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Control Cables

Control Cables for Industrial and Domestic Use

Currency Cables Control Cables are precision-engineered multi-core conductors designed to transmit vital control signals, measuring telemetry, and operating currents to automated machinery, protection relays, and industrial switchboards. Manufactured with high-conductivity electrolytic-grade annealed copper conductors in solid (Class 1) or stranded (Class 2) configurations, these cables feature high-dielectric PVC or XLPE insulation. Built in strict compliance with IS 1554 (Part 1) and IS 7098 (Part 1), our control cables are available in both unarmoured and rugged galvanized steel wire/strip armoured configurations to resist electromagnetic interference, chemical degradation, and mechanical crushing in demanding industrial switchyards.

Features & Key Benefits

Electrolytic-Grade Annealed Copper: Maximizes signal integrity, prevents data distortion, and ensures low conductor loop resistance across long automated control circuits.
Superior Mechanical Armour Protection: Galvanized steel round wire (WY) or flat strip (FY) armour defends the internal core bundle from underground stone crush, trench cave-ins, and rodent bites.
Sequential Numbered Core Identification: Distinct color coding (up to 5 cores) and clear, indelible continuous numerical printing on grey/black cores (above 5 cores) enables rapid, error-free panel terminations.
Chemical, Oil & Moisture Resistance: Extruded inner bedding and tough outer PVC sheath form an impermeable seal against industrial lubricants, coolants, and moisture ingress.
Flame Retardant Options (FR / FRLS): Formulated with a high oxygen and temperature index to suppress flame travel and emit low smoke in the event of an electrical panel fire.

Technical Specifications Overview

Specification parameter Standard Rating value
Voltage Grade (Uo/U) 650 / 1100 Volts (1.1 kV Grade)
Standard Compliance IS 1554 (Part 1) for PVC / IS 7098 (Part 1) for XLPE / IS 8130
Conductor Construction High-conductivity electrolytic bare annealed copper (Class 1 Solid or Class 2 Stranded)
Core Configurations & Sizes 2 Core to 61 Core (Standard sizes: 1.5 sq. mm and 2.5 sq. mm; custom up to 4.0 sq. mm)
Armouring & Sheath Formulations Galvanized Steel Strip (FY) / Round Wire (WY) with General Purpose, FR, or FRLS outer sheathing

Common Applications & Uses

  • Interconnecting control circuits between distribution panels, switchgears, and circuit breakers (VCBs/SF6).
  • Supervisory control, telemetry, and automated feedback loops in thermal, hydro, and solar power substations.
  • Process automation, programmable logic controllers (PLCs), and motor control centers (MCCs) in heavy processing mills.
  • Signalling, interlocking circuits, and actuator control systems in manufacturing, refinery, and rail infrastructure.
  • Conveyor interlocks, crane control desks, and heavy mining machinery operations.
Why Choose Currency Cables

Engineered with 99.97% pure electrolytic copper and precision-calibrated insulation layers, Currency Control Cables deliver zero signal distortion, robust mechanical shielding, and continuous industrial uptime backed by 30+ years of manufacturing pedigree.

Frequently Asked Questions

Power cables are designed to carry high electrical current and bulk power loads (commonly with larger cross-sections like 16 sq. mm up to 630 sq. mm in aluminium or copper). Control cables, by contrast, are designed to carry low-level operating signals, telemetry, metering data, and relay actuation commands to monitor and control equipment, using smaller standard copper conductor sizes (1.5 sq. mm and 2.5 sq. mm) across large multi-core counts (up to 61 cores).

Control circuits require dependable mechanical strength, reliable low contact resistance at terminals, and high flexibility inside crowded control panels. Copper provides higher tensile strength, minimal creep, lower electrical resistance, and better terminal contact stability than aluminium, ensuring uninterrupted signal transmission without accidental breakage.

For cables up to 5 cores, insulation colors follow standard IS coding (e.g., Red, Yellow, Blue, Black, Grey). For cables containing 6 cores and above, cores are uniformly colored (typically grey or black) with distinct, high-contrast numerical printing (1, 2, 3...) spaced at frequent intervals along the entire length, often accompanied by an adjacent earth core (green/yellow).

Armoured control cables (WY or FY) must be used whenever the cable is laid outdoors, buried directly underground in soil, placed on outdoor cable trays in substations, or installed where heavy machinery, vehicles, or rodents could crush or puncture the cable. Unarmoured control cables are best suited for indoor enclosed raceways, conduit pipes, and internal panel-to-panel wiring.

Yes. For environments with heavy electromagnetic interference (EMI) or radio frequency interference (RFI)—such as near variable frequency drives (VFDs) or large induction motors—Currency Cables manufactures screened control cables featuring an overall or individual-pair aluminium-mylar tape with an annealed tinned copper drain wire, or a copper wire braid screen to prevent signal noise.

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