Instrumentation Cables
By:
Setal Kalavadia
CABLE CONSTRUCTION
Single Core
Insulation
Core
CABLE CONSTRUCTION
Multi- Core
Insulation
Sheath Core
CABLE CONSTRUCTION
Multi- Core with Protection
Core Insulation
Sheath
Screen
Screened Multi- Core Cable
Core
Insulation
Inner
Sheath
Screen
Outer Sheath
Schedule Of Standard Cable Types
Conductor Material:
– Signal cable:
Annealed stranded copper
– Extension cable:
J type, K type, T type, S type
Schedule Of Standard Cable Types
Pair / Core/ Triad:
– Pair:
1, 2, 5, 10, 20
– Core:
2, 4, 7, 12, 19, 27, 37
– Triad:
1, 2, 5, 10, 20
Schedule Of Standard Cable Types
Conductor Size:
– 0.5 mm2
– 1.0 mm2
– 1.5 mm2
– 2.5 mm2
Schedule Of Standard Cable Types
Screen:
– Unscreen
– Overall Screen
– Individual Screen
– Overall & individual screen
Schedule Of Standard Cable Types
Conductor Insulation:
– Polyethylene (PE)
– Polyvinyl chloride (PVC)
– Cross linked polyethylene (XLPE)
Schedule Of Standard Cable Types
Armour (Galvanized steel round wire):
– Unarmoured
– 0.9 mm dia
– 1.25 mm dia
– 1.4 mm dia
– 1.6 mm dia
Schedule Of Standard Cable Types
Sheath (outer/inner) Material:
– PVC
Outer Sheath Colour:
– Blue (IS)
– Grey (Non IS)
– Black (Power)
– Yellow (K type)
Flexibility and Stranding
Solid Conductors
are not flexible
FLEXIBILITY
7 wire Multi Strand
slightly flexible
Class 5 flexible
Class 6 Super
Flexible
Conductor Stranding
class 6: super wire stranding
Fle
xi b
class 5: fine wire stranding
ilit
y
class 2: multi-strands
class 1: single core
ADDITIVES
Fillers Chalk, Talc
- cost reduction
- improvement of electrical properties
Plastizisers
- oily substances or materials added
to the plastifiable compound to
improve ist softness
Stabilizers Heat , Cold, UV stabilizers
- increase of thermal stability
- absorb detrimental UV rays and
convert them into harmless
thermal energy
Comparison of Properties : Thermo plastics & TPE
POLY VINYL
MATERIAL CHLORIDE POLYETHYLENE POLYURETHANE POLYAMIDE
ABREVATIONS PVC / HRPVC LDPE / HDPE PUR PA
WORKING TEMP - 30 to + 70 / - 50 to + 70 / - 40 to + 90 / 100 - 40 to + 115
DEG CENT. - 20 to + 90 - 50 to + 100
DIELECTRIC 4.0 / 3.5 2.3 4 to 6 3.5 to 7.0
CONSTANT
VOLUME 1012 to 1015 1017 1012 1014
RESISTIVITY
TENSILE 10 to 25 20 to 30 / 30 30 to 45 50 to 180
STRENGTH
(N/mm2)
ELONGATION % 150 to 300 500 / 800 300 to 600 200 to 300
WATER 0.4 0.1 1.5 1.0 to 2.0
ABSORPTION %
@ 20 0 C
WEATHER MODRATE GOOD / VERY GOOD GOOD
RESISTANCE MODRATE
FUEL MODRATE POOR GOOD MODRATE
RESISTANCE
OIL
RESISTANCE GOOD MODRATE GOOD GOOD
FLAMEABILITY SELF FLAMEABLE SELF FLAMEABLE
EXTINGUSHING EXTINGUSHING
Comparison of Properties: Thermo plastics & Elastomers
POLY TETRA FLURO
MATERIAL FLURO ETHYLENE CHLOROPRENE SILICON RUBBER
ETHYLENE PROPYLENE RUBBER
ABREVATIONS PTFE FEP CR SI
WORKING TEMP - 190 to + 260 / - 100 to + 200 - 40 to + 100 - 60 to + 180
DEG CENT.
DIELECTRIC 2.1 2.1 6.0 to 8.0 2.8 to 3.2
CONSTANT
18 18 13 15
VOLUME 10 10 10 10
RESISTIVITY
TENSILE 14 to 40 20 to 25 25 5 to 10
STRENGTH
2
(N/mm )
ELONGATION % 240 to 400 250 / 350 450 200 to 350
WATER 0.01 0.01 1.0 1.0
ABSORPTION %
0
@ 20 C
WEATHER VERY GOOD VERY GOOD VERY GOOD VERY GOOD
RESISTANCE
FUEL VERY GOOD VERY GOOD POOR POOR
RESISTANCE
OIL
RESISTANCE VERY GOOD VERY GOOD GOOD MODRATE
FLAMEABILITY NON NON SELF LESS
FLAMEABLE FLAMEABLE EXTINGUSHING FLAMEABLE
Cross Talk
Signals of one circuit are picked
by another.
Increases with length
Increases with proximity
Increases with frequency
Wet/Damp atmosphere can
increase cross talk.
ATTENUATION
Loss of signal as it travels.
Expressed in dB/km (deciBel)
Difference between transmitted and received
signal strength.
dB Loss = -10xlog10 (Power Output/Input)
10 dB/km = 10% of the signal power
remains after 1 km
Attenuation increases with frequency and
as diameter decreases.
Protection classes
Protection against Contact Water protection
and foreign bodies Protection against:
Protection against 0 no protection
0 no protection 1 dripping water falling
1 large foreign bodies vertically
2 medium sized foreign 2 dripping water falling
bodies at an angle
3 small foreign bodies 3 sprayed water
4 granulated foreign bodies 4 splashed water
5 accumulation of dust 5 water jet
6 ingress of dust 6 flooding
7 immersion
8 submersion
Insulation Resistance
Individual conductor:
When a steady voltage of 500 V d.c is applied for 1 min. The
insulation resistance of each conductor measured against the
remaining bunched conductors/screens/armour shall not be
less than 5 G ohm for 1 Km at 20 deg. C
Individual Screens:
For cable with individually screened pairs, When a steady
voltage of 500 V d.c is applied for 1 min. The insulation
resistance measured between screens shall be not less than 1
M ohm for 1 Km at 20 deg. C.
Insulation Resistance
Conductor resistance:
The resistance of each conductor in the completed cable at 20
deg C shall not exceed the values given below
Area (mm2) Resistance (ohm / km)
0.50 36.8
1.00 18.4
Capacitance
Mutual capacitance:
The mutual capacitance of the pairs or adjacent cores shall
not exceed the below mentioned value at a frequency of 1
khz.
0.5 mm2 1.0 mm2 1.5 mm2
pF/m pF/m pF/m
w/o screen 75 75 85
Collective screen 75 75 85
Individual screen 115 115 115
L/R Ratio
Mutual capacitance:
The L/R ratio for adjacent cores shall not exceed the
following maximum values:
Conductor Max L/R ratio
0.5 mm2 25 uH/ohm
1.0 mm2 25 uH/ohm
1.5 mm2 40 uH/ohm
