We may often hear about power and control cables in electrical engineering projects. Power cables vs control cables are both important types of cables used to transmit current and signals, but do you really understand the difference between them?

You can find more information on our web, so please take a look.

In this new installment of our blog series, we will delve into the following notable difference roles between these two types of cables in a variety of ways to help you better choose the right cable for your project’s needs.

• Power cables: the role of transmitting energy
• Control cables: the role of sending signals and controlling equipment.

What is a power cable?

Basically, a power cable is a common type of cable used to transmit electricity from a power source to a device. Power cables are used for overhead and underground energy transmission, as well as in industrial environments.

Depending on the application, cables can be installed overhead or buried and usually consist of two or more electrical conductors with an outer jacket. Copper and aluminum are the main conductors used because of their high electrical conductivity, while polyvinyl chloride (PVC) is the most common dielectric because of its good insulating ability. The outer jacket is usually made of materials such as PVC, PE (polyethylene) or halogen-free compounds.

Types of power cable

1. Low Voltage cable: LV cables intended for the transmission of electrical signals up to 1 kV. Common applications include data communications, security systems, and lighting control.

2. Medium Voltage Power Cable: Medium voltage cables are considered to be cables with a voltage rating between V and 30KV. They are typically used in industrial applications.

3. High Voltage Cable: High voltage cables are a type of cable used to transmit electricity above 35KV. They are mainly used in power plants and other large industrial applications.

4. Service Entrance Cable: Service entrance cables deliver power to residential buildings. Both SER and SEU cables are rated at 600 volts and are suitable for both dry and wet environments.

5. Aluminium Service Drop Cable: Service Drop Aluminum Conductor Cables are used to supply power from utility lines to customers. Its lightweight design and corrosion resistance make it ideal for residential and commercial electrical systems. It has a maximum temperature of 90°C for cross-linked insulated conductors and 75°C for polyethylene insulated conductors.

6. THHN wire: Thermoplastic High Heat Resistant Nylon Covered Wire (THHN) is a single-conductor wire featuring PVC insulation and a nylon jacket. It is widely used for electrical wiring within building conduits.

What is a control cable?

Control cables are multi-core cables used in automation systems and instrumentation applications. They send signals to various lines in electrical equipment. Cables have flexible qualities and must be able to withstand bending for trouble-free installation in the most difficult locations. They are vital for robots, assembly lines, and power distribution systems, among others. There are various types of cables used for control applications, with the main three being YY, CY, and SY cables.

Types of control cable

SY cables have a steel wire braid and are suitable for control applications where additional mechanical protection is required. CY cables are flexible control cables with a shield, similar in construction to the YY type, but with a tinned copper braid added to the laid core. YY cables are flexible control cables with PVC insulation and grey PVC sheaths. They are mainly used for connecting electrical equipment and distributing electricity in industrial applications.

Get further on sy, cy , yy cable detailed comparison：The Ultimate Guide to Understanding SY Cable

After reviewing the information above, we now have a better grasp of both types of cables. But, curious about what sets control cables apart from power cables? While both are essential in electrical systems, their purposes and structural designs markedly differ. In the subsequent section, we will jointly understand the disparities.

Difference Between Control Cables and Power Cables

Power cables are essential for transferring energy from the power source to various devices while control cables are used to send signals that regulate and manage the operation of equipment. Beyond that, we can read on to learn more about the differences between power cords and control cables.

• Difference in rated voltage:

Control cables typically come in voltage ratings ranging from 300V to 600V, while power cables are generally available in higher voltages of 0.6/1kV.

• Difference in number of cable cores:

Power cables usually contain fewer cores, ranging from a single core to five cores, depending on the specific requirements of the grid. On the other hand, control cables are specifically used to transmit control signals in different applications. Unlike power cables, control cables are available in a larger number of cores, usually ranging from 2 cores to 61 cores or even more. The higher number of cores allows for a wide range of requirements for modern control systems.

• Difference in core wire color:

Control cable insulation core is typically black with white lettering. In contrast, power cables are available in a variety of colors to differentiate between different functions and provide safety during installation and maintenance.

• Difference in cable sheaths:

Power cables require thicker insulation and jacketing than control cables when the same specifications are used in the same industrial environment.

• Difference in carrying capacity:

Control cables typically operate with a voltage range of 300V to 600V, making them suitable for managing and controlling electrical signals in various applications. On the other hand, power cables are designed to handle higher voltages, commonly rated at 0.6/1 kV, and are used to transmit electrical power over distances.

