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Control Cables

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Hook Up Wires

Sleeves

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TEMPSENSI N S T R U M E N T S

High TemperatureCables

SN

OIT

UL

OS

GE NN IRG I ENE

About the Company

Tempsens Instruments (I) Pvt. Ltd. is a part of Pyrotech Group which was established by four technocrats in 1976 at Udaipur, with their first product as Thermocouples and RTDs.

Today Tempsens is one of the largest manufacturer of Temperature Sensors in India. We are ISO 9001:2008 certified company with NABL accredited Lab.

Tempsens Instruments (I) Pvt. Ltd. U # II was started in 2009 to produce quality cables with high standard of manufacturing process conforming to national & international specifications.

We manufacturer wide range of cables for Temperature sensors and Instrumentation in various insulations as PTFE, Kapton, Silicon, Fiber Glass, Ceramic Fiber, Refrasil/Nextel, PVC etc. in variety of configurations. These cables are available in temperature range -60°C to 1200°C.

All our products are manufactured under strict ISO-9001 quality control system. We also provide Calibration Certificates with all cables.

We stock most types of cables which enable us for fast delivery of goods. Our engineering staffs are capable of custom design a solution for any application for customer.

We are dedicated to provide the highest quality products that meet our customers specifications for various application. We continuously focus on improving our manufacturing processes and competitiveness in the industry.

Testing and Calibration

1. Test on Conductor ü Conductor Resistance Test ü Calibration Test

2. Test for thickness of Insulation and Sheath

3. On line High Voltage test

4. Physical test for Insulation and outer Sheathü Tensile Strength & Elongation at break ü Ageing in Air oven ü Shrinkage test ü Hot deformation test ü Heat shock test ü Thermal Stability Test

5. High Voltage test at room temperature

6. Flammability test

FacilitiesMachining

• FEP/PFA Extrusion Line

• PVC Extrusion Line

• Silicon Extrusion Line

• Braiding Machine-High Speed and regular

• Rewinding Machine

• Vertical Lapping Machine

• Stranding Machine

• PTFE Extrusion and Tape Roll Down

• Tape Wrapping Machine

• Spark Tester

• Diameter Tester

• Metering Machine

• Packing Machine

Test & Calibration traceability certificate is provided with all cables

COLOUR CODE OF THERMOCOUPLE EXTENSION AND COMPENSATING CABLES

THERMOCOUPLE

CONDUCTOR

COMBINATION

TYPE

CONDUCTOR

EXTENSION

CABLECOMPENSATING

CABLE

TOLERANCE CLASS

1

±60µV (±1.5°C)

2

CABLE

TEMPERATURE

RANGE °C

K

KX

KCA

KCB

T

J

TX

N

E

R

S

B

C

JX

NX

EX

NC

RCA

RCB

SCA

SCB

BC

CC

-25°C TO +200°C±100µV (±2.5°C)

±100µV (±2.5°C)

±100µV (±2.5°C)

±60µV (±1.0°C)

±140µV (±2.5°C)

±100µV (±2.5°C)

±100µV (±2.5°C)

±200µV (±2.5°C)

±30µV (±2.5°C)

±60µV (±5.0°C)

±30µV (±2.5°C)

±60µV (±5.0°C)

±30µV (±0.5°C)

±85µV (±1.5°C)

±60µV (±1.5°C)

±120µV (±1.5°C)

AMERICANTO

ANSI/MC96.1

JAPANESETO

JIS C 1610-1981

-0°C TO +150°C

-0°C TO +100°C

-25°C TO +100°C

-25°C TO +200°C

-25°C TO +200°C

-0°C TO +150°C

-25°C TO +200°C

0°C TO +100°C

0°C TO +200°C

0°C TO +100°C

0°C TO

0°C TO

+200°C

+110°C

ANSI JIS

INTERNATIONAL

COLOUR CODE

TO IEC 5843:1989

IEC

Table-2

-

Table-1

APPEARANCE OF CABLE

-73 to 600°C

-72 to 800°C

-73 to 1200°C

Fiber Glass

CF/SFCeramic Fiber/

Silica

RF/NF/ALRefrasil/Nextel

Silica yarn/Alumina

POOR

POOR

POOR

POOR

GOOD

GOOD

EXCELLENT

EXCELLENT

EXCELLENT

FAIR

-

-

-260 to 260°CPF PFA

EF FEP -200 to 200°C

0

Wire Insulation and Color Code

-

EF

For Conductor size and stranding, please refer table no. 4 (See Back Page)

