Utama Cables Sdn Bhd. - npcdn.net

Utama Cables Sdn Bhd. was incorporated on July 2001. The factory was then situated at the

Pandan Industrial Estate, Johor Bahru, Johor. As the volume of the business advanced further, the

company aimed at the expansion of the business, subsequently bought over the existing piece of

the industrial land cum the existing factory lot with a total area of approx. 2 hectares on the year

2006 in Malacca. The office and the factory was then relocated on January, 2007.

Utama Cables Sdn. Bhd. manufactures and markets a totally integrated line of Low Voltage of

Polyvinyl Chloride (PVC) and Cross-Linked Polyethylene (XLPE) cables suitable for a wide variety of

application, locally and globally.

Our cables are manufactured to meet the stringent standards of quality, performance and

functionality, with the ultimate goal of customer’s satisfaction.

It has long been capital invested by the company to upgrade and purchasing of new, advanced

and sophiscated machinery in order to enhance our productions to meet up with the relevant

authority’s respective standards.

Our specifications are complied to British Standards (BS), Malaysian Standard (MS), and

International Electro-Technical Commission (IEC).

Our products has seek the approvals from the authority like SIRIM QAS International (SIRIM),

Suruhanjaya Tenaga (ST) and Jabatan Kerja Raya (JKR). Subsequent and special tests can also be

arranged outside Malaysia like PSB Corporation of Singapore.

Our factory is most strategically located in Merlimau Industrial Estate, Malacca linked by

expressways to market centers and ports around the country for prompt delivery and overseas

shipments. Our overseas markets so far are Singapore, Indonesia, Thailand, Myanmar, Cambodia.

Our Company Machine & Technical Supports OUR PRODUCTS Product Certifications Marketing & Logistic Supports

PVC INSULATED POWER CABLES ( Non-Armoured )

- For Electric POWER & LIGHTING

GUIDE TO THE USE OF PVC INSULATED CABLES

TECHNICAL DATA - CURRENT RATING

PVC NON-ARMOURED MULTI-CORE ( COPPER )

PVC NON-ARMOURED SINGLE-CORE ( COPPER )

METHODS OF INSTALLATION OF CABLES

PVC INSULATED CABLES FOR ELECTRIC SUPPLY

TECHNICAL DATA - CURRENT RATING

ALLOWABLE SHORT CIRCUIT CURRENT FOR PVC INSULATED CABLES

TECHNICAL DATA

xlpe introduction

construction of xlpe cables

cable structural description & construction data ( armoured & non-armoured )

PERMISSIBLE short circuit currentS

short circuit current rating - aluminium conductors short

circuit current rating - copper conductors construction of

xlpe cables

technical data, continuous current carrying capacity handling

& installation of xlpe cables technical data - wire gauges

APPENDIX TECHNICAL DATA COMMON CONVERSION FACTOR

AERIAL BUNDLED CABLES

1. INTRODUCTION

2. LOW VOLTAGE CONSTRUCTION

2.1 CONDUCTORS

2.2 INSULATION

2.3 TESTS

2.4 SHORT CIRCUIT RATING

2.5 SAG AND TENSION

3. TECHNICAL PARTICULARS FOR AERIAL BUNDLED CABLES

BARE ALUMINIUM CONDUCTOR

- STRANDED ALUMINIUM CONDUCTOR

- ALL ALUMINIUM CONDUCTOR - AAC

- ALL ALUMINIUM ALLOY CONDUCTOR - AAAC

- ALUMINIUM CONDUCTOR STEEL REINFORCED - ACSR

1 - 2 3 - 4 5 - 6 7 - 8 9 -10

11 - 19

20 21

22

23

24 - 25 26 - 38 39 - 45

46

47 - 49

50 51 - 52

53 - 63 64 65 66

67

68 - 70 71

72 - 73 74

75 76

77 - 82

83 - 84

85 - 87

SIRIM LICENCE AWARDS 12

1. MS 136 : 1995

MS 2112-3 : 2009

MS 2112-4 : 2009

PVC INSULATED CABLES FOR

ELECTRIC POWER AND LIGHTING

( NON-ARMOURED )

2. MS 274 : 1995

BS 6346 : 1997

PVC INSULATED CABLES FOR

ELECTRICITY SUPPLY

( NON-ARMOURED / ARMOURED )

3. IEC 60502-1 : 2004

MS 2104 : 2007

MS 2105 : 2007

MS 2106 : 2007

MS 2107 : 2007

XLPE POWER CABLES

( NON-ARMOURED / ARMOURED )

13 PVC power CABLES

P V C I N S U L A T E D C A B L E S

( N O N - A R M O U R E D )

F O R E L E C T R I C

P O W E R & L I G H T I N G

TO MS 2112-3 : 2009 (BS 6004 & MS 136)

PVC INSULATED CABLE 14

CONSTRUCTION

Conductor Plain annealed copper

Insulation General purpose PVC compound PVC/C-70

Colour of cores Red, Black or other colours

PVC INSULATED CABLE MS 2112-3 : 2009

(BS 6004 & MS 136, 450/750V)

Nominal Number/ Thickness Approx. Approx.

area Wire of insulation Overall weight

diameter diameter

of wires

mm2 No./mm mm mm kg/km

1.5 1/1.38 0.7 2.9 21

1.5 7/0.53 0.7 3.1 23

2.5 1/1.78 0.8 3.5 33

2.5 7/0.67 0.8 3.7 35

4 7/0.85 0.8 4.3 51

6 7/1.04 0.8 4.8 72

10 7/1.35 1.0 6.2 120

16 7/1.70 1.0 7.2 180

25 7/2.14 1.2 8.9 283

35 19/1.53 1.2 10.2 280

50 19/1.78 1.4 11.9 510

70 19/2.14 1.4 13.7 720

95 19/2.52 1.6 16.0 990

120 37/2.03 1.6 17.6 1230

150 37/2.25 1.8 19.6 1520

185 37/2.52 2.0 21.9 1900

240 61/2.25 2.2 25.0 2500

300 61/2.52 2.4 27.8 3130

400 61/2.85 2.6 31.2 3980

500 61/3.20 2.8 34.7 4990

630 61/3.65 2.8 38.7 6380

15 PVC INSULATED CABLE

CONSTRUCTION

Conductor Plain Annealed copper



PVC INSULATED CABLE SINGLE CORE

FLEXIBLE CONDUCTOR CABLES

MS 2112-3 : 2009 (MS 136, 450/750V)

Nominal Nominal No./ Maximum Radial Overall Approx.

area Nominal diameter of thickness of diameter weight

diameter wires insulation

of wire

mm2 mm mm mm mm kg/km

1.5 30/0.20 0.26 0.7 3.1 25

2.5 50/0.25 0.26 0.8 3.7 35

4.0 56/0.30 0.31 0.8 4.5 55

6.0 84/0.30 0.31 0.8 4.8 75

10.0 80/0.40 0.41 1.0 6.2 120

16.0 126/0.40 0.41 1.0 7.2 180

25.0 196/0.40 0.41 1.2 9.0 285

35.0 276/0.40 0.41 1.2 10.5 283

50.0 397/0.40 0.41 1.4 12.0 510

70.0 360/0.50 0.51 1.4 14.0 720

95.0 475/0.50 0.51 1.6 16.5 990

120.0 608/0.50 0.51 1.6 18.0 1230

150.0 756/0.50 0.51 1.8 20.0 1520

185.0 925/0.50 0.51 2.0 22.0 1900

240.0 1221/0.50 0.51 2.2 25.50 2500

PVC INSULATED CABLE 16

CONSTRUCTION




PVC INSULATED CABLE SINGLE CORE

FOR INTERNAL WIRING

MS 2112-3 : 2009 (MS 136, 300/500V)

Nominal Number/ Thickness Approx. Approx.

area Wire of insulation overall weight

diameter diameter

of wires

mm2 No./mm mm mm kg/km

0.5 1/0.8 0.6 2.2 8.9

0.75 1/0.98 0.6 2.4 11.8

1.0 1/1.13 0.6 2.5 14.2

1.25 3/0.73 0.7 3.2 20.6

17 PVC INSULATED PVC SHEATHED NON-ARMOURED CABLE

CONSTRUCTION

Conductor : Plain annealed copper

Insulation : General purpose PVC compound PVC/C-70

Colour of cores : Single core - red and black

2 cores - red and black

3 cores - red, yellow and blue

4 cores - red, yellow, blue and black

Formation : (i) Single core

(ii) 2, 3 or 4 cores

- stranded together and the interstices may be filled with the

sheathing compound or textile. A non-hygroscopic binder

tape may be applied over the laid-up cores.

Sheath : Black general purpose PVC compound PVC/ST4-70

PVC INSULATED, PVC SHEATHED

NON-ARMOURED CABLE (1-CORE)

MS 2112-4 : 2009 (BS 6004 & MS 136, 300/500V)

Nominal Number/ Thickness Thickness Approx. Approx.

area Wire of insulation of sheath Overall weight

diameter diameter

mm2 No./mm mm mm mm kg/km

1.5 1/1.38 0.7 0.8 4.7 37

2.5 1/1.78 0.8 0.8 5.3 51

4 7/0.85 0.8 0.9 6.3 76

6 7/1.04 0.8 0.9 6.8 99

10 7/1.35 1.0 0.9 8.2 150

16 7/1.70 1.0 1.0 9.4 220

25 7/2.14 1.2 1.1 11.3 340

35 19/1.53 1.2 1.1 12.6 440

PVC INSULATED CABLE PVC SHEATHED NON-ARMOURED CABLE 18



MS 2112-4 : 2009 (BS 6004 & MS 136, 300/500V)



diameter diameter


1.5 1/1.38 0.7 1.2 8.5 100

1.5 7/0.53 0.7 1.2 8.9 110

2.5 1/1.78 0.8 1.2 9.7 140

2.5 7/0.67 0.8 1.2 10.1 150

4 7/0.85 0.8 1.2 11.2 200

6 7/1.04 0.8 1.2 12.3 260

10 7/1.35 1.0 1.4 15.3 415



MS 2112-4 : 2009 (BS 6004 & MS 136, 300/500V)



diameter diameter


1.5 1/1.38 0.7 1.2 8.9 120

1.5 7/0.53 0.7 1.2 9.4 130

2.5 1/1.78 0.8 1.2 10.2 170

2.5 7/0.67 0.8 1.2 10.7 180

4 7/0.85 0.8 1.2 11.9 240

6 7/1.04 0.8 1.4 13.5 320

10 7/1.35 1.0 1.4 16.3 523



MS 2112-4 : 2009 (BS 6004 & MS 136, 300/500V)



diameter diameter


1.5 1/1.38 0.7 1.2 9.7 150

1.5 7/0.53 0.7 1.2 10.2 160

2.5 1/1.78 0.8 1.2 11.2 210

2.5 7/0.67 0.8 1.2 11.7 220

4 7/0.85 0.8 1.4 13.4 310

6 7/1.04 0.8 1.4 14.7 410

10 7/1.35 1.0 1.4 17.9 660

19 PVC INSULATED PVC SHEATHED CABLE

CONSTRUCTION


Insulation General purpose PVC compound TI 1 70°C

Sheath Black general purpose PVC compound TM1 70°C

Colour of cores White with numbering

PVC INSULATED, PVC SHEATHED NON-ARMOURED CABLE

(MULTI CORE) AUXILIARY

(BS 6004 & MS 136, 300/500V)

Number Cross- Number/ Thickness Thickness Approx. Approx.

of sectional Nominal of of overall weight

cores area Diameter insulation sheath diameter

of wires

mm2 mm mm mm mm kg/km

7 1.5 1/1.38 0.7 1.2 11.6 215

7 1.5 7/0.53 0.7 1.2 12.2 235

10 1.5 1/1.38 0.7 1.3 15.1 325

10 1.5 7/0.53 0.7 1.3 15.8 340

12 1.5 1/1.38 0.7 1.3 15.2 355

12 1.5 7/0.53 0.7 1.3 16.1 370

19 1.5 1/1.38 0.7 1.3 18.0 530

19 1.5 7/0.53 0.7 1.4 19.0 555

27 1.5 1/1.38 0.7 1.4 21.6 730

27 1.5 7/0.53 0.7 1.5 22.9 770

37 1.5 1/1.38 0.7 1.5 24.0 985

37 1.5 7/0.53 0.7 1.6 25.8 1030

7 2.5 1/1.78 0.8 1.3 13.2 315

7 2.5 7/0.67 0.8 1.3 13.7 330

10 2.5 1/1.78 0.8 1.4 17.0 440

10 2.5 7/0.67 0.8 1.4 17.8 460

12 2.5 1/1.78 0.8 1.4 17.0 500

12 2.5 7/0.67 0.8 1.4 18.0 535

19 2.5 1/1.78 0.8 1.5 20.6 760

19 2.5 7/0.67 0.8 1.5 21.5 800

27 2.5 1/1.78 0.8 1.6 25.5 1090

27 2.5 7/0.67 0.8 1.6 26.0 1140

37 2.5 1/1.78 0.8 1.7 27.5 1440

37 2.5 7/0.67 0.8 1.7 28.8 1500

7 4 7/0.85 0.8 1.4 16.0 515

10 4 7/0.85 0.8 1.5 20.2 680

12 4 7/0.85 0.8 1.5 20.8 800

Guide to the use of PVC - INSULATED cables 20

The cables are suitable for use where the combination ambient temperature and

temperature rise due to load results in a conductor temperature not exceeding

70°C and case of a short-circuit (maximum allowance time is 5 seconds) the

maximum conductor temperature does not exceed 160°C, up to and including 200

sq. mm. and 140°C for sizes above 300 sq. mm.

CABLE TYPE AND USE COMMENTS

Single core, non-sheathed

general purpose.

Installation in surface mounted or Suitable for use in channels with cover.

embedded Suitable for fixed protected installation in

conduits or similar closed systems. or lighting fittings and inside

appliances, up to 1000V ac or up to

750 V to earth, dc.

Single core, non-sheathed,

for internal wiring

Fixed protected installation. Inside Suitable for installation in surface mounted

appliances and in or on lighting fittings or embedded conduits, only for signalling

or control circuits.

Light PVC- sheathed

Fixed installation in dry or damp premises. Unsuitable for outdoor use or

embedding in concrete.

Single core, flat twin and flat 3-core,

PVC-sheathed, with and without

protective conductor.

Fixed installation in dry or damp premises. Suitable for installation in walls, on boards

and in channels, or embedded in plaster.

