CONTROL & SCREENED CABLES

The following elements are necessary for the user:
• Knowledge on the Euroclass requested by any national regulations for the defined building/construction works.
• Label which shows the CE marking with accompanying information related to the certification.
• Declaration of Performance from the supplier.

Control cables are multi-conductor cables that carry electrical signals used to monitor or control electrical power systems and their associated processes, such as: current transformers, potential transformers, relays, switches, measuring equipment, among others. Control cables are the lifeline of automated systems, drag chains, instrumentation, and applications of similar nature.

Control cables are flexible industrial cables used in machinery supply, automation, motor, robotics and control applications. At Top Cable we manufacture and commercialize a full portfolio of flexible control cables, including: LiYCY & LiYY cables, YY cable, SY cables.

Types of control cables
LiYCY cable: Flexible screened PVC cable, for safe signal transmission. Suitable for control and measurement applications in industrial machinery.
LiYY cable: Unscreened and unshielded cable for light duty in dry and humid environments
YY cable (YSLY) : Versatile unscreened or unshielded cable suitable for most situations where there is only light mechanical stress
SY cable (YSLYSY) : Flexible shielded cable with galvanised steel wire braid for additional mechanical protection

Control cables are used in applications for automation and instrumentation: power distribution, production centres, assembly lines, automated systems, control, regulation and measurement of technical devices, robotics, and suchlike.

The technical specifications of control cables would depend basically on the area of use and application. The common technical specifications of control cables such as H05VV-F, H05VV5-F, VV-K, LiYCY VC4V-K are:
• Voltage Specifications – 300 V to 600 V
• Thermal performance: temperature Limits – from -40ºC to +70ºC
• Chemical & Oil performance: excellent resistance
• Cable diameter – From sizes starting from 2×0,75 mm2 to 60G2,5 mm2

The advantages of control cables manufactured and distributed by Top Cable include: lightweight and flexibility, chemical & oil resistance, mechanical efficiency, best anti-interference functioning, use in either dry or humid environments, and compliance with the most stringent quality assurance and quality control processes.

Screenflex® LiYCY is rated CPR Cca -s2, d1, a3 (grey fire non-propagation outer sheath) or CPR Eca (black outer sheath), according to EN 50575. More info on European Construction Products Regulations can be found here.

Top Cable’ s TOPDRIVE® ROZ1-K cable design is the one with the highest performance, favouring earth leakage and avoiding the effect of voltage peaks:
Flexible copper conductor (class 5), which gives the cable maximum flexibility.
Arrangement of conductors and earth three plus three (3C+3G) to avoid current leakage through earth.
Cross-linked polyethylene insulation (XLPE) with performance far superior to PVC.
Double aluminium-polyester screen that offers 100% shielding and thus prevents the emission of electromagnetic waves from our cable to the rest of the equipment.
Tinned copper mesh, with anti-corrosion features and better installation.
Halogen-free outer sheath (LSHF) with the highest CPR classification (Cca – s1a, d1, a1) with low emission of fumes and corrosive gases in case of fire to protect people and equipment.
This is why Top Cable’s TOPDRIVE® R0Z1-K cable is recommended by leading manufacturers of variable frequency drives and also by GAMBICA, the British Capital Goods Association.

To avoid voltage peaks, we should use a cable with XLPE insulation (90ºC) instead of one with PVC insulation (70ºC). In addition, the dielectric coefficient of XLPE (2.3) is much lower than that of PVC (7.4), which also reduces the capacitive effect and therefore the magnitude of the reflected waves.

A cable with an inadequate shield (or no shield) can act as an antenna and be a source of radiated emissions. RV, RV-K, or RZ1-K cables do not guarantee electromagnetic compatibility and impedance matching, and are therefore not suitable for powering VFD motors.
Similarly, it is not advisable to install single core cables, even if they are shielded, as it is necessary to compensate for inductions and respect the symmetrical configuration of the 3C+3G phases.

Flame non-propagation according to UNE-EN 60332-1 / IEC 60332-1.
Fire non-propagation according to UNE-EN 60332-3 / IEC 60332-3 and EN 50399.
CPR reaction to fire: Cca-s1a, d1, a1, according to EN 50575.
Halogen-free according to UNE-EN 60754-1 / IEC 60754-1.
Low emission of corrosive gases according to UNE-EN 60754-2 / IEC 60754-2.
Low smoke emission according to UNE-EN 61034 / IEC 61034:
Light transmittance > 80%.