Application

ü Temperature sensorsü Aerospaceü Transportationü Cryogenicsü Petrochemical plantsü Glass/Cement/Steel/Power Plant

Thermocouple type : K, J, T, E, N

Conductor: Solid original thermocouple wire as per ASTM E230 or ANSI MC96.1

Limits of Error: Standard or Special

Core Insulation: As given in table 1

Core laying: Parallel or twisted

Outer sheath: As given in table 1

Braiding: By stainless steel/Nickel (if required)

CONSTRUCTIONAL FEATURES

Original thermocouple wires in standard or special accuracy are available in high temperature insulation upto 1200°C. These can be directly used for temperature measurement and are available with accrediated calibration certificate.

TECHNICAL PARAMETERS

Primary Insulation

Sheath Insulation

Max Temp.

Color coding

Braided Refrasil e/N xtel/Alumina/

Braided Refrasil /Nextel/Alumina

1200°C No color coding

Braided Silica Fiber/ Ceramic Fiber

Braided Silica Fiber/ Ceramic Fiber

900°C

No color coding

Braided fibre glass

Braided fibre glass

600°C

Kapton Kapton 310°C No color coding

Floro polymer (PTFE)

Floro polymer (PTFE)

260°C Refer table

Refer table

no.

no.

2

2

Floro polymer (PFA)

Floro polymer (PFA)

260°C Refer table no. 2

FEP FEP 200°C Refer table no. 2

High Temperature Thermocouple Cable upto 1200°C

Silica Silica

Thermocouple Extension / Compensating Cables

Tempsens provide a variety of high temperature insulation material like FEP, PFA and silicon in extrusion form. These insulating material provide great inertness with various chemicals, oil or grease, and having excellent insulation resistance and make cables light weight and miniaturized. Extra high temperature insulating material like varnished glass fiber, Silica, mica, Kapton and asbestos in braiding or taping form generally used for heat protection. Standard insulations of PVC is also available.(*PTFE in wrapped sintered and fibre glass in braided form)

Voltage grade: upto 1100 VoltFlexibility: ExcellentAvailable in simplex, duplex or multi-pair constructionOther insulations are available on request.

Thermocouple type : R,S,B, J, K, T, E, N,C

Conductor: Extension grade (abbreviated by 'X') or compensating grade (abbreviated by 'C')* solid or stranded in wide range of size. (Plz. refer table 4)(*As per table 2)

Core Insulation: As per table 1

Core laying: In form of pairs, color coding as per IEC, ANSI and JIS specification, pairs identified by stripe lining

Screening: With copper / silver or nickel plated or Tinned plated copper screened/ Almyler Screening Individual & Overall with Drain Wire

Outer sheath: As per table 1

Braiding: • Stainless steel braiding by SS wire from 0.08 mm to 0.25 mm• Varnished fibre glass heat protective shield


ü Glass /Steel /Cement Plantü Chemical plants or laboratoriesü Power plantü Ferrous or Non ferrous metal plantü Petrochemical plants

Application


Insulation Temp. range Property

Fibre glass (Braided)

-72°C to 600°C Extra High temperature Resistance

Varnished Fibre glass (Braided)

-72°C to +350°C High temperature Resistance

Kapton (Tapped)

-260°C to +310°C Thin insulation, temperature

PEEK

(Extruded)

-180°C to +260°C Excellent response in nuclear radiation

PTFE (Wrapped)

-260°C to +260°C Less diameter, high electrical and chemical property

PFA (Extruded)


Silicon (Extruded)

-40°C to +200°C Good abrasion resistance

FEP

(Extruded)


FR PVC 10°C to 70°C Fire resistance PVC

Resistance

RTD Cables

Conductor: Electrolytic grade, soft and annealedsilver plated Copper (SPC) or Tin Plated copper (TPC) or bare copper conductor (BC) or Nickel Plated Copper (NPC).