21 Te ch ni c al data Current Rating

Current rating are based on the following condition

1) Ambient air temperature 30°C

2) Max. conductor operating temperature 70°C

Rating Factors

For Ambient Temperature

25° 30°

35°

40°

45°

50° 55°

60° 65°

Factor (General purpose

1.03 1

0.97

0.94

0.91

0.87 0.84

0.69 0.48

PVC Insulation)

FOR GROUPS

Correction factor (c)

Reference method of installation Number of circuits or multicore cables

2 3 4 5 6 7 8 9 10 12 14 16 18 20

Enclosed bunched and clipped direct to 0.80 0.70 0.65 0.60 0.57 0.54 0.52 0.50 0.48 0.45 0.43 0.41 0.39 0.38

a non- metallic surface

Single layer clipped to Touching 0.85 0.79 0.75 0.73 0.72 0.72 0.71 0.70 - - - - -

a non-metallic surface

Spaced* 0.94 0.90 0.90 0.90 0.90 0.90 0.90 0.90 0.90 0.90 0.90 0.90 0.90 0.90

Single layer multicore on a perforated metal Touching 0.86 0.81 0.77 0.75 0.74 0.73 0.73 0.72 0.71 0.70 - - - -

cable tray, vertical or Spaced* 0.91 0.89 0.88 0.87 0.87 - - - - - - - - -

horizontal

Single layer single- Horizontal 0.90 0.85 - - - - - - - - - - - - core on a perforated

metal cable Vertical 0.85 - - - - - - -

- - - - - - tray, touching

Single layer multicore touching on 0.86 0.82 0.80 0.79 0.78 0.78 0.78 0.77 ladder supports

* ‘Space’ means a clearance between adjacent surfaces of at least one cable diameter (D)

Where the horizontal clearances between adjacent cables exceeds 2D, no correction

factor need to be applied.

Notes 1. The factors in the table are applicable to groups of cables all of one size. The value of current derived from application of the appropriate factors is the maximum continuous current to be carried by any of the cables in the group.

2. If, due to known operating conditions, a cable is expected to carry not more than 30% of

its grouped rating, it may be ignored for the purpose of obtaining the rating factor for

the rest of the group.

PVC Non-Armoured Multi-Core (1.0mm2 To 400mm2 ) -Copper 22

The ratings tabulated apply where the cable is provided with close excess-current

production

Conductor Laid on cable tray Clipped direct to a non-metallic surface

2 core 3 or 4 core 2 core 3 or 4 core

single-phase, ac or dc 3-phase, ac single-phase, ac or dc three-phase, ac

Nominal

cross- Volt drop Volt drop Volt drop Volt drop

sectional No. and dia. Current per ampere Current per ampere Curent per ampere Current per ampere

area (mm) of wires rating per metre rating per metre rating per metre rating per metre

1 2 3 4 5 6 7 8 9 10

mm2 A mV/A/m A mV/A/m A mV/A/m A mV/A/m

1.0 1/1.13 17 44 14.5 38 15 44 13.5 38

{1/1.38}

1.5 {7/0.53} 22 29 18.5 25 19.5 29 17.5 25

{1/1.78}

2.5 {7/0.67} 30 18 25 15 27 18 24 15

4 7/0.85 40 11 34 9.5 36 11 32 9.5

6 7/1.04 51 7.3 43 6.4 46 7.3 41 6.4

10 7/1.35 70 4.4 60 3.8 63 4.4 57 3.8

16 7/1.70 76 2.8 68 2.4 87 2.8 79 2.4

25 7/2.14 119 1.75 101 1.5 112 1.75 1.5 1.5

35 19/1.53 148 1.25 126 1.1 138 1.25 119 1.1

ac dc ac dc

50 19/1.78 180 0.94 0.93 153 0.81 168 0.94 0.93 144 0.81

70 19/2.14 232 0.65 0.63 196 0.57 213 0.65 0.63 223 0.57

95 19/2.52 282 0.50 0.46 238 0.43 258 0.50 0.46 223 0.43

120 37/2.03 328 0.41 0.36 276 0.35 299 0.41 0.36 259 0.35

150 37/2.25 379 0.34 0.29 319 0.29 344 0.34 0.29 299 0.29

185 37/2.52 434 0.29 0.23 364 0.25 392 0.29 0.23 341 0.25

240 61/2.25 514 0.24 0.18 430 0.21 461 0.24 0.18 403 0.21

300 61/2.52 593 0.21 0.145 497 0.185 530 0.21 0.145 464 0.185

400 61/2.85 715 0.185 0.105 597 0.160 634 0.185 0.105 557 0.160

23 PVC, Non-Armoured SINGLE-Core (1.0mm2 To 630mm2) -Copper

The ratings tabulated apply where the cable is provided with close excess-current

production

Conductor Enclosed in Conduit or Trunking Cables Clipped direct to a non-metallic surface

2 Cables 3 or 4 Cables 2 Cables 3 or 4 Cables

single-phase Three-phase single-phase three-phase

Nominal

cross- Volt drop Volt drop Volt drop Volt drop

sectional No. and dia. Current per ampere Current per ampere Curent per ampere Current per ampere

area (mm) of wires rating per metre rating per metre rating per metre rating per metre

1 2 3 4 5 6 7 8 9 10


1.0 1/1.13 13.5 44 12 38 15.5 44 14 38

{1/1.38}

1.5 {7/0.53} 17.5 29 15.5 25 20 29 18 25

{1/1.78}

2.5 {7/0.67} 24 18 21 15 27 18 25 15

4 7/0.85 32 11 28 9.5 37 11 33 9.5

6 7/1.04 41 7.3 36 6.4 47 7.3 43 6.4

10 7/1.35 57 4.4 50 3.8 65 4.4 59 3.8

16 7/1.70 76 2.8 68 2.4 87 2.8 79 2.4

ac dc

25 7/2.14 101 1.8 1.75 89 1.55 114 1.75 104 1.5

35 19/1.53 125 1.3 1.25 110 1.1 141 1.25 129 1.1

ac dc

50 19/1.78 151 1.1 0.93 134 0.85 182 0.95 0.93 167 0.82

70 19/2.14 192 0.72 0.63 171 0.61 234 0.66 0.63 214 0.57

95 19/2.52 232 0.56 0.46 207 0.48 284 0.50 0.46 261 0.43

120 37/2.03 269 0.47 0.36 239 0.41 330 0.41 0.36 303 0.36

150 37/2.25 300 0.41 0.29 262 0.36 381 0.34 0.29 349 0.3

185 37/2.52 341 0.37 0.23 296 0.32 436 0.29 0.23 400 0.26

240 61/2.25 400 0.33 0.18 346 0.29 515 0.25 0.18 472 0.22

300 61/2.52 458 0.31 0.145 394 0.27 594 0.22 0.145 545 0.19

400 61/2.85 546 0.29 0.105 467 0.25 694 0.2 0.105 634 0.175

500 61/3.20 626 0.28 0.086 533 0.25 792 0.185 0.086 723 0.16

630 61/3.65 720 0.27 0.068 611 0.24 904 0.175 0.068 826 0.15

Me tho d s of Installation of Cables 24

Installation Method Examples Appropriate Reference

Number Description Method for determining current-carrying

capacities

1 2 3 4

Open and clipped direct:

1 Sheathed cables Method 1 clipped direct to or

lying on a non-metallic

surface

In conduit :

3 Single-core non-sheathed Method 3 cables in metallic or non-

metallic conduit on

a wall or ceiling

5 Multicore cables having Method 3 non-metallic sheath, in

metallic or non-metallic

conduit on a wall or

ceiling

In trunking :

8 Cables in trunking on a Method 3

wall or suspended in air

9 Cables in flush floor Method 3

trunking

10 Single-core cables in Method 3

skirting trunking

25 Methods of Installation of Cables

Installation Method Examples Appropriate Reference

Number Description Method for determining current-carrying

capacities

1 2 3 4

On trays

11 Sheathed cables on a Method 11 perforated cable tray,

bunched and unenclosed.

A perforated cable tray is

considered as a tray in

which the holes occupy at

least 30 % of the surface

area.

In free air

12 Sheathed single-core Method 12 cables in free air (any

supporting metal work

under the cables

occupying less than 10%

of the plan area):

- Two or three cables

vertically one above the

other, distance between

cables equal to the overall

cable diameter (De);

distance from the wall not

less than 0.5 (De)

- Two or three cables

horizontally, with spacing as above

- Three cables in trefoll,

distance between wall

and surface of nearest

cable 0.5 De or nearest cables 0.75 De

13 Sheathed multicore Method 13

cables in free air

distance between wall

and cable surface not

less than 0.3 De

(any supporting

metalwork occupying less than 10 % of the plan area)

Pvc power CABLES 26

P V C I N S U L A T E D C A B L E S

F O R E L E C T R I C S U P P L Y

T O B S 6 3 4 6 & M S 2 7 4

27 PVC INSULATED PVC sheathed NON-armoured cable

CONSTRUCTION



Colour of cores Single core - red and black




Formation (i) Single core


- stranded together and the interstices may be filled with

the sheathing compound or textile. A non-hygroscopic

binde tape may be applied over the laid-up cores.




(BS 6346 & MS 274, 600/1000V)



diameter diameter


50 19/1.78 1.4 1.4 14.9 610

70 19/2.14 1.4 1.4 16.9 830

95 19/2.52 1.6 1.5 19.2 1130

120 37/2.03 1.6 1.5 20.8 1380

150 37/2.25 1.8 1.6 23.0 1690

185 37/2.52 2.0 1.7 25.5 2100

240 61/2.25 2.2 1.8 28.8 2740

300 61/2.52 2.4 1.9 31.8 3410

400 61/2.85 2.6 2.0 35.4 4310

500 61/3.20 2.8 2.1 39.1 5380

630 61/3.65 2.8 2.2 43.3 6820

800 127/2.85 2.8 2.3 47.8 8590

1000 127/3.20 3.0 2.5 53.1 10760

PVC INSULATED PVC sheathed NON-armoured cable 28

CONSTRUCTION











binder tape may be applied over the laid-up cores.




(BS 6346 & MS 274, 600/1000V)



diameter diameter


10 7/1.35 1.0 1.8 16.2 450

16 7/1.70 1.0 1.8 18.3 620

25 7/2.14 1.2 1.8 21.0 880

35 19/1.53 1.2 1.8 19.9 920

50 19/1.78 1.4 1.8 22.7 1220

70 19/2.14 1.4 1.9 25.5 1670

95 19/2.52 1.6 2.0 29.2 2270

120 37/2.03 1.6 2.1 31.8 2800

150 37/2.25 1.8 2.2 35.0 3410

185 37/2.52 2.0 2.4 39.1 4270

240 61/2.25 2.2 2.5 43.9 5560

300 61/2.52 2.4 2.7 48.6 6930

400 61/2.85 2.6 2.9 53.9 8770

29 PVC INSULATED PVC sheathed NON-armoured cable

CONSTRUCTION















(BS 6346 & MS 274, 600/1000V)



diameter diameter


10 7/1.35 1.0 1.8 17.2 530

16 7/1.70 1.0 1.8 19.4 750

25 7/2.14 1.2 1.8 22.3 1090

35 19/1.53 1.2 1.8 22.8 1360

50 19/1.78 1.4 1.8 26.1 1810

70 19/2.14 1.4 1.9 29.5 2480

95 19/2.52 1.6 2.1 34.1 3390

120 37/2.03 1.6 2.2 37.1 4180

150 37/2.25 1.8 2.3 40.9 5110

185 37/2.52 2.0 2.5 45.7 6410

240 61/2.25 2.2 2.6 51.4 8360

300 61/2.52 2.4 2.8 57.0 10420

400 61/2.85 2.6 3.1 63.6 13210

PVC INSULATED PVC sheathed NON-armoured cable 30

CONSTRUCTION





3 cores - red, yellow and blue 4 cores - red, yellow, blue and black






Bedding Black general purpose PVC compound

Armour Single core - Aluminium wire

2, 3 or 4 cores - Galvanised steel wire




(BS 6346 & MS 274, 600/1000V)



diameter diameter


10 7/1.35 1.0 1.8 18.7 700

16 7/1.70 1.0 1.8 21.3 960

25 7/2.14 1.2 1.8 24.5 1400

35 19/1.53 1.2 1.8 25.6 1820

50 19/1.78 1.4 1.9 29.6 2450

70 19/2.14 1.4 2.0 33.5 3350

95 19/2.52 1.6 2.2 38.7 4580

120 37/2.03 1.6 2.3 42.1 5630

150 37/2.25 1.8 2.5 46.6 6920

185 37/2.52 2.0 2.6 51.9 8640

240 61/2.25 2.2 2.8 58.6 11290

300 61/2.52 2.4 3.1 65.3 14110

400 61/2.85 2.6 3.3 72.6 17860

31 PVC INSULATED PVC sheathed armoured cable

CONSTRUCTION

















ARMOURED CABLE (1-CORE)

(BS 6346 & MS 274, 600/1000V)

Nominal Number/ Thickness Thickness Diameter of Thickness Approx. Approx. area Wire of insulation of bedding armour wire of sheath Overall weight

diameter diameter

mm2 No./mm mm mm mm mm mm kg/km

50 19/1.78 1.4 0.8 1.25 1.5 19.4 840

70 19/2.14 1.4 0.8 1.25 1.6 21.4 1090 95 19/2.52 1.6 0.8 1.25 1.6 23.7 1410

120 37/2.03 1.6 1.0 1.6 1.7 26.6 1790

150 37/2.25 1.8 1.0 1.6 1.7 28.6 2120 185 37/2.52 2.0 1.0 1.6 1.8 31.1 2580

240 61/2.25 2.2 1.0 1.6 1.9 34.4 3270

300 61/2.52 2.4 1.0 1.6 1.9 37.2 3970

400 61/2.85 2.6 1.2 2.0 2.1 42.2 5110

500 61/3.20 2.8 1.2 2.0 2.1 45.7 5230 630 61/3.65 2.8 1.2 2.0 2.2 49.9 7760

800 127/2.85 2.8 1.4 2.5 2.4 55.9 9890

1000 127/3.20 3.0 1.4 2.5 2.5 61.1 12180

PVC INSULATED PVC sheathed armoured cable 32

CONSTRUCTION
















PVC INSULATED, PVC SHEATHED ARMOURED CABLE (2-CORE)

(BS 6346 & MS 274, 600/1000V)


diameter diameter


1.5 1/1.38 0.6 0.8 0.9 1.3 11.9 290

1.5 7/0.53 0.6 0.8 0.9 1.4 12.5 310

2.5 1/1.78 0.7 0.8 0.9 1.4 13.3 360

2.5 7/0.67 0.7 0.8 0.9 1.4 13.7 380

4 7/0.85 0.8 0.8 0.9 1.4 15.2 460 6 7/1.04 0.8 0.8 0.9 1.5 16.5 550

10 7/1.35 1.0 0.8 1.25 1.6 20.1 870

16 7/1.70 1.0 0.8 1.25 1.6 22.2 1090

25 7/2.14 1.2 1.0 1.6 1.7 26.2 1610

35 19/1.53 1.2 1.0 1.6 1.8 25.3 1690 50 19/1.78 1.4 1.0 1.6 1.9 28.3 2100

70 19/2.14 1.4 1.0 1.6 1.9 30.9 2640

95 19/2.52 1.6 1.2 2.0 2.1 36.0 3680 120 37/2.03 1.6 1.2 2.0 2.2 38.6 4310

150 37/2.25 1.8 1.2 2.0 2.3 41.8 5060

185 37/2.52 2.0 1.4 2.5 2.4 47.1 6570

240 61/2.25 2.2 1.4 2.5 2.5 51.9 8110 300 61/2.52 2.4 1.6 2.5 2.7 57.0 9790

400 61/2.85 2.6 1.6 2.5 2.9 62.3 11940

33 PVC INSULATED PVC sheathed armoured cable

CONSTRUCTION

















(BS 6346 & MS 274, 600/1000V)

