Instrumentation Cables
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Instrumentation Cable Solutions
Contents Introduction - Oman Cables Industry (SAOG)........................................................................................... 3 Quality Standards................................................................................................................................. 3 Instrumentation Cables......................................................................................................................... 3 Mutipair Instrumentation Cables ............................................................................................................... 4 BS5308 Part 1 Polyethylene Insulated ................................................................................................. 4 Construction ..................................................................................................................................... 4 Electrical Characteristics .................................................................................................................. 5 BS5308 Part 1 – Collectively Screened, Unarmored Type-1 Cables................................................. 6 BS5308 Part 1 – Collectively Screened, Armored Type–2 Cables. ................................................... 7 BS5308 Part 1 – Individually & Collectively Screened, Unarmored Type – 1 Cables. ....................... 8 BS5308 Part 1 – Individually & Collectively Screened, Armored Type – 2 Cables. ........................... 9 Multicore Instrumentation Cables ........................................................................................................... 10 BS5308 Part 2 PVC Insulated (300/500V) .......................................................................................... 10 Construction ................................................................................................................................... 10 Electrical Characteristics ................................................................................................................ 10 BS5308 Part 2 – Collectively Screened, Unarmored Type –1 Cables ............................................. 11 BS5308 Part 2 – Collectively Screened, Armored Type–2 Cables .................................................. 12 BS5308 Part 2 – Individually & Collectively Screened, Unarmored Type – 1 Cables ...................... 13 BS5308 Part 1 – Individually & Collectively Screened, Armored Type – 2 Cables .......................... 14 BS5308 Part 2 – Collectively screened Unarmoured – Type 1 Cables............................................ 15 BS5308 Part 2 – Collectively screened Armoured – Type 2 Cables................................................ 16 Cable Construction and Characteristics.................................................................................................. 17 Insulation Materials ............................................................................................................................ 17 Core/Pair Identification ....................................................................................................................... 17 Multipair Cables.............................................................................................................................. 17 Cable Assembly ................................................................................................................................. 17 Communications Core or Pair............................................................................................................. 18 Electrical Screening............................................................................................................................ 18 Armouring/Mechanical Protection....................................................................................................... 18 Galvanised Steel Wire Armour........................................................................................................ 18 Non-Metallic Sheaths ......................................................................................................................... 18 Inner Sheath/Bedding..................................................................................................................... 18 Outer Sheath .................................................................................................................................. 18 Appendix 1 ............................................................................................................................................. 20 Colour Coding .................................................................................................................................... 20 As per BS 5308 Part 1.................................................................................................................... 20 Colour Coding .................................................................................................................................... 21 As per BS5308 Part 2..................................................................................................................... 21 Last Revision Date: August 2005
Page 2 of 21
Instrumentation Cable Solutions
Introduction - Oman Cables Industry (SAOG) OCI develops, manufactures and markets a totally integrated product line of instrumentation cables for a diverse variety if technological applications. Oman Cables Industry (SAOG) was formed in 1984 by the current Chairman, Mr. Mustafa bin Mukhtar, Vice Chairman and managing Director, Mr. Hussain bin Salman. Located in Rusayl, the Sultanates largest industrial complex, the company has grown by turnover into one of the top ten industrial companies in Oman. Starting with a modest number of 10 employees, Oman Cables has now over 300 dedicated personnel. Oman Cables has won His Majesty Sultan Qaboos’s Trophy for best industry 4 times in 1991, 1992,1996 and 1997. The company is judged on many criteria including quality, Omanisation, exports, training, safety, use of local materials, sales turnover, financial strength and other important factors. In September 1997, Oman Cables attracted the attention of Draka Holding N.V. of the Netherlands and became an affiliated member of the Draka Holding group following a 34% financial participation by Draka. As an affiliate of the Draka Holding organization with operations in Europe, the United States and the Far East, OCI is ideally positioned to service customers on both a national and a global scale. The OCI offer combines unrivaled experience and a vast product range, developed organically at the leading edge of technology, with the support, strength and the resources of one of the worlds most significant cable companies. OCI is driven by a central philosophy based upon three key issues - PARTNERSHIP, INNOVATION and QUALITY. OCI aims at a maximum understanding of customer requirements for technical specifications through to service and reliability. Quality Standards OCI holds several important international approvals and manufactures it's products in accordance with the relevant IEC, CENELEC and British Standards specifications. The OCI quality system is approved by TUV of Germany to ISO 9001. Instrumentation Cables The variety of Instrumentation cables is vast with very few countries having national Standards covering this area. The uk is one exception where the British Standard BS5308 Parts 1 and 2 cover the requirements for muliticore and multipair instrumentation cables with PVC or polyethylene insulation and with various forms of mechanical protection. Even with the existence of a National Standard, our experience is that customers still require variants from the use of different core identification schemes to intermediate pair configurations to materials with enhanced characteristics for a particular environment. In this brochure we give details of the more commonly used types. OCI prides itself on its ability to offer products to each customer’s specific needs quickly, efficiently and with an assurance of product quality. The standard range includes multicore and multipair copper conductor instrumentation cables.
Last Revision Date: August 2005
Page 3 of 21
Instrumentation Cable Solutions
Mutipair Instrumentation Cables BS5308 Part 1 Polyethylene Insulated 300/500V Construction Constructors
Plain annealed copper conductors complying with BS6360
Insulation
Polyethylene type 03 to BS 6234
Pairing
Two insulated conductors uniformly twisted together with a lay length not exceeding 100mm
Pair identification
COLLECTIVELY SCREENED CABLES
- Colour coded in accordance with Appendix 1
or by numbered tape. Individual Pair Screened Cables
One blue core and one black core in each pair. Pairs are identified by a numbered pair screen isolation tape or colour coded as per appendix-1.
Pair Screens
An aluminum / polyester tape applied with a metallic side down in continuous electrical conduct with a 0.5mm2 tinned copper drain wire. An isolation tape is applied over the screen tape.
Cable Assembly
Pairs are assembled in concentric layers using the reciprocating lay technique
Binder
A non-hygroscopic binder tape is applied over the final lair of pairs.
Collective Screen
An aluminum / polyester tape is applied with the metallic side down in continuous electrical conduct with a 0.5mm2 tinned copper drain wire over the binder tape.
Outer Protection
TYPE 1
Extruded PVC sheath of type TM1
TYPE 2
Extruded polyethylene bedding of type 2C or type 03 black Galvanized steel wire Armour Extruded PVC sheath type TM1 Standard sheath colour Black
IMPORTANT NOTICE. THESE CABLES ARE NOT FOR DIRECT CONNECTION TO THE PUBLIC MAINS ELECTRICAL SUPPLY
Last Revision Date: August 2005
Page 4 of 21
Instrumentation Cable Solutions Electrical Characteristics Unit of measure ment
0.5mm 1/0.8mm
0.5mm 16/0.2mm
1.00mm 1/1.13mm
1.5mm 7/0.53mm
a. Cables with only collective screen (excl. one pair and two pair [quad])
pF/m
75
75
75
85
b. One pair and two pair cables with collective screened and all cables with individually screened pairs
pF/m
115
115
115
115
mH/ohm
25
25
25
40
Ohms
36.8
39.7
18.4
12.3
Insulation resistance (min) a. Core to Core / Screen / Armour o for 1km at 20 C
G.Ω
5
5
5
5
b. Screen to Screen for 1km at o 20 C
M.Ω
1
1
1
1
Conductor Size
L/R ratio (max) Max. Conductor Resistance (D. o C.) at 20 C
2
2
2
2
Rated voltage 300/500 volt Test voltage 1000 volt.
