CONTROL OR AUXILLARY (ARMOURED & UN-ARMOURED) CABLES

All cable conform to IS : 1554 (Part -1) : 1988 for working voltages upto 1100 volts. Wherever required, KCP can offer cables as per other
national or international standards or special requirements.

CONDUCTOR : Copper or Aluminium

APPLICABLE STANDARD : IS : 1554 (Part -1) : 1988
RANGE : 5C x 1.5 sq. mm to 37C x 1.5 sq. mm
5C x 2.5 sq. mm to 37C x 2.5 sq. mm

CABLE CONSTRUCTION

Conductor:
Solid stranded or Flexible Annealed Electrolytic Copper bare/tinned coated conforming to IS: 8130: 1984

Insulation:
Extruded layer of PVC 70°C/85°C/105°C (conforming to IS: 5831: 1984) with colours as per specification or cores are identified by printing
numbers under scheme as per IS: 1554(Part – 1): 1988.
Core Identification:
For Control cables upto 5 cores, the cores are identified by different colours as per IS 1554:

Single Core : Red, Black, Yellow or Blue

2 Core : Red and Black
3 Core : Red, Yellow and Blue
4 Core : Red, Yellow, Blue and Black
5 Core : Red, Yellow, Blue, Black and Grey

Where the number of cores exceeds 5, two adjacent cores are blue for reference and yellow for direction in each layer. The remaining cores in
each layer are grey. On specific request we can also provide core numbering for Control cables.

Laying:
Insulated conductors are laid in successive layers, in opposite direction to form cable cores.

Inner Sheath / Bedding:

An extruded layer of PVC is applied as bedding or PVC tape (conforming to IS: 5831: 1984).

Armouring (if requested):

Galvanized Steel Wires / Galvanized Steel Strips / Galvanized Steel Wire Braid conforming to IS: 3975

Screen (if requested):

Over the bedded cores a layer of Aluminium/Copper Mylar Tape or Copper/Aluminium wire braid is applied to form the screen. Screening for
cables depends on the type of application of the cable. Control cables if laid along with Power cables or MV cables or other cables having its
magnetic filed can cause problem in transmitting the signal. Cable construction is as per IEC 60502 Part 1

Sheath:
An extruded layer of PVC (ST1/ST2) is applied as the outer sheath conforming to IS: 5831: 1984. Sheath colour as per customer
specification.

CUSTOMIZATION

Other construction can be supplied on request:

FR [Flame Retardant PVC]
FRLS [Flame Retardant Low Smoke PVC]
Zero halogen/ Low Halogen Low smoke Cables: with polymeric insulation and sheath
High Temperature Cables: With ETFE/FEP/PTFE tape (wrap) insulation/sheath

APPLICATION
These cables are suitable for control purposes or measuring circuits in generating stations, substations, industrial installations etc. On account
of the armoring, the cables can withstand rough installation and operation conditions and tensile stresses. These can be laid in water or
buried direct in the ground even on steep slopes. They can also be installed indoors or outdoors, in air or in cable ducts.

TECHNICAL ADVISORY SERVICES

KCP’s staff includes specialist engineers with wide knowledge and decade long experience in the field of cables and their applications. This
time tested technical expertise and experience is available to all the clients in the selection of appropriate cable design.