Nominal Number/ Thickness Thickness Diameter of Thickness Approx. Approx.

area Wire of insulation of bedding armour wire of sheath Overall weight

diameter diameter


1.5 1/1.38 0.6 0.8 0.9 1.4 12.3 320 1.5 7/0.53 0.6 0.8 0.9 1.4 12.9 340 2.5 1/1.78 0.7 0.8 0.9 1.4 13.5 380 2.5 7/0.67 0.7 0.8 0.9 1.4 14.3 410

4 7/0.85 0.8 0.8 0.9 1.4 15.9 530

6 7/1.04 0.8 0.8 1.25 1.5 18.0 750 10 7/1.35 1.0 0.8 1.25 1.6 21.1 1020 16 7/1.70 1.0 0.8 1.25 1.6 23.3 1300

25 7/2.14 1.2 1.0 1.6 1.7 27.5 1930 35 19/1.53 1.2 1.0 1.6 1.8 28.2 2230 50 19/1.78 1.4 1.0 1.6 1.9 31.7 2820

70 19/2.14 1.4 1.0 2.0 2.0 36.3 3900

95 19/2.52 1.6 1.2 2.0 2.1 40.7 4990 120 37/2.03 1.6 1.2 2.0 2.2 43.7 5910 150 37/2.25 1.8 1.4 2.5 2.4 49.1 7530

185 37/2.52 2.0 1.4 2.5 2.5 53.7 9060

240 61/2.25 2.2 1.6 2.5 2.6 59.8 11410

300 61/2.52 2.4 1.6 2.5 2.8 65.4 13780

400 61/2.85 2.6 1.6 2.5 3.0 71.8 16860

PVC INSULATED PVC sheathed armoured cable 34

CONSTRUCTION





3 cores - red, yellow and blue 4 cores - red, yellow, blue and black











(BS 6346 & MS 274, 600/1000V)


diameter diameter


1.5 1/1.38 0.6 0.8 0.9 1.4 13.0 360 1.5 7/0.53 0.6 0.8 0.9 1.4 13.7 380 2.5 1/1.78 0.7 0.8 0.9 1.4 14.6 450

2.5 7/0.67 0.7 0.8 0.9 1.4 15.2 470

4 7/0.85 0.8 0.8 1.25 1.5 17.9 730 6 7/1.04 0.8 0.8 1.25 1.5 19.2 870

10 7/1.35 1.0 0.8 1.25 1.6 22.6 1200

16 7/1.70 1.0 1.0 1.6 1.7 26.5 1770

25 7/2.14 1.2 1.0 1.6 1.8 29.9 2340 35 19/1.53 1.2 1.0 1.6 1.9 31.2 2810

50 19/1.78 1.4 1.2 2.0 2.0 36.4 3880

70 19/2.14 1.4 1.2 2.0 2.1 40.3 4960

95 19/2.52 1.6 1.2 2.0 2.2 45.3 6400

120 37/2.03 1.6 1.4 2.5 2.4 50.3 8110

150 37/2.25 1.8 1.4 2.5 2.5 54.6 9630

185 37/2.52 2.0 1.6 2.5 2.6 60.3 11700

240 61/2.25 2.2 1.6 2.5 2.8 67.0 14750 300 61/2.52 2.4 1.6 2.5 3.0 73.5 17860

400 61/2.85 2.6 1.8 3.15 3.3 82.7 23110

35 PVC INSULATED PVC sheatheD armoured AUXILIARY cable

CONSTRUCTION



Colour of cores White with black numbering

Formation Stranded together and the interstices may be filled with the

sheathing compound. A non-hygroscopic binder tape may

be applied over the laid-up cores.

Bedding Black general purpose PVC compound TM1 70°C

Armour Galvanised steel wire



ARMOURED AUXILIARY CABLE (1.5MM2)

(BS 6346 & MS 274, 600/1000V)

Number Nominal Construction Thickness Thickness Diameter Thickness Approx. Approx.

of core sectional Number/ of insulation of Bedding of armour of sheath overall weight

area Wire wire diameter

diameter


5 1.5 7/0.53 0.6 0.8 0.9 1.4 14.5 430

7 1.5 7/0.53 0.6 0.8 0.9 1.4 15.4 500

10 1.5 7/0.53 0.6 0.8 1.25 1.5 19.2 780

12 1.5 7/0.53 0.6 0.8 1.25 1.5 18.6 830

19 1.5 7/0.53 0.6 0.8 1.25 1.6 22.3 1090

27 1.5 7/0.53 0.6 1.0 1.6 1.7 26.9 1600

37 1.5 7/0.53 0.6 1.0 1.6 1.8 29.5 1940

48 1.5 7/0.53 0.6 1.0 1.6 1.9 33.1 2360

PVC INSULATED PVC sheatheD armoured AUXILIARY cable 36


ARMOURED AUXILIARY CABLE (2.5MM2)

(BS 6346 & MS 274, 600/1000V)




diameter


5 2.5 7/0.67 0.7 0.8 0.9 1.5 16.4 550

7 2.5 7/0.67 0.7 0.8 1.25 1.5 18.1 750

10 2.5 7/0.67 0.7 0.8 1.25 1.6 21.8 1000

12 2.5 7/0.67 0.7 0.8 1.25 1.6 22.4 1080

19 2.5 7/0.67 0.7 1.0 1.6 1.7 26.7 1640

27 2.5 7/0.67 0.7 1.0 1.6 1.8 30.9 2110

37 2.5 7/0.67 0.7 1.0 1.6 1.9 34.1 2600

48 2.5 7/0.67 0.7 1.2 2.0 2.1 39.8 3520


ARMOURED AUXILIARY CABLE (4MM2)

(BS 6346 & MS 274, 600/1000V)




diameter


5 4 7/0.85 0.8 0.8 1.25 1.5 19.1 820

7 4 7/0.85 0.8 0.8 1.25 1.6 20.6 970

10 4 7/0.85 0.8 1.0 1.6 1.7 26.1 1500

12 4 7/0.85 0.8 1.0 1.6 1.7 26.8 1630

19 4 7/0.85 0.8 1.0 1.6 1.8 30.6 2170

27 4 7/0.85 0.8 1.2 2.0 2.0 37.2 3170

37 4 7/0.85 0.8 1.2 2.0 2.1 41.0 3910

48 4 7/0.85 0.8 1.2 2.0 2.2 46.1 4790

37 PVC INSULATED PVC sheathed NON-armoured With Reduced Neutral Cable

CONSTRUCTION



Colour of cores Red, yellow, blue and black (neutral)





PVC INSULATED, PVC SHEATHED NON-ARMOURED

WITH REDUCED NEUTRAL CABLE (4-core) (BS 6346

& MS 274, 600/1000V)

Phase conductor Neutral conductor

Nominal Construction Thickness Nominal Construction Thickness Thickness Approx. Approx.

sectional Number/ of insulation sectional Number/ of insulation of sheath overall weight

area Wire area Wire diameter

diameter diameter

mm2 No./mm mm mm2 No./mm mm mm mm kg/km

25 7/2.14 1.2 16 7/1.70 1.0 1.8 24.5 1290

35 19/1.53 1.2 16 7/1.70 1.0 1.8 25.6 1650

50 19/1.78 1.4 25 7/2.14 1.2 1.9 29.6 2250

70 19/2.14 1.4 35 19/1.53 1.2 2.0 33.5 3060

95 19/2.52 1.6 50 19/1.78 1.4 2.1 38.5 4150

120 37/2.03 1.6 70 19/2.14 1.4 2.2 41.9 5160

150 37/2.25 1.8 70 19/2.14 1.4 2.4 46.4 6230

185 37/2.52 2.0 95 19/2.52 1.6 2.5 51.7 7850

240 61/2.25 2.2 120 37/2.03 1.6 2.7 58.4 10190

300 61/2.52 2.4 150 37/2.25 1.8 2.9 64.8 12670

300 61/2.52 2.4 185 3/7/2.52 2.0 2.9 64.8 12940

400 61/2.85 2.6 185 37/2.52 2.0 3.2 72.4 16050

PVC INSULATED PVC sheatheD armoured WITH REDUCED NEUTRAL CABLE

38

CONSTRUCTION



Colour of cores Red, yellow, blue and black (neutral)





PVC INSULATED, PVC SHEATHED ARMOURED

WITH REDUCED NEUTRAL CABLE (4-core) (BS

6346 & MS 274, 600/1000V)

Phase conductor Neutral conductor

Nominal Construction Thickness Nominal Construction Thickness Thickness Diameter Thickness Approx. Approx.

sectional Number/ of insulation sectional Number/ of insulation of bedding of armour of sheath overall weight

area Wire area Wire Wire diameter

diameter diameter

mm2 No./mm mm mm2 No./mm mm mm mm mm mm kg/km

25 7/2.14 1.2 16 7/1.70 1.0 1.0 1.6 1.8 29.9 2220

35 19/1.53 1.2 16 7/1.70 1.0 1.0 1.6 1.8 31.0 2630

50 19/1.78 1.4 25 7/2.14 1.2 1.0 1.6 1.9 35.0 3370

70 19/2.14 1.4 35 19/1.53 1.2 1.2 2.0 2.0 40.1 4650

95 19/2.52 1.6 50 19/1.78 1.4 1.2 2.0 2.2 45.3 5980

120 37/2.03 1.6 70 19/2.14 1.4 1.4 2.5 2.3 50.1 7630

150 37/2.25 1.8 70 19/2.14 1.4 1.4 2.5 2.4 54.4 7930

185 37/2.52 2.0 95 19/2.52 1.6 1.4 2.5 2.5 59.7 10840

240 61/2.25 2.2 120 37/2.03 1.6 1.6 2.5 2.7 66.8 13640

300 61/2.52 2.4 150 37/2.25 1.8 1.6 2.5 2.9 73.2 16440

300 61/2.52 2.4 185 3/7/2.52 2.0 1.6 2.5 2.9 73.2 16710

400 61/2.85 2.6 185 37/2.52 2.0 1.8 3.15 3.1 82.3 21260

39 Technical data Current Rating

TECHNICAL DATA

Current ratings are based on the following conditions:

1. Ambient air temperature 30°C

2. Ground temperature 15°C

3. Soil thermal resistivity 1.2°C m/w

4. Depth of laying: (a) For 600/1000V cables 0.5m

(b) For 1900/3300V cables 0.8m

5. Maximum conductor operating temperature 70°C

Rating factors of other temperature:

Cable in air

Temperature 25°C 30°C 35°C 40°C 45°C

Factor 1.06 1.00 0.94 0.87 0.79

Cables in ground


Factor 1.00 0.95 0.90 0.90 0.80

600/1000V COPPER CONDUCTOR

PVC NON-ARMOURED CABLES (SINGLE-CORE)

Clipped direct Laid in free air

Nominal 2 cables, single-phase 3 or 4 cables 2 cables, single-phase 3 cables,

cross ac or dc 3-phase, ac 3 cables, 3-phase ac 3-phase

sectional Horizontal flat spaced ac trefoil

area of Current Volt Current Volt Current Volt Current Volt

conductor rating drop rating drop rating drop rating drop


50 182 0.95 167 0.82 219 0.97 167 0.82

70 234 0.66 214 0.57 281 0.69 216 0.57

95 284 0.50 261 0.43 341 0.54 264 0.43

120 330 0.41 303 0.36 396 0.45 308 0.36

150 381 0.34 349 0.30 456 0.39 356 0.30

185 436 0.29 400 0.26 521 0.35 409 0.26

240 515 0.25 472 0.22 615 0.31 485 0.22

300 594 0.22 545 0.19 709 0.29 561 0.19

400 694 0.20 634 0.175 852 0.27 656 0.18

500 792 0.185 723 0.16 982 0.26 749 0.16

630 904 0.175 826 0.15 1138 0.25 855 0.15

800 1030 0.165 943 0.145 1265 0.25 971 0.15

1000 1154 0.16 1058 0.14 1420 0.24 1079 0.14

Technical data Current Rating 40









Cable in air


Factor 1.06 1.00 0.94 0.87 0.79

Cables in ground


Factor 1.00 0.95 0.90 0.85 0.80


PVC NON-ARMOURED CABLES (MULTI-CORE)

Clipped direct Laid on cable tray

Nominal

3 & 4-core 2 core 3 & 4-core 2-core

cross single-phase, ac or dc 3-phase, ac Single-phase, ac or dc 3-phase, ac

sectional

area of Current Volt Current Volt Current Volt Current Volt

conductor rating drop rating drop rating drop rating drop


1.5 19.5 29 17.5 25 22 29 18.5 25

2.5 27 18 24 15 30 18 25 15

4 36 11 32 9.5 40 11 34 9.5

6 46 7.3 41 6.4 51 7.3 43 6.4

10 63 4.4 57 3.8 70 4.4 60 3.8

16 85 2.8 76 2.4 94 2.8 80 2.4

25 112 1.75 96 1.5 119 1.75 101 1.5

35 138 1.25 119 1.1 148 1.25 126 1.1

ac dc ac dc

50 168 0.94 0.93 144 0.81 180 0.94 0.93 153 0.81

70 213 0.65 0.63 184 0.57 232 0.65 0.63 196 0.57

95 258 0.50 0.46 223 0.43 282 0.50 0.46 238 0.43

120 299 0.41 0.36 259 0.35 328 0.41 0.36 276 0.35

150 344 0.34 0.29 299 0.29 379 0.34 0.29 319 0.29

185 392 0.29 0.23 341 0.25 434 0.29 0.23 364 0.25

240 461 0.24 0.18 403 0.21 514 0.24 0.18 430 0.21

300 530 0.21 0.145 464 0.185 593 0.21 0.145 497 0.185

400 634 0.185 0.105 557 0.160 715 0.185 0.105 597 0.160

4. Technical data Current Rating









Cable in air


Factor 1.06 1.00 0.94 0.87 0.79

Cables in ground


Factor 1.00 0.95 0.90 0.89 0.80


PVC ARMOURED CABLES (SINGLE-CORE)

