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Instrumentation Cables

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Instrumentation Cables

K C Powertracks manufactures a wide variety of Instrumentation Cables suitable for the process Instrumentation. In the projects related to power generation and distribution, the process instrumentation plays a vital role in measurement, supervision and control of the process.

  • Chemicals & Water Resistant
  • Exposure to UV
  • Flexibility
  • High Tensile Strength

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 :
  • Conductor temperature
  • Electrical characteristics required
  • Flexibility
  • 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 :
  • By printing a reference code on one insulated conductor, or both of them, that indicates the number of that single pair.
  • By a numbered non - hygroscopic tape applied over the pair.
  • By using different colour combinations to uniquely identify the pair.

Pair / Traid / 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.

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 :
  • Temperature
  • Flexibility
  • Electrical characteristics
  • Smoke and acid gas emission limitations
  • Resistance to chemicals
  • Water resistance
  • 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 Applications
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
  • Collectively screened, unarmoured “type – 1” cable, multi-pair PVC insulated without individual pair screens but collectively screened
  • Collectively screened, armoured “type – 2” cables, multi-pair PVC insulated without individual pair screens but collectively screened
  • Individually & collectively screened, unarmoured “type – 1” cables, multi-pair PVC insulated cables with individual pair screens and collectively screened
  • Individually & collectively screened, armoured “type – 2” cables, multi-pair PVC insulated cables with individual pair screens and collectively screened
  • Collectively screened unarmoured “type – 1” cables, multi-core PVC insulated cables collectively screened
  • Collectively screened armoured “type – 2” cables, multi-core PVC insulated cables with collectively screened


Electrical Characteristics
Conductor SizeUnit of Measurement0.5 mm2 (16/0.2)1.00 mm2 (24/0.2)1.5 mm2 (7/0.53)
Mutual capacitance core to core (max)pF/m250250250
L/R ratio (max)mH/ohm252540
Conductor Resistance at 20oCOhms39.726.512.3
Insulation resistance core - core/screen / armour for 1 hr at 20CM/ohms252525
Screen to Screen for 1 hr at 20oM/ohms111
Rated voltage 300/500 volt; test voltage 1100 volt for 1 min
Conductor Nominal AreaNom. Insulation Thickness (mm)Maximum Core Diameter (mm)
0.50 (16/0.2)0.502.35
0.75 (24/0.2)0.602.55
1.50 (7/0.53)0.603.00


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