CURRENT RATINGS
The current rating of Armoured Cables Table & Unarmoured Cables Table is based on the normal condition of installation as described
below.
1. Maximum conductor temperature 70 °C
2. Ambient air temperature 40 °C
3. Ground temperature 30 °C
4. Depth of laying (for cable laid directly in ground) 75 cm (1.1 KV)
5. Thermal resistivity of soil 150 °C cm/watt
6. Thermal resistivity of cable 650 °C cm/watt
7. Max. short-circuit conductor temperature 160 °C
8. Max. ambient air temperature 55 °C
TABLE I: PVC INSULATED STRANDED COPPER CONDUCTOR ARMOURED CONTROL CABLE IN VOILTAGE GRADE UPTO &
INCLUDING 1100 V (IS : 1554 (Part – 1) :1988)
 Thickness of Thickness of (SAC) (WAC) Current
No. of Cores (SAC) (SAC) (WAC) (WAC)
PVC Inner Sheath Thickness of Round Rating Current
& cross Strip Approx Thickness of Approx.
Insulation (min.) PVC Outer Wire Direct in Rating in Air
Section Area Size in O.D in PVC Outer O.D. in
(Nom.) in Extruded in Sheath in Dia. in Grd. in in Amps
(No.xmm) mm mm Sheath in mm mm
mm mm mm mm Apms
2 x 1.5 0.8 0.3 - - - 1.4 1.24 13.6 23 20
3 x 1.5 0.8 0.3 - - - 1.4 1.24 14.1 21 17
4 x 1.5 0.8 0.3 - - - 1.4 1.24 15 21 17
5 x 1.5 0.8 0.3 - - - 1.4 1.24 16 16 14
6 x 1.5 0.8 0.3 - - - 1.4 1.24 17 15 13
7 x 1.5 0.8 0.3 - - - 1.4 1.24 17 14 13
10 x 1.5 0.8 0.3 - - - 1.4 1.24 20.6 13 11
12 x 1.5 0.8 0.3 4 x0.8 1.24 19.5 1.6 1.40 21.5 12 10
14 x 1.5 0.8 0.3 4 x0.8 1.4 20.8 1.6 1.40 22.4 11 10
16 x 1.5 0.8 0.3 4 x0.8 1.4 21.7 1.6 1.40 23.3 11 9
19 x 1.5 0.8 0.3 4 x0.8 1.4 23.1 1.6 1.40 24.7 10 9
24 x 1.5 0.8 0.3 4 x0.8 1.4 26.4 1.6 1.40 28.0 9 8
27 x 1.5 0.8 0.3 4 x0.8 1.4 26.9 1.6 1.40 28.5 9 8
30 x 1.5 0.8 0.3 4 x0.8 1.4 27.8 1.6 1.40 29.4 9 7
37 x 1.5 0.8 0.3 4 x0.8 1.4 29.7 1.6 1.40 31.5 8 7

2 x 2.5 0.9 0.3 - - - 1.4 1.24 14.8 32 27

3 x 2.5 0.9 0.3 - - - 1.4 1.24 15.4 27 24
4 x 2.5 0.9 0.3 - - - 1.4 1.24 16.4 27 24
5 x 2.5 0.9 0.3 - - - 1.4 1.24 17.5 23 19
6 x 2.5 0.9 0.3 - - - 1.4 1.24 18.7 21 18
7 x 2.5 0.9 0.3 - - - 1.4 1.24 18.7 20 17
10 x 2.5 0.9 0.3 4 x0.8 1.4 21.0 1.6 1.4 22.5 18 15
12 x 2.5 0.9 0.3 4 x0.8 1.4 22.8 1.6 1.4 24 17 14
14 x 2.5 0.9 0.3 4 x0.8 1.4 23.4 1.6 1.4 25 16 13
16 x 2.5 0.9 0.3 4 x0.8 1.4 24.9 1.6 1.4 26.5 15 13
19 x 2.5 0.9 0.3 4 x0.8 1.4 25.6 1.6 1.4 27.2 14 12
24 x 2.5 0.9 0.3 4 x0.8 1.4 30 1.6 1.56 32 13 11
27 x 2.5 0.9 0.3 4 x0.8 1.4 30.6 1.6 1.56 32.6 12 10
30 x 2.5 0.9 0.3 4 x0.8 1.56 32 1.6 1.56 33.6 12 10
37 x 2.5 0.9 0.4 4 x0.8 1.56 34.7 2.0 1.56 37.1 11 9
Cables with stranded conductor can be manufactured on order basis.
TABLE II: PVC INSULATED STRANDED COPPER CONDUCTOR UN – ARMOURED CONTROL CABLE IN VOILTAGE GRADE UPTO &
INCLUDING 1100 V (IS : 1554 (Part – 1) :1988)
 No. of Cores & cross Thickness of PVC Thickness of Inner Thickness of PVC Current Rating
Approx. Current Rating in
Section Area Insulation (Nom.) in Sheath (min.) Extruded Outter Sheath Direct in Grd. in
O.D. Air in Amps
(No.xmm) mm in mm (Nom.) Apms
2 x 1.5 0.8 0.3 1.8 11.5 23 20
3 x 1.5 0.8 0.3 1.8 12.0 21 17
4 x 1.5 0.8 0.3 1.8 12.5 21 17
5 x 1.5 0.8 0.3 1.8 13.5 16 14
6 x 1.5 0.8 0.3 1.8 14.5 15 13
7 x 1.5 0.8 0.3 1.8 14.5 14 13
10 x 1.5 0.8 0.3 1.8 17.5 13 11
12 x 1.5 0.8 0.3 1.8 18 12 10
14 x 1.5 0.8 0.3 1.8 19 11 10
16 x 1.5 0.8 0.3 1.8 20 11 9
19 x 1.5 0.8 0.3 2.0 21.5 10 9
24 x 1.5 0.8 0.3 2.0 24.5 9 8
27 x 1.5 0.8 0.3 2.0 25 9 8
30 x 1.5 0.8 0.3 2.0 26 9 7
37 x 1.5 0.8 0.3 2.0 27.5 8 7