Laid on cable tray Laid in free air Laid direct

Nominal 2 cables, single-phase 3 or 4 cables, 3-phase 2 cables, dc cables, 3 phase in ground

cross ac flat & touching ac flat & touching Horizontal space ac trefoil (30°C trefoil)

sectional Current Volt Current Volt Current Volt Current Volt Current

area of rating drop rating drop rating drop rating drop rating

conductor

mm2 A mV/A/m A mV/A/m A mV/A/m A mV/A/m A

50 205 0.95 189 0.84 229 0.93 181 0.82 170

70 259 0.68 238 0.62 294 0.63 231 0.58 208

95 313 0.52 285 0.5 357 0.46 280 0.45 250

120 360 0.43 327 0.43 415 0.36 324 0.37 285

150 413 0.37 373 0.38 479 0.29 373 0.32 314

185 469 0.32 422 0.34 548 0.23 425 0.27 353

240 550 0.27 492 0.3 648 0.18 501 0.23 408

300 624 0.24 547 0.28 748 0.145 567 0.21 450

400 723 0.22 618 0.26 885 0.105 657 0.195 501

500 805 0.21 673 0.25 1035 0.085 731 0.18 544

630 891 0.195 728 0.24 1218 0.068 809 0.17 603

800 976 0.185 777 0.22 1441 0.053 886 0.16 629

1000 1041 0.185 808 0.21 1685 0.042 945 0.16 663










Cable in air


Factor 1.06 1.00 0.94 0.87 0.79

Cables in ground


Factor 1.00 0.95 0.90 0.85 0.80


PVC ARMOURED CABLES (MULTI-CORE)

Laid on cable tray

Laid in free air

Laid direct

Nominal in ground

( 30°C trefoil) cross 2 core 3 & 4 core 2 core 3 & 4 core

sectional Current Volt Current Volt Current Volt Current Volt Current

area of rating drop rating drop rating drop rating drop rating

conductor

mm2 A mV/A/m A mV/A/m A mV/A/m A mV/A/m A

1.5 21 29 18 25 22 29 19 25 22 2.5 28 18 25 15 31 18 26 15 29 4 38 11 33 9.5 41 11 35 9.5 38

6 49 7.3 42 6.4 53 7.3 45 6.4 48

10 67 4.4 58 3.8 72 4.4 62 3.8 64

16 89 2.8 77 2.4 97 2.8 83 2.4 83

25 118 1.75 102 1.5 128 1.75 110 1.5 110

35 145 1.25 125 1.1 157 1.25 135 1.1 131 50 175 0.94 151 0.81 190 0.94 163 0.81 157

70 222 0.65 192 0.57 241 0.65 207 0.57 191 95 269 0.5 231 0.43 291 0.5 251 0.43 229 120 310 0.41 267 0.35 336 0.41 290 0.35 263 150 355 0.34 306 0.29 386 0.34 332 0.29 293 185 405 0.29 348 0.25 439 0.29 378 0.25 331

240 476 0.24 409 0.21 516 0.24 445 0.21 387

300 547 0.21 469 0.185 592 0.21 510 0.185 433

400 621 0.185 540 0.16 683 0.185 590 0.16 485

- Technical data Current Rating









Cable in air


Factor 1.06 1.00 0.94 0.87 0.79

Cables in ground


Factor 1.00 0.95 0.90 0.85 0.80

600/1000V ALUMINIUM CONDUCTOR

PVC NON-ARMOURED CABLES (SINGLE-CORE)

Bunched and Enclosed in Conduit or Trunking Clipped Direct to a Surface or on Cable Tray,

Conductor Bunched and Unenclosed

Nominal 2 Cables, Single-Phase 3 or 4 Cables 3-Phase 2 Cables, Single-Phase 3 or 4 Cables 3-Phase

Cross- ac or dc ac ac or dc ac

Sectional Current Volt Curent Volt Curent Volt Current Volt

Area Rating Drop Rating Drop Rating drop Rating drop


ac dc ac dc

16 60 4.5 4.5 52 3.9 72 4.5 4.5 65 3.9

25 78 2.9 2.8 67 2.5 94 2.8 2.8 85 2.5

35 96 2.1 2.0 83 1.8 115 2.1 2.0 105 1.8

50 120 1.6 1.5 100 1.4 140 1.5 1.5 125 1.3

70 150 1.2 1.0 125 1.0 175 1.1 1.0 155 0.93

95 175 0.93 0.8 150 0.80 210 0.77 0.75 185 0.69

120 205 0.80 0.6 175 0.70 240 0.62 0.6 215 0.56

150 235 0.73 0.5 200 0.64 275 0.51 0.49 245 0.48

185 - - - - - 320 0.42 0.39 285 0.4

240 - - - - - 380 0.34 0.29 340 0.34

300 - - - - - 440 0.29 0.23 390 0.3

400 - - - - - 530 0.25 0.18 475 0.27

500 - - - - - 620 0.22 0.15 550 0.25

630 - - - - - 720 0.20 0.11 640 0.24

4. The Volt drop between consumer’s teminals and any other point in the installation

must not exceed 2.5% of the nominal voltage.










Cable in air


Factor 1.06 1.00 0.94 0.87 0.79

Cables in ground


Factor 1.00 0.95 0.90 0.85 0.80


PVC NON-ARMOURED CABLES (MULTI-CORE)

Enclosed in Conduit or Trunking Clipped Direct to a Surface or on Cable Tray, Unenclosed

Conductor

Nominal One Twin Cables, Single-Phase One 3 or 4-core Cable One Twin Cables, Single-Phase One 3 or 4 -core Cable

Cross- ac or dc 3-Phase ac ac or dc 3-Phase ac




ac dc ac dc

16 49 4.6 4.6 43 4.0 58 4.6 4.6 52 4

25 64 2.9 2.9 57 2.6 76 2.9 2.9 67 2.5

35 79 2.2 2.1 70 1.9 92 2.1 2.1 82 1.8

50 99 1.7 1.5 87 1.4 115 1.6 1.5 100 1.3

70 - - - - - 140 1.1 1.1 120 0.93

95 - - - - - 165 0.79 0.77 150 0.63

120 - - - - - 195 0.63 0.61 170 0.54

150 - - - - - 220 0.52 0.50 195 0.45

185 - - - - - 250 0.43 0.40 220 0.37

240 - - - - - 300 0.34 0.31 260 0.3

300 - - - - - 340 0.29 0.25 300 0.25

14 Technical data Current Rating









Cable in air


Factor 1.06 1.00 0.94 0.87 0.79

Cables in ground


Factor 1.00 0.95 0.90 0.85 0.80


PVC ARMOURED CABLES (MULTI-CORE)

Clipped Direct to a Surface of on a Cable Defined Conditions

Conductor Tray, and Unenclosed

One Twin Cable, Single-Phase One 3 or 4-core Cable Nominal One Twin Cable, Single-Phase One 3 or 4-core Cable Cross- ac or dc Three - Phase ac or dc Three-Phase




1.5 14 28 13 24 - - - -

2.5 20 17 17 15 - - - -

4 26 11 22 9.1 - - - -

6 32 7.0 28 6.0 38 7.0 32 6.0

10 45 4.1 38 3.6 52 4.1 44 3.6

16 58 2.6 50 2.2 68 2.6 58 2.2

25 76 1.70 66 1.5 91 1.7 77 1.5

35 93 1.2 80 1.0 112 1.2 94 1.0

ac dc ac dc

50 150 0.92 0.92 125 0.81 180 0.92 0.92 155 0.81

70 180 0.65 0.64 155 0.57 220 0.65 0.64 190 0.57

95 225 0.48 0.46 190 0.42 270 0.48 0.46 230 0.42

120 260 0.40 0.36 220 0.34 310 0.40 0.36 270 0.34

150 290 0.32 0.25 250 0.29 355 0.32 0.25 310 0.29

185 340 0.29 0.23 290 0.24 410 0.29 0.23 350 0.24

240 400 0.25 0.18 350 0.2 485 0.25 0.18 420 0.2

300 460 0.23 0.14 400 0.18 550 0.23 0.14 475 0.18

400 520 0.22 0.11 460 0.17 620 0.22 0.11 550 0.17

16 The Volt drop between consumer’s terminals and any otherpoint in the installation

must not exceed 2.5% of the nominal voltage.

Allowable Short Circuit Current for PVC Insulated cables 46

Conductor : Copper Insulation : PVC Curves based on formula - I = 0.1154 A

t

Where —

18 = Short circuit

current (KA) A = Conductor

area t = Time of short circuit (seconds)

CONDUCTOR SIZE (mm2)

20 Technical data

MINIMUM INSULATION RESISTANCE VALUES OF 600/1000V CABLES

CONDUCTOR INSULATION RESISTANCE

SIZE PER KM @ 20°C

sq. mm. MΩ

1.5 10 2.5 9

4 8

6 7

10 7

16 6

25 5

35 5

50 5

70 5

95 5

120 5

150 5

185 5

240 5

300 5

400 5

500 5

630 5

800 5

1000 5

MINIMUM INSTALLATION RADIUS

OVERALL MINIMUM INTERNAL

TYPE OF CONDUCTOR AND CABLE* DIAMETER, D RADIUS OF BEND

mm mm

CIRCULAR COPPER CONDUCTOR, <10mm 3D

NON-ARMOURED

4D >10mm <25mm 4D

6D >25mm

CIRCULAR COPPER CONDUCTOR, ANY 6D

ARMOURED

SOLID ALUMINIUM OR SHAPED COPPER ANY 8D CONDUCTORS, ARMOURED OR

NON-ARMOURED

* Armoured or Non-Armoured

Technical data 48

Maximum Resistance Of Conductor For Single Core And Multicore Cables.

Maximum DC Resistance Maximum DC Resistance Nominal of conductor at 20°C Nominal of Conductor at 20°C

Cross-sectional Copper Aluminium Cross-sectional Copper Aluminium

Area Conductor Conductor Area Conductor Conductor

mm2 No./mm ohm/km ohm/km mm2 No./mm ohm/km ohm/km

1.5 {1/1.38} 12.1 - 120 37/2.03 0.153 0.253 {7/0.53}

2.5 {1/1.78} 7.41 - 150 37/2.25 0.124 0.206

{7/0.67} 4 7/0.85 4.61 7.41 185 { 37/2.52} 0.0991 0.164

6 7/1.04 3.08 4.61 240 { 37/2.88} 0.0754 0.125

10 7/1.35 1.83 3.08 { 61/2.25}

16 7/1.70 1.15 1.91 300 61/2.52 0.0601 0.100

25 7/2.14 0.727 1.20 400 61/2.85 0.0470 0.0778

35 19/1.53 0.524 0.868 500 61/3.20 0.0366 0.0605

50 19/1.78 0.387 0.641 630 127/2.52 0.0283 0.0469

70 19/2.14 0.268 0.443 800 127/2.85 0.0221 0.0367

95 19/2.52 0.193 0.320 1000 127/3.20 0.0176 0.0291

Properties of Conductors

Properties Unit Aluminium Annealed copper

Density g/cm3 2.703 8.89 Volume Resistivity ohm mm3/Km 28.264 17.241

Coefficient of Resistance Per°C 0.00403 0.00393

Melting Point °C 660 1073

Coefficient of expansion Per°C x 10° 25.5 16.8

Ultimate Tensile Strength N/mm2 205 275

Typical Properties of Various Insulation materials

Insulation Specific Relative Thermal Volume Max. Cond. Max. Short

Gravity Permitivity Resistivity Resistivity Temp. Circuit Temp.

(°C m/w) 20°C (ohm-cm) (°C) (°C)

PVC 1.44 5.0 - 8.0 5.0 - 6.0 10 14 70 160

PE 0.92 2.3 3.5 10 16 70 130

XLPE 0.92 2.5 3.5 10 16 90 250

EPR 1.2 3.5 - 5.0 3.5 - 5.0 10 15 90 250

Impregnated

paper 1.1 6 6 10 15 65 - 80 160 - 250

22 Technical data

FORMULA FOR ELECTRICAL CALCULATION

To calculate Given D.C. A.C. single phase A.C. 3 phase

Current ( A) kW A= 1000 x kW A= 1000 x kW A= 1000 x kW

V V x pf 1.73 x V x pf

Current ( A) kVA - A= 1000 x kVA A= 1000 x kVA

V 1.73 x V

Current ( A) hp A= 746 x hp A= 746 x hp A= 746 x

hp

V x eff V x eff x pf 1.73 x V x eff x pf

Power (kW) VA kW = A x V kW= A x V x pf kW = 1.73 x A x V x pf

1000 1000 1000

Apparent Power VA - kVA= A x V kVA= 1.73 x A x V

(kVA) 1000 1000

pf - Power factor of equipment or system under consideration

eff - Efficiency of motor or machinery

V - Line voltage

XLPE INTRODUCTION 50

“Cross-Linked Polyethylene”, one kind of excellent thermosetting plastic insulation material, had come to

be used for all low, medium, high voltage cable recently, and commonly abbreviated “XLPE” or “PEX” .

XLPE molecules bonded in a three dimensional network, it’s different from conventional polyethylene,

therefore, “XLPE” has particular properties in thermic, electrical and mechanical.

“XLPE” Insulation Offers These Advantages

3) Outstanding physical and mechanical toughness

4) Extremely low moisture absorption

5) Excellent ozone resistance

6) Strong resistance to chemicals fumes and gases

7) Low SIC and power factor

8) High impulsed strength

9) High insulation resistance and dielectric strength

10) Capability of carrying and terminating

11) Easy to splicing and terminating

STRUCTURE OF PE and XLPE

Polyethylene

Crosslinked Polyethylene

* C ons tr u ction of XLPE Cable

CONDUCTOR

Conductor shall be made of plain annealed copper wires and hard

drawn aluminium wires complying with IEC 60228.

Maximum resistance of conductor for

single-core and multicore cables (20°C)

Nominal Copper conductor Aluminium conductor cross-sectional area

Ω/km Ω/km mm2

2.5 7.41 -

4.0 4.61 7.41

6.0 3.08 4.61

10 1.83 3.08

16 1.15 1.91

25 0.727 1.20

35 0.524 0.868

50 0.387 0.641

70 0.268 0.443

95 0.193 0.320

120 0.153 0.253

150 0.124 0.206

185 0.0991 0.164

240 0.0754 0.125

300 0.0601 0.100

400 0.0470 0.0778

500 0.0366 0.0605

630 0.0283 0.0469

800 0.0221 0.0367

1000 0.0176 0.0291

52

Insulation shall be XLPE compound complying with IEC 60502-1

Test Voltage Duration 5 minutes

Rated Voltage Uo/U (kV) 0.6/1

Test Voltage r.m.s. (kV) 3.5

Insulation resistance Rated Min insulation resistance at 20°C MΩ-km

Normal

voltage

(Uo/U) 0.6/1

cross (kV)

section area mm2

1.5 2,400 2.5 2,100

4 1,800

6 1,500

10 1,200

16 1,100

25 1,100 35 1,000

INSULATION 50 900

70 900

95 800

120 800 150 800

185 800

240 700

300 700

400 700 500 700

630 600

800 600

1,000 600

Core identification shall be made by different colouring and the colour

scheme shall be as follows 0.6/1 kV Twin : Red and Black

Three : Red, Yellow and Blue

Four : Red, Yellow, Blue and Black

3. CABLE StructurAL DESCRIPTION AND CONSTRUCTION DATA

0 . 6 / 1kV XLPE

INSULATED NON - ARMOURED CABLE

DESCRIPTION

Single core and multi core cables with copper or aluminium conductors XLPE insulated and PVC

sheathed. Cables are rated 0.6/1 kV and conform to IEC 60502-1 : 2004.

