LV Control Cables: Types, Applications, and Key Benefits Explained

Control cables are very specialized electrical cables used to carry signals and information through a broad spectrum of industrial applications and infrastructures. They have several individually insulated conductors and every conductor with a different signal. This design enables structured, secure, and very reliable communication. Their significance is highlighted in applications such as construction, power generation, automation, and precision instrumentation.

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Low Voltage (LV) control cables are unique as compared to other cables because they provide efficient and secure signal transmission in low-voltage environments. Tempsens Cables, a world-renowned name in high-performance cable solutions, is an expert in offering high-quality LV control cables that conform to the most demanding relevant standards. Backed by a reputation for superior performance, durability, and reliability, Tempsens is a partner of choice in a broad spectrum of industries.

Significance of LV Control Cables

LV control cables are the backbone for most industries, such as but not restricted to steel production, glass manufacturing, chemical processing, fertilizer production, and energy distribution. They are designed to function effectively under harsh operating conditions including high temperatures, moisture exposure, mechanical abrasion, and electromagnetic interference (EMI).

The main purpose of LV control cables is to deliver control signals accurately and efficiently, allowing smooth and safe operation of automatic systems, instrumentation systems, and power distribution systems. Their rigid structure guarantees continuous operations even under some of the most extreme industrial settings one can imagine today.

Some exceptional attributes of our LV Control Cables are:

•Reliable management: Enable dependable and exact regulation of machinery and operations.

•Safety: Our cables consist of resistant materials, immune to heat, chemicals, and mechanical pressure.

•Efficiency: Allow optimized performance of automated systems.

•Flexibility: Made to withstand constant movement and bending.

•Durability: Made for heavy industrial conditions.

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, LSZH Polymer, FR PVC, XLPE, XLPO etc. Screening Aluminum Foil type/Mesh Braided type Inner/Outer Sheath PE, PVC, LSZH Polymer, HR PVC, FR PVC,  PUR, XLPO etc. Armoring G.I. Round Wire / Flat Strip Armouring (As per IS : 99) Standards IEC , IEC -1, IEC , IS 694, IS , IS

Key Components of LV Control Cables

1. Conductor: It is the metal wire that conducts the electric current from one point to another, composed of high-conductivity substances such as copper (bare, tinned, nickel-plated, or silver-plated) to conduct power or signals effectively, located in the middle.
2. Insulation: A protective cover that can operate over temperature ranges of -267 °C to °C with heat and chemical resistance, is non-conductive, and allows for safe and efficient working conditions overall by isolating the conductors from one another, protecting from the environment, and preventing the possibility of a short circuit.
3. Inner Sheath: Serving as an additional layer of protection, the inner sheath provides mechanical defense for the insulated conductors. Commonly used materials include PVC, silicone, or Teflon, selected for their durability and capacity to endure challenging environments.
4. Outer Sheath: The ultimate protective coating, constructed to defend the cable against external harm. Typical materials employed are the robust forms of PVC, silicone rubber, or strengthened fiberglass composites.
5. Construction: Cables may be twisted to minimize electromagnetic interference and enhance ruggedness.
6. Screening: A conductive layer is added around the conductors or cores to protect from external electromagnetic or radio frequency interference to the signal or transmission of power, and there are two types of screening:
   1. Aluminum foil provides full coverage and includes a copper drain wire.
   2. Mesh Braided: These are constructed using copper wire with 70%-95% coverage.

LV Control Cables Applications

The following industries often employ these cables:

• Oil & Gas – Employed in refineries, pipelines, and drilling operations.
• Cement Industry – For supporting automation and material handling systems.
• Chemical & Fertilizers – It is crucial for the safe and reliable operation of processing facilities.
• Power Distribution –Employed in monitoring, controlling, and managing electrical grids and substation operations.
• Steel Industry – Facilitating control and monitoring of heavy machinery.

How to find your LV Control Cable?

Choosing the proper low-voltage (LV) control cable is important to achieve maximum performance and long-term reliability. The underneath are some factors needs to be considered:

• Environmental Conditions: Evaluate the environmental conditions the cable will be subjected to, including extreme temperatures, moisture levels, and possible chemical exposure.
• Electrical Needs: Clearly identify the electrical requirements, which include voltage, current rating, and type of signals to be carried.
• Life Expectancy Requirements: Assess anticipated mechanical loads, such as motion, vibration, and wear, and choose cables that are developed to meet those challenges.

Why Choose Tempsens Cables?

