Instrumentation Cables—XLPE Insulated,Individual &Overall Screened,Unarmoured PVC Sheathed Cables(CU/XLPE/IOSCR/PVC)
Instrumentation Cables are multi-conductor cables that carry and transport low-voltage electrical signals. These low-voltage signals are used to control and monitor electrical power systems. Instrumentation cables have many different industrial applications that include broadcasting, equipment control, such as drilling and pumping in the oil and gas industry, and data transfer, which includes analog and digital signals. They are manufactured according to the BS EN 50288-7 and BS EN 50288-1 standards to ensure quality.
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, Individual & Overall Screened, Unarmoured PVC Sheathed Cables(CU/XLPE/IOSCR/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,Individual &Overall Screened,Unarmoured PVC Sheathed Cables(CU/XLPE/IOSCR/PVC)
Instrumentation Cables Main Specifications
Instrumentation Cables—XLPE Insulated, Individual & Overall Screened, Unarmoured PVC Sheathed Cables(CU/XLPE/IOSCR/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] |
| 2 | 10.0 | 11.0 | 11.5 | 12.5 | 15.0 | 100 | 115 | 130 | 160 | 220 | 1000 |
| 5 | 13.0 | 14.0 | 14.5 | 16.5 | 19.5 | 180 | 215 | 245 | 310 | 440 | 1000 |
| 10 | 18.0 | 19.5 | 20.5 | 23.0 | 27.5 | 330 | 395 | 455 | 575 | 835 | 1000 |
| 20 | 23.0 | 25.0 | 27.0 | 30.0 | 36.0 | 580 | 715 | 835 | 1075 | 1555 | 1000 |
| 30 | 27.5 | 30 | 32 | 36 | 835 | 1035 | 1215 | 1560 | 2265 | 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] |
| 2 | 11.0 | 12.0 | 13.0 | 14.0 | 16.5 | 120 | 145 | 165 | 200 | 285 | 1000 |
| 5 | 14.0 | 15.5 | 16.5 | 18.5 | 22.0 | 225 | 280 | 330 | 415 | 595 | 1000 |
| 10 | 20.0 | 22.0 | 23.5 | 26.0 | 31.0 | 415 | 515 | 615 | 775 | 1140 | 1000 |
| 20 | 26.0 | 28.5 | 30.5 | 34.0 | 750 | 940 | 1145 | 1455 | 500 | ||
| 30 | 31.0 | 33.5 | 36.0 | 1085 | 1370 | 1650 | 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] |
| 2 | 13.0 | 14.0 | 14.5 | 16.5 | 19.5 | 145 | 175 | 205 | 255 | 365 | 1000 |
| 5 | 16.5 | 18.0 | 19.0 | 21.5 | 25.5 | 280 | 355 | 415 | 530 | 770 | 1000 |
| 10 | 23.5 | 25.5 | 27.5 | 30.5 | 37.0 | 515 | 655 | 790 | 1010 | 1490 | 1000 |
| 20 | 30.5 | 33.5 | 35.5 | 945 | 1215 | 1455 | 500 | ||||
| 30 | 36.0 | 1370 | 500 | ||||||||
Note: Cable OD and Cable weight are subject to change based on the latest manufacturing practice.
Quality Control
Instrumentation Cables—XLPE Insulated,Individual &Overall Screened,Unarmoured PVC Sheathed Cables(CU/XLPE/IOSCR/PVC)
Raw Material Test
For the Instrumentation Cables—XLPE Insulated, Individual & Overall Screened, Unarmoured PVC Sheathed Cables (CU/XLPE/IOSCR/PVC), raw material testing aligns with BS EN 50288-7. Step 1: Confirm copper conductor purity via spectrometry to meet 99.99% per IEC 60228. Step 2: Test XLPE insulation tensile strength (≥12.5 N/mm²) and elongation (≥150%) using mechanical pull testers. Step 3: Evaluate individual/overall screening tapes for thickness, adhesion, and conductivity through micrometers and peel tests. Step 4: Assess PVC sheath flame retardancy via oxygen index (>27%). Step 5: Conduct immersion tests on XLPE/PVC in chemicals, oils, and water for 168 hours to verify resistance. Step 6: Measure drain wire diameter and resistivity with precision tools. Step 7: Perform thermal aging on XLPE at 135°C for 168 hours to check cross-linking.
Process inspection
During production of the Instrumentation Cables—XLPE Insulated, Individual & Overall Screened, Unarmoured PVC Sheathed Cables (CU/XLPE/IOSCR/PVC), process inspection follows BS EN 50288-1. Step 1: Monitor conductor stranding uniformity with gauges every 100 meters. Step 2: Scan XLPE insulation thickness (0.7mm nominal) using lasers, rejecting >5% variances. Step 3: Inspect pair/triad twisting and individual screening application visually. Step 4: Apply the overall screen and verify coverage with ultrasonic devices. Step 5: Conduct in-line capacitance, continuity, and crosstalk tests for low interference. Step 6: Check PVC sheath adhesion via peel strength (≥10 N/cm). Step 7: Sample shifts for dimensional and screening integrity checks. This step-by-step oversight minimizes defects, ensuring dual-screened high-temperature reliability and compliance.
Finished Product
The finished Instrumentation Cables—XLPE Insulated, Individual & Overall Screened, Unarmoured PVC Sheathed Cables (CU/XLPE/IOSCR/PVC) are tested per BS EN 50288-7. Step 1: Apply 1.5 kV voltage withstand for 1 minute on insulation. Step 2: Measure insulation resistance (>100 MΩ/km) with megohmmeters. Step 3: Test conductor resistance to IEC 60228 specs. Step 4: Evaluate dual screening via transfer impedance (<1 Ω/m at 1 MHz). Step 5: Perform flame tests (IEC 60332-1) and bending (10x diameter). Step 6: Assess capacitance unbalance, crosstalk, and attenuation. Step 7: Cycle temperatures (-15°C to 90°C) for 48 hours. Step 8: Conduct final electrical and visual inspections. Using calibrated equipment, 100% critical testing ensures dual-screened high-temperature performance for industrial applications.
Application
Instrumentation Cables—XLPE Insulated, Individual & Overall Screened, Unarmoured PVC Sheathed Cables (CU/XLPE/IOSCR/PVC) are suited for oil & gas facilities, chemical processing, power stations, and automation lines. They deliver dual-screened signal integrity in ducts, trays, and high-temp indoor/outdoor environments for monitoring and control systems.
Technical Advantages
● 30+ years of manufacturing experience
● ISO and UL certified production
● Customized cable and transformer solutions
Product Packaging
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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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