Conductor Nominal Area (mm²) 0.5 (1/0.8)
Nom. Insulation Thickness (mm) 0.50
Maximum Core Diameter (mm) 1.90
0.5 (16/0.2)
0.50
2.35
1.0 (1/1.13)
0.60
2.45
1.5 (7/0.53)
0.60
3.00
Combiline machine
Last Revision Date: August 2005
Page 5 of 21
Instrumentation Cable Solutions BS5308 Part 1 – Collectively Screened, Unarmored Type-1 Cables Multipair Polyethylene insulated without Individual pair screens but collectively screened.
TABLE-1
mm
Nominal Overall Diameter mm
1 2 (Quad) 5 10 15 20 30 50
0.8 0.8 1.1 1.2 1.2 1.3 1.3 1.5
6.3 7.1 11.6 15.0 17.1 19.4 23.0 28.9
0.50 ( 16/ 0.2)
1 2 (Quad) 5 10 15 20 30 50
0.8 0.8 1.1 1.2 1.3 1.3 1.5 1.7
7.0 7.9 13.1 17.2 19.8 22.3 26.9 33.9
1.0 (1/1.13)
1 2 (Quad) 5 10 15 20 30 50
0.8 0.8 1.2 1.2 1.3 1.5 1.5 2.0
7.4 8.4 14.2 18.4 21.3 24.4 29.0 37.3
1.5 (7/0.53)
1 2 (Quad) 5 10 15 20 30 50
0.8 0.9 1.2 1.3 1.5 1.5 1.7 2.0
8.3 9.7 16.4 21.6 25.2 28.5 34.3 43.6
Conductor size
Number of Pairs
mm² 0.50 ( 1/ 0.8)
Last Revision Date: August 2005
Thickness of Sheath
Page 6 of 21
Instrumentation Cable Solutions BS5308 Part 1 – Collectively Screened, Armored Type–2 Cables. Multipair Polyethylene insulated without Individual pair screens but collectively screened
TABLE-2 Conductor size mm² 0.50 ( 1/ 0.8)
0.50 ( 16/ 0.2)
1.0 (1/1.13)
1.5 (7/0.53)
Number of Pairs
Thickness of Bedding
Size of Armour wire
Thickness of Sheath
Nominal Overall Diameter
mm
mm
mm
mm
1
0.8
0.9
1.3
10.7
2 (Quad) 5
0.8 1.1
0.9 0.9
1.3 1.4
11.5 16.2
10 15
1.2 1.2
1.25 1.25
1.6 1.6
20.7 22.8
20 30
1.3 1.3
1.6 1.6
1.7 1.8
26.0 29.8
50
1.5
1.6
2.0
36.1
1 2 (Quad)
0.8 0.8
0.9 0.9
1.3 1.3
11.4 12.3
5
1.1
0.9
1.5
17.9
10 15
1.2 1.3
1.25 1.6
1.6 1.7
22.9 26.4
20 30
1.3 1.5
1.6 1.6
1.8 1.9
29.1 33.9
50
1.7
2.0
2.1
42.1
1
0.8
0.9
1.3
11.8
2 (Quad)
0.8
0.9
1.4
13.0
5 10
1.2 1.2
1.25 1.25
1.5 1.7
19.7 24.3
15
1.3
1.6
1.8
28.1
20 30
1.5 1.5
1.6 1.6
1.8 2.0
30.2 36.2
50
2.0
2.0
2.2
45.7
1
0.8
0.9
1.4
12.9
2 (Quad)
0.9
0.9
1.4
14.3
5 10
1.2 1.3
1.25 1.6
1.6 1.8
22.1 28.4
15 20
1.5 1.5
1.6 1.6
1.9 2.0
32.2 35.7
30
1.7
2.0
2.1
42.5
50
2.0
2.5
2.4
53.4
Last Revision Date: August 2005
Page 7 of 21
Instrumentation Cable Solutions BS5308 Part 1 – Individually & Collectively Screened, Unarmored Type – 1 Cables. Multipair Polyethylene insulated cables with Individual pair screens and collectively screened
TABLE-3 Conductor size
Number of Pairs
mm² 0.50 ( 1/ 0.8)
0.50 ( 16/ 0.2)
1.0 (1/1.13)
1.5 (7/0.53)
Last Revision Date: August 2005
Thickness of Sheath
Nominal Overall Diameter
mm
mm
2
0.9
10.3
5
1.2
13.5
10
1.2
18.3
15
1.3
21.1
20
1.3
23.5
30
1.5
27.9
50
2.0
36.1
2
1.1
12.0
5
1.2
15.2
10
1.3
21.1
15
1.5
24.5
20
1.5
27.3
30
1.7
32.3
50
2.2
41.7
2
1.1
12.8
5
1.2
15.2
10
1.3
22.6
15
1.5
26.2
20
1.7
29.8
30
2.0
35.4
50
2.2
44.9
2
1.2
14.7
5
1.3
18.8
10
1.5
26.5
15
1.7
30.8
20
1.7
34.4
30
2.0
41.0
50
2.2
52.2
Page 8 of 21
Instrumentation Cable Solutions BS5308 Part 1 – Individually & Collectively Screened, Armored Type – 2 Cables. Multipair Polyethylene insulated cables with Individual pair screens and collectively screened
TABLE-4 Conductor size mm² 0.50 ( 1/ 0.8)
0.50 ( 16/ 0.2)
1.0 (1/1.13)
1.5 (7/0.53)
Number of Pairs
Thickness of Bedding
Size of Armour wire
Thickness of Sheath
Nominal Overall Diameter
mm
mm
mm
mm
2
0.8
0.9
1.3
11.5
5 10
1.1 1.2
0.9 1.25
1.4 1.6
16.2 20.7
15
1.2
1.25
1.6
22.8
20 30
1.3 1.3
1.6 1.6
1.7 1.8
26.0 29.8
50
1.5
1.6
2.0
36.1
2
1.1
0.9
1.5
16.8
5
1.2
1.25
1.6
20.9
10 15
1.3 1.5
1.6 1.6
1.8 1.8
27.9 31.3
20 30
1.5 1.7
1.6 2.0
1.9 2.1
34.3 40.5
50
2.2
2.5
2.4
51.5
2
1.1
0.9
1.5
17.6
5
1.2
1.25
1.6
21.9
10 15
1.3 1.5
1.6 1.6
1.8 1.9
29.4 33.2
20
1.7
2.0
2.0
37.8
30 50
2.0 2.2
2.0 2.5
2.2 2.5
43.8 54.9
2 5
1.2 1.3
1.25 1.6
1.6 1.7
20.4 25.4
10
1.5
1.6
1.9
33.5
15 20
1.7 1.7
2.0 2.0
2.0 2.1
38.8 42.6
30 50
2.0 2.2
2.5 2.5
2.4 2.7
50.8 62.6
Last Revision Date: August 2005
Page 9 of 21
Instrumentation Cable Solutions
Multicore Instrumentation Cables BS5308 Part 2 PVC Insulated (300/500V) Construction Conductors
Plain annealed copper conductors complying with BS6360
Insulation
PVC type TI1 to BS7655
Pairing
Two insulated conductors uniformly twisted together with a lay length not exceeding 100 mm.
Pair identification COLLECTIVELY SCREENED CABLES
Colour coded in accordance with appendix 2 or by number of tapes
Cable Assembly
Pairs are assembled in concentric layers using the reciprocating lay technique.
Binder
A non-hygroscopic binder tape is applied over the final layer of pairs.
Collective Screen
An aluminum / polyester tape is applied with the metallic side down in continuous contact with a 0.5mm2 tinned copper drain wire over the binder tape.
