Industrial Control Cable — VDE 0812/0815 / IEC 60227 Multi-Core PVC/XLPE Insulated and PVC Sheathed Flexible Control Cable with Numbered Cores, Optional Overall Shield, and 300/500 V Rating for Industrial Automation, PLC I/O, Relay and Contactor Wiring, Machine Tool Control, and Conveyor System Interconnection
Industrial, Mining & Control Cables /Industrial Control Cable

Industrial Control Cable — VDE 0812/0815 / IEC 60227 Multi-Core PVC/XLPE Insulated and PVC Sheathed Flexible Control Cable with Numbered Cores, Optional Overall Shield, and 300/500 V Rating for Industrial Automation, PLC I/O, Relay and Contactor Wiring, Machine Tool Control, and Conveyor System Interconnection

Industrial control cable: VDE 0812/0815 / IEC 60227, multi-core PVC/XLPE insulated, PVC sheathed, 300/500V. 2-61 cores, 0.5-35 mm². Numbered cores, optional overall shield. For PLC, relay, contactor, machine tool, conveyor control wiring. Flame retardant. CE, RoHS, VDE.

Key Features

VDE 0812 / VDE 0815 / IEC 60227 compliant — the German and international standards for multi-core flexible control cables; VDE 0812 covers screened (shielded) control cables and VDE 0815 covers unscreened types; the standards define the core count, conductor cross-section, insulation thickness, core numbering, and test requirements
2–61 cores, 0.5–35 mm² — the full industrial control cable range from a simple 2-core start/stop circuit cable to a 61-core cable carrying all the I/O signals between a PLC rack and a remote terminal block; the high core count eliminates multiple smaller cables and simplifies the control panel wiring
Numbered black cores per VDE 0293 — each core is printed with a number (1, 2, 3...N) along its length; the numbering is permanent (heat-embossed or printed with durable ink that does not rub off during cable stripping and termination); the installer identifies each core by its number and connects it to the corresponding terminal per the wiring diagram
Optional overall tinned copper braid shield (≥85% coverage) — the screen protects the low-voltage (24 V DC) control signals from electromagnetic interference coupled from adjacent power cables in the same cable tray or conduit; the screen also prevents the control cable's switching transients (relay coil flyback, contactor inrush) from radiating EMI that could affect sensitive instrumentation circuits
PVC or XLPE core insulation — PVC (70°C) for standard industrial control applications where the control panel and cable route ambient temperature does not exceed 40°C; XLPE (90°C) for control cables routed through higher-temperature areas of the plant (near furnaces, ovens, steam pipes) or where the control panel internal temperature is elevated by power electronics heat dissipation
PVC outer sheath — the standard sheath for industrial control cables; grey (RAL 7001) for indoor general industrial control; black (RAL 9005) for outdoor and heavy industrial; transparent (for visual inspection of the core assembly, typically for low-voltage control panel wiring only)
Flexible Class 5 stranded copper conductor — the stranded construction provides the flexibility to route the cable from the PLC panel through the cable tray, down the conduit, and into the machine's terminal box without the cable fighting the installer or kinking at tight bends
Flame retardant to IEC 60332-1-2 — the cable does not propagate fire along its length; in the cable-intensive environment of an industrial control room or cable tray, fire propagation along control cables from a single ignition point is a significant fire safety hazard that flame-retardant cable construction mitigates

Applications

PLC I/O wiring — multi-core control cable connecting the PLC output modules to the relay and contactor terminals in the motor control centre (MCC); a 25-core cable carries the PLC outputs for 25 motor starters, replacing 25 individual 2-core cables and reducing the control panel wiring density and installation timeMachine tool control wiring — multi-core cable for the control circuits of CNC machine tools, transfer lines, and special-purpose production machinery; the cable connects the machine's operator panel, limit switches, solenoid valves, and sensor inputs to the control cabinetConveyor and material handling control — control cable for the distributed motor starters, position sensors, and emergency stop circuits along a conveyor system; a single multi-core cable runs along the conveyor route, connecting to junction boxes at each motor and sensor locationProcess plant motor control — multi-core control cable from the DCS (distributed control system) marshalling cabinet to the motor starter panel for each process pump, fan, and compressor; the cable carries the start/stop, running feedback, fault, and speed reference signals per the motor control philosophyBuilding services control — control cable for HVAC damper actuators, VAV box controllers, boiler and chiller control, and lighting contactor circuits in commercial building automation systemsWater and wastewater treatment — control cable for pump starters, valve actuators, level sensors, and flow meter connections in water and wastewater treatment plants where the cable is often installed in outdoor, damp, and corrosive environments