• Difference in usage:

A power cable is a type of cable used to transmit and distribute electric energy. It is commonly utilized in urban underground power grids, power station outlets, and underwater transmission lines. On the other hand, a control cable is used in computer systems and information transmission systems. It includes fiber optic cables, electromagnetic wires, and power communications. Shielded control cables, in particular, provide good shielding performance and are extensively used in power plants and power stations.

Power Cable VS Control Cable Conclusion

Electrical Wire and Electrical Cables

Electrical wire and electrical cable are a means of electrical connectivity between switches, outlets, appliances, and more. The installation and design of electrical wires and cables are regulated by OSHA safety standards and the National Electric Code® (NEC®). Electrical wires and cables should be sized and installed correctly to ensure safe operation.

Zhongyi Cable are exported all over the world and different industries with quality first. Our belief is to provide our customers with more and better high value-added products. Let's create a better future together.

Electrical Wire vs Electrical Cable

Wire Conductor Materials

Electric wiring conductors are usually made of aluminum or copper. Both aluminum wire and copper wire have their advantages — aluminum is cheaper but becomes less conductive when oxidized. Copper wire has a higher cost but is more efficient over time. Both materials can be used in numerous settings and applications with proper installation.

Wire Size — Gauge

There are two sizing standards for wires depending on how small they are. The American Wire Gauge (AWG) standards are for common, everyday-use electrical wiring seen in residential and commercial spaces whereas MCM (kcmil) measures the diameter of large wires seen in public and industrial spaces.

AWG Wire Size

AWG wire is sized according to the American Wire Gauge which specifies the physical size of an electrical wire. The higher the gauge number the thinner the wire, which means a 16 Gauge would be smaller (thinner) than a 2 Gauge. Wire size limits how much electrical current can pass through the wire; the lower the gauge number, the higher the amp capacity.

MCM (kcmil) Wire Size

MCM and kcmil are interchangeable terms measuring wire size in thousands of Circular Mils. A Circular Mil (cmil) is the area of a circle with a diameter of a mil. A mil is a unit of length equal to 1/ of an inch. MCM wire sizes have larger diameters than AWG wires. MCM (kcmil) wire size will affect how much current can pass through the wire; the higher the wire size, the higher the amps capacity.

Stranded Wire vs. Solid Wire

Solid wire and stranded wire are two common types of electrical conductors used in wiring and cabling. The main differences between solid and stranded wire are their construction, flexibility, and applications. Choosing between solid or stranded wire depends on the specific application and requirements of the wiring system.

Insulated Wire vs. Bare Copper Wire

Types of Electrical Cable and Electrical Wire

Building and House Wire and Cable

Building and house wire and cable are used for retail and residential projects when constructing wiring systems for the properties. For residential and retail projects, these may be called branch circuit wiring.

Electrical Wire Colors for Commercial and Residential Buildings

Whether thermoplastic or thermoset wires, these electrical wires will often be insulated so a color-coded system can be used for installation and maintenance according to NEMA guidelines.

Wire Naming Conventions for Residential and Commercial Building Electrical Wire

The NEC® standardized identification letters printed on electrical wires and electrical cables describe the protective capabilities of their insulation.

Common Types of Building Wire and Cable

Romex™ Wire or NM Cable (Types NM, NMC, NMS)

Cable Color Coding System for Romex™ Equivalents

Romex™ equivalent NM cables have an insulated jacket that comes in a variety of colors that represent the size or use of electrical wires housed within the cable. As this coding system is not standardized but rather something most manufacturers choose to follow, all cable jackets have labeling on the outside to indicate how many wires and what kind of wires are inside the sheathing. Additionally, often the wires within the cable jacket have their own color-coded system to indicate neutral (white) and hot (black or red) wires.

Most manufacturers follow these guidelines:

Machine Tool Wire (MTW)

PV Wire (Solar Photovoltaic)

Solar photovoltaic (PV) wire is a single conductor wire that connects the different components of solar panels (PV systems). PV wire works well for these jobs as they can operate under intense heat, sunlight, and weather conditions. PV wire has thick XLPE insulation for above-ground or direct burial installation.

Feeder Cable and Underground Cable — Direct Burial Wire

Underground Cables

Underground cables and wires are made to safely be installed and remain underground without the need for a conduit or additional protective covering. Typically, they have a conductor, insulating system, and sheath/jacket dependent on the environment in which they're used to provide resistance to moisture, sunlight, and soil chemicals.