CONSTRUCTION

Conductor Plain circular or sector stranded copper or aluminium conductors, conform to IEC 60228 class 2.

Insulation XLPE ( cross-linked polyethylene) rated 90 °C

Colours for core identification Single core - red ( black on request) Two core - red & black

Three core - red, yellow and blue Four Core - red, yellow, blue and black

Assembly Two, three or four insulated conductors are laid up together, if necessary filled with non-hygroscopic

material compatible with the insulation.The filling may be omitted provided the outer shape of the

cable remains practically circular and no adhesion occurs between cores and sheath.

Sheath PVC type ST2 to IEC 60502-1 : 2004 colour black

APPLICATIONS

These cables are designed for general use including underground burial, where they are not likely to

suffer mechanical damage.

NOTE : Cables complying with BS5467 and customer’s specification are available upon request.

Modifications which serve to improve our products will be implemented without notice.

CABLE StructurAL DESCRIPTION AND CONSTRUCTION DATA 54

0.6 / 1kV SINGLE CORE,

XLPE INSULATED, PVC SHEATHED

NON-ARMOURED CABLES

Conductor Approx. cable weight

Nominal Nominal Nominal Approx. cross- thickness thickness overall

Copper Aluminium sectional Shape of insulation of sheath diameter

area

mm2 mm mm mm kg/km kg/km

1.5 c.s. 0.7 1.4 6.1 45 - 2.5 c.s. 0.7 1.4 6.8 60 -

4 c.s. 0.7 1.4 7.1 78 -

6 c.s. 0.7 1.4 7.6 105 -

10 c.s. 0.7 1.4 8.4 153 -

16 c.c. 0.7 1.4 10.1 215 115

25 c.c. 0.9 1.4 10.9 315 160

35 c.c 0.9 1.4 12.0 415 195

50 c.c. 1.0 1.4 13.4 540 240

70 c.c. 1.1 1.4 15.3 755 325

95 c.c. 1.1 1.5 17.2 1020 420

120 c.c. 1.2 1.5 18.9 1270 515

150 c.c. 1.4 1.6 21.1 1560 630

185 c.c. 1.6 1.6 23.2 1955 780

240 c.c. 1.7 1.7 26.0 2540 995

300 c.c. 1.8 1.8 28.7 3160 1220

400 c.c. 2.0 1.9 32.2 4015 1535

500 c.c. 2.2 2.0 35.7 5035 1910

630 c.c. 2.4 2.2 42.5 6530 2485

800 c.c. 2.6 2.3 47.8 8070 2910

1000 c.c. 2.8 2.4 52.6 10380 3870

Notes: c.s - circular stranded conductor

c.c - circular compacted stranded conductor

24 CABLE StructurAL DESCRIPTION AND CONSTRUCTION DATA

0.6/1kV Two Cores,


NON-ARMOURED CABLES


Nominal Nominal Nominal Approx.

cross- thickness thickness overall


area


1.5 c.s. 0.7 1.8 12.1 134 -

2.5 c.s. 0.7 1.8 10.9 155 -

4 c.s. 0.7 1.8 12.0 200 -

6 c.s. 0.7 1.8 13.1 255 -

10 c.s. 0.7 1.8 15.0 365 -

16 c.c. 0.7 1.8 17.2 490 285

25 c.c. 0.9 1.8 17.0 655 330

35 c.c. 0.9 1.8 18.7 845 395

50 c.c. 1.0 1.8 21.0 1110 500

70 c.c. 1.1 1.8 24.0 1540 660

95 s.s. 1.1 1.9 26.9 2040 820

120 s.s. 1.2 2.0 29.9 2570 1030

150 s.s. 1.4 2.2 33.4 3130 1235

185 s.s. 1.6 2.3 37.1 3920 1545

240 s.s. 1.7 2.5 41.7 5050 1900

300 s.s. 1.8 2.6 45.8 6350 2395

400 s.s. 2.0 2.9 51.6 8000 2940

Note: c.s. - circular stranded conductor c.c. - circular compacted stranded conductor s.s. - sectoral stranded conductor, circular conductors can be produced on request.


0.6/1kV Three Cores,


NON-ARMOURED CABLES


Nominal Nominal Nominal Approx. cross- thickness thickness overall

sectional Shape of insulation of sheath diameter Copper Aluminium

area


1.5 c.s. 0.7 1.8 10.5 149 -

2.5 c.s. 0.7 1.8 11.4 185 -

4 c.s. 0.7 1.8 12.6 245 -

6 c.s. 0.7 1.8 13.8 320 -

10 c.s. 0.7 1.8 15.8 470 -

16 c.c. 0.7 1.8 17.3 650 345

25 c.c. 0.9 1.8 19.4 935 450

35 c.c 0.9 1.8 21.4 1235 560 50 c.c. 1.0 1.8 24.1 1610 695

70 c.c. 1.1 1.9 27.9 2285 965 95 s.s. 1.1 2.0 31.4 3090 1260 120 s.s. 1.2 2.1 34.9 3875 1560 150 s.s. 1.4 2.3 39.1 4780 1940 185 s.s. 1.6 2.4 43.5 5960 2395

240 s.s. 1.7 2.6 48.8 7810 3080 300 s.s. 1.8 2.8 53.7 9700 3765

400 s.s. 2.0 3.0 60.7 12400 4810



0.6/1kV Four Cores,


NON-ARMOURED CABLES

Conductor Nominal Nominal Approx.

Approx. cable weight Nominal

cross- thickness thickness overall


area


1.5 c.s. 0.7 1.8 11.3 175 - 2.5 c.s. 0.7 1.8 12.3 225 - 4 c.s. 0.7 1.8 13.6 305 - 6 c.s. 0.7 1.8 15.0 400 -

10 c.s. 0.7 1.8 17.3 595 - 16 c.c. 0.7 1.8 18.9 830 420

25 c.c. 0.9 1.8 21.7 1230 580 35 c.c 0.9 1.8 24.1 1630 730

50 c.c. 1.0 1.9 27.1 2150 935

70 c.c. 1.1 2.0 31.7 3050 1290 95 s.s. 1.1 2.1 35.8 4125 1685

120 s.s. 1.2 2.3 39.8 5158 2100

150 s.s. 1.4 2.4 44.4 6375 2590 185 s.s. 1.6 2.6 49.6 7980 3230 240 s.s. 1.7 2.8 55.8 10455 4150 300 s.s. 1.8 3.0 61.7 13020 5110

400 s.s. 2.0 3.3 68.8 16100 5980



0.6/1 kV XLPE

Insulated Armoured Cable

DESCRIPTION

Single core and multi core cables with copper or aluminium conductors XLPE insulated and PVC

sheathed. Cables are rated 0.6/1 kV and conform to IEC 60502-1 : 2004 / MS 2104 : 2007 / MS 2105 : 2007 /

MS 2106 : 2007 / MS 2107 : 2007.

CONSTRUCTION

Conductor Plain circular or sector stranded copper or aluminium conductors, conform to IEC 60228 class 2.

Insulation XLPE ( cross-linked polyethylene) rated 90°C

Colours for core identification Single core - red

Two core - red & black

Three core - red, yellow and blue Four Core - red, yellow, blue and black

Assembly Two, three or four insulated conductors are laid up together, if necessary filled with non-hygroscopic

material compatible with the insulation and cover with layer of PVC bedding which may be an integral

part of the filling.

Armour Galvanized steel wires applied over the PVC bedding.

PVC Sheath type ST2 to IEC 60502-1 : 2004 colour black.

APPLICATIONS

These cables are most suitable for underground burial where there is a risk of mechanical damage.

NOTE : Cables complying with BS5467 and customer’s specification are available upon request.

Modifications which serve to improve our products will be implemented without notice.


0 . 6 / 1 k V S i n g l e C o r e ,


ARMOURED CABLES

Conductor Approx. cable weight Nominal Nominal Nominal Nominal Approx.

cross- thickness diameter of thickness overall Copper Aluminium

sectional Shape of insulation aluminium of sheath diameter

area wire

mm2 mm mm mm mm kg/km kg/km

50 c.c. 1.0 0.80 1.8 20.0 760 460 70 c.c. 1.1 0.80 1.8 21.0 985 555 95 c.c. 1.1 1.6 1.8 21.8 1260 660

120 c.c. 1.2 1.6 1.8 25.8 1645 890

150 c.c. 1.4 1.6 1.8 27.7 1970 1040

185 c.c. 1.6 1.6 1.8 30.0 2385 1220

240 c.c. 1.7 1.6 1.9 32.7 3020 1475

300 c.c. 1.8 1.6 1.9 35.1 3665 1725 400 c.c. 2.0 2.0 2.1 40.0 4740 2260 500 c.c. 2.2 2.0 2.2 43.5 5830 2705

630 c.c. 2.4 2.4 2.3 48.2 7390 3345

800 c.c. 2.6 2.5 2.5 53.9 9540 4375

1000 c.c. 2.8 2.5 2.7 62.5 11860 6530

Note: c.c. - compacted circular stranded conductor


0 . 6 / 1 k V T w o C o r e s ,


ARMOURED CABLES

Conductor Approx.

Approx.cable weight Nominal Nominal Nominal Nominal


sectional Shape of insulation steel of sheath diameter

area wire


1.5 c.s. 0.7 0.8 1.8 14.0 350 -

2.5 c.s. 0.7 0.8 1.8 14.9 400 -

4 c.s. 0.7 0.8 1.8 16.0 475 - 6 c.s. 0.7 0.8 1.8 17.1 550 -

10 c.s. 0.7 0.8 1.8 19.0 700 -

16 c.c. 0.7 0.8 1.8 20.3 860 655

25 c.c. 0.9 1.6 1.8 23.7 1280 955 35 c.c 0.9 1.6 1.8 24.9 1525 1075 50 c.c. 1.0 1.6 1.8 27.1 1870 1260

70 c.c. 1.1 1.6 2.0 30.5 2450 1570

95 s.s. 1.1 2.0 2.1 34.2 3310 2090 120 s.s. 1.2 2.0 2.2 37.5 4010 2470

150 s.s. 1.4 2.0 2.3 40.9 4740 2845

185 s.s. 1.6 2.5 2.5 45.9 6120 3745 240 s.s. 1.7 2.5 2.7 50.8 7650 4500 300 s.s. 1.8 2.5 2.8 54.8 9115 5160

400 s.s. 2.0 2.5 3.1 61.2 11335 6275



0 . 6 / 1 k V T h r e e C o r e s ,


ARMOURED CABLES

Conductor Approx.

Approx.cable weight Nominal Nominal Nominal Nominal



area wire


1.5 c.s. 0.7 0.8 1.8 14.5 385 -

2.5 c.s. 0.7 0.8 1.8 15.4 450 -

4 c.s. 0.7 0.8 1.8 16.6 535 -

6 c.s. 0.7 0.8 1.8 17.8 640 -

10 c.s. 0.7 0.8 1.8 19.8 830 -

16 c.c. 0.7 0.8 1.8 21.3 1030 725 25 c.c. 0.9 1.6 1.8 25.7 1650 1165

35 c.c 0.9 1.6 1.8 27.7 2015 1340

50 c.c. 1.0 1.6 1.8 30.5 2520 1605 70 c.c. 1.1 1.6 2.0 35.1 3535 2215

95 s.s. 1.1 2.0 2.2 39.3 4565 2735

120 s.s. 1.2 2.0 2.3 42.7 5510 3200 150 s.s. 1.4 2.5 2.5 47.9 6990 4150

185 s.s. 1.6 2.5 2.6 52.7 8120 4555 240 s.s. 1.7 2.5 2.8 58.1 10500 5770

300 s.s. 1.8 2.5 3.0 63.7 12695 6760

400 s.s. 2.0 2.5 3.2 70.3 15540 7950

Note: c.s. - circular stranded conductor

c.c. - circular compacted stranded conductor s.s. - sectoral stranded conductor, circular conductors can be produced on request.


0 . 6 / 1 k V F o u r C o r e s ,


ARMOURED CABLES

Conductor

Approx.

Approx.cable weight Nominal

Nominal Nominal Nominal



area wire


1.5 c.s. 0.7 0.8 1.8 15.3 435 -

2.5 c.s. 0.7 0.8 1.8 16.3 510 - 4 c.s. 0.7 0.8 1.8 17.6 615 - 6 c.s. 0.7 0.8 1.8 19.0 740 -

10 c.s. 0.7 0.8 1.8 21.3 990 -

16 c.c. 0.7 0.8 1.8 25.2 1530 1120 25 c.c. 0.9 1.6 1.8 28.0 2030 1380 35 c.c 0.9 1.6 1.9 30.5 2525 1625

50 c.c. 1.0 1.6 2.0 33.7 3160 1945 70 c.c. 1.1 2.0 2.2 39.5 4555 2795

95 s.s. 1.1 2.0 2.3 43.7 5795 3355

120 s.s. 1.2 2.5 2.5 49.1 7485 4400

150 s.s. 1.4 2.5 2.6 53.7 8925 5135 185 s.s. 1.6 2.5 2.8 58.9 10830 6080 240 s.s. 1.7 2.5 3.0 65.5 13720 7415

300 s.s. 1.8 2.5 3.2 71.3 16585 8675

400 s.s. 2.0 3.15 3.5 80.9 21580 11460



0 . 6 / 1 k V F o u r C o r e s

With Reduced Neutral Conductor, XLPE

Insulated, PVC Sheathed NON-armoured

Cables

Conductor Approx.cable weight Nominal Nominal Nominal Nominal Approx.

cross- cross- thickness thickness overall Copper Aluminium

sectional Shape sectional Shape of insulation of sheath diameter

area area

Phase Neutral Phase Neutral

mm2 mm2 mm mm mm mm kg/km kg/km

10 c.s. 6 c.s. 0.7 0.7 1.8 17.3 560 - 16 c.c. 10 c.s. 0.7 0.7 1.8 18.9 780 -

25 c.c. 16 c.s. 0.9 0.7 1.8 21.7 1165 580

35 c.c. 16 c.s. 0.9 0.7 1.8 24.1 1515 740

50 c.c. 25 c.s. 1.0 0.9 1.8 27.1 1945 870 70 c.c. 35 c.s. 1.1 0.9 1.9 31.7 2840 1300 95 s.s. 50 c.s. 1.1 1.0 2.1 35.8 3650 1390

120 s.s. 70 c.s. 1.2 1.1 2.2 39.8 4850 1780 150 s.s. 70 c.s. 1.4 1.1 2.3 44.4 5660 2390 185 s.s.. 95 c.s. 1.6 1.1 2.5 49.6 7045 2885

240 s.s. 120 c.s. 1.7 1.2 2.7 55.8 9115 3630 300 s.s. 150 c.s. 1.8 1.4 2.9 61.7 11300 4440

400 s.s. 185 c.s. 2.0 1.6 3.1 68.8 14580 5825


Permissible Short Circuit Currents 64

XLPE Insulated Conductor

The permissible short-circuit current of a cable as determined by the maximum permissible

conductor temperature and by the duration of the short circuir current. At high peak currents the

dynamic forces between the conductors must be taken into account.

