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Control cables have become essential across industries and sectors. Today, they have become one of the most common components users will come across while setting up an electronic network or automated systems. Control cables have become principal parts of such systems and have to chosen carefully, after considering a variety of factors. Here is a brief guide on control cables and everything one needs to know about them to make an informed purchase.

What are Control Cables?

Control cables are electrical cables that are used to transmit signals to machines, equipment, or systems to start, stop, or change speed. Such cables do not carry high power and are mainly used to transmit signals to control how equipment operates. Normally, control cables are most frequently used in factories, industrial automation systems, elevators, and more.

Control cables also connect control centers to individual systems to transmit signals or manage operating functions. Control cables fall under the larger family of instrumentation cables. Usually, instrumentation cables, low-voltage electrical cables, are used to control the display panels of indicators and instruments, operations of relays and switchgear, interlock systems, etc. With rapid innovation, the demand for control cables has increased and choosing the right one has become more important than ever before.

What are the Characteristics of a Control Cable?

– Screened control cables are used across sectors in factories, mines, power plants, and transport networks. Such cables carry AC control signals up to 450/750 volts.

– When an instrumentation cable is placed near a safety system, it has to be made with special insulation to ensure that it is properly protected and durable.

– Low-fire control cables are designed to withstand the harmful effects of fire-even when they are exposed to flames, they do not short circuit easily and are perfect for emergency systems.

– Often, building control cables are made using materials that do not emit too much smoke if they get heated or are halogen-free and do not release toxic gases. As a result, they are suitable for eco-sensitive or indoor spaces where air quality matters.

– Control cables carry smaller currents, so they do not have to be very thick. Usually, they are not bigger than 10 mm2. However, since instrumentation cables carry signals and not power, they do not contain many cores, from 2 to 61 depending on the specific use.

How to Use Control Cables Correctly?

Here are a few simple rules to adhere to while using control cables:

– It is important to make sure that separate control cables are used to protect lines and trip control circuits. Doing so helps mitigate the effects of insulation breakage or mechanical damage.

– If control cables are being laid on supports in trenches or tunnels, it is best to map out the position and laying order in advance to avoid cable crossings.

– It is important to check the appearance of the head of cable before laying it. Similarly, the direction of rotation of the cable tray during laying also matters since it helps to avoid damaging the outer jacket.

– When a spare core of a control cable is grounded, the amplitude of disturbing voltage can be cut down to 25-50%.

– Unshielded control cables can be placed inside fire-resistant control cables and the result can be fixed in areas subject to high mechanical forces, like trenches and underground pipes.

What Factors Affect the Service Life of Control Cables?

To ensure that a control cable works at its highest capacity, it is important to preserve its service life. Here are the factors that can affect the shelf-life of a control cable:

Room Temperature

If a control cable is installed in a space where the room temperature is too high, it can break the insulation of the wire. So, before installing a control cable it is important to pay attention to the ambient temperature. Similarly, if a control cable is overloaded for a long time, the temperature within the wire will rise and speed up the aging of the insulation. The heating of pipes, chemical corrosion of acids and bases, and welding sparks can cause the cable to catch fire. It is best to opt for industrial control cables in such environments to ensure they work at their highest capacity.

Weather

Moisture can have a significant impact on the insulation of control cables. So, it is crucial to act accordingly when the weather worsens, especially during monsoons or storms. In case of a power failure, it is best to cut the supply to a control cable and seek the help of an electrician to determine the cause and fix it. The weather can have a detrimental effect on power control cables that carry both signals and electric current.

Corrosion

A control cable’s insulated sheath can lose its efficacy due to corrosion, as a result of toxic gases. The insulating performance of the cable will gradually decline and the cover will age and harden. To avoid corrosive damage, it is best not to place control cables in strongly acidic or alkaline environments.

Control cables play a pertinent role in the operation of various industries and essential control systems. At Electric Way, we understand the importance of control cables and carry only the best for you to choose from. We source high-quality control cables from the most reputed brands and ensure that when you purchase from us you can rest easy knowing you are safe.