What Are Control Cables? Types, Uses & Selection Guide

What are control cables? Control cables are multi-core electrical cables used to transmit commands, switching signals, control functions and, in suitable circuits, low-voltage electrical energy between industrial equipment. They commonly connect control panels, PLC systems, relays, contactors, actuators, motors, valves and other automation devices.

However, control cable is not one fixed construction. Some designs use PVC insulation and sheath, while others use halogen-free materials. In addition, engineers can choose screened or unscreened versions, different conductor sizes, different core-identification systems and different voltage ratings.

For example, YSLY is an unscreened flexible PVC control-cable family. YSLCY adds a tinned-copper braid screen. YSLYCY adds both screening and an additional inner sheath. Meanwhile, HSLH and HSLCH families use halogen-free materials for projects that require a different fire and material strategy.

Therefore, selecting the correct control cable requires more than choosing a familiar product code. Engineers should define the electrical circuit, conductor size, core count, voltage rating, electromagnetic environment, installation method, sheath material and fire requirements.

ETK Kablo manufactures a broad industrial automation cable portfolio for machinery, control panels, production systems, HVAC, building automation and other control applications.

Quick answer: Control cables connect control equipment and field devices in automation systems. Choose an unscreened design where electromagnetic interference is limited. Select a screened construction when the route requires additional EMI protection. Then specify PVC or halogen-free materials, conductor size, voltage rating and core identification according to the actual circuit and installation environment.

What Are Control Cables Used For?

What are control cables used for in practice? Their main role is to connect devices that command, monitor or coordinate industrial and building systems.

Typical circuits include:

• PLC outputs
• Relay circuits
• Contactor control
• Motor-start commands
• Valve and actuator control
• Machine interlocks
• Limit switches
• Control-panel field connections
• HVAC controls
• Conveyor systems
• Production-line controls
• Building automation

As a result, control cables appear in almost every automated industrial facility.

Nevertheless, the cable does not define the control protocol by itself. The connected equipment and circuit design determine what signal or electrical function travels through each core.

What Are Control Cables Made Of?

A typical flexible control cable contains several insulated copper conductors assembled into one multi-core cable.

The construction can include:

• Class 5 stranded copper conductors
• PVC or halogen-free insulation
• Number-coded or color-coded cores
• Green-yellow protective conductor where required
• Polyester tape or another separator
• Tinned-copper braid screen
• Al/PET foil in selected screened designs
• Inner sheath in specific constructions
• PVC or halogen-free outer sheath

However, not every control cable contains every layer. The project requirements determine the final construction.

Control Cable Construction at a Glance

Component	Typical Option	Main Function
Conductor	Class 5 stranded copper	Electrical conduction and installation flexibility
Insulation	PVC or halogen-free compound	Electrical separation between cores
Core identification	Number or color coding	Installation and circuit identification
Protective conductor	Green-yellow core where specified	Protective-earth connection
Screen	Tinned-copper braid and/or foil	EMI control
Inner sheath	Product-dependent	Additional structural layer
Outer sheath	PVC or halogen-free compound	Mechanical and environmental protection

Therefore, product names that look similar can hide meaningful structural differences.

Class 5 Copper Conductors

Many ETK flexible control-cable families use Class 5 stranded copper conductors.

IEC 60228 defines conductor classes and resistance requirements for insulated cable conductors. The current IEC 60228:2023 standard includes requirements for flexible copper conductors such as Class 5.

Class 5 construction uses multiple fine copper wires rather than one solid conductor. Therefore, it provides greater installation flexibility than a solid conductor of the same nominal cross-section.

However, an important distinction is necessary:

Class 5 flexible conductor does not automatically mean continuous-flex cable.

A cable can use Class 5 conductors and still be intended mainly for fixed installation or occasional movement. Continuous movement in drag chains, robotics or repeated torsion requires a cable specifically designed and tested for that duty.

Flexible Does Not Mean Drag-Chain Rated

This distinction prevents a common specification mistake.

