WIRES & CABLES

INSTRUMENTATION
& CONTROL CABLES
 WIRES & CABLES

ABOUT US
Today’s manufacturing and processing operations are largely controlled and measured
by electronic circuit. To ensure accuracy and greater control, interconnecting cables have
to be reliable and durable. Instrumentation cables from ROLLIFLEX are designed and
manufactured to ensure ease of installation, minimum interference in transmission of
signals and full compliance to recognized industrial standards.

Instrumentation cables have very diverse applications. Manufactured to BS 5308, these

cables are designed for use in communication and instrumentation applications in and
around process industries like oil exploration, cement, paper, steel, power generation,
petrochemical and others. Cables made to specific rigid requirements are utilized in
process controls, transmission of signals, computers, data transmission, control systems
and monitor networks as well as in intrinsically safe systems in hazardous areas like
petrochemical plants and thermal power plants.

ROLLIFLEX Brand Instrumentation cables are long Life, Less maintenance, carries best
fire, flame retardant properties Along with top electrical & mechanical characteristics.
Rolliflex have available wide range of instrumentation cables which are Eco-friendly also.
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GENERAL SPECIFICATIONS
Instrumentation & control cables manufactured by us are manufactured to BS 5308 / IS:1554 which are suitable for operations
at voltages up to and including 300V r.m.s core to earth and 500V r.m.s core to core

Typical Categories Screening

Type 1 : Two insulated conductors are uniformly twisted to form pairs
a. PE insulated / PVC sheathed which are then assembled.
b. PVC insulated / PVC sheathed The paired conductors may be :
• Unscreened
Type 2 : • Individually and overall screened
a. PE insulated, PE bedded. Single wire armoured and • Overall screened
PVC oversheathed Screening materials can be aluminium tape, copper tape or
copper wire braiding as per customers specifications.
b. PVC insulated, PVC bedded, Single wire armoured and
PVC oversheathed
Armouring
Instrumentation cables may be armoured or non armoured.
Type 3 :
Armouring which basically serves as mechanical protection can
a. PE insulated
be in the form galvanized steel wire/strip, tape or braiding wire.
b. PVC bedded.
c. Single wire armoured and PVC sheathed Sheathing
The sheath protects the cable from damage and provides
Conductor resistance to abrasion, impact, moisture and chemicals.
Conductors shall be pain annealed copper wires which are Shething may be :
solid (Class I), stranded (Class 2) or flexible (Class 5) • PVC (polyvinyl chloride)
• ST1 & St2
Insulation • ST1 & St2
The instrumentation cables may be insulated with : • FRLS & FR PVC
• PVC (polyvinyl chloride) • ZHLS
• PE (polyethylene) • PE.
• XLPE (cross-linked polyethylene)
• EPR. (ethylene propylene rubber)

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PVC/PVC OVERALL SCREENED

INSTRUMENT CABLE
BS 5308 PART 2 : TYPE 1 300/500V
Polyvinyl Chloride Insulated Polyvinyl
Chloride Sheathed Overall Screened
Instrument Cable

DESCRIPTION

Single pair and multi-pair cables with copper conductor, PVC insulated,
overall screened and PVC sheathed.
Voltage rated at 300/500V.

CONSTRUCTION
1
1 Conductor
Plain annealed/tinned circular stranded copper conductor, conform to
BS 6360 / IS:8130

2 Insulation
PVC (Polyvinyl Chloride) / PE
2
3 Pairing
Two insulated cores shall be uniformly twisted together to form a pair
with maximum lay length of 100 mm.

Note :Two pair cables with overall screen shall have four cores laid in
quad formation.

4 Pair identification
Colour code as per Appendix B or as per customer specification 6
5 Cabling
Twisted pairs are laid up together, if necessary filled with non-
hygroscopic material compatible with the insulation.

6 Overall Screening
Accumulated pairs screened with aluminium/mylar tape, helically
applied with the metallic side down, in electrical contact with a tinned
annealed copper drain wire of 0.5 mm2. 7
7 Sheath
PVC (Polyvinyl Chloride).