Outer Protection
TYPE 1
Extruded PVC sheath type TM1 or type 6
TYPE 2
Extruded PVC bedding of type TM1 Galvanized steel wire armour Extruded PVC sheath of type TM1 Standard sheath colour – Black.
Electrical Characteristics Conductor Size
Unit of Measurement
Mutual capacitance core to core (max) pF/m L/R ratio (max) mH/ohm o Conductor Resistance Resistance at 20 C Ohms Insulation resistance Core –core/ Screen/Armour for 1 hr at 20ºC M.ohms Screen to screen for 1 hr at 20ºC M.ohms Rated voltage 300/500 volt test voltage 1000 volt for 1 min. Conductor Nominal Area (mm²) 0.50 (16/0.2) 0.75 (24/0.2) 1.50 (7/0.53)
Last Revision Date: August 2005
Nom. Insulation Thickness (mm) 0.50 0.60 0.60
2
1.00 mm
(16/0.2) 250 25 39.7
(24/0.2) 250 25 26.5
(7/0.53) 250 40 12.3
25 1
25 1
25 1
0.5 mm
2
1.5 mm
2
Maximum Core Diameter (mm) 2.35 2.55 3.00
Page 10 of 21
Instrumentation Cable Solutions BS5308 Part 2 – Collectively Screened, Unarmored Type –1 Cables Multipair PVC insulated without Individual pair screens but collectively screened.
TABLE-5 Conductor size mm² 0.50 ( 16/ 0.2)
0.75 (24/0.2)
1.5 (7/0.53)
Number of Pairs
Thickness of Sheath mm
Nominal Overall Diameter mm
1
0.8
7.0
2 (Quad) 5
0.8 1.1
7.9 13.1
10 15
1.2 1.3
17.2 19.8
20
1.3
22.3
30 50
1.5 1.7
26.9 33.9
1
0.8
7.3
2 (Quad) 5
0.8 1.2
8.3 14.3
10 15
1.3 1.3
18.7 21.4
20 30
1.5 1.7
24.5 29.5
50
2.0
37.4
1 2 (Quad)
0.8 0.9
8.3 9.7
5
1.2
16.4
10 15
1.3 1.5
21.6 25.2
20 30
1.5 1.7
28.5 34.3
50
2.0
43.6
Last Revision Date: August 2005
Page 11 of 21
Instrumentation Cable Solutions BS5308 Part 2 – Collectively Screened, Armored Type–2 Cables Multipair PVC insulated without Individual pair screens but collectively screened
TABLE-6 Conductor size mm² 0.50 ( 16/ 0.2)
0.75 (24/0.2)
1.5 (7/0.53)
Number of Pairs
Thickness of Bedding
Size of Armour wire
Thickness of Sheath
Nominal Overall Diameter
mm
Mm
mm
mm
1 2 (Quad)
0.8 0.8
0.9 0.9
1.3 1.3
11.4 12.3
5
1.1
0.9
1.5
17.9
10 15
1.2 1.3
1.25 1.6
1.6 1.7
22.9 26.4
20 30
1.3 1.5
1.6 1.6
1.8 1.9
29.1 33.9
50
1.7
2.0
2.1
42.1
1
0.8
0.9
1.3
11.7
2 (Quad)
0.8
0.9
1.4
12.9
5 10
1.2 1.3
1.25 1.6
1.5 1.7
19.8 25.3
15
1.3
1.6
1.8
28.2
20 30
1.5 1.7
1.6 2.0
1.8 2.0
31.3 37.5
50
2.0
2.0
2.2
45.8
1
0.8
0.9
1.4
12.9
2 (Quad)
0.9
0.9
1.4
14.3
5 10
1.2 1.3
1.25 1.6
1.6 1.8
22.1 28.4
15 20
1.5 1.5
1.6 1.6
1.9 2.0
32.2 35.7
30
1.7
2.0
2.1
42.5
50
2.0
2.5
2.4
53.4
Last Revision Date: August 2005
Page 12 of 21
Instrumentation Cable Solutions BS5308 Part 2 – Individually & Collectively Screened, Unarmored Type – 1 Cables Multipair PVC insulated cables with Individual pair screens and collectively screened
TABLE-7 Conductor size mm² 0.50 ( 16/ 0.2)
Number of Pairs
Thickness of Sheath mm
Nominal Overall Diameter mm
2
1.1
12.0
5 10
1.2 1.3
15.2 21.1
15 20
1.5 1.5
24.5 27.3
30
1.7
32.3
50
2.2
41.7
2
1.1
12.8
5
1.2
16.3
10 15
1.3 1.5
22.7 26.4
20 30
1.7 2.0
28.8 35.5
50
2.2
45.0
2
1.2
14.7
0.75 (24/0.2)
1.5 (7/0.53)
5
1.3
18.8
10 15
1.5 1.7
26.5 30.8
20
1.7
34.4
30 50
2.0 2.2
41.0 52.2
84 Bobbin Armouring machine Last Revision Date: August 2005
Page 13 of 21
Instrumentation Cable Solutions BS5308 Part 1 – Individually & Collectively Screened, Armored Type – 2 Cables Multipair PVC insulated cables with Individual pair screens and collectively screened
TABLE-8 Conductor size mm² 0.50 ( 16/ 0.2)
0.75 (24/0.2)
1.5 (7/0.53)
Thickness of Bedding
Size of Armour wire
Thickness of Sheath
Nominal Overall Diameter
mm
mm
mm
mm
2
1.1
0.9
1.5
16.8
5 10
1.2 1.3
1.25 1.6
1.6 1.8
20.9 27.9
15 20
1.5 1.5
1.6 1.6
1.8 1.9
31.3 34.3
30
1.7
2.0
2.1
40.5
50
2.2
2.5
2.4
51.5
2
1.1
0.9
1.5
17.6
5 10
1.2 1.3
1.25 1.6
1.6 1.8
22.0 29.5
15
1.5
1.6
1.9
33.4
20 30
1.7 2.0
2.0 2.0
2.0 2.2
37.8 43.9
50
2.2
2.5
2.5
55.0
2
1.2
1.25
1.6
20.4
5
1.3
1.6
1.7
25.4
10 15
1.5 1.7
1.6 2.0
1.9 2.0
33.5 38.8
20 30
1.7 2.0
2.0 2.5
2.1 2.4
42.6 50.8
50
2.2
2.5
2.7
62.6
Number of Pairs
Last Revision Date: August 2005
Page 14 of 21
Instrumentation Cable Solutions BS5308 Part 2 – Collectively screened Unarmoured – Type 1 Cables Multicore PVC insulated cables Collectively screened
TABLE-9 Conductor size mm² 0.50 ( 16/ 0.2)
0.75 (24/0.2)
1.5 (7/0.53)
Number of Cores
Thickness of Sheath
Nominal Overall Diameter
mm
mm
2
0.8
7.0
3
0.8
7.3
4
0.8
7.9
6
0.9
9.3
10
1.1
11.9
20
1.2
14.9
40
1.3
20.1
80
1.5
26.3
2
0.8
7.3
3
0.8
7.7
4
0.8
8.3
6
0.9
9.9
10
1.1
12.7
20
1.2
16.0
40
1.3
21.7
80
1.5
28.5
2
0.8
8.3
3
0.9
8.9
4
0.9
9.7
6
1.1
11.7
10
1.2
14.7
20
1.3
18.7
40
1.5
24.6
80
1.7
33.6
Last Revision Date: August 2005
Page 15 of 21
Instrumentation Cable Solutions BS5308 Part 2 – Collectively screened Armoured – Type 2 Cables Multicore PVC insulated cables with Collectively screened
TABLE-10 Conductor size mm² 0.50 ( 16/ 0.2)
0.75 (24/0.2)
1.5 (7/0.53)
Thickness of Bedding
Size of Armour wire
Thickness of Sheath
Nominal Overall Diameter
mm
mm
mm
mm
2
0.8
0.9
1.3
11.4
3
0.8
0.9
1.3
11.7
4
0.8
0.9
1.3
12.3
6
0.9
0.9
1.4
13.9
10
1.1
0.9
1.5
16.7
20
1.2
1.3
1.6
19.6
40
1.3
1.6
1.7
26.7
80
1.5
1.6
1.9
33.3
2
0.8
0.9
1.3
11.7
3
0.8
0.9
1.3
12.1
4
0.8
0.9
1.4
12.9
6
0.9
0.9
1.4
14.5
10
1.1
0.9
1.5
17.5
20
1.2
1.25
1.6
21.7
40
1.3
1.6
1.8
28.5
80
1.5
1.6
2.0
35.7
2
0.8
0.9
1.4
12.9
3
0.9
0.9
1.4
13.5
4
0.9
0.9
1.4
14.3
6
1.1
0.9
1.4
16.3
10
1.2
1.25
1.6
20.4
20
1.3
1.6
1.7
25.3
40
1.5
1.6
1.9
31.6
80
1.7
2.0
2.1
41.8
Number of Cores
Last Revision Date: August 2005
Page 16 of 21
Instrumentation Cable Solutions