2 x 2.5 0.9 0.3 1.8 12.5 32 27

3 x 2.5 0.9 0.3 1.8 13 27 24
4 x 2.5 0.9 0.3 1.8 14 27 24
5 x 2.5 0.9 0.3 1.8 15 23 19
6 x 2.5 0.9 0.3 1.8 16.5 21 18
7 x 2.5 0.9 0.3 1.8 16.5 20 17
10 x 2.5 0.9 0.3 1.8 20 18 15
12 x 2.5 0.9 0.3 2.0 21 17 14
14 x 2.5 0.9 0.3 2.0 22 16 13
16 x 2.5 0.9 0.3 2.0 23 15 13
19 x 2.5 0.9 0.3 2.0 24.5 14 12
24 x 2.5 0.9 0.3 2.0 28 13 11
27 x 2.5 0.9 0.3 2.0 29 12 10
30 x 2.5 0.9 0.3 2.0 30 12 10
37 x 2.5 0.9 0.4 2.2 32.5 11 9
Cables with stranded conductor can be manufactured on order basis.

TABLE VI: 2 Core, 3 Core & 4 Core Copper Conductor, PVC Insulated, PVC Sheathed, Unarmoured (YY) / Armoured (YWY &
YFY) Cables – 1100 Volts
No. of Nominal Unarmoured Armoured Max. DC AC Current Rating
Cores Thickness Conductor In Air at 40°C In Ground at 30°C
 Nominal
Approx. Approx.
Approx. Armour Approx PVC HRPVC PVC HRPVC
Overall Overall
Nominal of PVC Wt. Size Wt. Resistance Insulation Insulation Insulation Insulation
Dia. Dia.
Area of Insulation W F at 20°C
mm2 mm mm Kg/Km mm mm Kg/Km Ohm/Km Amps Amps Amps Amps
2 Core 4 1 14 250 1.4 18 620 4.61 35 42 41 47
6 1 15 300 1.4 19 700 3.08 45 54 50 57
10 1 18 430 1.4 22 900 1.83 60 72 70 80
16 1 20 600 4X0.8 23 950 1.15 78 94 90 103
3 Core 4 1 15 300 1.4 18 680 4.61 30 36 36 41
6 1 16 380 1.4 19 780 3.08 39 47 45 51
10 1 19 560 1.4 22 1040 1.83 52 62 60 68
16 1 21 770 4X0.8 24 1150 1.15 66 79 77 88
4Core 4 1 16 370 1.4 19 790 4.61 30 36 36 41
6 1 17 470 1.4 21 930 3.08 39 47 45 51
10 1 20 720 4X0.8 23 1040 1.83 52 62 60 68
16 1 23 1000 4X0.8 26 1380 1.15 66 79 77 88
Cables with stranded conductor can be manufactured on order basis.
 RECOMMENDATIONS FOR STORAGE & INSTALLATION OF CABLES
For easy and convenient installation conditions, and desired performance, following recommendations are made:

1. No drums should be stored one above the other.

2. Drums should be stored on a plain ground without having any projected hard stones above the ground surface. The drums should be
stored preferably in the shade.
3. Drums should be stored and kept in such a way that the bottom cable end does not get damaged.
4. Drums should be rotated only in the direction marked on the drum.
5. While laying the cable in a trench, the cable end should be pulled with a pulling eye only after mounting the drum on the jack.
6. 100% drums should be checked for continuity and cross continuity to ensure that there is no internal damage to the cable during
transportation.
7. Insulation resistance should be measured with 500 V megger between the cores and all the cores to earth (Armour).
8. After the cable is installed, before commissioning, it should be tested for high DC voltage. The recommended volts and duration of the
test between each core and metallic armour (earth) is 3 KVDC for 5 minutes. During High Voltage test, all the electrical equipment
related to the cable installation must be earthed and adequate clearance should be maintained from the other equipments and from
work, to prevent flash over.
9. Where the cable is to be joined with an existing cable, the sequence of cores at the two ends to be joined should be in the opposite
direction i.e., if at one end it is in the clockwise direction, at the other end it should be in the anticlockwise direction. This is necessary
to avoid the crossing of cores while jointing. This will also decide the direction in which the cable is to be pulled.
10. The minimum bending radius for cable should not be less than the values shown below. Wherever possible 25% higher value should
be adopted.
8 x overall diameter: Single core cables as per table I
12 x overall diameter: Multi-core cables as per tables II, III, IV, V, VI, VII & VIII
11. Avoid excessively high temperature when sealing joints of cable. Cool the sealant to about 1000C before pouring.
 INSTRUMENTATION CABLES
K C POWERTRACKS manufactures a wide variety of cables suitable for process instrumentation. In the projects related to power generation &
distribution, chemical & fertilizer industries and various other types of engineering industries, the process instrumentation plays a vital role in
measurement, supervision and control of the process. Introduction of microprocessor based/computerized instrumentation has demanded
stringent quality requirements along with special electrical parameters for instrumentation cables. Very low level electrical signals pass
between measuring end and display units/controllers which are situated far off, these low level signals are prone to external noise pickups
and heavy attenuation during transmission. KCP with its meticulous efforts in maintaining quality, stringent in process control during
manufacture and the knowledge of cable of designing, is proud to say that it is capable of supplying instrumentation cables meeting any
Indian/international standard or a specific requirement desired by project authority. The efforts done by KCP are rewarded by acceptance of
our quality by the country's prime organizations such as Electricity Boards, BES&T Undertaking, ESSAR, ICF, Telecommunication Sectors,
Development Consultants, etc.

CONSTRUCTION OF INSTRUMENTATION CABLES:

CONDUCTOR Annealed bare/ uniform coated with Tinned/Silver Platted, High Conductivity, and Electrolytic Grade Solid/Stranded/Flexible
Conductor.

DIELECTRIC Conductor is insulated with General Purpose/HR PVC Compound/Solid/Cellular PE/PP/or any other dielectric material as per
customers’ specification. The choice of insulation material to be used for any application is dependant on:
1. Conductor temperature
2. Electrical characteristics required
3. Flexibility
4. Compatibility: These are the most common types of extruded material used in the manufacture of Instrumentation cables.
CORE/PAIR IDENTIFICATION
MULTI-PAIR CABLES
The cores within a pair are identified by one of the following methods:
1. By printing a reference code on one insulated conductor, or both of them, that indicates the number of that single pair.
2. By a numbered non - hygroscopic tape applied over the pair.
 3. By using different colour combinations to uniquely identify the pair.

PAIR/TRIAD/QUAD Two/Three/Four cores are uniformly twisted together to form a Pair / Triad / Quad with maximum lay length 80 mm / as
per requirement of customer. The lay shall be so chosen as to minimize cross talk in the cable.

COMMUNICATIONS CORE OR PAIR A communication core or pair for telephone communication can be applied in the outer layer of the
assembly. The most common configuration of the communication wire(s) is 7/0.3 mm (0.5mm2) of plain
annealed copper insulated with the same material as the main conductors. The colour of the
communication wire(s) can be easily identified from that of the main cores.