A standard flexible industrial control cable can simplify routing inside machinery and panels. It can also tolerate movement during installation.

However, repeated dynamic movement creates a different mechanical load.

Applications such as these need dedicated evaluation:

• Drag chains
• Robotics
• Repeated bending
• Torsional movement
• High-cycle machine axes
• Moving gantries

Therefore, buyers should never infer continuous-flex capability from the word “flexible” alone.

YSLY Control Cable

YSLY represents one of the most common flexible PVC control-cable families.

A typical construction uses:

• Class 5 stranded copper conductors
• PVC conductor insulation
• Layer stranding
• PVC outer sheath
• No metallic screen

As a result, YSLY provides a relatively simple and flexible construction for control circuits where strong electromagnetic interference is not a major concern.

Typical applications include machine wiring, control cabinets, production lines, HVAC systems and conveyor equipment.

YSLY-JZ Control Cable

YSLY-JZ combines the YSLY construction with a particular core-identification arrangement.

ETK Kablo’s YSLY-JZ product uses Class 5 stranded copper conductors, PVC insulation and a PVC outer sheath. The cores are black with white numbers and include a green-yellow protective conductor.

ETK’s current standard YSLY-JZ range includes conductor sizes from 0.50 mm² to 16 mm² and a published operating-voltage value of 300/500 V for these variants.

However, buyers should always use the datasheet for the exact ordered size and construction.

JZ, OZ, JB and OB: What Do the Codes Mean?

Control-cable designations often include additional letters that describe core identification and the presence of a protective conductor.

Code	Typical Meaning
JZ	Number-coded cores with green-yellow protective conductor
OZ	Number-coded cores without green-yellow protective conductor
JB	Color-coded cores with green-yellow protective conductor
OB	Color-coded cores without green-yellow protective conductor

This identification system helps installation teams select the correct cable for panel and machine wiring.

Nevertheless, buyers should verify the manufacturer’s actual product documentation. Commercial naming conventions can vary across markets and product families.

Screened vs Unscreened Control Cable

One of the most important decisions involves electromagnetic screening.

An unscreened cable relies on its basic conductor geometry and installation environment. Therefore, it can provide an efficient solution where EMI levels remain controlled.

A screened construction adds a conductive layer around the cable core. A tinned-copper braid is common in flexible industrial control cables.

The screen can help reduce the influence of external electromagnetic fields on sensitive circuits.

However, more screening does not automatically create a better cable. Screening increases material, diameter, weight and termination requirements.

Therefore, the route should justify the screen.

When Should You Use a Screened Control Cable?

Screened designs become more relevant where control circuits run near strong electrical-noise sources.

Examples include:

• Variable-frequency drives
• Large electric motors
• Transformers
• Switchgear
• High-current power cables
• Power converters
• Dense industrial electrical panels

In these environments, a copper braid can improve electromagnetic compatibility.

However, correct routing, separation and screen termination remain important. A screened cable alone cannot repair poor system design.

YSLY vs YSLCY vs YSLYCY

These three families illustrate how one basic control-cable concept changes through screening and additional construction layers.

Feature	YSLY	YSLCY	YSLYCY
Conductor	Class 5 copper	Class 5 copper	Class 5 copper
Insulation	PVC	PVC	PVC
Metallic screen	No	Tinned-copper braid	Tinned-copper braid
Inner sheath	No	No extruded inner sheath in the standard ETK construction	PVC inner sheath
Outer sheath	PVC	PVC	PVC
General selection direction	Low-EMI control	Screened control	Screened control with additional inner-sheath structure

Therefore, the difference between YSLCY and YSLYCY is not simply screening. Both are screened. The additional inner sheath distinguishes YSLYCY from ETK’s standard YSLCY construction.

For a complete technical comparison, see our YSLY, YSLCY and YSLYCY comparison.

PVC Control Cables

PVC remains widely used in industrial control cabling.