The short circuit capacity of the conductor and metallic shield of a cable are related principally to

their heat capacities and are limited by the maximum temperature permitted under short circuit

conditions . The temperature limits established for XLPE power cables are as follows :-

at conductor 250ºC

The two graphs on provide curves from which the short circuit capacity of copper or aluminium

conductors (based on a temperature rise from 90ºC to 250ºC) can be determined. These curves are

plotted for durations given in cycles ( 60Hz basis)

Logarithmic interpolation between the curves will give estimated values for other durations.

The curves may be used also to determine the amount of conducting material required to carry a

known short-circuit current for given duration.

34 Short circuit current rating for aluminium conductors

Short circuit current rating for COPPER conductors 66

5. Construction

Technical data, Continuous current carrying CAPACITY 68

Continuous Current Carrying Capacity For 600/1000 V XLPE/PVC (PE) Armoured Cable

Conductor Laid in Air Laid Direct in Ground Drawn in To Duct Conductor

Nom.cross Single Core 3 or Single Core 3 or Single Core 3 or 1 sec. 3 sec.

sectional

4 - core

4 - core

4 - core Fault Fault

current current area Trefoil Flat

Trefoil Flat

Trefoil Flat

rating rating

sqmm (A) (A) (A) (A) (A) (A)

(A) (A) (A) (kA) (kA)

Copper Conductors

16 105 125 100 110 115 110 100 105 80 2.3 1.3

25 145 165 130 145 150 140 130 135 105 3.5 2.0

35 175 200 160 170 180 170 155 160 125 4.9 2.8

50 210 240 195 205 210 200 185 185 150 7.0 4.1

70 265 305 245 250 255 245 225 230 185 9.9 5.7

95 320 370 300 295 305 295 280 285 220 13.4 7.7

120 370 430 345 335 345 335 320 325 250 17.0 9.0

150 430 500 395 380 390 375 360 370 285 21.2 12.2

185 495 570 450 425 440 420 410 420 320 26.2 15.1

240 585 680 530 490 510 485 475 485 390 34.0 19.6

300 670 780 605 555 575 545 535 550 435 42.5 24.5

400 780 910 695 630 660 615 610 630 500 56.7 32.7

500 900 1060 795 710 750 690 690 715 560 70.9 40.9

630 1040 1235 900 800 855 770 775 815 630 89.4 51.6

800 1190 1425 1010 890 965 845 865 920 695 113.0 65.0

1000 1345 1620 1105 980 1075 915 945 1020 750 141.9 81.9

Aluminium Conductors

16 85 95 75 90 90 85 80 80 60 1.5 0.9

25 115 130 100 115 115 110 100 105 80 2.3 1.3

35 135 160 125 135 140 130 120 125 95 3.3 1.9

50 165 190 150 160 160 155 140 145 115 4.7 2.7

70 205 235 190 195 200 190 175 180 140 6.7 3.8

95 250 290 235 230 235 235 220 220 170 9.1 5.2

120 290 335 270 260 270 260 250 255 195 11.4 6.6

150 335 385 305 295 300 290 280 285 220 14.3 8.2

185 385 445 350 330 340 330 320 325 250 17.7 10.2

240 455 530 415 385 395 380 370 380 305 22.9 13.2

300 525 605 475 435 450 425 420 425 345 28.7 16.5

400 615 710 555 495 515 490 480 490 395 38.3 22.1

500 715 835 640 565 590 555 545 565 455 47.0 27.6

630 840 980 740 645 675 630 625 645 515 60.6 34.8

800 975 1140 845 730 775 710 705 735 580 76.6 44.2

1000 1120 1320 945 815 875 780 790 830 640 95.7 55.3

- Technical data, Continuous current carrying CAPACITY

The tabulated current rating have been calculated in accordance with IEC 287. They are for single

circuit with the standard conditions as follows : -

5. Maximum permissable conductor temperature at continuous operation is 90°C.

ii ) Ground temperature is 25°C

15 Ambient temperature is 40°C

16 Ground thermal resistivity is 1.2 km/W

17 Cables laying depth is ground : - cable’s voltage up to 1 kV........500mm cable’s voltage above 1 kV .......800 mm

18 Spacing between cables :-

In flat formation........... 2 times of the cable overall diameter In trefoil formation........... cables touching

19 Cable’s sheath or armour solidly bonded at both ends.

20 Cables shielded from direct sun rays

For conditions of operation different from those on which the continuous current capacity tables are based,

ratings can be determined by application of “Rating Factor” in table below.

Rating Factor

Rating Factors For Cables in Air

Ambient air temperature 10 15 20 25 30 35 40 45 50 55 60

Rating Factors 1.26 1.22 1.18

1.1

4 1.10 1.05 1.0 1.0 0.89 0.84 0.78

Rating Factors For Ground Temperature Ground Factors 10 15 20 25 30 35 40 45 50 55 60

Rating Factors 1.11 1.07 1.04 1.00 0.96 0.92 0.88 0.83 0.78 0.73 0.68

Rating Factors for Thermal Resistivity of Ground

Conductor size ( mm2) Thermal Resistivity ( Km/W) 0.8 0.9 1.0 1.2 1.5 2.0 2.5 3.0

Single Core Cable

Up to 150

1.16 1.11 1.07 1.0 0.91 0.81 0.73 0.67

From 185 to 400

1.17 1.12 1.07 1.0 0.90 0.80 0.72 0.66

From 500 to 12000

1.18 1.13 1.08 1.0 0.90 0.79 0.71 0.65

Multicore cables

Up to 16

1.09 1.06 1.0 1.0 1.0 0.86 0.79 0.74

From 25 to 150

1.14 1.10 1.1 1.0 0.9 0.84 0.76 0.70

From 185 - 400 1.1

6 1.11 1.1 1.0 0.9 0.82 0.74 0.68

Rating Factors For Depth of Laying

Depth of laying 0.6 / 1kV cables

70mm2 to 300mm2 above 300mm2

(m) up to 50mm2

0.50 1.00 1.00 1.00

0.60 0.99 0.98 0.97

0.80 0.97 0.96 0.94

1.00 0.95 0.94 0.92

1.25 0.94 0.92 0.90

1.50 0.93 0.91 0.89

1.75 0.92 0.89 0.87

2.00 0.91 0.88 0.86

2.50 0.90 0.87 0.85

3.0 or more 0.89 0.86 0.83

70

Group Derating Factors

Derating Factors for groups of cables installed in air Multiple circuits Number vertically 1 2

Number of cable horizontally 1 2 3 6.0 7-20 2 3 4 5 6 7 8-20

S=d 1.00 0.85 0.80 0.70 0.70 0.70 0.60 0.60 0.56 0.53 0.51 0.50

Spacing S=2d 1.00 0.95 0.95 0.80 0.80 0.90 0.90 0.85 0.73 0.72 0.71 0.70 S=3d 1.00 1.00 1.00 0.95 - 0.95 0.95 0.90 - - - -

Number vertically

Number of cables horizontally 3 4 5 6 7 8 9-10 11-12 13-15 16-19 20 N/A

S=d 0.48 0.41 0.37 0.34 0.32 0.31 0.30 0.30 0.30 0.30 0.30

Spacing S=2d 0.80 0.80 0.68 0.66 0.65 0.65 0.64 0.63 0.62 0.61 0.60

S=3d 0.85 0.85 - - - - - - - - -

Derating Factors for groups of cables laid direct in ground Three single core cables in trefoil and

laid flat touching, horizontal formation. Cable Number Spacing of circuits ( between centres of cable groups)

Voltage of Touching

( kV) Circuits Trefoil Laid flat 0.15m* 0.3m 0.45m 0.6m

0.6/1 2 0.77 0.80 0.82 0.88 0.90 0.93 3 0.65 0.68 0.72 0.79 0.83 0.87

4 0.59 0.63 0.67 0.75 0.81 0.85

5 0.55 0.58 0.63 0.72 0.78 0.83

6 0.52 0.56 0.6 0.70 0.77 0.82

*This spacing will not be possible for some of the larger diameter cables

Derating factors for groups of cables laid direct in ground Multicore cables in horizontal formation

Cable Number Spacing of circuits (between centres of cable groups) Voltage of Touching

0.6m

(kV) circuits 0.15* 0.3m 0.45m

2 0.85 0.87 0.91 0.93 0.94 3 0.70 0.78 0.84 0.87 0.90

4 0.63 0.74 0.81 0.86 0.89

0.6/1 5 0.59 0.70 0.78 0.83 0.87

6 0.55 0.67 0.76 0.82 0.86

*This spacing will not be possible for some of the larger diameter cables

17 Handling And Installation Of XLPE CableS

19 Minimum bending radius and permissible maximum pulling tension For

safety installation without damaging electrical physical properties, the

following minimum bending radius and permissible maximum pulling

tension must be observed :

Minimum bending radius D : Overall dia. of cable

Number of core Single core Multi core

Type of cable Round conductor Four segmental stranded conductor

600 V cable 10D 12D 8D

3,300 V cable and higher 10D 12D 8D

Triplex type cable - - 8D

Corrugated metal armoured cable 10D 12D 8D

Flat tape armoured cable 10D 12D 8D

Wire armoured cable 10D 12D 8D

Lead sheathed cable 10D 12D 10D

Permissible maximum pulling tension

Pulling tool Material of conductor Permissible maximum pulling tension (kg)

Pulling eye Copper 7x ( Number of core) x ( Core-sectional area of conductor)

Aluminium 7x ( Number of core) x ( Core-sectional area of conductor)

Cable grip Copper & aluminium The same as using the pulling eye, but the minimum tension

should be less than two tons

Note: When cable grip is used it should cover more than 500 mm in length of the cable end be

bound to the cable sheath.

21 Side wall pressure to cable Permissible maximum side wall pressure to the cable at bending point during installation is 500kg/m.

Note:

Side wall pressure to cable = Pulling tension (kg)

= T Bending radius (m) = R

23 Pulling tension (kg)

12) Bending radius (m)

3. Removal of sheath or tape Special care must be taken not to harm the insulation when removing the sheath or tapes with knife otherwise it may result in a dialectric breakdown. 4. Cleaning the surface of insulation The surface of insulation should be cleaned to avoid a flash over at the cable termination or joint. 5. Applying of self-adhesive tape When applying a self-adhesive tape after joint or terminating of XLPE cable, stretch it properly

about 1.2 times as long as the original one. If it is over-stretched crack may occur on the tape in the long run and if not stretch properly, tape will not be adhered between each layer. * Water proof treatment for out-door termination

For out-door termination water proof treatment is

necessary to avoid the water penetrating into the

cable and special care must be taken to apply

tapes and terminals. It is desirable to use a

compression or solder type terminal.