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PVC/PVC INDIVIDUAL & OVERALL

SCREENED INSTRUMENT CABLE
BS 5308 PART 2 : TYPE 1 300/500V
Polyvinyl Chloride Insulated
Polyvinyl Chloride Sheathed Individual
& Overall Screened Instrument Cable

DESCRIPTION

Multi-pair cables with copper conductor, PVC insulated, individual &

overall screened and PVC sheathed.
Voltage rated at 300/500V.

1
CONSTRUCTION

1 Conductor
Plain annealed/tinned circular stranded copper conductor, conform to
BS 6360 / IS:8130 2

2 Insulation
PVC (Polyvinyl Chloride) / PE

3 Pairing
Two insulated cores shall be uniformly twisted together to form a pair
with maximum lay length of 100 mm. 5
Note :Two pair cables with overall screen shall have four cores laid in
quad formation.

4 Pair identification
Colour code as per Appendix B or as per customer specification

5 Individual Screening 7
Each pair screened with aluminium/mylar tape, helically applied with
the metallic side down, in electrical contact with a tinned annealed
copper drain wire of 0.5 mm2.

6 Cabling
Twisted pairs are laid up together, if necessary filled with non-
hygroscopic material compatible with the insulation
8
7 Overall Screening
Accumulated pairs screened with aluminium/mylar tape, helically
applied with the metallic side down, in electrical contact with a tinned
annealed copper drain wire of 0.5 mm2.

8 Sheath
PVC (Polyvinyl Chloride).

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PVC/PVC/SWA/PVC OVERALL
SCREENED INSTRUMENT CABLE
BS 5308 PART 2 : TYPE 2 300/500V
Polyvinyl Chloride Insulated Polyvinyl
Chloride Bedding Steel Wire Armoured
Polyvinyl Chloride Sheathed Overall Screened Instrument Cable

DESCRIPTION

Single pair and multi-pair cables with copper conductor, PVC insulated,
overall screened, PVC bedding, Steel wire armoured and PVC sheathed.
Voltage rated at 300/500V

CONSTRUCTION

1 Conductor 1
Plain annealed/tinned circular stranded copper conductor, conform to
BS 6360 / IS:8130

2 Insulation
PVC (Polyvinyl Chloride) / PE
2
3 Pairing
Two insulated cores shall be uniformly twisted together to form a pair
with maximum lay length of 100 mm.

Note :Two pair cables with overall screen shall have four cores laid in
quad formation. 6

4 Pair identification
Colour code as per Appendix B or as per customer specification 7

5 Cabling
Twisted pairs are laid up together, if necessary filled with non- 8
hygroscopic material compatible with the insulation

6 Overall Screening
Accumulated pairs screened with aluminium/mylar tape, helically
applied with the metallic side down, in electrical contact with a tinned
annealed copper drain wire of 0.5 mm2.

7 Bedding
9
PVC (Polyvinyl Chloride).

8 Armouring
Galvanized steel round wire over the bedding.

9 Sheath
PVC (Polyvinyl Chloride).

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PVC/PVC/SWA/PVC INDIVIDUAL & OVERALL

SCREENED INSTRUMENT CABLE
BS 5308 PART 2 : TYPE 2 300/500V
Polyvinyl Chloride Insulated Polyvinyl Chloride
Bedding Steel Wire Armoured Polyvinyl Chloride
Sheathed Individual & Overall Screened Instrument Cable

DESCRIPTION

Multi-pair cables with copper conductor, PVC insulated, individual & overall
screened, PVC bedding, Steel wire armoured and PVC sheathed.
Voltage rated at 300/500V

1
CONSTRUCTION

1 Conductor 2
Plain annealed/tinned circular stranded copper conductor, conform to
BS 6360 / IS:8130

2 Insulation
PVC (Polyvinyl Chloride) / PE
5
3 Pairing
Two insulated cores shall be uniformly twisted together to form a pair
with maximum lay length of 100 mm.

4 Pair identification
Colour code as per Appendix B or as per customer specification 7
5 Individual Screening
Each pair screened with aluminium/mylar tape, helically applied with 8
the metallic side down, in electrical contact with a tinned annealed
copper drain wire of 0.5 mm2.

