KVVR-450/750V
KVVR Flexible PVC Control Cable — Class 5 Conductors, 450/750 V
Class 5 fine-wire conductors for control circuits that move, bend or vibrate.
The R in KVVR marks flexible construction: instead of the 7-wire Class 2 conductor used in KVV, each core is built from fine wires — 16/0.20 at 0.5 mm² up to 56/0.30 at 4 mm² — to IEC 60228 Class 5. That changes the mechanical behaviour rather than the electrical rating: the cable still works at 450/750 V with the same 70 °C PVC insulation, but it tolerates bending radii down to 6 × overall diameter and repeated flexing in machine-mounted service.
Specify KVVR where the wiring is terminated on something that moves: machine tool carriages, control pendants, cubicle door harnesses, vibrating pump skids. Voltcore bunches the conductors with a short lay length so the strands share the strain rather than the outer layer taking it all, and the sheath compound is plasticised for low-temperature flexibility; below 0 °C the cable must be warmed before installation.
Specification
| Item | Value |
|---|---|
| Rated voltage U0/U | 450/750 V |
| Conductor | Class 5 flexible plain annealed copper, IEC 60228 |
| Number of cores | 2 – 61 |
| Cross-section range | 0.5 – 4 mm² |
| Insulation | PVC/A flexible grade, 70 °C rated |
| Sheath | Flexible PVC, black, grey to special order |
| Max. continuous conductor temperature | 70 °C |
| Short-circuit conductor temperature | 160 °C for 5 s maximum |
| Test voltage | 2.5 kV rms for 5 min, no breakdown |
| Minimum bending radius | 6 × cable overall diameter in moving service |
| Installation temperature | Not below 0 °C; warm the cable before handling below 5 °C |
| Core identification | Numbered print or colour coded |
Layer-by-layer construction
Listed from the conductor outward. Read this alongside the specification table — the two together tell you whether the cable will survive its installation method.
- 1. ConductorBunched fine-wire plain annealed copper, Class 5 to IEC 60228, 0.20–0.30 mm single wire
- 2. InsulationFlexible PVC/A extruded per core, 0.6–0.8 mm wall
- 3. Lay-upCores stranded in concentric layers with a short lay length for flexibility
- 4. FillerNon-hygroscopic filler or a central filler cord to maintain a circular section
- 5. BinderLight polyester or non-woven tape over the bundle, allowing layers to slide against each other
- 6. SheathFlexible PVC black, 1.0–1.4 mm nominal, plasticised for low-temperature handling
Reference dimensions and weights
| Cores × cross-section (mm²) | Conductor structure (No./mm) | Insulation thickness (mm) | Sheath thickness (mm) | Approx. overall diameter (mm) | Approx. weight (kg/km) | Max. DC resistance at 20 °C (Ω/km) |
|---|---|---|---|---|---|---|
| 4×0.5 | 16/0.20 | 0.6 | 1.0 | 6.8 | 82 | 39.0 |
| 4×0.75 | 24/0.20 | 0.6 | 1.0 | 7.4 | 104 | 26.0 |
| 4×1.0 | 32/0.20 | 0.6 | 1.0 | 7.8 | 122 | 19.5 |
| 4×1.5 | 30/0.25 | 0.7 | 1.2 | 8.9 | 168 | 13.3 |
| 4×2.5 | 50/0.25 | 0.7 | 1.2 | 10.4 | 242 | 7.98 |
| 4×4 | 56/0.30 | 0.8 | 1.4 | 12.3 | 348 | 4.95 |
Reference figures for preliminary sizing and drum planning. Overall diameter and weight vary with strand construction and sheath thickness tolerance; certified drawings are issued with each quotation.
Engineering characteristics
- Class 5 conductors of 0.20–0.30 mm wires give a bending radius of 6 × overall diameter
- Flexible sheath compound rated 70 °C continuous and 160 °C for 5 s short circuit
- 450/750 V rating with 2.5 kV rms for 5 min test voltage
- Higher DC resistance than Class 2 at the same nominal section, so check voltage drop on long runs
- Short lay length bunching distributes bending strain across the strand instead of the outer layer
- Available in 2 to 61 cores from 0.5 mm² to 4 mm²
- ZR-KVVR flame-retardant sheath to GB/T 19666 for machine enclosures
Typical applications
- Machine tool control wiring on carriages, turrets and moving heads
- Cubicle and control desk door harnesses that open repeatedly
- Pendant stations, handheld control boxes and portable test sets
- Vibrating equipment: pump skids, screens, compressors and fan housings
- Appliance and panel builder harnesses where tight bends are unavoidable
Ordering options
- ZR-KVVR flame-retardant sheath to GB/T 19666
- KVVRP: adds a copper wire braid screen for flexible screened circuits
- Tinned Class 5 conductors for humid or coastal installations
- Grey, orange or customer-specified sheath colour for identification on a machine
- Cut-to-length harness sets with printed ferrule marking and bagged kits
Standards manufactured to
- GB/T 9330
- IEC 60228 Class 5 (conductor)
- GB/T 19666 (flame-retardant grades)
- IEC 60332-1-2 (flame propagation)
- RoHS and REACH compliant compounds
Manufactured to other standards on request. Send the standard number with your RFQ and we will quote against it rather than against a near-equivalent.
Price and availability for KVVR Flexible Control Cable
Include cross-section, core count, voltage grade, route length and installation method — those five determine price more than anything else on the page.
- Engineer-reviewed before pricing
- Reference drawings issued with the quotation
- Free sample up to free sample up to 5 m
KVVR Flexible Control Cable — frequently asked questions
What is the practical difference between KVV and KVVR?
KVV uses Class 2 conductors and is installed once; KVVR uses Class 5 fine-wire conductors and tolerates repeated bending. Electrically they are both 450/750 V with 70 °C PVC, but KVVR has a slightly higher DC resistance at the same nominal section and costs more per metre.
Can KVVR be used in a drag chain?
It is suitable for occasional flexing and moderate bending cycles, not for continuous high-speed cable carrier duty. For a drag chain running millions of cycles, specify a purpose-built PUR-sheathed chain cable; Voltcore will quote that separately.
Why is the DC resistance of KVVR higher than KVV at 1.5 mm²?
Class 5 stranding uses many fine wires with a short lay length measured along the helical path, so the effective conductor length per metre of cable is slightly greater. The IEC 60228 limit is 13.3 Ω/km for Class 5 against 12.1 Ω/km for Class 2.
Is KVVR oil resistant?
Standard PVC sheath resists mineral oil splash but not continuous immersion. For machine tools with cutting-oil exposure, ask for an oil-resistant PVC/PUR sheath variant; Voltcore supplies it with a modified compound and confirms the rating on the datasheet.
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