Technical data 72

Wire Gauges

Gauge system Diameter Cross-sectional area Weight of Weight of

copper aluminium

A.W.G. S.W.G. mm mil mm2 sq.mil CM kg/km kg/km

6/0 - 14.732 580 170.5 264200 336400 1515 460.2

5/0 - 13.119 516.5 135.2 209500 266800 1202 365.0

- 7/0 12.700 500 126.7 196400 250000 1126 342.0

- 6/0 11.786 464 109.1 169100 215300 969.9 294.6

4/0 - 11.684 460 107.2 166200 211600 953.2 289.5

- 5/0 10.973 432 94.56 146600 186600 840.6 255.3

3/0 - 10.404 409.6 85.01 131800 167800 755.8 229.5

- 4/0 10.160 400 81.07 125700 160000 720.7 218.9

- 3/0 9.449 372 70.12 108700 138400 623.4 189.3

2/0 - 9.266 364.8 67.43 104500 133100 599.5 182.1

- 2/0 8.839 348 61.36 95110 121100 545.5 165.7

0 - 8.252 324.9 53.49 82910 105600 475.5 144.4

- 0 8.230 324 53.19 82450 105000 472.9 143.6

- 1 7.620 300 45.60 70690 90000 405.4 123.1

1 - 7.348 289.3 42.41 65730 83690 377.0 114.5

- 2 7.011 276 38.60 59830 76180 343.2 104.2

2 - 6.544 257.6 33.63 52120 66370 299.0 90.80

- 3 6.401 252 32.18 49880 63500 286.1 86.88

- 4 5.893 232 27.27 42270 53820 242.4 73.63

3 - 5.827 229.4 26.66 41330 52620 237.0 71.99

- 5 5.385 212 22.77 35300 44940 202.4 61.49

4 - 5.189 204.3 21.15 32780 41730 188.0 57.10

- 6 4.877 192 18.68 28950 36860 166.1 50.43

5 - 4.621 181.9 16.77 26000 33100 149.1 45.28

- 7 4.470 176 15.69 24320 30970 139.5 42.37

6 - 4.115 162 13.30 20620 26250 118.3 35.92

- 8 4.064 160 12.97 20110 25600 115.3 35.02

7 - 3.665 144.3 10.55 16350 20820 93.78 28.48

- 9 3.658 144 10.51 16290 20740 93.41 28.37

8 - 3.264 128.5 8.367 12970 16510 74.39 22.59

- 10 3.251 128 8.302 12870 16380 73.80 22.42

- 11 2.946 116 6.818 10570 13460 60.61 18.41

9 - 2.906 114.4 6.633 10280 13090 58.96 17.91

- 12 2.642 104 5.481 8495 10820 48.72 14.80

10 - 2.588 101.9 5.261 8155 10380 46.77 14.21

- 13 2.337 92 4.289 6648 8465 38.13 11.58

11 - 2.305 90.74 4.172 6467 8234 37.09 11.26

12 - 2.053 80.81 3.309 5129 6531 29.42 8.935

- 14 2.032 80 3.243 5027 6400 28.83 8.756

- 15 1.829 72 2.627 4072 5185 23.35 7.093

13 - 1.828 71.96 2.624 4067 5178 23.33 7.085

14 - 1.628 64.08 2.081 3225 4107 18.50 5.618

- 16 1.626 64 2.075 3217 4096 18.45 5.604

15 - 1.450 57.07 1.650 2558 3257 14.67 4.456

- 17 1.422 56 1.589 2463 3136 14.13 4.290

16 - 1.291 50.82 1.309 2029 2583 11.63 3.534

- 18 1.219 48 1.167 1810 2304 10.38 3.152

17 - 1.150 45.26 1.0380 1609 2048 9.226 2.802

18 - 1.024 40.3 0.8227 1275 1624 7.314 2.221

- 19 1.016 40 0.8107 1257 1600 7.207 2.189

- 20 0.9144 36 0.6567 1018 1296 5.838 1.773

19 - 0.9117 35.89 0.6529 1012 1288 5.804 1.763

- 21 0.8128 32 0.5189 804.2 1024 4.613 1.401

20 - 0.8116 31.95 0.5174 801.9 1021 4.600 1.397

21 - 0.7230 28.46 0.4105 636.3 810.1 3.649 1.108

4. Appendix - Technical data

Wire Gauges - Continued

Gauge system Diameter Cross-sectional area Weight of Weight of

copper aluminium

A.W.G. S.W.G. mm mil mm2 sq.mil CM kg/km kg/km

- 22 0.7112 28 0.3973 615.8 784.0 3.532 1.073

22 - 0.6439 25.35 0.3256 504.7 642.6 2.895 0.8792

- 23 0.6096 24 0.2919 452.4 576.0 2.595 0.7880

23 - 0.5733 22.57 0.2581 400.1 509.4 2.295 0.6970

- 24 0.5588 22 0.2452 380.1 484.0 2.180 0.6622

24 - 0.5106 20.1 0.2047 317.3 404.0 1.820 0.5528

- 25 0.5080 20 0.2027 314.2 400.0 1.802 0.5472

- 26 0.4572 18 0.1642 254.5 324.0 1.460 0.4433

25 - 0.4546 17.9 0.1623 251.6 320.4 1.443 0.4383

- 27 0.4166 16.4 0.1363 211.3 269.0 1.212 0.3680

26 - 0.4049 15.94 0.1288 199.6 254.1 1.145 0.3477

- 28 0.3759 14.8 0.1110 172.0 219.0 0.9867 0.2997

27 - 0.3606 14.2 0.1021 158.3 201.5 0.9077 0.2757

- 29 0.3454 13.6 0.09372 145.3 185.0 0.8332 0.2530

28 - 0.3211 12.64 0.08097 125.5 159.8 0.7198 0.2186

- 30 0.3150 12.4 0.07791 120.8 153.8 0.6926 0.2104

- 31 0.2947 11.6 0.06819 105.7 134.6 0.6062 0.1841

29 - 0.2860 11.26 0.06422 99.54 126.7 0.5709 0.1734

- 32 0.2743 10.8 0.05908 91.58 116.6 0.5252 0.1595

30 - 0.2548 10.03 0.05097 79.01 100.6 0.4531 0.1376

- 33 0.2540 10 0.05067 78.54 100.0 0.4505 0.1368

- 34 0.2337 9.2 0.04289 66.48 84.64 0.3813 0.1158

31 - 0.2268 8.928 0.06422 62.60 79.71 0.3590 0.1090

- 35 0.2134 8.4 0.05908 55.42 70.56 0.3178 0.09653

32 - 0.2019 7.95 0.05097 49.64 63.20 0.2847 0.08647

- 36 0.1930 7.6 0.02927 45.36 57.76 0.2602 0.07902

33 - 0.1798 7.08 0.02540 39.37 50.13 0.2258 0.06858

- 37 0.1727 6.8 0.02343 36.32 46.24 0.2083 0.06326

34 - 0.1602 6.305 0.02014 31.22 39.75 0.1791 0.05439

- 38 0.1524 6 0.01824 28.27 36.00 0.1622 0.04925

35 - 0.1426 5.615 0.01597 24.76 31.53 0.1420 0.04313

- 39 0.1321 5.2 0.01370 21.24 27.04 0.1218 0.03700

36 - 0.1270 5 0.01267 19.63 25.00 0.1126 0.03420

- 40 0.1219 4.8 0.01167 18.10 23.04 0.1038 0.03152

37 - 0.1131 4.453 0.01005 15.57 19.83 0.08931 0.02713

- 41 0.1118 4.4 0.009810 15.21 19.36 0.08721 0.02649

- 42 0.1016 4 0.008107 12.57 16.00 0.07207 0.02189

38 - 0.1007 3.965 0.007968 12.35 15.72 0.07084 0.02151

- 43 0.09140 3.6 0.006567 10.18 12.96 0.05838 0.01773

39 - 0.08970 3.531 0.006319 9.794 12.47 0.05618 0.01706

- 44 0.08128 3.2 0.005189 8.042 10.24 0.04613 0.01401

40 - 0.07988 3.145 0.005012 7.768 9.891 0.04456 0.01353

41 45 0.07113 2.8 0.003973 6.159 7.842 0.03532 0.01073

42 - 0.06334 2.494 0.003151 4.884 6.219 0.02801 0.008508

- 46 0.06096 2.4 0.002919 4.524 5.760 0.02595 0.007880

43 - 0.05641 2.221 0.002499 3.873 4.932 0.02222 0.006747

- 47 0.05080 2 0.002027 3.142 4.000 0.01802 0.005472

44 - 0.05023 1.978 0.001982 3.072 3.911 0.01762 0.005351

45 - 0.04474 1.761 0.001572 2.436 3.102 0.01397 0.004244

- 48 0.04064 1.6 0.001297 2.011 2.560 0.01153 0.003502

46 - 0.03984 1.568 0.001246 1.932 2.460 0.01108 0.003365

47 - 0.03548 1.397 0.0009884 1.532 1.951 0.008787 0.002669

48 - 0.03159 1.244 0.0007838 1.215 1.547 0.006968 0.002116

- 49 0.03048 1.2 0.0007297 1.131 1.440 0.006487 0.001970

49 - 0.02813 1.108 0.0006216 0.9635 1.227 0.005526 0.001678

- 50 0.02540 1 0.0005067 0.7854 1.000 0.004505 0.001368

50 - 0.02505 0.9863 0.0004929 0.7641 0.9728 0.004382 0.001331

Appendix Technical Data Common Conversion Factor 74

Equivalent Reciprocal

Mass

1 cwt = 50.802 kg 0.0197

1oz = 28.349 gm 0.0352

1 Ib = 0.4536 kg 2.2046

1 Ib = 0.00454 tonne (metric) 220.26

1 ton ( long) = 1.016 tonne ( metric) 0.09842

Length

1in = 25.4 mm 0.03937

1 ft = 0.3048 m 3.2808

1 yd = 0.9144 m 1.0936

1 mile = 1.6093 km 0.6214

Area

1 in2 = 645.16 mm2 0.00155

1 ft2 = 0.0929 m2 10.7642

1 yd2 = 0.8361 m2 1.196

Volume

1 in3 = 16.387 cm3 (ml or cc) 0.061

1 ft3 = 0.0283 m3 35.3335

1 ft3 = 6.229 gal (Imp) 0.1605

1 ft3 = 28.328 I 0.0353

1 yd3 = 0.7645 m3 1.3079

1 gal (USA) = 0.8327 gal (Imp) 1.2009

Force

1 Ibf = 0.4535 kgf 2.2046

1 kgf = 9.8065 N 0.1019

1 ton ( long) f = 9.964 kN 0.10036

Pressure and Stress

1 atm = 0.1013 Mpa 9.869

1 atm = 1.0133 bar 0.9869

1 Ib/in2 ( psi) = 6.894 kN/mm2 (kPa) 0.145

1 bar = 1.0197 kgf/cm2 0.09806

Energy ( Work and Heat)

1 HP.h = 2544.5 Btu 0.00393

1 Btu = 0.000293 kW.h 3413

1 Btu = 1.0551 kJ 0.9478

1 Btu = 107.59 kgf.m 0.00929

1 cat = 4.187 J 0.239

1 mil = 0.001 in = 0.0254 mm 1 CM(Circular mil) = 0.7854 x 10 in2 = 0.5067 x 10 mm2

POLYETHYLENE AND CROSSLINKED POLYETHYLENE

76 INSULATED AERIAL BUNDLED CABLES

1. INTRODUCTION

The concept of insulated aerial bundled cables was developed in the early 1960's in Europe to provide a reliable, safe and economical alternative system of electrification.

The development was accelerated due to progress achieved in the field of synthetic insulating materials such as polyvinyl chloride (PVC) and polyethylene (PE). Crosslinked polyethylene (XLPE) was later added to the list.

National standards from a few European countries have been issued specifically for insulated aerial bundled cables employing designs from experiences and research. Although these are mainly for low voltage installation, standards for high voltage cables have been derived from specifications such as IEC 60502 which incorporates several extruded dielectrics for low voltage cables.

Aluminium and its alloys are used universally as conductors or neutral supports due to their inherent lightness while steel wires, traditionally used in ACSR constructions are used as the supporting catenary especially for heavier cables such as medium and high voltage cables.

2. AERIAL BUNDLED CABLES CONSTRUCTION The low voltage construction usually consists of three insulated phase conductors and one insulated messenger which also acts as the neutral. Street lighting conductor may be included if required.

2.1 CONDUCTORS

The phase and street lighting conductors consists of seven or more hard drawn

aluminium wires, of size and construction to BS 6360 and BS 215 respectively.

The messenger consists of Al-Mg-Si type alloys wires of materials and

construction to BS 3242.

The characteristic before stranding is : - 25 Minimum tensile strength 300 N/mm2

26 Minimum resistivity 3.28 microhm.cm

2.2 INSULATION

The insulation is usually high density polyethylene with a 2 percent nominal

content of carbon black.

Cross-linked polyethylene which has better thermal and mechanical properties, may be provided as an alternative insulation. The nominal thickness shall complied to IEC 60502.

The markings of aerial bundled cable shall be as followed : -

Low voltage

Phase : Numerical 1, 2, 3 Messenger : UTAMA CABLES BERHAD ELECTRICAL CABLE 600/1000 V

Street Lighting : S/L

77

2.3 TEST

Routine tests at works include :

27 Spark Test

The core is subjected to an AC spark test during the insulating process in

accordance to BS 5099.

29 Voltage Test

An AC test voltage of 3.5 kV at 50 Hz applied is between the insulated

conductors for a duration of 5 minutes.

31 Conductor Resistance Test

The D.C. resistance of each conductor shall be measured at room temperature

and after correction to 20˚C, shall not exceed the values given in the technical

particulars.

33 Special Tests :

Other tests which may be requested include Insulation Resistance between

conductors, Mechanical properties and dimensional measurements tests.

78

2.4 SHORT CIRCUIT RATING

The short circuit ratings in Table 1 are calculated using the adiabatic method neglecting the heat loss from the conductor during a short circuit based on the temperatures stated.

The accessories associated with the cable shall be able to withstand the same conditions.

The ratings are given for a fault duration of one second. For other durations, the value shall be divided by the square root of the duration in seconds.

TABLE 1

Insulation Fault temp Rating in Amps for various sizes

(˚C )

type

16 25

35 50 70

95 120 Start/End

HDPE 75 130 970 1510 2110 3020 4230 5740 7250

XLPE 90 250 1500 2300 3250 4450 6200 8600 11200

Caution should be exercised when applying the ratings as high mechanical forces inherent to installation practices may result in deformation at high temperatures sufficient to cause failure.

2.5 SAG AND TENSION

Once a cable is selected, details of sags and tensions will be determined by calculations

based on known parameters and assumptions.

The calculations are derived from established parabolic equations which are usually

sufficiently accurate :

Initial change final conductor + in = conductor

length length length

L + W12L3 + L (t2-t1) + (T2-T1)L = L + W2

2L3

24T12 EA 24T2

2

Subtracting L from each side and multiplying throughout by EA/L.

eqn. (A)

where E

A

t1

t2

W1

WL2

T1

T2

EA (t2-t1) + W12L2EA - T1 = W2 2L2EA - T2 24T1

2 24T22

35 modulus of elasticity (N/mm2) 36 Cross-sectional area (mm2) 37 Linear coefficient of expansion (/˚C) 38 Initial temperature (˚C) 39 Final temperature (˚C) 40 Initial weight (N/m) 41 Final weight (N/m) 42 Span length (m) 43 Initial tension (N)

44 Final tension (N)

eqn. (B)

79

SAMPLE CALCULATION

Cable Sample :

3Cx95mm2 + 70mm2 stranded aluminium conductor and aluminium alloy messenger, high

density polyethylene insulated, laid up without binders or sheath.

Cable diameter = 34.9mm Cable weight = 1.245 (kg/m)x9.81

= 12.21N

Operating conditions : Minimum ambient temperature Maximum ambient temperature Average ambient temperature Maximum wind pressure

36 21˚C 37 40˚C 38 32˚C

39 430N/m2

Assumptions : 38 Total tension carried by messenger 39 Tension in the insulation ignored 40 Cable assumed circular for wind loading 41 Level spans assumed

Basis for messenger : a) Modulus of elasticity = 7000 N/mm2

b) Cross-sectional area = 70mm2

c) Linear coeff. of expansion = 23x10-6/˚C

d) Breaking load = 19150N

Calculations :

CONDITION 1

32˚C ambient temperature with no wind load at a span of 50m.

At the designed normal conditions, the tension is often referred to as the every day stress (E.D.S) which is 20 percent of cable breaking load. In our example, this would only involve the messenger;

T(1) = E.D.S tension = 0.2 X 19150

= 3830 N

The classic sag equation is : Sag(S) = WL2(m)

eqn.(C) 8T

Therefore S(1) = 12.21 X 502 8 X 3830

= 10m

From the safely safety factor equation :

SE(normal) = Breaking load eqn.(D)

Tension

= 19150 3830

= 5

which would be expected from the 20% designed stress.

80

CONDITION 2

As above but with wind pressure at 430 N/mm2

Wind load = wind pressure X cable diameter = 430X34.9

1000

= 15N/m eqn.(E)

Effective weight of cable, W2 = √

W12 X (wind load)2

=

√12.212 + 15.02

= 19.35 N/m eqn.(F)

From equation (B): EA (t2-t1) + W11

2L2EA - T1 = W22L2EA - T2

24T12 24T2

2

Separating the elements :

EA (t2-t1) = 70000 X 70 X 23 X 10 -6 X (32-32)

= 0

W12L2

2EA = 12.22 X 502 X 70000 X 70 24T1

2 24 X 38302

= 5190

W22L2EA = 19.352 X 502 X 70000 X 70

24 24

= 1.911 X 1011

Substituting in equation (B) :

5190 - 3830 = 1.911 X 1011 - T2

T2 2

T22(T2 + 1360) = 1.911 X 1011

This is of the form T2(T+A) = B where A and B are known and may be solved by trial

and error using a slide rule or by computing using the iterative method.

