Instrumentation Cable

Design Base
Instrumentation cables are designed for Transmission of Analog & Digital signals in instruments
and Control Systems. GCI make instrumentation cables are designed to maintain high level of
accuracy and sensitivity of the system without drop in signal. It is designed to obtain Maximum
rejection of Electromagnetic noise, minimal cross-talk and minimal Electrostatically or
Electromagnetically induced noise & common mode interference.
Individual pairs or Triads are Colour coded for simplified identification & hook-up. Rugged
armoured versions are recommended for use in Intrinsically Safe Systems.
The Aluminium Myler Tape screening ensures exact data and pulse transmission, protecting
the cable against electromagnetic disturbances and interferences.
Fire performance options are Designed to resist and withstand extreme fire conditions, with
minimal emission of Toxic gases.
Lead sheath provides excellent resistant to chemical, oil, gas & radial water blocking.
Characteristics
Signal protection between pairs.
Good electromagnetic protection from external influences.
Excellent Electrical, Thermal & Physical properties.
Flame Retardant, Fire Retardant & Fire resistant - Highly recommended in areas with high
explosion & fire risks.
Lead sheath provides radial water tightness and resistance to chemicals & hydrocarbons.
Excellent mechanical protection during laying, installation & service.
Extra pulling force.
Option class-5 conductor provides extra flexibility.
Application
Generally used for transmission of signals in control systems
Typical applications include audio, intercom, control, energy measurements, alarm circuits.
Suitable for use in wet and dry locations.
Armoured cables are recommended for Outdoor & Direct Burial.
Unarmoured cables are recommended for indoor use.
Category of Cables
Other than Conductor & insulation variances Instrumentation cables are categorized broadly by the following :
Type-1 Unarmoured Collectively Screened Collective Screen / Sheath
Individually & Collectively Screened Individual Screen / Collective Screen /
Sheath
Type-2-Armoured Collectively Screened Collective Screen / Sheath or Bedding /
Armoured / Overall Sheath
Individually & Collectively Screened Individual Screen / Collective Screen /
Sheath or Bedding / Armoured / Overall
Sheath
Type-3-Lead Sheathed Collectively Screened Collective Screen / Sheath or Bedding /
& Armoured lead Sheath / bedding / Armour / Overall
Sheath
Individually & Collectively Screened Individual Screen / Collective Screen /
Sheath or Bedding / Lead Sheath / Bedding /
Armour / Overall Sheath
Instrumentation Cable
Class of Conductor
Cond. Size in Sq. mm. No./ Dia (mm) of wires
0.5 1 / 0.8 7 / 0.3 16 / 0.2
0.75 1 / 0.98 7 / 0.37 24 / 0.2
1.0 1 / 1.13 7 / 0.43 32 / 0.2
1.5 1 / 1.38 7 / 0.53 30 / 0.25
2.5 1 / 1.78 7 / 0.67 50 / 0.25
Solid (Class 1) Stranded (Class 2) Flexible (Class 5)
Electrical & Transmission Characteristics Refer Specification
Conductor resistance IS :1554 Part-1 / BS:5308 Part - 1&2
Dielectric constant IS : 5608 Part I / BS:5308 Part - 1&2
Volume resistivity at 27C IS : 5608 Part II / BS:5308 Part - 1&2
Mutual capacitance IS : 5608 Part III / BS:5308 Part - 1&2
Co-axial capacitance BS, 5308 Part 1&2
Characteristic impedence IEC - 189 / BS:5308 Part 1&2
Cross talk / attenuation VDE 0815
Inductance VDE 0816 / BS:5308 Part 1&2
Electrical & Transmission Characteristics
Constructional Excellence
Conductor Electrolytic grade Annealed high conductivity plain or tinned,
solid or stranded or flexible copper wires.
Insulation PVC/ HRPVC/ POLYETHYLENE (PE) / XLPE
Colouring of Insulation, number printing, Ring marking or
combination of above schemes.
Core & Pair Identification
Two cores twisted to form a pair with staggered lay lengths for
minimizing cross talk.