Cable Construction and Characteristics Insulation Materials Two types of insulating materials are used in the manufacture of Instrumentation cables PVC or polyethylene. These materials comply with International (IEC) or British Standards. 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. Specification PVC BS 7655 section 3.1 BS 7655 section 3.1 BS 7655 section 3.1 BS 7655 section 3.1 BS 7655 section 3.1
Designation
Max Operating Temp General Application
TI 1 TI 2 TI 3 TI 4 TI 5
70 °C 70 °C 90 °C 70 °C 70 °C
General purpose Flexible (incl. Transparent) Heat Resistant Low temperature installations Flexible for low temperature installations
03
65 °C
Telecommunications and data cables
Polyethylene BS 6234
Core/Pair Identification Multipair Cables
The cores within a pair are identified by one of the following methods: A. By printing a reference code on one insulated conductor, or both of them, that indicates the number of that single pair. B. By a numbered non - hygroscopic tape applied over the pair. C. By using different colour combinations to uniquely identify the pair. Cable Assembly Elements from the cable (cores or pairs) are assembled to form the cable. A non-hygroscopic binder tape is usually applied over the final layer.
Last Revision Date: August 2005
Page 17 of 21
Instrumentation Cable Solutions 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. Armouring/Mechanical Protection Galvanised Steel Wire Armour
Galvanised steel wires applied spirally over an inner sheath or bedding, giving a full coverage offering mechanical protection of the cable assembly. The diameter of the armour wire varies with the diameter of the cable assembly. The armour can be used as the pulling medium when installing cables. This type of armouring is very common in the Middle East. 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.
Non-Metallic Sheaths Inner Sheath/Bedding
An inner sheath or bedding is normally applied between the screened cable assembly and the metallic sheath or armour. Materials commonly used by Oman Cables are PVC or Polyethylene compounds. Where the inner sheath is primarily for mechanical purposes the materials may have no specific requirements. Outer Sheath
Most of the commonly used sheathing materials comply with International (IEC), or British Standards. The choice of sheathing materials to be used for any application is dependent on : o o o o o o o
Temperature Flexibility Electrical characteristics Smoke and acid gas emission limitations Resistance to chemicals Water resistance Exposure to UV
Last Revision Date: August 2005
Page 18 of 21
Instrumentation Cable Solutions The following are the most common types of extruded material used for sheathing of Instrumentation cables Specifications
Designation
Max. operating temperature
Application
PVC
BS 7655 Section 4.1 BS 7655 Section 4.1 BS 7655 Section 4.1
TM1 TM2 TM4
70ºC 70ºC 70ºC
General Purpose General Purpose – flexible Low Temperature
BS 7655 Section 4.2 BS 7655 Section 4.2
Type 5 Type 6
85ºC 70ºC
BS 7655 Section 4.2
Type 9
-
High Temperature – hard General purpose Use over cables operating at a max. conductor temperature of 90oC
Wire Drawing
Last Revision Date: August 2005
Page 19 of 21
Instrumentation Cable Solutions
Appendix 1 Colour Coding As per BS 5308 Part 1
Two-pair unscreened cables are cabled in quad formation and colour coded in clockwise order of rotation, Black, Blue, Green, Brown. All other cables up to 50 pairs conform to the following coding: Pair Number
A wire
B wire
Pair Number
A Wire
B Wire
1 2 3 4 5
Black Black Blue Black Blue
Blue Green Green Brown Brown
26 27 28 29 30
White Red Orange Black Blue
Yellow Yellow Yellow Grey Grey
6 7 8 9 10
Green Black Blue Green Brown
Brown White White White White
31 32 33 34 35
Green Brown White Red Orange
Grey Grey Grey Grey Grey
11 12 13 14 15
Black Blue Green Brown White
Red Red Red Red Red
36 37 38 39 40
Yellow Black Blue Green Brown
Grey Violet Violet Violet Violet
16 17 18 19 20
Black Blue Green Brown White
Orange Orange Orange Orange Orange
41 42 43 44 45
White Red Orange Yellow Grey
Violet Violet Violet Violet Violet
21 22 23 24 25
Red Black Blue Green Brown
Orange Yellow Yellow Yellow Yellow
46 47 48 49 50
Black Blue Green Brown White
Turquoise Turquoise Turquoise Turquoise Turquoise
Last Revision Date: August 2005
Page 20 of 21
Instrumentation Cable Solutions Colour Coding As per BS5308 Part 2 Identification of pairs
Two-pair unscreened or collectively screened cables are quad formation and colour coded in clockwise order of rotation, Blue, Green, Orange, Brown. All other cables up to 50 pairs conform to the following coding.
Pair Number
A wire
B wire
Pair Number
A Wire
B Wire
1 2 3 4 5
White White White White White
Blue Orange Green Brown Grey
26 27 28 29 30
RED-Blue RED-Blue RED-Blue RED-Blue RED-Blue
Blue Orange Green Brown Grey
6 7 8 9 10
Red Red Red Red Red
Blue Orange Green Brown Grey
31 32 33 34 35
BLUE-Black BLUE-Black BLUE-Black BLUE-Black BLUE-Black
Blue Orange Green Brown Grey
11 12 13 14 15
Black Black Black Black Black
Blue Orange Green Brown Grey
36 37 38 39 40
YELLOW-Blue YELLOW-Blue YELLOW-Blue YELLOW-Blue YELLOW-Blue
Blue Orange Green Brown Grey
16 17 18 19 20
Yellow Yellow Yellow Yellow Yellow
Blue Orange Green Brown Grey
41 42 43 44 45
WHITE-Orange WHITE-Orange WHITE-Orange WHITE-Orange WHITE-Orange
Blue Orange Green Brown Grey
21 22 23 24 25
WHITE-Blue WHITE-Blue WHITE-Blue WHITE-Blue WHITE-Blue
Blue Orange Green Brown Grey
46 47 48 49 50
ORANGE-Red ORANGE-Red ORANGE-Red ORANGE-Red ORANGE-Red
Blue Orange Green Brown Grey
NOTE Except in the case of bi-colour extrusion the colour indicated in block letters is known as the base colour & is a) the extruded colour and b) the colour with the greater area if exposure on the finished wire.