It can provide a practical combination of:

• Flexibility
• Mechanical durability
• Cost efficiency
• Processability
• Industrial installation convenience

For this reason, YSLY and related families commonly use PVC insulation and sheath systems.

However, PVC does not suit every fire or material requirement.

Halogen-Free Control Cables

Projects that prioritize low-smoke and halogen-free materials can use HSLH or HSLCH-type constructions.

In general terms, the halogen-free family replaces the PVC insulation and sheath approach with halogen-free compounds.

Meanwhile, screened versions add electromagnetic protection where required.

However, halogen-free does not automatically mean fire-resistant. It also does not automatically define a specific CPR Euroclass.

These are separate properties.

For a broader material comparison, see our LSZH vs PVC cable guide.

Flame Retardant vs Fire Resistant

Control-cable specifications often mix these two concepts.

A flame-retardant test evaluates how a cable behaves when exposed to flame and whether flame propagation remains within defined criteria.

Fire resistance addresses a different question: can the cable maintain its required electrical function during a specified fire test?

Therefore, a cable that passes a flame-propagation test does not automatically provide fire-resistant circuit integrity.

Likewise, LSZH material characteristics do not automatically create fire resistance.

Control Cable Voltage Ratings

There is no single universal voltage rating for all control cables.

ETK’s current product portfolio includes common control families at 300/500 V as well as dedicated 450/750 V constructions.

Therefore, engineers should select the voltage class from the actual circuit and the exact product datasheet.

Do not assume that two cables with similar names have identical voltage ratings.

300/500 V vs 450/750 V Control Cable

The higher voltage designation does not automatically make a cable better for every application.

The correct choice depends on the electrical circuit and applicable installation rules.

A 300/500 V control cable can provide the appropriate solution for many automation circuits. Meanwhile, other machine or industrial systems may require a 450/750 V product family.

Therefore, voltage rating should form part of the original specification rather than an afterthought.

What Conductor Size Should a Control Cable Use?

Control-cable conductor sizes vary according to circuit function.

Common sizes include:

• 0.50 mm²
• 0.75 mm²
• 1.00 mm²
• 1.50 mm²
• 2.50 mm²
• 4.00 mm²
• 6.00 mm²
• Larger project-specific sizes

However, popularity should not determine conductor size.

Engineers should consider:

• Circuit current
• Route length
• Voltage drop
• Conductor resistance
• Protective-device requirements
• Terminal size
• Ambient temperature
• Installation conditions

As a result, one machine can use several conductor sizes across different control circuits.

How Many Cores Should a Control Cable Have?

Control cables can contain a few cores or several dozen.

The required number depends on the automation architecture.

For example, a simple actuator can need only a few connections. By contrast, a large field junction or machine interface can require many individual control circuits in one cable.

However, additional spare cores can also help future expansion.

The project should therefore balance current demand, spare capacity, cable diameter and termination complexity.

What Are Control Cables in Industrial Automation?

What are control cables in an automation system? They form the electrical connection between the control logic and the equipment that carries out commands.

A typical system can include:

• PLC
• Control panel
• Relays
• Contactors
• Motor starters
• Valves
• Actuators
• Limit switches
• Machine sensors
• Field junction boxes

Control cabling allows these components to interact reliably.

However, high-speed industrial Ethernet, precision instrumentation and servo-motor power circuits may require different specialized cable families.

Control Cable vs Signal Cable

Control and signal cables can overlap in real industrial systems. However, their design priorities often differ.

Control cables commonly handle switching, commands, interlocks and auxiliary control circuits. They often use multi-core Class 5 conductors and relatively broad conductor-size ranges.

Signal cables often focus more heavily on low-level signal transmission, capacitance and electromagnetic protection.

For example, LIYY, LIYCY, LIHH and LIHCH belong to ETK’s separate signal and low-level control range.

Therefore, designers should classify the actual circuit rather than choosing between the words “signal” and “control” from a product name alone.