6 Cabling 9
Twisted pairs are laid up together, if necessary filled with non-
hygroscopic material compatible with the insulation

7 Overall Screening
Accumulated pairs screened with aluminium/mylar tape, helically
applied with the metallic side down, in electrical contact with a tinned
annealed copper drain wire of 0.5 mm2.
10
8 Bedding
PVC (Polyvinyl Chloride).

9 Armouring
Galvanized steel round wire over the bedding.

10 Sheath
PVC (Polyvinyl Chloride).

7
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APPENDIX B :
IDENTIFICATION OF PAIR TO BS 5308 PART 2
A) Identification of Pairs by colour code

Pair Pair
Ref. No. a-wire b-wire Ref. No. a-wire b-wire
1 White Blue 26 Red - Blue Blue
2 White Orange 27 Red - Blue Orange
3 White Green 28 Red - Blue Green
4 White Brown 29 Red - Blue Brown
5 White Grey 30 Red - Blue Grey

6 Red Blue 31 Blue - Black Blue

7 Red Orange 32 Blue - Black Orange
8 Red Green 33 Blue - Black Green
9 Red Brown 34 Blue - Black Brown
10 Red Grey 35 Blue - Black Grey

11 Black Blue 36 Yellow - Blue Blue

12 Black Orange 37 Yellow - Blue Orange
13 Black Green 38 Yellow - Blue Green
14 Black Brown 39 Yellow - Blue Brown
15 Black Grey 40 Yellow - Blue Grey

16 Yellow Blue 41 White - Orange Blue

17 Yellow Orange 42 White - Orange Orange
18 Yellow Green 43 White - Orange Green
19 Yellow Brown 44 White - Orange Brown
20 Yellow Grey 45 White - Orange Grey

21 White - Blue Blue 46 Orange - Red Blue

22 White - Blue Orange 47 Orange - Red Orange
23 White - Blue Green 48 Orange - Red Green
24 White - Blue Brown 49 Orange - Red Brown
25 White - Blue Grey 50 Orange - Red Grey

Note : Two pairs collectively screened cable shall be cabled in quad formation and colour coded in
clockwise rotation : Blue, Green, Orange and Brown.

B ) Alternative method of identification of cable pairs.

Pair number a-wire b-wire

1 White Black
White with pair Black with pair
2 to 50 number. number.

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Instrument Cable Constructional Specifications:

S.No. Part Type Range/Spec.
1. Conductor (Copper) Stranded Conductor (ABC/ATC) 0.50sqmm (7/0.30mm)
As per IS 8130 / (Class-II) 0.75sqmm (7/0.37mm)
IEC 60228
1.00sqmm (7/0.43mm)
1.50sqmm (7/0.53mm)
2.50sqmm (7/0.67mm)

Flexible Conductor (ABC/ATC) 0.50sqmm (16/0 .20mm)

(Class V) 0.75sqmm (24/0.20mm)
1.00sqmm (32/0.20mm)
1.50sqmm (48/0.20mm)
2.50sqmm (80/0.20mm)

2. Core Insulation PVC Type A- 70ºC Standard Insulation Thickness: 0.60mm

PVC Type C-85ºC Colour code as per BS 5308/IS-1554-I
PVC Type C-105ºC or as per customer requirements.
LDPE Insulation
Any other grade as per customer requirement.

3. Units Core Colour code as per BS 5308/IS-1554-I

Pair or as per customer requirements.
Triad Twisting:
Quad Minimum 12 crossover Twists/meter

4. Unit Screen 1 layer of polyster tape Polyster tape 25 micron thick

1 tinned copper drain wire 0.50sqmm ATC
1 Layer of Aluminium backed myler Al. Myler tape 25micron thick
tape with 25% overlap for 100% coverage.
1 Layer of Polyster Tape. Polyster tape 25 micron thick

5. Number of Units Single Unit

Multi Unit
6. Communication Pair 0.50sqmm ABC insulated, Twisted Pair Provided for cables with 6
Pairs/6Triads/6Quads and above.
7. Overall Screen Same as for Unit screen (Cl. 4)