Underground Tracer Wire

Tracer wire is typically a coated copper wire that is resistant to chemicals, moisture, abrasions, pressure, and oil. A tracer wire is similar to a THHN wire except it lasts longer and provides more protection. Since they are meant for direct burial, tracer wires also have a signal for easy location.

Service Entrance Cable and Service Drop Cable (Type SE Cable)

Flexible and Portable Wires, Cables, and Cords

Flexible and portable wires, also known as portable cords or flexible cords, are electrical cables designed for applications that require mobility, flexibility, and resistance to bending, twisting, and stretching. These wires are constructed with stranded conductors to enhance flexibility, and they are typically encased in durable yet pliable insulation materials, such as rubber or thermoplastic.

Lamp Cord

SPT-1 vs SPT-2 Wire

SO Cable

Flexible and portable wires, cables, and cords have a standardized naming system that indicates the intended use for each wire/cable. These are referred to as SO cables, as each type has these two letters.

Industrial Cable and Wire

Industrial cable refers to a broad category of electrical cables engineered for toughness, durability, and versatility, making them suitable for a wide range of industrial applications, including manufacturing, automation, machinery, and control systems. Industrial cables come in various types designed to transmit electrical power, signals, or data while withstanding exposure to chemicals, extreme temperatures, moisture, mechanical stress, and electromagnetic interference, which makes them a critical component of modern industrial infrastructure.

Cable Tray Wire (Tray Cable)

Types of Tray Cables:

Armored Cable and Metal Clad Cable

AC (Armored Cable also called BX), MC (Metal Clad), SWA (Steel Wire Armored), AWA (Aluminum Wire Armored), and STA (Steel Tape Armored) cables are types of electrical cables used for wiring in residential, commercial, and industrial settings. These cables provide a layer of physical protection for the enclosed conductors, reducing the risk of damage due to mechanical stress, impact, or abrasion. This is especially crucial in areas where cables may be exposed to physical hazards. For these reasons, many electrical codes and standards require the use of these cables in specific applications to ensure compliance with safety and performance requirements.

What is Armored Cable?

When to Use Armored Cable?

Armored Cable (AC Cable) should be used in indoor electrical installations where the wiring will need additional physical protection and grounding capabilities. AC cable is often used as residential wiring for branch circuits and feeder wiring. In commercial and industrial locations, AC cable is used in various applications where wiring needs protection against mechanical stress, impact, or environmental factors. Armored cable

Armored Cable (AC) vs Metal Clad Cable (MC)

Although armored cable and metal-clad cable both have a metal-based sheath, there are several differences in their design, wires, and function. AC cable uses its outer sheath as part of the ground, but MC Cable does not use the sheath as part of its grounding and instead uses a ground wire. AC cable is for indoor use only because it doesn't have a PVC thermoplastic jacket. MC cable has a PVC water-resistant jacket, making it appropriate for indoor or outdoor and underground locations.

Steel Wire Armored (SWA) Cable and Aluminum Wire Armored (AWA) Cable

Steel Tape Armored (STA) Cable

Steel tape armored cable, also known as STA cable, features a layer of steel tape wound around the insulated conductors. The steel tape serves as a protective armor, providing mechanical protection against crushing, bending, and impact. STA cable is commonly used in industrial and heavy-duty applications where robust mechanical protection is required such as underground installations.

Marine and Drilling Cable

Low Voltage Wire — Structured Cable

Low-voltage wiring, also called structured wiring, is used to connect doorbells, TVs, thermostats, and data communication networks connecting computers, routers, phones, and printers. Because low-voltage wire has more energy lost per foot of cable compared to high-voltage cable, low-voltage cable typically has a limited range of 100-150 feet. Low-voltage, structured cable and wire carry 50 amps or less current.

Network Data Cable

With locations across multiple states, Elliott Electric Supply understands the electrical industry and your needs, unlike big-box retailers and e‑commerce corporations. Now, you can access our supplies and services more conveniently using our mobile‑friendly website and through our updated customer app.

From copper wire to armored cable, we've got your electrical needs covered. With great pricing, extensive inventory, and fast delivery, you'll find no better wholesale electrical supplies distributor online than Elliott Electric Supply.

Are you interested in learning more about Power Cable And Control Cable? Contact us today to secure an expert consultation!