Instrumentation Cables—XLPE Insulated, Overall Screened ,Unarmoured PVC Sheathed Cables(CU/XLPE/OSCR/PVC)
Instrumentation cables come in twisted pairs, triads, and quads, depending on the customer’s applications; twisting reduces any electromagnetic interference by reducing the chances of electrical voltages and currents being induced in the conductor. Individual and overall screening are also applied in instrumentation cables to optimize the signal transferred and further reduce any electromagnetic interference. Screening of pairs, triads, or quads also includes a drain wire earthed to the ground, which ensures a noise-free signal transmission.
Depending on the application, instrumentation cables can be insulated with PVC or XLPE; the cables can be armoured or unarmoured. The sheathing materials can be of PVC, LSZH, or PE. The cables can have additional flame retardant or flame retardant properties, and they can be manufactured with special protections such as lead sheaths, or DRYLAM or AIRBAG technology.
- Standard BS EN 50288-7, IEC 60502-1 (General)
Construction
Technical Specifications
Quality Control
Application
Construction
XLPE Insulated, Overall Screened, Unarmoured PVC Sheathed Cables(CU/XLPE/OSCR/PVC)
Conductor
Instrumentation cable shall have an annealed plain copper conductor or a tinned copper conductor. Depending upon cable application, conductor can be solid (Class-1), Stranded (Class-2), or flexible (Class-5) type as defined in BS EN / IEC 60228
Insulation
Instrumentation cable shall have PVC, XLPE, or HR-PVC insulation. Insulation material shall be selected based on the maximum operating temperature. PVC insulation is suitable for a continuous operating temperature of 70°C, whereas XLPE or HR-PVC is suitable for a continuous operating temperature of 90°C. Fire-rated / fire resistance instrumentation cables shall have Glass Mica Tape layer below insulation & shall have XLPE insulation.
Individual and Overall Screen
The screen is made of aluminum, mylar tape, + ATC drain wire. Aluminum mylar tape is made of aluminum with a thin layer of polyester. It helps in minimizing the crosstalk and prevents shorting.
Armour
Steel wire armour is applied to cables to shield against mechanical stresses and ensure that the core of the cable remains protected.
Inner and Outer Sheath
The sheath can be made of PVC, Polyethylene, or LSZH
Technical Specifications
Instrumentation Cables—XLPE Insulated, Overall Screened ,Unarmoured PVC Sheathed Cables(CU/XLPE/OSCR/PVC)
Instrumentation Cables Main Specifications
Instrumentation Cables—XLPE Insulated, Overall Screened ,Unarmoured PVC Sheathed Cables(CU/XLPE/OSCR/PVC)
| Conductor Size | Max. Conductor DC Resistance at 20°C for Plain Copper |
Max. Conductor DC Resistance at 20°C for Tinned Copper |
||
| Solid, Class - 1 & Stranded, Class - 2 |
Flexible, Class-5 | Solid, Class - 1 & Stranded, Class - 2 |
Flexible, Class-5 | |
| [mm2] | [Ω/km] | [Ω/km] | [Ω/km] | [Ω/km] |
| 0.50 | 36.72 | 39.78 | 37.434 | 40.902 |
| 0.75 | 24.99 | 26.52 | 25.296 | 27.234 |
| 1.00 | 18.462 | 19.89 | 18.564 | 20.4 |
| 1.50 | 12.342 | 13.566 | 12.444 | 13.974 |
| 2.50 | 7.5582 | 8.1396 | 7.7112 | 8.3742 |
| Conductor Size | Insulation Thickness | |||
| 90V | 300V | 500V | 1000V | |
| [mm2] | [mm] | [mm] | [mm] | [mm] |
| 0.50 | 0.20 | 0.26 | 0.44 | 0.70 |
| 0.75 | 0.20 | 0.26 | 0.44 | 0.70 |
| 1.00 | 0.26 | 0.26 | 0.44 | 0.70 |
| 1.50 | 0.30 | 0.35 | 0.44 | 0.70 |