Last Revision Date: August 2005
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Contents Introduction - Oman Cables Industry (SAOG)........................................................................................... 3 Quality Standards................................................................................................................................. 3 Instrumentation Cables......................................................................................................................... 3 Mutipair Instrumentation Cables ............................................................................................................... 4 BS5308 Part 1 Polyethylene Insulated ................................................................................................. 4 Construction ..................................................................................................................................... 4 Electrical Characteristics .................................................................................................................. 5 BS5308 Part 1 – Collectively Screened, Unarmored Type-1 Cables................................................. 6 BS5308 Part 1 – Collectively Screened, Armored Type–2 Cables. ................................................... 7 BS5308 Part 1 – Individually & Collectively Screened, Unarmored Type – 1 Cables. ....................... 8 BS5308 Part 1 – Individually & Collectively Screened, Armored Type – 2 Cables. ........................... 9 Multicore Instrumentation Cables ........................................................................................................... 10 BS5308 Part 2 PVC Insulated (300/500V) .......................................................................................... 10 Construction ................................................................................................................................... 10 Electrical Characteristics ................................................................................................................ 10 BS5308 Part 2 – Collectively Screened, Unarmored Type –1 Cables ............................................. 11 BS5308 Part 2 – Collectively Screened, Armored Type–2 Cables .................................................. 12 BS5308 Part 2 – Individually & Collectively Screened, Unarmored Type – 1 Cables ...................... 13 BS5308 Part 1 – Individually & Collectively Screened, Armored Type – 2 Cables .......................... 14 BS5308 Part 2 – Collectively screened Unarmoured – Type 1 Cables............................................ 15 BS5308 Part 2 – Collectively screened Armoured – Type 2 Cables................................................ 16 Cable Construction and Characteristics.................................................................................................. 17 Insulation Materials ............................................................................................................................ 17 Core/Pair Identification ....................................................................................................................... 17 Multipair Cables.............................................................................................................................. 17 Cable Assembly ................................................................................................................................. 17 Communications Core or Pair............................................................................................................. 18 Electrical Screening............................................................................................................................ 18 Armouring/Mechanical Protection....................................................................................................... 18 Galvanised Steel Wire Armour........................................................................................................ 18 Non-Metallic Sheaths ......................................................................................................................... 18 Inner Sheath/Bedding..................................................................................................................... 18 Outer Sheath .................................................................................................................................. 18 Appendix 1 ............................................................................................................................................. 20 Colour Coding .................................................................................................................................... 20 As per BS 5308 Part 1.................................................................................................................... 20 Colour Coding .................................................................................................................................... 21 As per BS5308 Part 2..................................................................................................................... 21 Last Revision Date: August 2005
Page 2 of 21
Instrumentation Cable Solutions
Introduction - Oman Cables Industry (SAOG) OCI develops, manufactures and markets a totally integrated product line of instrumentation cables for a diverse variety if technological applications. Oman Cables Industry (SAOG) was formed in 1984 by the current Chairman, Mr. Mustafa bin Mukhtar, Vice Chairman and managing Director, Mr. Hussain bin Salman. Located in Rusayl, the Sultanates largest industrial complex, the company has grown by turnover into one of the top ten industrial companies in Oman. Starting with a modest number of 10 employees, Oman Cables has now over 300 dedicated personnel. Oman Cables has won His Majesty Sultan Qaboos’s Trophy for best industry 4 times in 1991, 1992,1996 and 1997. The company is judged on many criteria including quality, Omanisation, exports, training, safety, use of local materials, sales turnover, financial strength and other important factors. In September 1997, Oman Cables attracted the attention of Draka Holding N.V. of the Netherlands and became an affiliated member of the Draka Holding group following a 34% financial participation by Draka. As an affiliate of the Draka Holding organization with operations in Europe, the United States and the Far East, OCI is ideally positioned to service customers on both a national and a global scale. The OCI offer combines unrivaled experience and a vast product range, developed organically at the leading edge of technology, with the support, strength and the resources of one of the worlds most significant cable companies. OCI is driven by a central philosophy based upon three key issues - PARTNERSHIP, INNOVATION and QUALITY. OCI aims at a maximum understanding of customer requirements for technical specifications through to service and reliability. Quality Standards OCI holds several important international approvals and manufactures it's products in accordance with the relevant IEC, CENELEC and British Standards specifications. The OCI quality system is approved by TUV of Germany to ISO 9001. Instrumentation Cables The variety of Instrumentation cables is vast with very few countries having national Standards covering this area. The uk is one exception where the British Standard BS5308 Parts 1 and 2 cover the requirements for muliticore and multipair instrumentation cables with PVC or polyethylene insulation and with various forms of mechanical protection. Even with the existence of a National Standard, our experience is that customers still require variants from the use of different core identification schemes to intermediate pair configurations to materials with enhanced characteristics for a particular environment. In this brochure we give details of the more commonly used types. OCI prides itself on its ability to offer products to each customer’s specific needs quickly, efficiently and with an assurance of product quality. The standard range includes multicore and multipair copper conductor instrumentation cables.
Last Revision Date: August 2005
Page 3 of 21
Instrumentation Cable Solutions
Mutipair Instrumentation Cables BS5308 Part 1 Polyethylene Insulated 300/500V Construction Constructors
Plain annealed copper conductors complying with BS6360
Insulation
Polyethylene type 03 to BS 6234
Pairing
Two insulated conductors uniformly twisted together with a lay length not exceeding 100mm
Pair identification
COLLECTIVELY SCREENED CABLES
- Colour coded in accordance with Appendix 1
or by numbered tape. Individual Pair Screened Cables
One blue core and one black core in each pair. Pairs are identified by a numbered pair screen isolation tape or colour coded as per appendix-1.
Pair Screens
An aluminum / polyester tape applied with a metallic side down in continuous electrical conduct with a 0.5mm2 tinned copper drain wire. An isolation tape is applied over the screen tape.
Cable Assembly
Pairs are assembled in concentric layers using the reciprocating lay technique
Binder
A non-hygroscopic binder tape is applied over the final lair of pairs.
Collective Screen
An aluminum / polyester tape is applied with the metallic side down in continuous electrical conduct with a 0.5mm2 tinned copper drain wire over the binder tape.
Outer Protection
TYPE 1
Extruded PVC sheath of type TM1
TYPE 2
Extruded polyethylene bedding of type 2C or type 03 black Galvanized steel wire Armour Extruded PVC sheath type TM1 Standard sheath colour Black
IMPORTANT NOTICE. THESE CABLES ARE NOT FOR DIRECT CONNECTION TO THE PUBLIC MAINS ELECTRICAL SUPPLY
Last Revision Date: August 2005
Page 4 of 21
Instrumentation Cable Solutions Electrical Characteristics Unit of measure ment
0.5mm 1/0.8mm
0.5mm 16/0.2mm
1.00mm 1/1.13mm
1.5mm 7/0.53mm
a. Cables with only collective screen (excl. one pair and two pair [quad])
pF/m
75
75
75
85
b. One pair and two pair cables with collective screened and all cables with individually screened pairs
pF/m
115
115
115
115
mH/ohm
25
25
25
40
Ohms
36.8
39.7
18.4
12.3
Insulation resistance (min) a. Core to Core / Screen / Armour o for 1km at 20 C
G.Ω
5
5
5
5
b. Screen to Screen for 1km at o 20 C
M.Ω
1
1
1
1
Conductor Size
L/R ratio (max) Max. Conductor Resistance (D. o C.) at 20 C
2
2
2
2
Rated voltage 300/500 volt Test voltage 1000 volt.