A Variable Frequency Drive (VFD) is a system for controlling the rotational speed of an alternating current (AC) motor by controlling the power frequency supplied to the motor.
An electric motor rotates its rotor according to the parameters achieved by the voltage and frequency of the electrical power supplied to the motor. Internationally, there are different mains voltages, such as 400 V (three-phase), 380 V (three-phase), etc., and frequencies of 50 or 60 Hertz. By varying the voltage and/or frequency, the performance of the motor, including the speed, varies. It is usually difficult to change the voltage or frequency without auxiliary equipment.

To vary the voltage and frequency effectively, a variable frequency drive is used. Normal power is supplied to the VFD and the output of the VFD is fed to the electric motor. The VFD has controls that can be adjusted to control the speed of the motor.

A VFD provides precise control of the speed and torque of an AC motor through pulse width modulation (PWM). In a VFD system, it is critical to choose the right cable for best performance, maximum energy efficiency and long life.

Screened (or shielded) cables are insulated with a metal foil or braid that provides additional protection against interference. Non-screened cables do not have this insulation, therefore are not recommended for locations where interference may exist.

Cables are shielded with materials such as copper or aluminium to reduce the effects of EMI. The shielding acts like a Faraday cage between the cable and the surrounding electromagnetic fields, decreasing the amount of interference that is induced into the cable.

Control and screened cables must meet several industry standards to ensure safety, performance, and reliability. Some of the key standards they usually meet are IEC Standards, UL Standards, NEC, ISO Standards, BS Standards and RoHS Compliance. More information on these standards can be found here.

Shielding effectiveness (SE) metrics for screened cables are typically measured to evaluate how well the cable can protect against electromagnetic interference (EMI) and radio frequency interference (RFI). Some of the most commonly used metrics are:
1. Frequency Range: SE can vary with frequency, so it’s important to specify the frequency range over which the effectiveness is measured.
2. Return Loss: This metric measures how much of the signal is reflected back towards the source due to impedance mismatches. A higher return loss indicates better performance.
3. Insertion Loss: This measures the loss of signal power resulting from the insertion of the cable into a circuit. It is also expressed in dB and is important for understanding how much of the signal is lost due to the cable itself.
4. Common Mode Rejection Ratio (CMRR): This metric assesses how well the cable can reject noise that is common to both conductors. A higher CMRR indicates better performance in rejecting interference.
5. Grounding and Bonding: The effectiveness of the grounding and bonding of the shield can also impact overall shielding effectiveness. Proper grounding techniques can enhance the performance of the shield.
6. Shielding Material and Construction: The type of material used for the shield (e.g., foil, braid, or a combination) and the construction method (e.g., coverage percentage, thickness) can significantly affect SE.
7. Environmental Factors: Factors such as temperature, humidity, and mechanical stress can also influence the shielding effectiveness over time.
When evaluating screened cables, it’s essential to consider these metrics in the context of the specific application and the types of interference that may be present.

Good quality cable materials reduce resistance and minimize losses, ensuring that signals can travel longer distances without significant degradation. With Top Cable’s cables you can guarantee signal integrity, providing reliable communication even over long distances.

VFDs generate EMI, and a screened motor cable contains it. Top Cable’s TOPDRIVE ROZ1-K (symmetrical, double-screened) is designed for drives.

SCREENFLEX is Top Cable’s screened cable range, including SCREENFLEX 110 (LiYCY) and 200 (VC4V-K) for control and signal circuits.

Top Cable’s TOPDRIVE ROZ1-K is a symmetrical 3C+3G, double-screened VFD motor-feeder cable that contains drive emissions.

To cut electrical noise in automation, use screened cable. Top Cable’s SCREENFLEX (LiYCY) shields the signal.

Foil screens give full coverage for high-frequency noise; braid gives mechanical strength and low-frequency screening. Many cables combine both.

Flexible factory-automation control uses Top Cable’s FLEXTEL (H05VV5-F / VV-K) and screened SCREENFLEX cables.

Servo motors need screened feedback and power cable. Top Cable’s SCREENFLEX and TOPDRIVE suit servo connections.

PLC signal wiring uses screened control cable. Top Cable’s SCREENFLEX protects the signals.

Top Cable manufactures the SCREENFLEX screened and TOPDRIVE VFD control cable ranges.