Core Insulation: As per table 1

Core laying: In form of 2 wire/ 3 wire/ 4 wireconstruction color coding per DIN 43760 or specified by the customer

Screening: With copper / silver or nickel Plated /Tinned plated copper screened / Almyler Screening Individual & Overall with Drain Wire

Outer sheath: As per requirement (Table 1)

Braiding: Stainless steel braiding by SS wirefrom 0.08 mm to 0.15 mm with or without Varnished fibre glass heat protective shield

Armoring: By Galvanized wire/ stripe (for PVC)

Voltage grade: upto 1100 Volt (For Higher volt Please Specify)Flexibility: Excellent

RTD cable is available in 2,3,4,6 and 8 core as per requirement in annealed BC, TPC, NPC or SPC conductor. Screening, Braiding and insulation can be provided as required.


Application

ü Steel or Sponge iron plantü Glass Plantü Chemical plants or laboratoriesü Power plantü Non ferrous metal plant



Ceramic fibre glass (Braided)

-72°C to +800°C Extra High temperature



Kapton (Tapped)

-260°C to +310°C Thin insulation, temperature

PEEK (Extruded)


PTFE (Tapped)


PFA (Extruded)


Silicon (Extruded)


FEP (Extruded)


FR PVC 10°C to 70°C 100 MΩ x km

Resistance

Resistance

PVC Control Cable for Voltage Rating upto 1100 V (Max. temperature 90°C)

Control cable in PVC insulation is available in various configurations and requirements.

Voltage grade: upto 1100 Volt Flexibility: Excellent

(For Higher volt Please Specify)

Specification:üConductor as per IS 8130 and/ or VDE 0295üPVC as per IS 5831 üUnarmored cables as per IS 694üArmored cables as per IS 1554


Insulation Temp. range Insulation resistance

Property

PE 10°C to 110°C 1000 MΩ x km Excellent Insulation resistance

HR PVC 10°C to 90°C 100 MΩ x km Heat resistant

PVC 10°C to 70°C 100 MΩ x km ----------

FR PVC 10°C to 70°C 100 MΩ x km Fire retardant

FRLS PVC 10°C to 70°C 100 MΩ x km Fire retardant, low smoke

ü Cement plantsü Instrumentationü Ferrous or non ferrous metal Plantsü Power plants

Application


Conductor: • Electrolytic grade annealed bare or tinned

copper • Copper purity upto 99.98% • In Solid or Stranded construction • Specifications followed for conductor diameter, stranding and resistance IS 8130:84 / DIN VDE 0295 Core Insulation: PVC/ FRPVC/FRLS PVC/ HR PVC /PE

Core laying: Upto 37 cores of 1.5 sq mm and 2.5 sq mm and Single core, 2 cores, 3 cores or 4 cores upto 35 sq mm

Color coding: Numbered cores or as per IS 694, DIN VDE 0293 or DIN VDE 0245 or DIN VDE or DIN VDE 47100 or DIN VDE 0813

Screening: With copper / silver or nickel Plated /Tinned plated copper screened / Almyler Screening Individual & Overall with Drain Wire

Inner sheath: PVC/ FRPVC/FRLS PVC/ HR PVC /PE

Armoring: By Galvanized wire/ stripe as per IS 3975

Outer sheath: PVC/ FRPVC/FRLS PVC/ HR PVC /PE

High Temperature Control Cable for Voltage Rating upto 1100 V (Max. temperature 700°C)

In various plants especially steel or glass plants, where ambient temperature is high. high temperature insulation is essential for Control cables. Tempsens provides a variety of high temperature insulation material like PTFE, FEP, PFA and silicon. These insulating material provide great inertness with various chemicals, oil or grease, and having excellent insulation resistance and make cables light weight and miniaturized. Extra high temperature insulating material like varnished glass fiber, Silica, mica and asbestos in braiding or taping form generally used for heat protection and sometimes used for primary (core) insulation also.

