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LT PVC & XLPE Control Cables — Reliable Signal & Control Transmission for Industry

BMI Cables manufactures LT PVC and XLPE-insulated control cables designed for reliable control signal and low-level power transmission in industrial automation, power plants, refineries, and infrastructure projects. Multicore armoured and unarmoured configurations — manufactured to IS 1554 & IS 7098

Product Overview

What Are LT PVC & XLPE Control Cables And When to Specify Each

Control cables are multicore electrical cables used for transmitting control signals, interlocking signals, and low-level power in industrial control systems, automation panels, switchgear, motor control centres (MCCs), and instrumentation networks. They connect field devices limit switches, pushbuttons, solenoids, sensors to control panels and PLCs, and interconnect control circuits between switchgear panels in power plants and industrial facilities.

Unlike power cables, which carry the full operating current of motors and equipment, control cables carry low-level signals and control currents typically not more than a few amperes per core. The critical performance parameters are signal integrity (minimising voltage drop across long cable runs), electrical insulation quality (preventing cross-talk and earth leakage between cores), and mechanical durability (withstanding the installation conditions of the facility, including cable trays, conduits, or direct burial).

BMI manufactures LT PVC and XLPE control cables in two primary insulation grades PVC (per IS 1554 ) for standard industrial control applications, and XLPE (per IS 7098) for higher temperature environments, chemical exposure, and applications requiring enhanced insulation life. Both grades are available in armoured (with galvanised steel wire or strip armouring) and unarmoured configurations, in core counts from 2-core to 61-core, and in conductor cross-sections from 1.0 sq.mm to 2.5 sq mm — covering the full range of control cable requirements in Indian industry and infrastructure.

LTMV PVCXLPE Control Cables - BMI Cables
LTMV PVCXLPE Control Cables 2 - BMI Cables
PVC vs XLPE

PVC Control Cables vs XLPE Control Cables - Choosing the Right Insulation

Both PVC and XLPE are proven insulation materials for industrial control cables. The right choice depends on the operating temperature of the installation, chemical exposure, and the expected service life of the cable in the application.

PVC Insulated Control Cables

Best for: Standard industrial control, MCC wiring, switchgear interconnections, and general commercial and infrastructure control cable applications

XLPE Insulated Control Cables

Best for: Chemical plants, refineries, power stations, high-temperature environments, underground direct burial, and long-service-life applications
Cable Range

LT Control Cable Range - PVC, XLPE, Armoured & Unarmoured

BMI manufactures control cables across PVC and XLPE insulation grades, in armoured and unarmoured constructions, with outer sheaths in PVC,FR, FRLS, and LSZH covering all standard industrial control cable specifications.

PVC Insulated Unarmoured Control Cables

Standard PVC insulated, PVC sheathed unarmoured control cables for installation in cable trays, conduits, and protected indoor environments. The most widely used control cable type for MCC wiring, switchgear interconnection, and general industrial control applications across India.

InsulationPVC — 70°C rated
SheathPVC / FR / FRLS outer sheath
ArmouringNone — cable tray / conduit installation
Cores2C to 61C
Cross-Section1.0 sq.mm to 2.5 sq.mm
StandardIS 7098

PVC Insulated Armoured Control Cables

PVC insulated control cables with galvanised steel wire armouring (SWA) or galvanised steel strip armouring (STA) for direct buried installations, cable duct crossings, and harsh industrial environments requiring mechanical protection of the cable cores against ground movement, rodent attack, and physical damage.

InsulationPVC — 70°C rated
ArmouringGalvanised Steel Wire (SWA) or Strip (STA)
SheathPVC / FR/ FRLS outer sheath over armour
Cores2C to 61C
Cross-Section1.5 sq.mm to 2.5 sq.mm
StandardIS 7098

XLPE Insulated Unarmoured Control Cables

Cross-Linked Polyethylene insulated control cables for high-temperature environments, chemical process plants, refineries, and applications requiring superior insulation longevity. 90°C conductor temperature rating and enhanced chemical resistance compared to PVC for cable tray and conduit installation in demanding process environments.

InsulationXLPE — 90°C rated
SheathPVC / FR / FRLS / LSZH outer sheath
ArmouringNone
Cores2C to 61C
Cross-Section1.0 sq.mm to 2.5 sq.mm
StandardIS 7098

XLPE Insulated Armoured Control Cables

XLPE insulated armoured control cables combining the superior thermal and chemical performance of XLPE insulation with the mechanical protection of galvanised steel wire armouring for direct burial in chemically aggressive soils, underground cable duct crossings in industrial plants, and outdoor installations in harsh process environments.