YSLY vs LIYY: Are They the Same?

No.

Both can use flexible copper conductors and PVC materials, but they belong to different product families and serve different specification priorities.

YSLY commonly addresses industrial control and machine circuits. LIYY commonly serves lower-level signal and electronic-control applications.

Likewise, YSLCY and LIYCY are both screened families, but this does not make the products interchangeable.

Conductor sizes, electrical values, core identification, voltage classes and intended applications can differ.

For the LI-family structure, see our LIYCY, LIYY, LIHCH and LIHH comparison.

Control Cable vs Instrumentation Cable

Instrumentation cables focus on measurement and process signals.

Typical circuits include:

• 4–20 mA loops
• RTD connections
• Pressure transmitters
• Flow transmitters
• Temperature measurement
• Process sensors

As a result, instrumentation cables often use pair or triad architectures. They can also use individual and overall screens.

Control cables, by contrast, commonly use multi-core structures for commands, interlocks and equipment control.

For a deeper explanation, see our instrumentation cable guide.

Control Cable vs Power Cable

A control cable should not automatically replace a power-distribution cable.

Power cables primarily carry electrical energy to loads. Therefore, current-carrying capacity, insulation system and power-cable standards dominate their design.

Control cables primarily serve command, switching and auxiliary functions.

Some control cables can carry low-voltage electrical energy within their specified limits. However, this does not turn them into general-purpose power-distribution cables.

The circuit function and applicable product standard should determine the cable family.

Control Cable vs Data Cable

Control cables also differ from Ethernet and other high-frequency data cables.

A Cat 6 cable, for example, uses controlled twisted-pair geometry and transmission requirements for Ethernet.

A YSLY cable does not become an Ethernet cable simply because it connects two control devices.

Therefore, high-speed network communication needs a suitable data-cable system rather than a generic control cable.

Control Cables Near VFDs and Motors

Variable-frequency drives can create significant electromagnetic noise.

Therefore, control circuits near drives need careful routing and cable selection.

Project engineers should review:

• Distance from motor power cables
• Parallel cable runs
• Screening requirement
• Screen termination
• Grounding and bonding strategy
• Control-signal sensitivity

A screened control cable can help in this environment. However, cable screening should complement good EMC design rather than replace it.

What Are Control Cables Used for in Machinery?

Machine builders use control cables between panels, field devices and internal machine components.

Common applications include:

• Packaging machinery
• Conveyor systems
• Assembly machines
• Production lines
• Pumps
• Fans
• Compressors
• Material-handling systems

In these environments, installers often value flexibility because machine layouts can involve narrow cable routes.

Nevertheless, continuous movement requires a purpose-designed dynamic cable when the duty demands it.

What Are Control Cables Used for in Building Automation?

Building systems also use control circuits.

Examples include:

• HVAC
• Pumps and fans
• Building-management systems
• Control panels
• Actuator circuits
• Mechanical services

However, the building environment can add fire and material requirements.

Therefore, designers should evaluate both the electrical function and the installation regulations before selecting PVC or halogen-free products.

What Are Control Cables Used for in Process Plants?

Process facilities can contain control, instrumentation, data and power circuits in the same general area.

Therefore, correct cable classification becomes especially important.

A motor-control command may use a control cable. A 4–20 mA transmitter can use an instrumentation cable. Meanwhile, Ethernet equipment requires a suitable data cable.

This separation helps the project specify the right electrical and EMC performance for each circuit.

Fixed Installation vs Movement

Installation conditions have a major effect on cable life.

A standard flexible control cable can suit fixed installation and can simplify routing during assembly.

However, frequent movement creates additional mechanical stress.

Therefore, designers should specify whether the cable will experience:

• Fixed installation
• Occasional movement
• Continuous flexing
• Torsion
• Drag-chain movement
• Repeated acceleration

This detail should appear in the RFQ whenever movement forms part of normal operation.