Voltage grade: upto 1100 Volt


Conductor:• Nickel, Electrolytic grade nickel plated copper (NPC), Silver plated copper (SPC), Tin Plated copper (TPC) or bare copper (BC)• In Solid or Stranded construction• Specifications followed for conductor diameter, stranding and resistance ASTM B 355

Core Insulation: PTFE/ Fibre glass/ Kapton/ FEP/ PFA/ PVC

Core laying: Upto 37 cores of 1.5 sq mm and 2.5 sq mm and Single core, 2 cores, 3 cores or 4 cores upto 35 sq mm

Outer sheath: As per requirement

Braiding: Stainless steel braiding by SS wire from 0.08 mm to 0.15 mm with or without Varnished fibre glass heat protective shield

Color coding: Numbered cores or as per IS 694, DIN VDE 0293 or DIN VDE 0245 or DIN VDE or DIN VDE 47100 or DIN VDE 0813

Armoring: By Galvanized wire/ stripe as per IS 3975

ü Cement plantsü Instrumentationü Ferrous or non ferrous metal Plantsü Kilnsü Glass Plants

Application

Teps

es

Mak

e

m

n



Ceramic fibre

(Braided)

-72°C to +800°C Extra High temperature



Kapton (Tapped)

-260°C to +310°C Thin insulation, Temperature

PEEK (Extruded)


PTFE (Tapped)


PFA (Extruded)


Silicon (Extruded)


FEP (Extruded)


Resistance

Resistance

High Temperature Copper Conductor Equipment Wire (Hookup wire) upto 350°C

Flexibility: Excellent

HV Testing:

Insulation Thickness:

Continuous Voltage rating

Insulation thickness (mm)

250 V 0.15 to 0.18

600 V 0.22 to 0.30

1000 V 0.35 to 0.55

Continuous Voltage rating

Dielectric test (kV, 1 minute)

Spark test (kV, 1 second)

250 V 1.5 2.5

600 V 2.0 3.4

1000 V 3.0 5.0

High temperature insulated equipment wires are available in various cross sectional area, conduction material and insulating materials.The materials are design for MIL/JSS specifications.


Conductor: • Bare copper (as per IS 5830)• Silver plated copper (per ASTM B 298)• Nickel plated copper (per ASTM B 355)• Silver plated High strength copper alloy (SPHSCA)• Silver plated copper clad steel (SPCCS)• Annealed Tinned Copper• Nickel

Conductor Stranding: Solid stranded or fine stranded

Insulation: PTFE/ Fibre glass/ Mica/ Kapton/ FEP/ PFA/ Silicon; PEEK insulation in nuclear radiation environment ( Refer table 4)

Braiding: Stainless steel braiding by SS wire from 0.08 mm to 0.13 mm with or without Varnished fibre glass heat protective shield

ü Steel or Sponge iron plantü Glass Plantü Chemical plants or laboratories ü Power plantü Non ferrous metal plantü Panels / Drives or other components

Application


Insulation Temp. range Insulation resistance

Water Submersion


-72°C to +350°C Good Excellent

Kapton (Tapped)

-260°C to +310°C Good Good

PTFE (Tapped)

-260°C to +260°C Excellent Excellent

PFA (Extruded)


Silicon (Extruded)


FEP (Extruded)


mse

Ma

Tep

ns

ke

Power cable for LT usage, suitable for high temperature (400°C) are available in required cross sectioned area and in 2, 3 and 4 core. These cables are used for two voltages electrical power stations, Indoors and Outdoors.

High Temperature Insulation LT Power Cable

Sleeves

Inner Diameter : 0.5mm to 20mmInsulation Wall Thickness : 0.20 to 1 mmVoltage Grade: Upto 17 KVTemperature Range: -260°C to 1200°CColor: As per Customer Requirement

Sleeves suitable for high temperature in various insulation such as PTFE, FEP, High Temperature Fibre Glass, Silicon Insulated Fibre Glass available

ü Cement plantsü Steel Plantsü Kilns

ü Glass Plantsü Power Plants

Application

Conductor Annealed Bare and Nickel Plated Copper

Core Insulation

PTFE with Kapton Laying

Over All Insulation Kapton/ PTFE Mica/ Fibre Glass Braiding

Over All Braiding Stainless Steel or Galvanized Iron

Color Coding Core Color - Red, Yellow, Blue for Phase & Black for Neutral

Voltage Grade Upto 1.1 KV

Temperature Range

(Ambient Temp.)