| 2.50 | - | - | 0.53 | 0.70 |
| Conductor Size | Mutual Capacitance | Max. Continuous Operating Temperature | Inductance to Resistance Ratio (L/R) |
||
| XLPE | PVC | XLPE or HR - PVC | PVC | ||
| [mm2] | [nF/km] | [nF/km] | [°C] | [°C] | [μH/Ω] |
| 0.50 | 150 | 250 | 90 | 70 | < 25 |
| 0.75 | 150 | 250 | 90 | 70 | < 25 |
| 1.00 | 150 | 250 | 90 | 70 | < 25 |
| 1.50 | 150 | 250 | 90 | 70 | < 40 |
| 2.50 | 150 | 250 | 90 | 70 | < 60 |
| Number of Pair | Cable OD | Cable Weight | Drum Length | ||||||||
| 0.5mm² | 0.75mm² | 1.0mm² | 1.5mm² | 2.5mm² | 0.5mm² | 0.75mm² | 1.0mm² | 1.5mm² | 2.5mm² | ||
| [Nos] | [mm] | [mm] | [mm] | [mm] | [mm] | [kg/km] | [kg/km] | [kg/km] | [kg/km] | [kg/km] | [m] |
| 1 | 6.5 | 7.0 | 7.5 | 8.0 | 9.0 | 50 | 55 | 65 | 75 | 100 | 1000 |
| 2 | 9.0 | 10.0 | 10.5 | 11.5 | 14.0 | 80 | 95 | 110 | 135 | 190 | 1000 |
| 5 | 11.5 | 13.0 | 13.5 | 15.0 | 17.5 | 140 | 175 | 210 | 265 | 385 | 1000 |
| 10 | 16.5 | 17.5 | 19.0 | 21.0 | 25.5 | 250 | 315 | 375 | 490 | 735 | 1000 |
| 20 | 21.0 | 23.0 | 24.5 | 27.5 | 33.0 | 435 | 565 | 685 | 900 | 1360 | 1000 |
| 30 | 24.5 | 27.0 | 29.0 | 32.5 | 615 | 805 | 1000 | 1310 | 500 | ||
| Number of Triad | Cable OD | Cable Weight | Drum Length | ||||||||
| 0.5mm² | 0.75mm² | 1.0mm² | 1.5mm² | 2.5mm² | 0.5mm² | 0.75mm² | 1.0mm² | 1.5mm² | 2.5mm² | ||
| [Nos] | [mm] | [mm] | [mm] | [mm] | [mm] | [kg/km] | [kg/km] | [kg/km] | [kg/km] | [kg/km] | [m] |
| 1 | 7 | 7.5 | 7.5 | 8.5 | 10 | 55 | 70 | 80 | 95 | 135 | 1000 |
| 2 | 10 | 11 | 11.5 | 13 | 15 | 100 | 120 | 145 | 180 | 255 | 1000 |
| 5 | 13 | 14 | 15 | 16.5 | 20 | 185 | 235 | 280 | 365 | 540 | 1000 |
| 10 | 18 | 20 | 21 | 23.5 | 28.5 | 330 | 435 | 525 | 685 | 1035 | 1000 |
| 20 | 23.5 | 26 | 27.5 | 31 | 600 | 790 | 970 | 1275 | 500 | ||
| 30 | 28 | 30.5 | 33 | 855 | 1135 | 1415 | 500 | ||||
| Number of Quad | Cable OD | Cable Weight | Drum Length | ||||||||
| 0.5mm² | 0.75mm² | 1.0mm² | 1.5mm² | 2.5mm² | 0.5mm² | 0.75mm² | 1.0mm² | 1.5mm² | 2.5mm² | ||
| [Nos] | [mm] | [mm] | [mm] | [mm] | [mm] | [kg/km] | [kg/km] | [kg/km] | [kg/km] | [kg/km] | [m] |
| 1 | 7.5 | 8.0 | 8.5 | 9.0 | 10.5 | 65 | 80 | 95 | 115 | 165 | 1000 |
| 2 | 12.5 | 13.5 | 14.5 | 16.0 | 19.5 | 130 | 160 | 190 | 240 | 350 | 1000 |
| 5 | 16.0 | 17.5 | 19.0 | 21.0 | 25.0 | 245 | 310 | 375 | 485 | 730 | 1000 |
| 10 | 23.0 | 25.0 | 27.0 | 30.0 | 36.0 | 450 | 575 | 710 | 925 | 1395 | 1000 |
| 20 | 29.5 | 32.5 | 35.0 | 810 | 1065 | 1305 | 500 | ||||
| 30 | 35.5 | 1165 | 500 | ||||||||
Note: Cable OD and Cable weight are subject to change based on the latest manufacturing practice.
Quality Control
Instrumentation Cables—XLPE Insulated, Overall Screened ,Unarmoured PVC Sheathed Cables(CU/XLPE/OSCR/PVC)
Raw Material Test
Raw material testing for the Instrumentation Cables—XLPE Insulated, Overall Screened, Unarmoured PVC Sheathed Cables (CU/XLPE/OSCR/PVC) adheres to BS EN 50288-7. Step 1: Analyze copper purity via X-ray fluorescence per IEC 60228. Step 2: Test XLPE for dielectric strength (20 kV/mm) using high-voltage equipment. Step 3: Inspect the screening foil for conductivity and thickness with meters. Step 4: Evaluate PVC retardants through limiting oxygen index tests. Step 5: Measure drain wire resistivity. Step 6: Conduct elongation and tensile tests on XLPE. Step 7: Perform solvent immersion for chemical compatibility. Step 8: Document traceability with batch codes. Sampling 15% ensures quality for enhanced electrical screened cables.