Solving. T2(2) = 5340

And sag. S(2) = 12.21 x 502

8 x 5340

= 0.71m

Therefore, SF(2) = 19150 5340

= 3.59

81

CONDITION 3

Wind pressure at 430 N/m2 and minimum temperature of 21˚C

The tension of the cable under these conditions is called the maximum

working tension. The designer will find out from the equations whether the

cable erection will be within the safety factor allowed.

Again, using equation (B).

EA (t2-t1) + W12L2EA - T1 = W2

2L2EA - T2

24T12 24T2

2

Separating the elements : EA (t2-t1) = 70000 X 70 X 23 X 10-6 X ( 21-32)

= -1239.7

W12L2EA = 5190

24T12

W22L2EA = 1.911 X 1011

24

Substituting. –12397 + 5190 – 3830 = 1.911 X 1011 - T2

T22

T22(T2 + 120.3) = 1.911 X 1011

Solving. T2(3) = 5720

And sag. S(3) = 12. 21 X 502

8 X 5720

= 0.67m

Therefore, SF(3) = 19150

5720

= 3.35

A request for a conductor design would therefore, specify the maximum allowable

tension or safety factor, every day stress or normal working tension and if necessary,

the maximum vertical sag limits. The most demanding of these conditions will have

to be established and the rest will then be calculated within the limits.

A complete table for the above example is enclosed with the values of tensions, sag

and safety factors at various span lengths. (Refer Table 2 and Table 3)

SAG AND TENSION DATA 3CX95MM2 + 70MM2

600/100V AERIAL BUNDLED CABLES 82

Table 2 Sag and Safety Factor :

Span (m) 20 30 40 50 60 70

TEMP (°C) Sag(m) SF Sag(m) SF Sag(m) SF

Sag(m

) SF Sag(m) SF

Sag(m

) SF

21 0.11 3.60 0.25 3.49 0.43 3.41 0.67 3.35 0.95 3.31 1.28 3.27

27 0.13 3.94 0.27 3.73 0.46 3.58 0.69 3.48 0.98 3.41 1.31 3.35

32 0.14 4.25 0.28 3.94 0.48 3.73 0.71 3.59 1.00 3.49 1.34 3.42

40 0.15 4.78 0.31 4.27 0.51 3.96 0.75 3.76 1.04 3.62 1.38 3.52

75 0.23 7.32 0.41 5.75 0.63 4.96 0.89 4.48 1.20 4.17 1.55 3.96

Table 3 Resultant Tension :

SPAN(m) 20 30 40 50 60 70

TEMP(°C) N N N N N N

21 5320 5486 5620 5720 5794 5848

27 4858 5134 5348 5506 5623 5710

32 4506 4866 5139 5340 5489 5600

40 4005 4483 4836 5096 5289 5435

75 2617 3328 3862 4271 4587 4835

CONDITIONS

- Initial safety factor at 32°C and no wind loading 5

- Maximum conductor temperature 75°C

- Maximum wind pressure 430 N/mm2

- Coefficient of linear expansion 23 x 10/°C

- Modulus of elasticity 70kN/mm2

The mechanical loading on

the cable is assumed to be

carried by the insulated

aluminium alloy messenger

CROSS SECTION OF LOW VOLTAGE AERIAL BUNDLED CABLES

1. Insulated Phase Conductor

2. Insulated messenger

3. Insulated Street Lighting Conductor

Three Core + Messenger + Street Lighting

Insulated Low Voltage Aerial Bundled Cables

40 AERIAL BUNDLED CABLE (ABC)

0.6/1.0KV ALUMINIUM AERIAL BUNDLE CABLE

0.6/1.0 KV AL - Aerial Bundled Cable for Overhead Distribution Lines.

BS 2627, IEC 228, IEC 228A, BS 3242, IEC 811, TNB Specification.

S/N Cable Size Standard Packing Phase Conductor Messenger/Neutral Street Lighting Per-drum Conductor

Length Weight No. of Diameter Cross- Max. No. of Diameter Cross- Max. No. of Diameter Cross- Max. Continuous

(m) (Kg) strands (mm) section conductor strands (mm) section conductor strands (mm) section conductor current

area resistance area resistance area resistance rating

(mm2) at 20˚C (mm2) at 20˚C (mm2) at 20˚C at 30˚C

deg deg deg ambient

(ohm/Km) (ohm/Km) (ohm/Km) temp (A)

1

1x 16 mm2

1000 170 7 4.9 16 1.91 7 6.0 25 1.38 - - - - 55 1 x 25 mm2

2 3 x 16 mm2

1000 285 7 4.9 16 1.91 7 6.0 25 1.38 - - - - 50 +1 x 25 mm2

3 3 x 35 mm2

1000 500 7 7.0 35 0.868 7 5.9 25 1.38 - - - - 123 +1 x 25 mm2

4 3 x 50 mm2

1000 680 7 8.4 50 0.641 7 7.0 35 0.99 - - - - 147 +1 x 35 mm2

5 3 x 70 mm2

1000 940 19 9.9 70 0.443 7 8.4 50 0.69 - - - - 164 +1 x 50 mm2

6 3 x 95 mm2

+1 x 70 mm2

500 848 19 11.7 95 0.320 19 9.9 70 0.49 7 4.9 16 1.91 189 +1 x 16 mm2

7 3 x 185 mm2 +1 x 120 mm2

XLPE INSULATED/CU TAPE SHIELDED/PE SHEATHED (ALUMINIUM CABLE)

SINGLE, THREE & FOUR CORE

0.6/1 KV XLPE INSULATED/CU TAPE SHIELDED/PE SHEATHED (ALUMINIUM CABLE) - FOUR CORE (TNB SPEC)

Conductor Electrical Characteristics

Current Rating Conductor Resistance

Nominal Shape Nominal Approx. Approx. In air at In the D.C. at A.C. at Reactance Copper tape

cross- of insulation overall cable 40°C

ground at 20°C 90°C

at short circuit

sectional conductor thickness diameter weight 25°C

50 Hz current for

area

1 sec

mm2 mm mm Kg/Km A A Ω/Km Ω/Km Ω/Km KA

25 0.90 24.21 762 89 100 1.200 1.540 0.079 1.21

70 SHAPED

1.10 35.06 1517 170 180 0.443 0.568 0.075 1.83

120 STRANDED 1.20 42.78 2334 240 240 0.253 0.325 0.072 2.27

185 1.60 52.90 3457 320 310 0.164 0.211 0.073 2.84

300 1.80 64.89 5291 440 415 0.100 0.130 0.072 3.52

Identification of cores - extruded coloured XLPE insulation compound

AERIAL BUNDLED CABLE (ABC) 84

0.6/1.0 kV AL-Aerial Bundled Cable for Overhead Distribution Lines.

IEC 60228 , IEC 60228A , IEC 60811, BS 2627, BS 3242 .

S/N Cable Size Standard Packing

Phase Conductor Messenger/Neutral

Street Lighting

Conductor

Length Weight No. of Diameter Cross- Max. No. of Diameter Cross- Max. No. of Diameter Cross- Max. Continuous

(m) (Kg) strands (mm) section conductor strands (mm) section conductor strands (mm) section conductor current

area resistance area resistance area resistance rating

at 20˚C at 20˚C at 20˚C at 30˚C

deg deg deg ambient

(ohm/Km) (ohm/Km)

mm2

(ohm/Km) temp (A)

mm2 mm2

1

1x 16 mm2

1000 170 7 4.9 16 1.91 7 6.0 25

1.38 - - - - 55 1 x 25 mm2

2

3 x 16 mm2

1000 285 7 4.9 16 1.91 7 6.0 25

1.38 - - - - 50 +1 x 25 mm2

3

3 x 35 mm2

1000 500 7 7.0 35 0.868 7 5.9 25

1.38 - - - - 123 +1 x 25 mm2

4 3 x 50 mm2

1000 680 7 8.4 50 0.641 7 7.0 35

0.99 - - - - 147 +1 x 35 mm2

5 3 x 70 mm2

1000 940 19 9.9 70 0.443 7 8.4 50

0.69 - - - - 164 +1 x 50 mm2

6 3 x 95 mm2

+1 x 70 mm2

500 848 19 11.7 95 0.320 19 9.9 70

0.49 7 4.9 16 1.91 189 +1 x 16 mm2

7 3 x 185 mm2

+1 x 120 mm2

500 1540 37 16.2 185 0.164 19 13.0 120

0.29 7 4.9 16 1.91 279 +1 x 16 mm2

85 Bare Aluminium Conductor

Material : Aluminium of Material G1E

Condition of Conductor : For cross-sectional area less than 16mm2, tensile strength is

95 N/mm2, minimum and 125 N/mm2 maximum (H4)

: For cross sectional area 16mm2 and above, tensile strength

is 125 N/mm2, minimum and 205 N/mm2 maximum (H68)

Stranded Aluminium Conductor,

Stranded Multi Wires to BS 6360 : 1991

Size of Conductor Nominal Maximum Resistance At 20˚C Approx.

Nominal Area No. & size of diameter Single Core Multi Core mass

wire of conductor

mm2 No./mm mm Ω/Km Ω/Km Kg/Km

1 7/0.40 1.20 34.8 35.4 2.4

1.5 7/0.53 1.59 22.2 22.7 3.8

2.5 7/0.67 2.01 12.1 12.4 6.8

4 7/0.85 2.55 7.55 7.70 10.9

6 7/1.04 3.12 4.99 5.09 16.4

10 7/1.35 4.05 2.96 3.02 27.7

16 7/1.70 5.10 1.87 1.91 43.9

25 19/1.35 6.42 1.18 1.20 69.5

35 19/1.53 7.65 0.851 0.868 96.4

50 19/1.78 8.90 0.628 0.641 131

70 19/2.14 10.70 0.435 0.443 189

95 19/2.52 12.60 0.313 0.320 262

120 37/2.03 14.21 0.248 0.253 331

150 37/2.25 15.75 0.202 0.206 406

185 37/2.52 17.64 0.161 0.164 509

240 61/2.25 20.25 0.122 0.125 669

300 61/2.52 22.68 0.0976 0.100 839

400 61/2.85 25.65 0.0763 0.0778 1073

500 61/3.20 28.80 0.0605 0.0617 1353

630 127/2.52 32.76 0.0469 0.0478 1746

800 127/2.85 37.05 0.0367 0.0374 2233

1000 127/3.20 41.60 0.0291 0.0297 2816

Bare Aluminium Conductor 86

All Aluminium Conductors (AAC)

Standard Sizes of All Aluminium Conductors for Overhead Power Transmission

Conductor

Nominal Equivalent Construction

Approx. Calculated Calculated Approx. Code No./Size of Al. copper overall breaking D.C. weight name

area area wire diameter load resistance

at 20˚C

mm2 mm2 No./mm mm KN ohm/Km Kg/Km

22 14.2 7/2.06 6.18 3.99 1.227 64 Midge

50 32.2 7/3.10 9.30 8.28 0.5419 145 Ant

60 38.8 7/3.40 10.20 9.90 0.4505 174 Fly

100 64.7 7/4.39 13.17 16.00 0.2702 290 Wasp

150 96 19/3.25 16.25 24.70 0.1825 434 Hornet

200 130 19/3.78 18.90 32.40 0.1349 587 Chafer

250 162 19/4.22 21.10 40.40 0.10830 731 Cockroach

300 197 19/4.65 23.25 48.75 0.08916 888 Butterfly

400 253 37/3.78 26.46 63.10 0.06944 1145 Centipede

Note : Conductor details of other specifications can be provided upon request.

Bare Aluminium Conductor

All Aluminium Alloy Conductor (AAAC)

Standard Sizes of All Aluminium Conductors for Overhead Power Transmission

Conductor

Construction

Nominal Equivalent No./Size of

Approx. Calculated Calculated Approx. Code Al. copper overall breaking D.C. weight name

area area wire diameter load resistance

at 20˚C

mm2 mm2 No./mm mm KN ohm/Km Kg/Km

25 16.2 7/2.34 7.02 8.44 1.094 82 Almond

30 19.1 7/2.54 7.62 9.94 0.9281 97 Cedar

40 25.8 7/2.95 8.85 13.40 0.6880 131 Fir

50 32.3 7/3.30 9.90 16.80 0.5498 164 Hazel

100 64.5 7/4.65 13.95 33.30 0.2769 325 Oak

150 97 19/3.48 17.40 50.65 0.1830 497 Ash

175 113 19/3.76 18.80 59.10 0.1568 580 Elm

300 194 37/3.53 24.71 101.50 0.09155 997 Upas

Note : Conductor details of other specifications can be provided upon request.

87 Bare Aluminium Conductor

Aluminium Conductor Steel Reinforced (ACSR)

Standard Sizes of Aluminium Conductors Steel Reinforced for Overhead Power

Transmission

Conductor

Calculated

Equivalent

Actual Construction Approx. Calculated

Approx. Weight Code Nominal Sectional No./Size of Wire D.C. name

Al. copper

Al. Steel Al.

Steel

overall breaking resistance

Al. Steel

area area diameter load at 20˚C

mm2 mm2 mm2 mm2 No./mm No./mm mm KN ohm/Km Kg/Km Kg/Km

25 16.0 26.25 4.37 6/2.36 1/2.36 7.08 9.61 1.093 72 34 Gopher

30 19.3 31.61 5.27 6/2.59 1/2.59 7.77 11.45 0.9077 87 41 Weasel

40 25.8 42.41 7.07 6/3.00 1/3.00 9.00 15.20 0.6766 117 55 Ferret

50 32.3 52.88 8.81 6/3.35 1/3.35 10.05 18.35 0.5426 145 69 Rabbit

*60 38.6 63.22 36.88 12/2.59 7/2.59 12.95 52.94 0.4566 175 289 Skunk

70 44.8 73.37 42.8 12/2.79 7/2.79 13.95 61.20 0.3936 203 335 Horse

100 64.0 105.0 13.5 6/4.72 7/1.57 14.15 32.70 0.2733 288 106 Dog

150 96.4 158.1 36.8 30/2.59 7/2.59 18.13 69.20 0.1828 437 289 Wolf

150 96.8 158.7 8.8 18/3.35 1/3.35 16.75 35.70 0.1815 437 69 Dingo

175 111.9 183.4 42.8 30/2.79 7/2.79 19.53 79.80 0.1576 507 335 Lynx

175 112.4 184.3 10.2 18/3.61 1/3.61 18.05 41.10 0.1563 507 81 Caracal

200 129.0 212.1 49.5 30/3.00 7/3.00 21.00 92.25 0.1363 586 388 Panther

200 128.0 210.6 11.7 18/3.86 1/3.86 19.30 46.55 0.13670 580 91 Jaguar

*300 197.0 323.0 15.5 18/4.78 7/1.68 24.16 69.67 0.08914 887 123 Batang

400 262.0 428.9 55.6 54/3.18 7/3.18 28.62 131.90 0.06740 1186 435 Zebra

Note : 1) * Not A Standard Size in BS 215 : Part 2. 2) Conductor details of other specifications can be provided upon request.

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