Industrial automation systems are the backbone of modern manufacturing, and they hinge on the seamless communication between various components, including machines, sensors, and control equipment. This intricate web of connectivity is vital for ensuring that processes run smoothly, efficiently, and safely. Programmable Logic Controllers (PLCs), motor controls, safety systems, and industrial networks are all integral parts of this framework. Each of these elements must work in perfect harmony, relying on precise control wiring to transmit signals and power accurately.  

The importance of maintaining uptime cannot be overstated, as even minor disruptions can lead to significant production delays or safety hazards. Therefore, the integrity and reliability of control wiring are paramount in ensuring the effectiveness of industrial operations. Power-Limited Tray Cable (PLTC) has been specifically engineered to thrive in the demanding environments typical of industrial settings. Its design caters to the unique challenges posed by harsh conditions, such as extreme temperatures, moisture, and mechanical stress. When utilized in conjunction with rugged mesh cable trays, PLTC becomes an even more powerful solution for managing the complex web of control and power wiring necessary for automation systems.  

Key Takeaways 

  • PLTC cables are ideal for low-voltage, power-limited automation circuits 
  • Tray-rated design simplifies installation and inspection 
  • Shielded PLTC cables protect against EMI in industrial environments 
  • Mesh cable trays improve airflow, organization, and scalability 
  • Proper separation of control and power wiring prevents signal issues 
  • Modular tray systems support future automation growth 

What Is PLTC Cable? 

PLTC, or Power-Limited Tray Cable, is a specialized type of control cable that is engineered specifically for use in Class 2 and Class 3 circuits. These circuits are typically employed in applications that require a lower voltage, generally operating at 300 volts or less. The design of PLTC cables ensures that they can be safely installed in cable trays, which are commonly used in commercial and industrial settings to organize and protect wiring systems. 

These cables are commonly used for: 

  • Industrial control systems 
  • Instrumentation and signaling 
  • Automation and process control 
  • Low-voltage power-limited applications 

PLTC cables are approved for installation in cable trays, making them ideal for open, accessible routing methods used in modern manufacturing facilities. 

When Should You Use PLTC Cables in Automation? 

PLTC cables, short for Power Limited Tray Cables, are an excellent option for a wide range of applications that demand consistent and dependable low-voltage control signaling. These cables are specifically designed to handle the unique requirements of control systems, making them a preferred choice in environments where reliable communication is critical. Unlike high-voltage power cabling, which can be complex and expensive to install and maintain, PLTC cables provide a more straightforward solution that simplifies the wiring process. 

Use PLTC Cable When: 

  • Control circuits are power-limited (≤300V) 
  • Signal integrity is critical for PLCs, sensors, and actuators 
  • Cables must be routed in open cable trays 
  • EMI protection is required in electrically noisy environments 
  • Systems require easy inspection, troubleshooting, and expansion 

Shielded PLTC designs are especially valuable in manufacturing environments with motors, drives, and high-current power cables nearby. 

Managing PLTC and Power Cables in Shared Tray Systems 

Plant floors rarely run only one type of cable. Control wiring, power distribution, Ethernet, and fiber often share the same pathways. Instead, they often accommodate a variety of wiring types, including control wiring for machinery, power distribution lines for electrical systems, Ethernet cables for networking, and fiber optic cables for high-speed data transmission.  When best practices are adhered to, these trays facilitate an organized layout, minimizing clutter and ensuring that cables are easily identifiable and accessible for maintenance or upgrades. Proper installation techniques, such as maintaining adequate spacing between different cable types and securing cables to prevent movement, are critical to maximizing the benefits of mesh trays. 