InsulationXLPE — 90°C rated
ArmouringGalvanised Steel Wire (SWA)
SheathPVC / FR / FRLS / LSZH outer sheath
Cores2C to 61C
Cross-Section1.5 sq.mm to 2.5 sq.mm
StandardIS 7098

FR / FRLS / LSZH Sheathed Control Cables

Control cables with Flame Retardant (FR), Flame Retardant Low Smoke (FRLS), or Low Smoke Zero Halogen (LSZH) outer sheathing for installations in buildings, power stations, metro and rail infrastructure, data centres, and any facility where fire performance of the cable installation is a critical safety specification.

InsulationPVC or XLPE
SheathFR-PVC / FRLS-PVC / LSZH
Fire PerformanceIS 7098
LSZH — Zero HalogenIEC 60754 compliant
Cores2C to 61C

Custom Specification Control Cables

Non-standard core counts, bespoke cross-sections, screened (shielded) constructions, special insulation colours, project-specific drum lengths, and export-standard cables for EPC contractors, OEM panel builders, and large infrastructure projects. Feasibility confirmed within 24 hours of a complete specification enquiry.

Core CountCustom — per project specification
Cross-SectionCustom — per design requirement
ScreeningIndividual / Overall screen available
StandardIS / IEC / BS — project requirement
Lead TimeConfirmed at enquiry stage
Cable Construction

Control Cable Construction - Layer by Layer & Designation Abbreviations

Understanding how a control cable is constructed and what the abbreviations in its designation mean ensures the correct cable is specified for every installation type and environment.

Armoured Multicore Control Cable — Construction

1. Conductor — ETP Copper / EC Aluminium

Individual PVC or XLPE insulation applied over each conductor colour coded for core identification per IS/IEC convention. Provides electrical isolation between adjacent conductors in the multicore cable

 

2. Fillers, Binder Tape & Laid-Up Cores

Individual insulated cores laid up in a specific arrangement with non-hygroscopic fillers and a binder tape maintaining circular cross-section and core arrangement for correct core identification

 

3. Inner PVC Sheath / Bedding

PVC bedding over the assembled cores provides a smooth, firm surface for armouring application and protects core insulation from armouring wire abrasion

 

4. Galvanised Steel Wire Armouring (SWA)

Single or double layer of galvanised steel wires — provides mechanical protection against impact, crushing, and rodent attack for direct buried and harsh environment installations. Omitted in unarmoured versions

 
 

5. Outer PVC / FRLS / LSZH Sheath

Overall protective outer sheath provides final mechanical protection, colour identification, and fire performance rating. FRLS or LSZH compounds available for fire-critical installations

 
 

Cable Designation Abbreviations

Cu / Al

Copper (Cu) or Aluminium (Al) conductor ETP copper standard for control cables; aluminium available for cost-optimised specifications
 

PVC

Polyvinyl Chloride — standard insulation and sheath for control cables rated to 70°C conductor operating temperature. IS 1554 / IEC 60227
 

XLPE

Cross-Linked Polyethylene — enhanced insulation for 90°C conductor temperature, superior chemical resistance, longer service life. IEC 60502
 

SWA / STA

Steel Wire Armoured / Steel Tape Armoured galvanised steel wire or strip armouring layer providing mechanical protection for armoured control cables
 

FRLS

Flame Retardant Low Smoke  outer sheath compound that limits smoke density during fire. Required in occupied buildings and areas with fire evacuation requirements
 

LSZH / ZHFR

Low Smoke Zero Halogen  outer sheath with no halogen content. Zero HCl / HF gas emission per IEC 60754. For metro, rail, data centres, offshore
 

nC × Xmm²

Cable designation format: n = number of cores, C = core, X = cross-section in sq.mm. Example: 12C × 2.5mm² = 12-core, 2.5 sq.mm per core control cable
Key Features

What Makes BMI LT/MV Control Cables the Reliable Choice for Industrial Projects

Performance parameters that matter to EPC contractors, panel builders, and industrial project engineers built into BMI’s manufacturing and verified before every drum leaves the plant.

Corporate / Sales & Marketing Office
SF-1, 1st Floor, Bhikaji Cama Bhawan, Bhikaji Cama Place,
Delhi 110066, India

Works
F-83+84, Riico Industrial Area, Kushkhera, Bhiwadi, Alwar, Rajasthan 301019, India