Pairing
Individual pair screening Pairs screened with Aluminium Mylar Tape (100% coverage)
having Tinned Copper drain wire under the screen longitudinally
along the length, in contact with the Aluminium face.
Pair laid up in suitable condition Pair laying-up
Mylar Tape Binder tape (optional)
Collective screening
Sheath or Bedding
With Aluminium Mylar Tape (100% coverage) having Tinned
Copper drain wire under the screen longitudinally along the
length, in contact with the Aluminium face.
Process Features with Materials
PVC / HR PVC / FRLS / ZHLS Bedding
Single layer of round galvanized steel wires or flat galvanized
steel strips.
Armour
PVC / HR PVC / FRLS / ZHLS Overall Sheath
PVC / HR PVC / PE / FRLS / ZHLS
Lead Sheath Lead AlloyE sheath
Instrumentation
Cable
Power & Control
Cable
Building Wire &
Flexible Cable
ACSS
Conductor
General Cable India
Corporate Office : IRIS Tech Park, Unit No. 508 - 510, 5th Floor,
Block - A, Sector 48, Sohna Road, Gurgaon - 122018, Haryana, INDIA
Phone : +91 124 4326000 Fax ; +91 124 4326019 E-mail : marketing@generalcable.co.in
Website : www.generalcable.com
Registered Office : A-38, Kailash Colony, New Delhi
Factory : Unit-I, Village Bhatouli Khurd, Baddi, Dist: Solan - 173 205 (Himachal Pradesh), India
Tel : +91 1795 645130, Fax : +91 0124 4326019
The General Cable Corporation (NYSE:BGC) is one of the Fortune 500 companies, a world leader when it
comes to developing, designing manufacturing, marketing and selling copper, aluminum and glass-fiber
cables plus products in the energy, industrial and telecommunication sectors. It has 47 manufacturing
facilities in 25 countries. The Company offers competitive strength in such areas as breadth of product line,
brand recognition, distribution and logistics, sales and service, and operating efficiency.
General Cable Energy India Pvt. Ltd. (Subsidiary of General Cable Corporation, US) headquartered in
Gurgaon has set up a state of the art manufacturing facility at Baddi in Himachal Pradesh. In India,
presently our product range includes LV XLPE power & control cables, entire range of fire performance
cables, Specially Instrumentation cables, MV cables up to 33KV, HV cables up to 132KV and slowly extend
to working voltages up to 220KV & Patented high ampacity bare aerial conductors (Transpower brand
ACSS/TW conductors).
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Properties of Fire Performance in Cables
Flame Retardant
IEC 60332-1
Flame Propagation
IEC 60332-3
Low Toxicity and Corrosivity of
Emitted Gases - IEC 60754-2
Low Emission of Dark
Fumes - ASTM D-2843
Fire Resistant
IEC 60331
Halogen Free
IEC 60754-1
Properties Covered
Types
Properties Ref. Standard Applicable Limit Applicable Limit Applicable Limit Applicable Limit
Oxygen Index ASTMD-2863 29% 29% 30% >30%
(Min) (Min) (Min) (Min)
Temperature ASTMD-2863 250C 250C 250C 280C
Index (Min) (Min) (Min) (Min)
Smoke Density ASTMD-2843 40% 20% 20%
Rating (Max) (Max) (Max)
Halogen Acid Gas IEC:60754-1 20% 0.5% <2%
Generation EN-50267-2-1 (Max) (Max) (Max)
Toxicity IEC:60754-2 5% 5%
Index EN-50267-2-2 (Max) (Max)
Corrosive IEC-60754-2 PH > 4.3 PH > 4.3
Gases EN-50267-2-2 Conductivity Conductivity
<100 s/cm <100 s/cm
Flame Test on IEC:60332-1 As per As per As per As per
Single Cable EN-50265 Specification Specification Specification Specification
Fire Test on IEC:60332-3 As per As per
Bunched Cable Specification Specification
Fire Resistant Test IEC 60331 As per
Specification
Applicable
Symbols
FR FRLS ZHLS
Fire Survival Flame Retardant Flame Retardant
Low Smoke
Zero Halogen
Low Smoke
FS