Process inspection
Process inspection of the Instrumentation Cables—XLPE Insulated, Overall Screened, Unarmoured PVC Sheathed Cables (CU/XLPE/OSCR/PVC) follows BS EN 50288-1. Step 1: Control stranding tension with dynamometers to avoid inconsistencies. Step 2: Monitor XLPE insulation uniformity via ultrasonic devices. Step 3: Check pair twisting for even lay lengths visually and mechanically. Step 4: Apply screen tape and inspect coverage with eddy current testers. Step 5: Run high-voltage continuity tests during extrusion. Step 6: Inspect jacket finish for defects with optical sensors. Step 7: Sample every 500 meters for cross-sectional analysis. Step 8: Maintain digital logs for quality audits. Adhering to standards, this oversight detects issues early, ensuring optimal electrical properties and screened integrity.
Finished Product
Finished product testing of the Instrumentation Cables—XLPE Insulated, Overall Screened, Unarmoured PVC Sheathed Cables (CU/XLPE/OSCR/PVC) confirms BS EN 50288-7 readiness. Step 1: Apply AC voltage tests at 1.5 kV for insulation breakdown. Step 2: Measure DC resistance to verify conductor efficiency. Step 3: Conduct partial discharge tests below rated voltage. Step 4: Simulate installation with repeated bending cycles. Step 5: Test heat resistance at 90°C for deformation. Step 6: Perform water absorption checks on sheaths. Step 7: Evaluate overall flexibility and torsion. Step 8: Certify with final electrical and mechanical reports. Full compliance testing on every batch guarantees enhanced electrical performance per standards.
Application
Instrumentation Cables—XLPE Insulated, Overall Screened, Unarmoured PVC Sheathed Cables (CU/XLPE/OSCR/PVC) thrive in oil refineries, utility stations, SCADA systems, and high-tech manufacturing. It offers screened reliability in EMI-heavy conduits and trays for precise instrumentation under thermal stress.
Technical Advantages
● 30+ years of manufacturing experience
● ISO and UL certified production
● Customized cable and transformer solutions
Product Packaging
Wires and Cables packaging (1)
Wires and Cables packaging (2)
Wires and Cables packaging (3)
Wires and Cables packaging (4)
Wires and Cables packaging (5)
Wires and Cables packaging (6)
Wires and Cables packaging (7)
Wires and Cables packaging (8)
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What are the advantages of power cables and overhead lines?(1) Reliable operation, because it is installed in a hidden place such as underground, it is less damaged by external forces, has less chance of failure, and the power supply is safe, and it will not cause harm to people; (2) The maintenance workload is small and frequent inspections are not required; (3) No need to erect towers; (4) Help improve power factor.
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Which aspects should be considered when choosing the cross section of a power cable?(1) The long-term allowable working current of the cable; (2) Thermal stability once short circuited; (3) The voltage drop on the line cannot exceed the allowable working range.
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What are the measures for cable fire prevention?(1) Use flame-retardant cables; (2) Use fireproof cable tray; (3) Use fireproof paint; (4) Fire partition walls and fire baffles are installed at cable tunnels, mezzanine exits, etc.; (5) Overhead cables should avoid oil pipelines and explosion-proof doors, otherwise local pipes or heat insulation and fire prevention measures should be taken.
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What should be paid attention to during the transportation and handling of cables?(1) During transportation, loading and unloading, cables and cable reels should not be damaged. It is strictly forbidden to push the cable reels directly from the vehicle. Generally, cables should not be transported and stored flat. (2) Before transporting or rolling the cable reel, ensure that the cable reel is firm, the cable is wound tightly, the oil pipe between the oil-filled cable and the pressure oil tank should be fixed without damage, the pressure oil tank should be firm, and the pressure indication should meet the requirements.
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What inspections should be carried out for the acceptance of cable lines?(1) The cable specifications should meet the regulations, the arrangement should be neat, no damage, and the signs should be complete, correct and clear; (2) The fixed bending radius of the cable, the related distance and the wiring of the metal sheath of the single-core power cable should meet the requirements; (3) The cable terminal and the middle head should not leak oil, and the installation should be firm. The oil pressure of the oil-filled cable and the meter setting should meet the requirements; (4) Good grounding; (5) The color of the cable terminal is correct, and the metal parts such as the bracket are completely painted; (6) There should be no debris in the cable trench, tunnel, and bridge, and the cover should be complete.
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