Indoor and Outdoor Installation

Many control-cable applications occur indoors. However, some industrial routes extend outdoors.

Outdoor installations can expose the cable to:

• UV radiation
• Moisture
• Temperature variation
• Abrasion
• Mechanical impact
• Chemical exposure

Therefore, an engineer should not assume that every standard indoor control cable suits an external route.

The complete sheath system and product specification must match the environment.

What Are Control Cables Selected By?

What are control cables selected by? The correct process starts with the circuit rather than the product code.

1. Define the Circuit Function

First, identify whether the circuit carries a command, switching function, low-level signal or auxiliary electrical load.

2. Select the Voltage Rating

Match 300/500 V, 450/750 V or another required class to the exact circuit and product specification.

3. Calculate Conductor Size

Use current, voltage drop, route length and installation conditions.

4. Determine the Core Count

Include active cores, protective conductor and sensible spare capacity.

5. Choose the Identification System

Specify JZ, OZ, JB, OB or another required core-identification arrangement.

6. Evaluate EMI

Choose screened or unscreened construction according to the electrical environment.

7. Select PVC or Halogen-Free Materials

Match the material system to project and fire requirements.

8. Define the Installation Duty

State whether the cable remains fixed or experiences repeated movement.

9. Check the Environment

Consider temperature, UV, moisture, chemicals and mechanical exposure.

10. Verify the Datasheet

Finally, confirm conductor resistance, voltage, test requirements, cable diameter and all project-specific limits.

Control Cable Selection Matrix

Project Requirement	Good Starting Direction
General industrial control, low EMI	Unscreened PVC control cable
Control circuit near electrical noise	Braid-screened control cable
Screening plus additional inner sheath	YSLYCY-type construction
Halogen-free material requirement	HSLH-type family
Halogen-free plus screening	HSLCH-type family
Number-coded cores with PE conductor	JZ configuration
Number-coded cores without PE conductor	OZ configuration
Higher voltage-class requirement	Check suitable 450/750 V family
Continuous dynamic movement	Dedicated continuous-flex cable, not standard flexible control cable by default
Precision process measurement	Evaluate instrumentation cable instead
Ethernet communication	Use suitable Data/LAN cable

This table provides a starting point. The final product must still match the exact circuit and installation conditions.

Common Control Cable Selection Mistakes

Assuming Every Flexible Cable Is Continuous-Flex

Class 5 conductor flexibility does not automatically provide drag-chain or robotic performance.

Using a Screened Cable Everywhere

A metallic braid adds cost, diameter and termination work. Use it where the EMC environment justifies it.

Assuming Halogen-Free Means Fire Resistant

Material composition and circuit integrity describe different performance areas.

Ignoring Voltage Rating

Two similar cable families can carry different voltage designations.

Selecting Conductor Size by Habit

Current, voltage drop and route conditions should determine cross-section.

Confusing Control and Instrumentation Cables

Process measurement often requires different pair, triad and screening architectures.

Using Control Cable for Ethernet

High-speed Ethernet requires a cable designed for the applicable transmission category.

Ignoring Core Identification

JZ, OZ and other configurations affect installation and protective-conductor availability.

Assuming Every Outdoor Route Uses the Same Cable

UV, moisture and mechanical conditions can vary significantly between installations.

What Should a Control Cable RFQ Include?

When buyers ask what are control cables for a specific project, a complete RFQ provides a much better answer than a product name alone.

Include at least:

• Required cable family or performance description
• Number of cores
• Conductor cross-section
• Conductor class
• Operating voltage
• Screened or unscreened construction
• Required screen type
• JZ, OZ, JB, OB or other identification
• PVC or halogen-free material requirement
• Fire-performance requirement
• Indoor or outdoor installation
• Fixed or dynamic duty
• Operating temperature
• UV or chemical exposure where relevant
• Maximum cable diameter where relevant
• Required packing length
• Cable marking
• Applicable standards
• Test reports and documentation

As a result, manufacturers can quote comparable constructions. In addition, procurement teams avoid comparing products that share a similar name but use different technical designs.