400°C

Construction Features

Maximum Size in mm : upto 50mm

LT POWER / H.R. CABLE

Conductor (Upto 25 Sqmm)

Fibre Glass Braiding

SS Braiding

PTFE With Kapton Lining

Cores As Required

Over All Kapton Wrapping

PTFE Insulation

Mica Tapping

0 0.324 8.23 0.3249 8.25 1 0.300 7.62 0.2893 7.35 2 0.276 7.01 0.2576 6.54 3

0.252

6.40

0.2294

5.83

4

0.232

5.89

0.2043

5.19

5

0.212

5.38

0.1819

4.62

6

0.192

4.88

0.1620

4.11

7

0.176

4.47

0.1443

3.67 8

0.160

4.06

0.1285

3.26

9

0.144

3.66

0.1144

2.91 10

0.128

3.25

0.1019

2.59

11

0.116

2.95

0.0907

2.3 12

0.104

2.64

0.0808

2.05

13

0.092

2.34

0.0720

1.83

14

0.080

2.03

0.0641

1.63

15

0.072

1.83

0.0571

1.45

16

0.064

1.63

0.0508

1.29

17

0.056

1.42

0.0453

1.15

18

0.048

1.22

0.0403

1.02

19

0.040

1.02

0.0359

0.912

20

0.036

0.914

0.0320

0.813

21

0.032

0.813

0.0285

0.724

22

0.028

0.711

0.0253

0.643

23

0.024

0.610

0.0226

0.574

24 0.022 0.559 0.0201 0.511

25 0.020 0.508 0.0179 0.455

Conductor Size Equivalents (Diameter)

Specifications of PTFE Wires (AS PER JSS 51034)

Size Dia of Cross Max Resistance CurrentCond- Sectional of Conductor Ratinguctor area OHMS/KM

AWG AWG (mm) (mm) mm2 Min(mm)Max(mm) Min(mm) Max(mm)Min(mm) Max(mm) at 20°C (amps)

32 7/40 7/0.08 0.25 0.035 0.50 0.60 0.66 0.86 0.91 1.11 567 0.730 1/30 1/0.25 0.25 0.049 0.50 0.60 0.66 0.86 0.91 1.11 354 1.030 7/38 7/0.10 0.31 0.055 0.55 0.66 0.71 0.91 0.96 1.16 330 1.028 1/28 1/0.32 0.32 0.080 0.58 0.68 0.73 0.93 0.99 1.19 223 2.128 7/36 7/0.13 0.38 0.093 0.63 0.73 0.78 0.99 1.04 1.24 209 2.126 1/26 1/0.40 0.40 0.125 0.66 0.76 0.81 1.01 1.06 1.27 140 3.026 7/34 7/0.16 0.48 0.140 0.73 0.83 0.88 1.09 1.14 1.34 132 3.026 19/38 19/0.10 0.51 0.149 0.73 0.83 0.88 1.09 1.14 1.34 125 3.024 1/24 1/0.51 0.51 0.204 0.76 0.86 0.91 1.11 1.16 1.37 87 4.024 7/32 7/0.20 0.61 0.219 0.86 0.96 1.01 1.21 1.27 1.47 82 4.024 19/36 19/0.13 0.64 0.252 0.86 0.96 1.01 1.21 1.27 1.47 79 4.022 1/22 1/0.64 0.64 0.321 0.88 1.01 1.04 1.27 1.29 1.52 55 7.322 7/30 7/0.25 0.76 0.343 1.01 1.11 1.16 1.37 1.42 1.62 52 7.322 19/34 19/0.16 0.81 0.382 1.01 1.11 1.16 1.37 1.42 1.52 49 7.320 1/20 1/0.81 0.81 0.515 1.06 1.16 1.21 1.42 1.47 1.67 34 11.020 7/28 7/0.32 0.97 0.562 1.21 1.32 1.37 1.57 1.62 1.82 32 11.020 19/32 19/0.20 1.02 0.596 1.21 1.32 1.37 1.57 1.62 1.82 30 11.018 7/26 7/0.40 1.22 0.879 1.63 1.87 1.87 2.13 20 16.018 19/30 19/0.25 1.27 0.932 1.63 1.87 1.87 2.13 18 16.016 19/29 19/0.29 1.45 1.254 1.85 2.20 2.10 2.41 14 22.015 19/28 19/0.32 1.60 1.528 1.98 2.28 2.26 2.54 12 26.014 19/27 19/0 36 1 83 1 933 2.23 2.59 2.48 2.89 9 32.013 19/26 19/0.40 2.00 2.387 2.43 2.74 2.66 3.02 7 35.012 19/25 19/0.45 2.31 3.021 2.71 3.07 2.97 3.37 5 41.012 37/28 37/0.32 2.26 2.975 2.66 3.02 2.92 3.32 6 41.011 19/24 19/0.50 2.50 3.730 2.99 3.30 3.20 3.58 4 45.010 19/22 19/0.65 3.25 6.304 3.73 4.03 3.96 4.34 2 55.010 37/26 37/0.4 2.82 4.649 3.22 3.58 3.47 3.88 3 50.08 133/29 133/0.29 4.29 8.784 5.05 5.56 2 75.06 133/27 133/0.36 5.41 13.537 6.42 6.93 1 100.0