ELECTRICAL SCREENING In addition to using twisted pairs to reduce crosstalk, the screening of the cables or an element of the cable, is often
required to protect signals from outside electromagnetic, electrostatic and radio frequency interference. Further
consideration could be the protection of electronic equipment in the locality from emission from the cable itself, or
the prevention of an antennae effect from the cable into electronic equipment.

INDIVIDUAL SHIELDING If required, Individual Shielding may be of Poly Aluminum [Thin Layer of Aluminum Foil bonded to Polyester Film]
Tape with Annealed Tinned Copper Drain Wire. It prevents the shorting of adjacent shield and minimizes the cross
talk and ground loops. A Tinned Copper drain Wire is installed to provide continuous contact with the shield and
allow to connection to ground. Tinning the drain wire reduces galvanic corrosion between drain and shield.

OVERALL SHIELDING If required, Overall l Shielding may be of Annealed Tinned Copper Braiding/Poly Aluminum [Thin Layer of Aluminum Foil
bonded to Polyester Film] Tape with Annealed Tinned Copper Drain Wire. Braiding ATC Shield has high tensile Strength
and provides better coverage in flexing application. They are easier to terminate. This provides effective shielding; cross
talk and noise are kept to an absolute minimum.

INNER SHEATH The laid up pair/triad/quad after shielding / screening are provided with an inner sheath, which may be either Extruded Inner
Sheath or wrap with PVC Tape.

ARMOURING It is applied over inner Sheath. It may consist of Galvanized Round Steel Wires or Galvanized Flat Steel Strips. Steel wire
armoured cables are suitable for direct burial. One or more copper wires can be incorporated in the armour to increase the
conductivity of the armour where it is being used as an earth return.

OUTER SHEATH It is applied over Armouring in case of Armoured Cable or over Inner Sheath in case of Unarmoured Cable. The Color of
Sheath is Black or Grey. The Sheath material may be General Purpose/HR/FRLS PVC Compound as per requirement of
specification. The choice of sheathing materials to be used for any application is dependent on:
1. Temperature 2. Flexibility
3. Electrical characteristics 4. Smoke and acid gas emission limitations
5. Resistance to chemicals 6. Water resistance
7. Exposure to UV

RIP CORD To simplify jacket removal, high tensile strength nylon Rip Cord is provided over laid up of pairs/triads/quads below the outer
sheath in case of Unarmoured cable or below the Inner Sheath in case of armoured Cable.
QUALITY ASSURANCE Quality Standards are built in every pagoda product. KCP cables are subjected to a series of required tests in our well-
equipped laboratory. Besides the rigid tests and checks at every stage from raw material through manufacturing
stages and finally up to the finished product.

TYPICAL APPLICATION Unscreened Cables: Suitable for use on AC systems for rated voltages upto and including 1100 volts (earthed and
unearthed). Also may be used on DC system for rated voltages upto and including 1500 volts to earth. Screened
Cables: Suitable for railway signalling currents particularly in areas where 25 kV, 50cps, AC is used for railway
traction; also applied in Connection of Instruments, Process Control Systems, Computers, Data Transmission, etc.

TYPES OF INSTRUMENTATION CABLES:

1. Collectively screened, unarmoured “type – 1” cable, multi-pair PVC insulated without individual pair screens but
collectively screened
2. Collectively screened, armoured “type – 2” cables, multi-pair PVC insulated without individual pair screens but collectively
screened
3. Individually & collectively screened, unarmoured “type – 1” cables, multi-pair PVC insulated cables with individual pair
screens and collectively screened
4. Individually & collectively screened, armoured “type – 2” cables, multi-pair PVC insulated cables with individual pair
screens and collectively screened
5. Collectively screened unarmoured “type – 1” cables, multi-core PVC insulated cables collectively screened
6. Collectively screened armoured “type – 2” cables, multi-core PVC insulated cables with collectively screened

ELECTRICAL CHARACTERISTICS

Rated voltage 300/500 volt; test voltage 1100 volt for 1 min