Why Mesh Cable Trays Work So Well 

  • Open-wire design improves airflow and heat dissipation 
  • Easy separation of cable types using spacing or dividers 
  • Fast installation and on-site modification 
  • Simplified future expansion for automation upgrades 

Preventing Interference Between Control and Power Wiring 

High-voltage power cables are a crucial component of modern electrical infrastructure, responsible for transmitting large amounts of electricity over considerable distances. However, one of the less frequently discussed challenges associated with these cables is their potential to introduce electromagnetic interference (EMI). As the current flows through these high-voltage lines, it generates electromagnetic fields that can extend into surrounding areas. When these fields intersect with nearby control systems or electronic devices, they can create unwanted noise and fluctuations, which may disrupt the integrity of control signals. 

Best Practices for PLTC Routing: 

  • Separate PLTC control cables from power cables whenever possible 
  • Use shielded PLTC cables for sensitive control circuits 
  • Route power and control cables in parallel trays or use dividers 
  • Avoid unnecessary crossing of power and signal lines 

Integrating Ethernet and Fiber with PLTC Systems 

Modern automation systems are increasingly reliant on robust communication infrastructures that leverage industrial Ethernet and fiber optic networks. These technologies are essential for facilitating real-time monitoring, Supervisory Control and Data Acquisition (SCADA), and Industrial Internet of Things (IIoT) applications. As industries embrace smart manufacturing and automation, the need for reliable and high-speed data transmission becomes paramount.  

Ethernet cables, ranging from Cat5e to Cat7, offer varying levels of performance and are designed to support the demanding networking requirements of industrial environments. These cables ensure seamless communication between machines, sensors, and control systems, which is critical for optimizing operational efficiency and enhancing productivity. 

To effectively manage the myriad of cables necessary for these advanced systems, the implementation of mesh trays has become increasingly popular. These trays are designed to support various cable types, including Ethernet and fiber optic cables, when organized and managed properly. Fiber optic cables, in particular, provide the advantage of EMI-free communication over long distances, making them ideal for environments where electromagnetic interference could disrupt signal integrity 

Compliance, Safety, and Long-Term Scalability 

PLTC (Power Limited Tray Cable) cables are specifically designed to meet the National Electrical Code (NEC) standards, making them a reliable choice for various installation environments. One of the standout features of PLTC cables is their approval for tray installation, which allows for a more streamlined approach to wiring in commercial and industrial settings.  With the cables installed in trays, technicians can easily access and evaluate the wiring without the obstructions typically associated with conduit systems. This improved accessibility is crucial, especially in complex setups where regular inspections are required to ensure compliance with safety standards and operational efficiency.  

Combined with mesh trays, they support: 

  • Faster troubleshooting and maintenance 
  • Reduced installation labor 
  • Safer cable routing practices 
  • Easy upgrades as automation systems expand 

This makes PLTC-based tray systems a smart investment for future-ready manufacturing facilities. 

Powder-coated mesh trays prove to be an invaluable asset in manufacturing environments by combining durability, efficiency, and versatility. Their resistance to corrosion and wear makes them ideal for handling various materials, while the open mesh design promotes airflow and visibility, reducing the risk of contamination. As manufacturers continue to prioritize safety and productivity, investing in these trays can streamline operations and enhance overall workflow. By embracing the practicality of powder-coated mesh trays. 

ShowMeCables offers a full range of network connectivity and infrastructure solutions for small and medium-sized businesses. In addition, our customer-focused approach includes a same-day shipping policy and U.S.-based customer service support.  Questions? Please call us at +1 (866) 545-8420, email us or visit our contact page.   

Frequently Asked Questions 

What does PLTC stand for? 

PLTC stands for Power-Limited Tray Cable, designed for Class 2 and Class 3 control circuits up to 300V. 

Can PLTC cables be run in cable trays? 

Yes. PLTC cables are specifically approved for installation in cable trays, making them ideal for industrial environments. 

Are PLTC cables suitable for harsh manufacturing environments? 

Absolutely. When shielded and paired with powder-coated mesh trays, PLTC cables perform reliably in high-noise, high-vibration settings. 

Can PLTC cables be routed alongside power cables? 

Yes, but proper separation or dividers should be used to minimize EMI from high-voltage power lines.