Conductor Nominal Area (mm²) 0.5 (1/0.8)
Nom. Insulation Thickness (mm) 0.50
Maximum Core Diameter (mm) 1.90
0.5 (16/0.2)
0.50
2.35
1.0 (1/1.13)
0.60
2.45
1.5 (7/0.53)
0.60
3.00
Combiline machine
Last Revision Date: August 2005
Page 5 of 21
Instrumentation Cable Solutions BS5308 Part 1 – Collectively Screened, Unarmored Type-1 Cables Multipair Polyethylene insulated without Individual pair screens but collectively screened.
TABLE-1
mm
Nominal Overall Diameter mm
1 2 (Quad) 5 10 15 20 30 50
0.8 0.8 1.1 1.2 1.2 1.3 1.3 1.5
6.3 7.1 11.6 15.0 17.1 19.4 23.0 28.9
0.50 ( 16/ 0.2)
1 2 (Quad) 5 10 15 20 30 50
0.8 0.8 1.1 1.2 1.3 1.3 1.5 1.7
7.0 7.9 13.1 17.2 19.8 22.3 26.9 33.9
1.0 (1/1.13)
1 2 (Quad) 5 10 15 20 30 50
0.8 0.8 1.2 1.2 1.3 1.5 1.5 2.0
7.4 8.4 14.2 18.4 21.3 24.4 29.0 37.3
1.5 (7/0.53)
1 2 (Quad) 5 10 15 20 30 50
0.8 0.9 1.2 1.3 1.5 1.5 1.7 2.0
8.3 9.7 16.4 21.6 25.2 28.5 34.3 43.6
Conductor size
Number of Pairs
mm² 0.50 ( 1/ 0.8)
Last Revision Date: August 2005
Thickness of Sheath
Page 6 of 21
Instrumentation Cable Solutions BS5308 Part 1 – Collectively Screened, Armored Type–2 Cables. Multipair Polyethylene insulated without Individual pair screens but collectively screened
TABLE-2 Conductor size mm² 0.50 ( 1/ 0.8)
0.50 ( 16/ 0.2)
1.0 (1/1.13)
1.5 (7/0.53)
Number of Pairs
Thickness of Bedding
Size of Armour wire
Thickness of Sheath
Nominal Overall Diameter
mm
mm
mm
mm
1
0.8
0.9
1.3
10.7
2 (Quad) 5
0.8 1.1
0.9 0.9
1.3 1.4
11.5 16.2
10 15
1.2 1.2
1.25 1.25
1.6 1.6
20.7 22.8
20 30
1.3 1.3
1.6 1.6
1.7 1.8
26.0 29.8
50
1.5
1.6
2.0
36.1
1 2 (Quad)
0.8 0.8
0.9 0.9
1.3 1.3
11.4 12.3
5
1.1
0.9
1.5
17.9
10 15
1.2 1.3
1.25 1.6
1.6 1.7
22.9 26.4
20 30
1.3 1.5
1.6 1.6
1.8 1.9
29.1 33.9
50
1.7
2.0
2.1
42.1
1
0.8
0.9
1.3
11.8
2 (Quad)
0.8
0.9
1.4
13.0
5 10
1.2 1.2
1.25 1.25
1.5 1.7
19.7 24.3
15
1.3
1.6
1.8
28.1
20 30
1.5 1.5
1.6 1.6
1.8 2.0
30.2 36.2
50
2.0
2.0
2.2
45.7
1
0.8
0.9
1.4
12.9
2 (Quad)
0.9
0.9
1.4
14.3
5 10
1.2 1.3
1.25 1.6
1.6 1.8
22.1 28.4
15 20
1.5 1.5
1.6 1.6
1.9 2.0
32.2 35.7
30
1.7
2.0
2.1
42.5
50
2.0
2.5
2.4
53.4
Last Revision Date: August 2005
Page 7 of 21
Instrumentation Cable Solutions BS5308 Part 1 – Individually & Collectively Screened, Unarmored Type – 1 Cables. Multipair Polyethylene insulated cables with Individual pair screens and collectively screened
TABLE-3 Conductor size
Number of Pairs
mm² 0.50 ( 1/ 0.8)
0.50 ( 16/ 0.2)
1.0 (1/1.13)
1.5 (7/0.53)
Last Revision Date: August 2005
Thickness of Sheath
Nominal Overall Diameter
mm
mm
2
0.9
10.3
5
1.2
13.5
10
1.2
18.3
15
1.3
21.1
20
1.3
23.5
30
1.5
27.9
50
2.0
36.1
2
1.1
12.0
5
1.2
15.2
10
1.3
21.1
15
1.5
24.5
20
1.5
27.3
30
1.7
32.3
50
2.2
41.7
2
1.1
12.8
5
1.2
15.2
10
1.3
22.6
15
1.5
26.2
20
1.7
29.8
30
2.0
35.4
50
2.2
44.9
2
1.2
14.7
5
1.3
18.8
10
1.5
26.5
15
1.7
30.8
20
1.7
34.4
30
2.0
41.0
50
2.2
52.2
Page 8 of 21
Instrumentation Cable Solutions BS5308 Part 1 – Individually & Collectively Screened, Armored Type – 2 Cables. Multipair Polyethylene insulated cables with Individual pair screens and collectively screened
TABLE-4 Conductor size mm² 0.50 ( 1/ 0.8)
0.50 ( 16/ 0.2)
1.0 (1/1.13)
1.5 (7/0.53)
Number of Pairs
Thickness of Bedding
Size of Armour wire
Thickness of Sheath
Nominal Overall Diameter
mm
mm
mm
mm
2
0.8
0.9
1.3
11.5
5 10
1.1 1.2
0.9 1.25
1.4 1.6
16.2 20.7
15
1.2
1.25
1.6
22.8
20 30
1.3 1.3
1.6 1.6
1.7 1.8
26.0 29.8
50
1.5
1.6
2.0
36.1
2
1.1
0.9
1.5
16.8
5
1.2
1.25
1.6
20.9
10 15
1.3 1.5
1.6 1.6
1.8 1.8
27.9 31.3
20 30
1.5 1.7
1.6 2.0
1.9 2.1
34.3 40.5
50
2.2
2.5
2.4
51.5
2
1.1
0.9
1.5
17.6
5
1.2
1.25
1.6
21.9
10 15
1.3 1.5
1.6 1.6
1.8 1.9
29.4 33.2
20
1.7
2.0
2.0
37.8
30 50
2.0 2.2
2.0 2.5
2.2 2.5
43.8 54.9
2 5
1.2 1.3
1.25 1.6
1.6 1.7
20.4 25.4
10
1.5
1.6
1.9
33.5
15 20
1.7 1.7
2.0 2.0
2.0 2.1
38.8 42.6
30 50
2.0 2.2
2.5 2.5
2.4 2.7
50.8 62.6
Last Revision Date: August 2005
Page 9 of 21
Instrumentation Cable Solutions
Multicore Instrumentation Cables BS5308 Part 2 PVC Insulated (300/500V) Construction Conductors
Plain annealed copper conductors complying with BS6360
Insulation
PVC type TI1 to BS7655
Pairing
Two insulated conductors uniformly twisted together with a lay length not exceeding 100 mm.
Pair identification COLLECTIVELY SCREENED CABLES
Colour coded in accordance with appendix 2 or by number of tapes
Cable Assembly
Pairs are assembled in concentric layers using the reciprocating lay technique.
Binder
A non-hygroscopic binder tape is applied over the final layer of pairs.
Collective Screen
An aluminum / polyester tape is applied with the metallic side down in continuous contact with a 0.5mm2 tinned copper drain wire over the binder tape.
