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
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.
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
- Standard specification for the majority of industrial control cable applications widely understood, specified, and stocked across India
- Lower material cost than XLPE - cost-effective for large-quantity control cable requirements on industrial projects
- Excellent oil and chemical resistance for most standard industrial environments
- 70°C maximum conductor operating temperature — Adequate for most control panel and industrial field wiring applications
- Lower maximum operating temperature than XLPE - not suitable for high-temperature environments near furnaces, boilers, or high-heat process equipment
- PVC emits chlorine gas during fire not suitable for enclosed spaces requiring LSZH or halogen-free cables
XLPE Insulated Control Cables
- Higher maximum conductor temperature — 90°C continuous, up to 250°C short circuit for installations near heat sources or in elevated ambient environments
- Superior chemical resistance compared to PVC - suitable for chemical plant, refinery, and pharmaceutical manufacturing environments
- Better moisture resistance and lower dielectric losses than PVC — preferred for underground direct buried cable runs in wet soil conditions
- Longer insulation service life under thermal stress the cross-linked molecular structure does not soften and flow at elevated temperatures the way PVC compounds can
- Higher material cost than PVC - typically specified where the performance advantage justifies the additional cost
- XLPE is slightly stiffer than PVC in cold weather relevant for installation in low ambient temperature environments
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.
| Insulation | PVC — 70°C rated |
| Sheath | PVC / FR / FRLS outer sheath |
| Armouring | None — cable tray / conduit installation |
| Cores | 2C to 61C |
| Cross-Section | 1.0 sq.mm to 2.5 sq.mm |
| Standard | IS 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.
| Insulation | PVC — 70°C rated |
| Armouring | Galvanised Steel Wire (SWA) or Strip (STA) |
| Sheath | PVC / FR/ FRLS outer sheath over armour |
| Cores | 2C to 61C |
| Cross-Section | 1.5 sq.mm to 2.5 sq.mm |
| Standard | IS 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.
| Insulation | XLPE — 90°C rated |
| Sheath | PVC / FR / FRLS / LSZH outer sheath |
| Armouring | None |
| Cores | 2C to 61C |
| Cross-Section | 1.0 sq.mm to 2.5 sq.mm |
| Standard | IS 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.
| Insulation | XLPE — 90°C rated |
| Armouring | Galvanised Steel Wire (SWA) |
| Sheath | PVC / FR / FRLS / LSZH outer sheath |
| Cores | 2C to 61C |
| Cross-Section | 1.5 sq.mm to 2.5 sq.mm |
| Standard | IS 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.
| Insulation | PVC or XLPE |
| Sheath | FR-PVC / FRLS-PVC / LSZH |
| Fire Performance | IS 7098 |
| LSZH — Zero Halogen | IEC 60754 compliant |
| Cores | 2C 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 Count | Custom — per project specification |
| Cross-Section | Custom — per design requirement |
| Screening | Individual / Overall screen available |
| Standard | IS / IEC / BS — project requirement |
| Lead Time | Confirmed at enquiry stage |
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
PVC
XLPE
SWA / STA
FRLS
LSZH / ZHFR
nC × Xmm²
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