Technical Specifications

Standard VDE 0812 (Screened flexible control cables with PVC insulation); VDE 0815 (Unscreened flexible control cables with PVC insulation); IEC 60227 (PVC insulated cables — applicable general requirements for control cable construction); HD 21 (CENELEC harmonized document for PVC cables)
Type Designation — Unscreened Various national designations: ÖLFLEX Classic 100 (Lapp Kabel — the industry reference for unscreened control cable); YSLY (PVC/PVC flexible control, Germany); JZ-500 (VDE 0815 unscreened control cable type)
Type Designation — Screened ÖLFLEX Classic 110 (screened variant); YSLYCY (PVC/PVC screened control, Germany); the 'CY' suffix indicates a tinned copper braid screen
Rated Voltage (U₀/U) 300/500 V (the standard voltage class for industrial control circuits — relay logic at 24 V DC or 110/230 V AC, PLC I/O at 24 V DC, contactor coils at 24–230 V AC)
Conductor Material Bare copper (standard) or tinned copper (for humid/corrosive environments); IEC 60228 Class 5 flexible stranded; single wire diameter 0.20–0.41 mm depending on cross-section
Conductor Cross-Sections 0.5, 0.75, 1.0, 1.5, 2.5 mm² (standard control cable range); 4, 6, 10, 16, 25, 35 mm² (for power control circuits where the control cable also carries motor power — e.g., direct-on-line starter wiring from the contactor to the motor)
Core Count — Standard Range 2, 3, 4, 5, 7, 12, 18, 25, 37, 50, 61 cores
Core Insulation — PVC PVC type TI1 per IEC 60227; 70°C continuous; the insulation is colour-coded with numbering — the base colour is black (standard for control cable) and the core number is printed in white numerals
Core Insulation — XLPE (Optional) XLPE; 90°C continuous; for control cables routed through elevated-temperature areas of the plant
Core Numbering Sequential numbering starting from 1; the numbering repeats every 500 mm along the core length; the number size and print quality are specified by VDE 0293 to ensure legibility at the stripped conductor end in the control panel terminal — the installer must be able to identify the core number at the point of termination without tracing the core back through the cable
Core Layering — Multi-Core Assembly For core counts up to 37, the cores are arranged in concentric layers around a central filler; each layer is stranded in the opposite direction to the previous layer (SZ or alternating lay) to prevent the cable from untwisting when cut; for 50 and 61 cores, multiple concentric layers are used with an increased overall cable OD
Binder Tape Polyester or PP tape wrap over the core assembly; provides mechanical stability for the screen application (screened types) or the sheath extrusion (unscreened types)
Overall Shield — Screened Types Tinned copper braid; ≥85% coverage; the shield provides EMI protection and serves as a common ground reference for all cores; the shield must be terminated at the earth terminal in the control panel — do not leave the shield floating or terminated at only one end (unless the installation is designed for single-point bonding to avoid ground loops)
Outer Sheath — PVC PVC type ST5 (flexible); grey RAL 7001 (standard indoor industrial control); black RAL 9005 (outdoor and heavy industrial); transparent (control panel internal wiring, on request); the sheath thickness per VDE 0812/0815 is designed for the industrial environment — thicker than a building wiring cable sheath to provide the mechanical protection for the cable tray and conduit installation environment
Sheath Marking Meter marking (sequential meter numbers printed along the sheath) for easy cable length measurement from the reel; the marking interval is typically 1 m with the number incrementing each meter
Maximum DC Conductor Resistance at 20°C Per IEC 60228 Class 5; 39.0 Ω/km (0.5 mm²) to 0.554 Ω/km (35 mm²)
Insulation Resistance at 20°C — PVC ≥20 MΩ·km (core-to-core at 500 V DC, 1 min)
Test Voltage (AC) — Routine 2 000 V AC / 5 min (core-to-core, core-to-screen); the test voltage is applied to every core combination on the finished cable per VDE 0812/0815
Temperature — Flexing -5°C to +50°C (PVC insulation becomes stiffer at low temperatures; for installation in unheated buildings or outdoor winter conditions, warm the cable before installation or specify XLPE insulation for cold-flex performance)
Temperature — Fixed -30°C to +70°C (PVC); -30°C to +90°C (XLPE)
Minimum Bend Radius — Flexing During Installation 15× cable OD (unscreened); 20× cable OD (screened — the braid screen limits the bend radius because tight bends can open the braid, reducing the coverage and EMI protection)
Minimum Bend Radius — Fixed Routing 6× cable OD
Current Rating — Single Core in Control Cable Bundle (Typical, 30°C Ambient, PVC 70°C) 0.5 mm² = 3 A; 0.75 mm² = 6 A; 1.0 mm² = 10 A; 1.5 mm² = 16 A; 2.5 mm² = 25 A; the current rating of individual cores in a multi-core control cable is de-rated compared to a single-core cable in free air because the cores are bundled together and mutually heated — the de-rating increases with the core count (a 25-core cable has a de-rating factor of approximately 0.4–0.5 compared to the single-core free-air rating)
Flame Retardant IEC 60332-1-2 (single cable); IEC 60332-3 Cat C (bunched, on request for cable tray installations)
Oil Resistance — PVC Sheath Moderate — the PVC sheath resists occasional contact with mineral oils but is not oil-resistant for prolonged immersion; for oil-exposed industrial environments (machine tool coolant, hydraulic oil), specify a PUR-sheathed control cable or provide cable protection (conduit)
Certifications CE; RoHS; VDE registration on request; HAR (harmonized) marking on request; ISO 9001 manufactured