Outer Protection
TYPE 1
Extruded PVC sheath type TM1 or type 6
TYPE 2
Extruded PVC bedding of type TM1 Galvanized steel wire armour Extruded PVC sheath of type TM1 Standard sheath colour – Black.
Electrical Characteristics Conductor Size
Unit of Measurement
Mutual capacitance core to core (max) pF/m L/R ratio (max) mH/ohm o Conductor Resistance Resistance at 20 C Ohms Insulation resistance Core –core/ Screen/Armour for 1 hr at 20ºC M.ohms Screen to screen for 1 hr at 20ºC M.ohms Rated voltage 300/500 volt test voltage 1000 volt for 1 min. Conductor Nominal Area (mm²) 0.50 (16/0.2) 0.75 (24/0.2) 1.50 (7/0.53)
Last Revision Date: August 2005
Nom. Insulation Thickness (mm) 0.50 0.60 0.60
2
1.00 mm
(16/0.2) 250 25 39.7
(24/0.2) 250 25 26.5
(7/0.53) 250 40 12.3
25 1
25 1
25 1
0.5 mm
2
1.5 mm
2
Maximum Core Diameter (mm) 2.35 2.55 3.00
Page 10 of 21
Instrumentation Cable Solutions BS5308 Part 2 – Collectively Screened, Unarmored Type –1 Cables Multipair PVC insulated without Individual pair screens but collectively screened.
TABLE-5 Conductor size mm² 0.50 ( 16/ 0.2)
0.75 (24/0.2)
1.5 (7/0.53)
Number of Pairs
Thickness of Sheath mm
Nominal Overall Diameter mm
1
0.8
7.0
2 (Quad) 5
0.8 1.1
7.9 13.1
10 15
1.2 1.3
17.2 19.8
20
1.3
22.3
30 50
1.5 1.7
26.9 33.9
1
0.8
7.3
2 (Quad) 5
0.8 1.2
8.3 14.3
10 15
1.3 1.3
18.7 21.4
20 30
1.5 1.7
24.5 29.5
50
2.0
37.4
1 2 (Quad)
0.8 0.9
8.3 9.7
5
1.2
16.4
10 15
1.3 1.5
21.6 25.2
20 30
1.5 1.7
28.5 34.3
50
2.0
43.6
Last Revision Date: August 2005
Page 11 of 21
Instrumentation Cable Solutions BS5308 Part 2 – Collectively Screened, Armored Type–2 Cables Multipair PVC insulated without Individual pair screens but collectively screened
TABLE-6 Conductor size mm² 0.50 ( 16/ 0.2)
0.75 (24/0.2)
1.5 (7/0.53)
Number of Pairs
Thickness of Bedding
Size of Armour wire
Thickness of Sheath
Nominal Overall Diameter
mm
Mm
mm
mm
1 2 (Quad)
0.8 0.8
0.9 0.9
1.3 1.3
11.4 12.3
5
1.1
0.9
1.5
17.9
10 15
1.2 1.3
1.25 1.6
1.6 1.7
22.9 26.4
20 30
1.3 1.5
1.6 1.6
1.8 1.9
29.1 33.9
50
1.7
2.0
2.1
42.1
1
0.8
0.9
1.3
11.7
2 (Quad)
0.8
0.9
1.4
12.9
5 10
1.2 1.3
1.25 1.6
1.5 1.7
19.8 25.3
15
1.3
1.6
1.8
28.2
20 30
1.5 1.7
1.6 2.0
1.8 2.0
31.3 37.5
50
2.0
2.0
2.2
45.8
1
0.8
0.9
1.4
12.9
2 (Quad)
0.9
0.9
1.4
14.3
5 10
1.2 1.3
1.25 1.6
1.6 1.8
22.1 28.4
15 20
1.5 1.5
1.6 1.6
1.9 2.0
32.2 35.7
30
1.7
2.0
2.1
42.5
50
2.0
2.5
2.4
53.4
Last Revision Date: August 2005
Page 12 of 21
Instrumentation Cable Solutions BS5308 Part 2 – Individually & Collectively Screened, Unarmored Type – 1 Cables Multipair PVC insulated cables with Individual pair screens and collectively screened
TABLE-7 Conductor size mm² 0.50 ( 16/ 0.2)
Number of Pairs
Thickness of Sheath mm
Nominal Overall Diameter mm
2
1.1
12.0
5 10
1.2 1.3
15.2 21.1
15 20
1.5 1.5
24.5 27.3
30
1.7
32.3
50
2.2
41.7
2
1.1
12.8
5
1.2
16.3
10 15
1.3 1.5
22.7 26.4
20 30
1.7 2.0
28.8 35.5
50
2.2
45.0
2
1.2
14.7
0.75 (24/0.2)
1.5 (7/0.53)
5
1.3
18.8
10 15
1.5 1.7
26.5 30.8
20
1.7
34.4
30 50
2.0 2.2
41.0 52.2
84 Bobbin Armouring machine Last Revision Date: August 2005
Page 13 of 21
Instrumentation Cable Solutions BS5308 Part 1 – Individually & Collectively Screened, Armored Type – 2 Cables Multipair PVC insulated cables with Individual pair screens and collectively screened
TABLE-8 Conductor size mm² 0.50 ( 16/ 0.2)
0.75 (24/0.2)
1.5 (7/0.53)
Thickness of Bedding
Size of Armour wire
Thickness of Sheath
Nominal Overall Diameter
mm
mm
mm
mm
2
1.1
0.9
1.5
16.8
5 10
1.2 1.3
1.25 1.6
1.6 1.8
20.9 27.9
15 20
1.5 1.5
1.6 1.6
1.8 1.9
31.3 34.3
30
1.7
2.0
2.1
40.5
50
2.2
2.5
2.4
51.5
2
1.1
0.9
1.5
17.6
5 10
1.2 1.3
1.25 1.6
1.6 1.8
22.0 29.5
15
1.5
1.6
1.9
33.4
20 30
1.7 2.0
2.0 2.0
2.0 2.2
37.8 43.9
50
2.2
2.5
2.5
55.0
2
1.2
1.25
1.6
20.4
5
1.3
1.6
1.7
25.4
10 15
1.5 1.7
1.6 2.0
1.9 2.0
33.5 38.8
20 30
1.7 2.0
2.0 2.5
2.1 2.4
42.6 50.8
50
2.2
2.5
2.7
62.6
Number of Pairs
Last Revision Date: August 2005
Page 14 of 21
Instrumentation Cable Solutions BS5308 Part 2 – Collectively screened Unarmoured – Type 1 Cables Multicore PVC insulated cables Collectively screened
TABLE-9 Conductor size mm² 0.50 ( 16/ 0.2)
0.75 (24/0.2)
1.5 (7/0.53)
Number of Cores
Thickness of Sheath
Nominal Overall Diameter
mm
mm
2
0.8
7.0
3
0.8
7.3
4
0.8
7.9
6
0.9
9.3
10
1.1
11.9
20
1.2
14.9
40
1.3
20.1
80
1.5
26.3
2
0.8
7.3
3
0.8
7.7
4
0.8
8.3
6
0.9
9.9
10
1.1
12.7
20
1.2
16.0
40
1.3
21.7
80
1.5
28.5
2
0.8
8.3
3
0.9
8.9
4
0.9
9.7
6
1.1
11.7
10
1.2
14.7
20
1.3
18.7
40
1.5
24.6
80
1.7
33.6
Last Revision Date: August 2005
Page 15 of 21
Instrumentation Cable Solutions BS5308 Part 2 – Collectively screened Armoured – Type 2 Cables Multicore PVC insulated cables with Collectively screened
TABLE-10 Conductor size mm² 0.50 ( 16/ 0.2)
0.75 (24/0.2)
1.5 (7/0.53)
Thickness of Bedding
Size of Armour wire
Thickness of Sheath
Nominal Overall Diameter
mm
mm
mm
mm
2
0.8
0.9
1.3
11.4
3
0.8
0.9
1.3
11.7
4
0.8
0.9
1.3
12.3
6
0.9
0.9
1.4
13.9
10
1.1
0.9
1.5
16.7
20
1.2
1.3
1.6
19.6
40
1.3
1.6
1.7
26.7
80
1.5
1.6
1.9
33.3
2
0.8
0.9
1.3
11.7
3
0.8
0.9
1.3
12.1
4
0.8
0.9
1.4
12.9
6
0.9
0.9
1.4
14.5
10
1.1
0.9
1.5
17.5
20
1.2
1.25
1.6
21.7
40
1.3
1.6
1.8
28.5
80
1.5
1.6
2.0
35.7
2
0.8
0.9
1.4
12.9
3
0.9
0.9
1.4
13.5
4
0.9
0.9
1.4
14.3
6
1.1
0.9
1.4
16.3
10
1.2
1.25
1.6
20.4
20
1.3
1.6
1.7
25.3
40
1.5
1.6
1.9
31.6
80
1.7
2.0
2.1
41.8
Number of Cores
Last Revision Date: August 2005
Page 16 of 21
Instrumentation Cable Solutions
Cable Construction and Characteristics Insulation Materials Two types of insulating materials are used in the manufacture of Instrumentation cables PVC or polyethylene. These materials comply with International (IEC) or British Standards. 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. Specification PVC BS 7655 section 3.1 BS 7655 section 3.1 BS 7655 section 3.1 BS 7655 section 3.1 BS 7655 section 3.1
