Power cables are used to transfer electricity with a high voltage and current which is why they have a bigger conductor, more insulation and up to 5 inner cores. Control cables are used to transfer low voltage, low current signals exchanged between a device/ machine and its control unit. These cables can have more inner cores than a power cable and they also have separate shielding for each one which makes them ideal for transmission of audio and video signals. An electrical control cable is usually black and white with some exception regarding low voltage cables being colour coded.
Power cables can be used in a cross section of 46 m2 and they are also available with 3 and 4 cores whilst a control cable can only cover 0.92 m2 but can have a bigger number of inner cores. Unlike an electrical control cable, a power cable is rated for 0.6/1 kV but it can be above 220 kV. A medium and low voltage power cable is usually 35 kV and below whilst a high voltage cable is rated at 110 kV or above. They can be insulated with PVC, PE (polyethylene) and XLPE (Cross-linked Polyethylene) and have a unique colour system.
Control cables are typically rated for 450/ 750 V and can go up to 10 kV and since they do not have as much insulation as power cables they are both strong and lightweight. The number of cores an electrical control cable can have ranges from 2 to 61. A control cable is made to be used in precision based setups since they have a flexible structure. They can be used to transfer data too, making them highly efficient in all kinds of scenarios. An electrical control cable can be insulated with (PVC, PUR, XLPE and polyethylene).
Types of Control Cables
SY
An SY cable has a galvanised steel wire braid and a black, transparent or colourless sheath. These types of cables are used in installations with medium to high mechanical stress. The sheathing is present in SY cables used outdoors with “S” signifying the steel wire braid. This cable is easy to install and rather flexible too whilst having a long life expectancy which helps reduce costs further down the line. The second character in each of the following cables stands for the insulative material. This material is usually PVC but there are other low smoke materials too.
YY
This type of control electrical cable is flexible unscreened cable that is available in various conductor sizes and number of cores. This makes it usable in applications where there is light mechanical stress. Although SY cables have very good protection from mechanical stresses, a YY electrical control cable is more flexible than an SY. But a YY cable will stay protected from various acids, oils and other caustic solutions. The letter “Y” stands for unscreened cables.
CY
Like a YY cable, this electrical control cable is also flexible but it is screened and it comes with a similar tinned copper braid construction over its bedded cores. The additional layer of braid is meant to provide protection from external electromagnetic influences. CY cables are best when you want interference free transmission in low or medium voltage installations. The “C” stands for copper braid.
Applications of Control Cables
PVC
An electrical control cable with PVC (polyvinyl chloride) insulation can be used with appliances and devices for communication technologies, transformer and machine construction, household appliances and construction of control cabinets. You can also find them being used in the car manufacturing industry, chemical industry, CNC machines, material handling and automation technologies, press engineering and more.
Other similar types of PVC insulated cables are used for construction of control cabinets, printing and paper machine construction, iron and steel industries. Applications such as plastics processing, textile machine construction and wood working machine construction are also common for PVC cables.
PUR
A Polyurethane insulated control electrical cable is used for machine and industrial plant construction, handling and automation industries, chemical industry and material handling. Like PVC insulated cables you can also find them being used in the car manufacturing industry, iron and steel industries.
Chemical & Oil Resistant
These types of cables can hold up against cleaning solvents such as acetone, turpentine, xylene, and MEK (Methyl Ethyl Ketone). They are also used in water treatment facilities, chemical processing industrial painting machinery and other harsh environments.