Tempsens is among the leading manufacturers of LV control cables and one of the largest thermal and cable solution suppliers. What actually makes us stand out is:

• Voltage Ranges: Can be supplied with various voltage cables up to 1.1kv.
• Quality Assurance: Our cables ensure high standards, reliability, and credibility.
• Expert Guidance: Our experienced personnel is here to assist you in selecting the optimum cable for your needs.
• Large Product Line: We offer a large product line of LV control cables to feed different applications.
• Tolerance: Can be withstood by oil, moisture, chemicals, weather etc.

Types of Control Cable Assemblies

The three types of control cable assemblies you will see on the market today include SY, YY, and SY types. CY is going to be a flexible cable that has been bulked up with additional EMI protection. SY cables are those with steel braided wire to be used in applications where max protection is key. YY is simply a regular, unshielded cable.

You’ll most likely hear control cables being referred to as “instrumentation cable assemblies” or “signal cable assemblies”. While they can share common characteristics, these are actually three different cable types. A signal cable assembly would include common cable types like coaxial cable assemblies and twisted pairs, as well as fiber optic cables. 

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True, a control cable assembly carries signals, but signal cables are typically utilized to transmit data, which means they’ll need engineering to combat electromagnetic interference (EMI). A typical control cable assembly might not require shielding, but this is also a popular option in electronically noisy applications. Instrumentation cable assemblies also fall under these broad terms that are used interchangeably with control cables. 

One of the main benefits of working with a custom cable manufacturer like Meridian is that we design well over 70% of the products we produce. With decades of experience and one of the most state-of-the-art production facilities in the U.S., we can produce whatever version of control assembly is required to meet your project’s specifications.

Customizing Your Control Cable Assembly

The ability to customize your project’s control cable assembly down to the smallest detail is what sets Meridian Cable apart from any off-the-shelf assembly out there. Built to spec and tested and re-tested for continuity, integrity, polarity, and functionality, our products are engineered to be depended on.

When deciding what options would benefit your project most, our cable designers consider all aspects of the application, as well as environmental variables requiring mitigation. A few of the many customizations our cable engineers employ throughout the process include:

Stranding 

Stranding utilizes twisted wires in a spiral to help transfer power more efficiently. Stranded cables include copper, tinned stranded, tinned conductors, or can include rare metals for max performance. Stranded cables also add increased flexural strength to a control cable assembly. 

Conductors 

Since control cable assemblies are typically deployed in automation control for equipment, measurement, and regulation, the most common conductor used is copper. This is due to copper’s superior conductivity. Utilizing UL-listed components means our engineers start the project with a product that has been tested, with known capabilities, rather than starting from scratch. Depending on the setup, various conductor sizes may be required. 

Our capabilities allow us to extrude as small as 34 gauge all the way up to 12 gauge. We can also employ mixed gauge cables with any combination of sizes when that’s most advantageous to the overall design.

Shielding 

Electromagnetic shielding material can be wrapped around a cable assembly in order to protect the assembly from all the electrical noise one would expect to find in “noisy” electronic environments such as a server room or industrial control system. The shielding protects the assembly so that the signal, power, or data transfer isn’t degraded. 

Meridian cable engineers deploy the right shielding for the application which can vary considerably but typically will involve metal braiding, tape, or foil. 

Color 

Proper cable management is key both for the installation and continuous maintenance of any system. Our team can create a custom control cable assembly in more than 25 different color combinations with any number of stripes, dashes, or even custom text so that the end user can quickly identify a cable’s intended port. 

Insulation and fillers 

Cable insulation and fillers are the true unsung heroes in the custom cable assembly world. Insulation plays an essential role in protecting conductors from the elements and keeping the structure of each individual cable exactly as it was designed. Meridian can provide insulation materials perfect for the application such as Teflon, natural rubber, PVC, PE, or PP. 

Filler materials can include cotton, nylon, Kevlar, PVC, and more all to suit the needs of the project. A control cable assembly that isn’t being deployed as a power cable can be perfectly set up with standard PVC insulation. 

Testing is Everything

It’s incredibly rare for a product to go from concept to volume production without a million tiny steps in between. Having advanced prototyping capability means our team gets to test different iterations of an assembly under harsh real-world conditions. If any component isn’t up to the Meridian standard, we’ll go back to the drawing board.

Start Your Control Cable Assembly Project with the Professionals

Meridian has been designing and manufacturing custom cable assemblies and wire harnesses for decades and within some of the most exacting industries. From medical and military to telecommunications and automotive OEMs, we’re proud to have our work represented across so many different fields. In the end, when it absolutely has to be done right, trust Meridian to get the job done.

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