Designation
Max Operating Temp General Application
TI 1 TI 2 TI 3 TI 4 TI 5
70 °C 70 °C 90 °C 70 °C 70 °C
General purpose Flexible (incl. Transparent) Heat Resistant Low temperature installations Flexible for low temperature installations
03
65 °C
Telecommunications and data cables
Polyethylene BS 6234
Core/Pair Identification Multipair Cables
The cores within a pair are identified by one of the following methods: A. By printing a reference code on one insulated conductor, or both of them, that indicates the number of that single pair. B. By a numbered non - hygroscopic tape applied over the pair. C. By using different colour combinations to uniquely identify the pair. Cable Assembly Elements from the cable (cores or pairs) are assembled to form the cable. A non-hygroscopic binder tape is usually applied over the final layer.
Last Revision Date: August 2005
Page 17 of 21
Instrumentation Cable Solutions 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. Armouring/Mechanical Protection Galvanised Steel Wire Armour
Galvanised steel wires applied spirally over an inner sheath or bedding, giving a full coverage offering mechanical protection of the cable assembly. The diameter of the armour wire varies with the diameter of the cable assembly. The armour can be used as the pulling medium when installing cables. This type of armouring is very common in the Middle East. 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.
Non-Metallic Sheaths Inner Sheath/Bedding
An inner sheath or bedding is normally applied between the screened cable assembly and the metallic sheath or armour. Materials commonly used by Oman Cables are PVC or Polyethylene compounds. Where the inner sheath is primarily for mechanical purposes the materials may have no specific requirements. Outer Sheath
Most of the commonly used sheathing materials comply with International (IEC), or British Standards. The choice of sheathing materials to be used for any application is dependent on : o o o o o o o
Temperature Flexibility Electrical characteristics Smoke and acid gas emission limitations Resistance to chemicals Water resistance Exposure to UV
Last Revision Date: August 2005
Page 18 of 21
Instrumentation Cable Solutions The following are the most common types of extruded material used for sheathing of Instrumentation cables Specifications
Designation
Max. operating temperature
Application
PVC
BS 7655 Section 4.1 BS 7655 Section 4.1 BS 7655 Section 4.1
TM1 TM2 TM4
70ºC 70ºC 70ºC
General Purpose General Purpose – flexible Low Temperature
BS 7655 Section 4.2 BS 7655 Section 4.2
Type 5 Type 6
85ºC 70ºC
BS 7655 Section 4.2
Type 9
-
High Temperature – hard General purpose Use over cables operating at a max. conductor temperature of 90oC
Wire Drawing
Last Revision Date: August 2005
Page 19 of 21
Instrumentation Cable Solutions
Appendix 1 Colour Coding As per BS 5308 Part 1
Two-pair unscreened cables are cabled in quad formation and colour coded in clockwise order of rotation, Black, Blue, Green, Brown. All other cables up to 50 pairs conform to the following coding: Pair Number
A wire
B wire
Pair Number
A Wire
B Wire
1 2 3 4 5
Black Black Blue Black Blue
Blue Green Green Brown Brown
26 27 28 29 30
White Red Orange Black Blue
Yellow Yellow Yellow Grey Grey
6 7 8 9 10
Green Black Blue Green Brown
Brown White White White White
31 32 33 34 35
Green Brown White Red Orange
Grey Grey Grey Grey Grey
11 12 13 14 15
Black Blue Green Brown White
Red Red Red Red Red
36 37 38 39 40
Yellow Black Blue Green Brown
Grey Violet Violet Violet Violet
16 17 18 19 20
Black Blue Green Brown White
Orange Orange Orange Orange Orange
41 42 43 44 45
White Red Orange Yellow Grey
Violet Violet Violet Violet Violet
21 22 23 24 25
Red Black Blue Green Brown
Orange Yellow Yellow Yellow Yellow
46 47 48 49 50
Black Blue Green Brown White
Turquoise Turquoise Turquoise Turquoise Turquoise
Last Revision Date: August 2005
Page 20 of 21
Instrumentation Cable Solutions Colour Coding As per BS5308 Part 2 Identification of pairs
Two-pair unscreened or collectively screened cables are quad formation and colour coded in clockwise order of rotation, Blue, Green, Orange, Brown. All other cables up to 50 pairs conform to the following coding.
Pair Number
A wire
B wire
Pair Number
A Wire
B Wire
1 2 3 4 5
White White White White White
Blue Orange Green Brown Grey
26 27 28 29 30
RED-Blue RED-Blue RED-Blue RED-Blue RED-Blue
Blue Orange Green Brown Grey
6 7 8 9 10
Red Red Red Red Red
Blue Orange Green Brown Grey
31 32 33 34 35
BLUE-Black BLUE-Black BLUE-Black BLUE-Black BLUE-Black
Blue Orange Green Brown Grey
11 12 13 14 15
Black Black Black Black Black
Blue Orange Green Brown Grey
36 37 38 39 40
YELLOW-Blue YELLOW-Blue YELLOW-Blue YELLOW-Blue YELLOW-Blue
Blue Orange Green Brown Grey
16 17 18 19 20
Yellow Yellow Yellow Yellow Yellow
Blue Orange Green Brown Grey
41 42 43 44 45
WHITE-Orange WHITE-Orange WHITE-Orange WHITE-Orange WHITE-Orange
Blue Orange Green Brown Grey
21 22 23 24 25
WHITE-Blue WHITE-Blue WHITE-Blue WHITE-Blue WHITE-Blue
Blue Orange Green Brown Grey
46 47 48 49 50
ORANGE-Red ORANGE-Red ORANGE-Red ORANGE-Red ORANGE-Red
Blue Orange Green Brown Grey
NOTE Except in the case of bi-colour extrusion the colour indicated in block letters is known as the base colour & is a) the extruded colour and b) the colour with the greater area if exposure on the finished wire.
Last Revision Date: August 2005
Page 21 of 21
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