial systems or power plants).

Single-Core: One conductor used for simple, low-voltage circuits.

Multi-Core: Multiple conductors, each individually insulated, allowing for more complex circuits with various signals or control paths.

Cores: The number of cores (conductors) can range from a few to several dozen, depending on the application needs (e.g., 2-core, 3-core, 5-core, or 7-core cables).

Shielding Type: Protects the cable from electromagnetic interference (EMI) or radio frequency interference (RFI).

Foil Shielding: Thin, conductive layers of aluminum or copper, applied around each conductor or group of conductors.

Braided Shielding: A mesh of copper or tinned copper wires that covers the entire set of conductors, offering better protection against EMI.

Overall Shielding: Some control cables have an additional shield around all cores to ensure greater protection from external noise.

Shielding Coverage: Measured as the percentage of coverage provided by the shield, which typically ranges from 60% to 100%. Higher percentages provide more effective protection against interference.

Material: Protects the internal conductors from mechanical damage, moisture, UV radiation, and chemical exposure.

PVC: Common sheath material for general-purpose cables.

LSZH (Low Smoke Zero Halogen): Often used in areas where fire safety and minimal smoke emission are essential.

Rubber/Elastomer: Used for high-flexibility or outdoor cables, offering resistance to temperature extremes and mechanical stresses.

Polyethylene: Used for cables designed for underground or direct burial applications, offering durability and chemical resistance.

Operating Temperature: Specifies the range of temperatures within which the cable can function effectively.

Low-Temperature Range: -40°C to 90°C (e.g., control cables used in cold environments or outdoor settings).

High-Temperature Range: Up to 120°C or higher for special applications requiring heat resistance (e.g., industrial machinery or furnaces).

Installation Temperature: Refers to the temperature range during the installation process, typically lower than the operating temperature range.

Fire-Retardant: Designed to prevent the spread of flames in case of fire, these cables will self-extinguish after the fire source is removed.

Fire-Resistant: These cables can maintain their integrity during a fire and continue to operate.

LSZH (Low Smoke Zero Halogen): These cables emit low smoke and no halogen gases in case of fire, providing increased safety in confined spaces.

Armored Cables: Some control cables are armored with a metal layer (steel wire or aluminum) for protection against mechanical damage, crushing, or rodent attacks.

Applications: Underground installations, areas with heavy foot traffic, or industrial environments with high mechanical stress.

Non-Armored Cables: More flexible and easier to install but offer less protection from physical damage.

Flexible Control Cables: Designed with stranded conductors and flexible insulation, these cables are ideal for moving machinery, robotics, and mobile equipment.

Rigid Control Cables: Solid conductors are used in fixed installations where no movement or flexibility is required.

IEC Standards: International Electrotechnical Commission standards (e.g., IEC 60227 for PVC cables, IEC 60332 for flame retardancy).

UL Certification: In the United States, cables may carry UL (Underwriters Laboratories) certification for safety and performance.

CE Marking: Indicates that the cable complies with European Union safety, health, and environmental protection standards.

RoHS Compliance: Ensures that cables do not contain hazardous substances, in line with the Restriction of Hazardous Substances directive.