8. Inner sheath PVC Type ST-1 70ºC Standard Thickness: 0.80mm

PVC Type ST2 -85ºC FR Colour code: Black.
PVC Type FRLS
9. Armour Galvanised round GI wire Standard size: 0.90 mm ,1.40 mm
(as per customer requirement )
Galvanised Flat GI Strips 4 x 0.80 mm
10 Outer Sheath PVC Type ST-1 70ºC Thickness as per BS- 5308 ,
PVC Type ST2 -85ºC FR IS-1554 P(i)
PVC Type FRLS As per customer requirement

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ELECTRICAL CHARACTRISTICS FOR INSTRUMENTATION CABLES

Conductor Resistance Mutual Capacitance (PE) Mutual Capacitance Inductance L/R
Size at 20ºC (PVC) Ratio
Maximum Operating Temperature: 70ºC
Core to Core Core to Core to Core to (After Insulation)
Screen Core Screen
Sqmm Ù/Km pF/mtr pF/mtr pF/mtr pF/mtr µH µH/Ù
Test Voltage
Stranded Core To Core : 1000V AC (r.m.s.) For 1 Minute.
0.50 36.8 75 115 250 400 1.20 25 Core To Screen : 500V AC (r.m.s.) For 1 Minute.
0.75 25.0 75 115 250 400 1.20 25
1.00 18.4 75 115 250 400 1.20 25 Insulation Resistance of conductor
1.50 12.3 85 120 250 400 1.20 40 at ambient Temperature
2.50 7.56 85 120 250 400 1.20 70
PE : >5G ohm/Km
PVC : >25 Mohm/Km
Flexible
0.50 39.7 75 115 250 400 1.20 25
Insulation Resistance of Screen
0.75 26.7 75 115 250 400 1.20 25
at ambient Temperature
1.00 19.7 75 115 250 400 1.20 25 PE/PVC : > 1 Mohm/Km
1.50 13.5 85 120 250 400 1.20 40
2.50 8.21 85 120 250 400 1.20 70

ROLLIFLEX THERMOCOUPLE EXTENSION & Compensating Cables

ROLLIFLEX THERMOCOUPLE EXTENSION and Compensating Cables have guaranteed identification characteristics to
their basic thermocouples in the restricted temperature span.

The Element Conductor can be extended to a position where a stable temperature is maintained, transferring the
effective cold junction to the remote end of the extension or compensating cable.

Each batch of cable is tested for Thermo-EMF performance and the electrical & Mechanical properties as per
international standard ANSI MC 96.1.

Special Customer requirements are catered for, through or research & development wing.

Specifications:

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Loop Resistance:
Thermocouple Extension/Compensating Cable
Conductor details Loop Resistance (ohm/mtr) +/- 10%@20*C
Dia C.S. Cable Type
AWG
(mm) Area KX VX/KX(A) JX TX SX/RX EX XK
1.381 1.50 0.66 0.31 0.40 0.31 0.086 0.83 0.83
16 1.29 1.31 0.76 0.39 0.46 0.39 0.104 0.97 0.97
18 1.02 0.823 1.21 0.62 0.76 0.62 0.169 1.52 1.52
20 0.81 0.50 1.98 0.97 1.20 0.97 0.266 2.50 2.50
20 7x 0.31 0.50 1.98 0.97 1.20 0.97 0.266 2.50 2.50

INTERNATIONAL COLOUR CODES FOR THERMOCOUPLE CABLES INSULATION

BRITISH AMERICAN GERMAN INDIAN
MATERIAL
Thermocouple OF MV
Type EXTENSION OUTPUT
CABLE
BS:1843 BS:1843 BS:1843 BS:1843

(+) (-ve
EXTENSION Lead Lead) 100°C 200°C

K Chromel/Alumel Ni/Cr NiAl 4.10 8.13

J Iron/Constantan Iron Constantan 5.26 10.77

T Copper/Constantan Copper Constantan 4.24 9.77

E Chromel/Constantan Ni/Cr Constantan 6.31 13.42

COMPENSATING

V Copper/Constantan
Copper Constantan 4.10
X (Com for Type K)

R Copper
X Constantan
S (com for Type
X R/S)

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Office : 202, Navkar Plaza, 104 Bajaj Road, Vile Parle (West), Mumbai - 400056. INDIA
Tel.: 022 26232858 / 59 / 60 • Email : [email protected] / [email protected]
Web: www.rolliflex.in