Detailed Description

What Is Industrial Control Cable?

Industrial control cable is a multi-core flexible cable with numbered PVC-insulated cores and a PVC outer sheath, designed for the control circuits of industrial automation equipment — the cables that carry the 24 V DC signals from the PLC output module to the relay coil, the 110 V AC contactor coil circuits in the motor control centre, the limit switch and pushbutton wiring on the machine tool control panel, and the sensor input wiring back to the PLC input module. It is the most common cable in any industrial control panel or motor control centre — the grey-jacketed, multi-core cable that connects the automation system to the plant equipment.

In the VDE (German) and international standards, the industry reference for industrial control cable is the VDE 0812 (screened) / VDE 0815 (unscreened) type, commonly known in the market by the Lapp Kabel ÖLFLEX brand designation. The core count (2 to 61 cores), the numbered core identification (each core printed with its number), the 300/500 V voltage rating, and the flexible Class 5 stranded copper conductor define the cable type. It is not a power cable — it is a signal and low-power control cable, designed to carry the milliamps to single-digit amp currents of industrial control circuits.

Why Choose Yichi Industrial Control Cables

  • VDE 0812/0815 / IEC 60227 compliant — the definitive control cable standard: The core insulation thickness, sheath thickness, core numbering legibility, spark test voltage, and finished cable high-voltage test are all per the VDE/IEC standard. The cable is not "similar to VDE 0815" — it is manufactured to meet the standard's requirements, and the construction is verified by routine testing on every production length
  • 2–61 cores, 0.5–35 mm² — the full control cable range: From 2-core start/stop circuits to 61-core PLC I/O marshalling cables — one cable type for the entire control system wiring specification. Consistent quality, consistent dimensional tolerances, and consistent core numbering legibility across the full core count range
  • Screened or unscreened — select for the EMI environment: Screened (VDE 0812 type) for control cables sharing a cable tray with VFD motor cables and power distribution circuits where EMI from the power conductors would couple into the control signals and cause erratic PLC input readings or relay coil chatter. Unscreened (VDE 0815 type) for dedicated control cable routes with no EMI risk and where the cost saving from the simpler cable construction is significant
  • Numbered cores — permanent, legible identification: The core numbers are the installer's only identification at the terminal strip. The numbering is printed with durable ink or heat-embossed, verified to remain legible after the cable has been pulled through conduit, stripped, and terminated. The number repeats every 500 mm along the core, and the last number before the stripped end is the core's identification — the installer does not need to trace the core back to find its number
  • Meter-marked sheath for length measurement from the reel: The sequential meter marking printed along the outer sheath enables the installer to measure the cable length directly from the reel — no separate measuring tape, no "I think that's about 20 meters" estimation. The meter mark is the definitive cable length for billing, stock control, and verifying that the cable reel contains the specified length

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Product: Industrial Control Cable — VDE 0812/0815 / IEC 60227 Multi-Core PVC/XLPE Insulated and PVC Sheathed Flexible Control Cable with Numbered Cores, Optional Overall Shield, and 300/500 V Rating for Industrial Automation, PLC I/O, Relay and Contactor Wiring, Machine Tool Control, and Conveyor System Interconnection

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