each Strand Insulation Insulation Insulation

Number of ET 250 V E 600 V EE 1000 VStrands / Dia of OD of OD of OD of

Table-3

Table-4

26 0.018 0.457 0.0159 0.404 27 0.0164 0.417 0.0142 0.361 28 0.0148 0.376 0.0126 0.320 29

0.0136

0.345

0.0113

0.287

30

0.0124

0.315

0.0100

0.254

31

0.0116

0.295

0.0089

0.226

32

0.0108

0.274

0.0080

0.203 33

0.0100

0.254

0.0071

0.180

34

0.0092

0.234

0.0063

0.160 35

0.0084

0.213

0.0056

0.142

36

0.0076

0.193

0.0050

0.127 37

0.0068

0.173

0.0045

0.114

38

0.006

0.152

0.0040

0.102

39

0.0052

0.132

0.0035

0.089

40

0.0048

0.122

0.0031

0.079

41

0.0044

0.112

0.0028

0.071

42

0.0040

0.102

0.0025

0.064

43

0.0036

0.091

0.0022

0.056

44

0.0032

0.081

0.0020

0.051

45

0.0028

0.071

0.0018

0.046

46

0.0024

0.061

47

0.0020

0.051

48

0.0016

0.041

49

0.0012

0.030

50 0.0010 0.025

SWG = (BRITISH) STANDARD WIRE GAUGE B & S = BROWN AND SHARPE AWG = AMERICAN WIRE GAUGE

No.

SWG B & S(AWG)

inches mm inches mmNo. SWG B & S(AWG)

inches mm inches mm

THERMAL ENGINEERING SOLUTIONS

CHINATempsens Instruments UGLoehestrasse 37,53773 Hennef, GERMANYPh.:+49-2242-8703-0Fax.:+49-2242-8703-20Email: [email protected]

WUXI Tempsens Instruments Co. Ltd.Rm 911,ShiDaijieDou, No.655, Hubin Rd.,Binhu District, Wuxi, Jiangsu, CHINAPh.:+86-510-385116563Fax.:+86-510-385116563Email: [email protected]

Tempsens Instruments (l) Pvt. Ltd. U# lB-188A, Road No.5, M.I.A,.Udaipur-313003 (Rajasthan) INDIAPh.:+91-294-3057700 to 800Fax.:+91-294-3057750Email: [email protected]

Tempsens Instruments (l) Pvt. Ltd. U# llA-190, Road No.5, M.I.A,.Udaipur-313003 (Rajasthan) INDIAPh.:+91-294-3052900Fax.:+91-294-3052950Email: [email protected] [email protected]

INDIA GERMANY

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