ETK Kablo Control Cable Solutions

ETK Kablo manufactures flexible control cables for industrial automation, machine builders, panel manufacturers, HVAC systems, production plants and commercial infrastructure.

The portfolio includes:

• YSLY-JZ and related unscreened PVC constructions
• YSLCY screened PVC control cables
• YSLYCY screened constructions with inner sheath
• HSLH halogen-free families
• HSLCH screened halogen-free families
• Foil and braid-screened variants
• 300/500 V families
• 450/750 V families
• Different core counts and cross-sections
• Project-specific identification and marking options

Therefore, project engineers can select screening, material, conductor size, voltage and core arrangement according to the actual automation circuit.

Frequently Asked Questions

What are control cables?

What are control cables? They are multi-core electrical cables used for commands, switching, control functions and suitable low-voltage auxiliary circuits between automation equipment.

Where are control cables used?

They commonly serve industrial machinery, PLC systems, control panels, HVAC, conveyors, production lines, actuators and building automation.

What is YSLY cable?

YSLY is an unscreened flexible PVC control-cable family with stranded copper conductors, PVC insulation and PVC outer sheath.

What is YSLCY cable?

YSLCY adds a tinned-copper braid screen to a flexible PVC control-cable construction. Therefore, it suits circuits that require additional EMI protection.

What is YSLYCY cable?

YSLYCY uses screening together with an additional inner-sheath layer. This construction differs from ETK’s standard YSLCY design.

What does JZ mean?

JZ commonly indicates numbered cores together with a green-yellow protective conductor.

What does OZ mean?

OZ commonly indicates numbered cores without a green-yellow protective conductor.

Are control cables shielded?

Some are and some are not. The electromagnetic environment should determine whether the project needs screening.

Are control cables flexible?

Many industrial control cables use Class 5 flexible copper conductors. However, this does not automatically make them suitable for continuous drag-chain movement.

What voltage are control cables?

Voltage depends on the specific product. Common ETK families include 300/500 V and 450/750 V constructions.

Is a control cable the same as a signal cable?

Not always. The families can overlap, but signal cables often prioritize low-level transmission and EMI behaviour while control cables commonly handle commands and auxiliary control functions.

Is a control cable the same as an instrumentation cable?

No. Instrumentation cables often use pair or triad constructions for measurement and process signals. Control cables more commonly use multi-core architectures for commands and machine-control circuits.

Can control cable carry power?

A suitable control cable can carry electrical energy within its specified circuit, conductor size and voltage limits. However, it should not automatically replace a power-distribution cable.

Is LSZH control cable fire resistant?

Not automatically. Halogen-free material characteristics, flame propagation and fire-resistant circuit integrity are separate performance requirements.

Which control cable should I choose?

Choose according to circuit function, voltage, conductor size, core count, electromagnetic environment, material requirement and installation duty.

Conclusion: What Are Control Cables and How Should You Choose Them?

What are control cables? They are the electrical links that allow automation equipment to send commands, switch functions and coordinate machinery and building systems.

However, one universal control-cable construction does not exist. An unscreened YSLY-type design can provide an efficient solution in a controlled electromagnetic environment. By contrast, YSLCY or YSLYCY can add screening when interference becomes more important.

Material choice creates another decision. PVC provides a practical industrial solution for many applications, while halogen-free families serve projects with different smoke and material requirements.

Next, define conductor size, core count and voltage rating. In addition, specify the correct JZ, OZ or other core-identification arrangement.

Finally, consider the real installation duty. A flexible Class 5 conductor can simplify fixed machine wiring, but continuous movement requires a cable designed for repeated dynamic stress.

Therefore, the best control cable is not simply the most flexible, most heavily screened or highest-voltage option. It is the construction that matches the electrical circuit, EMC environment, installation conditions and project requirements without unnecessary overengineering.