Conductor size and voltage optimization

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Conductor size and voltage optimization

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You are on page 1of 5

By Peter J. Stewart-Hay

Summary

This paper simplifies the American Wire Gage (AWG) and shows how it is used in the wire and

cable industry. Stranded conductors, including compact, compressed and other special designs

are also reviewed along with various bare wire stranding techniques.

Solid Conductors

The starting spot is the definition of the American Wire Gage (Sometimes referred to as the

Brown & Sharpe Wire Gage.) and this requires a review of simple mathematical progressions.

2,4,6,8,10,12 .......... is an arithmetic progression with an increase of 2 between the

individual cells.

2,4,8,16,32,64 .......... is a geometric progression with a multiplier of 2 between the

individual cells.

The American Wire Gage is also a geometric progression but it has a much different multiplier

between each of the cells in the progression. Lets look at the wire gage numbers lined up in the

6 x 10 matrix in Table 1 below.

49 39 29 19

9 2/0

48 38 28 18

8 3/0

47 37 27 17

7 4/0

56 46 36 26 16

6 5/0

55 45 35 25 15

5 6/0

54 44 34 24 14

53 43 33 23 13

52 42 32 22 12

51 41 31 21 11

50 40 30 20 10 1/0

Table 1

The American Wire Gage is defined as a geometric progression of solid wire diameters in inches

between the two defined diameters of 36 gage or 0.005 inches and 4/0 gage or 0.460 inches

(both highlighted in violet in Table 1).

The first thing to notice is that there are 38 gage sizes (highlighted in green in Table 1) between

36 and 4/0 so it is very easy to see that one must go one more step (39 steps) to get from one of

the defined wire sizes to the other. Thus the geometric progression cell multiplier can be

determined from the following equation:

or

This results in an next larger size multiplier of 1.122933 and a next smaller size multiplier of

0.890525 The diameters of all solid wires are calculated in this way. (If you try this on your

calculator however, we recommend that you use the scientific notation setting so that the fourth

decimal point in the solution is always accurate.)

A Couple Of Simple Points To Remember

If you go from a large AWG diameter to the next smaller AWG diameter, say from 12 to 13 AWG,

the new size (13 AWG) would have 20.7% less cross-sectional area and 26.1% more length.

If you go from a small AWG diameter to the next larger AWG diameter, say from 13 to 12 AWG,

the new size (12 AWG) would have 26.1% more cross-sectional area and 20.7% less length.

Stranded Conductors

Figure 1

7 Strand Conductor

Figure 2

19 Strand Conductor

As the gage size decreases and the conductor diameter increases, a solid wire gets more rigid

and harder to handle. Stranded conductors solve this problem but at a cost. The rule here is that

a stranded conductor has an almost identical cross-sectional area to a solid conductor of the

same gage size. This is by the sum of the areas of the individual strands making up that

stranded conductor. The simplest way of showing examples of this is to use circular mils.

Circular Mils

A circular Mil (CM) is the area of a circle with a diameter of 1/1000 of an inch (often referred

to as 1 mil). This gives an area of (/4)(d)2 or 0.7854 x (0.001)2and from this it is very easy

to see that the area of a conductor can be defined in circular mils by squaring the diameter

of the conductor in thousandths of inches.

For example the diameter of a solid conductor 36 gage wire is 0.005 inches so the area of

the conductor is 5 x 5 or 25 circular mils. Likewise, 4/0 gage solid conductor has a diameter

of 0.460 inches so the area of the conductor is 460 x 460 or 211,600 circular mils or 211.6

thousands of circular mils or MCM. This is now written as 211.6 KCMIL.

Calculating a Stranded Conductor Cross-Sectional Area in Circular Mils.

Lets use a 19 strand (Figure 2) 4/0 conductor which is made up of a central strand and two

layers (one of 6 strands and the other 12 strands) wound helically at different points and in

different directions around the central strand. All the strands have a diameter "d" of 0.1055

inches and the overall diameter of the stranded conductor is determined by the geometry (Figure

2). In this case it equals 5 x 0.1055 = 0.5275 or 0.528 inches. Likewise the cross-sectional area

of the 19 strands is 19 x 105.5 2 or 211,474.75 circular mils.

We previously calculated the cross-section area of our 4/0 solid conductor to be 211,600 circular

mils and this this very close to our 19 strand cross sectional area (211, 474.75 circular mils). The

difference between our solid conductor diameter of 0.460 inches and our stranded conductor

diameter of 0.528 inches however is the penalty we pay for flexibility.

Square Millimeters

Often conductor cross-sectional areas are defined in square millimeters and this is

especially true if the conductors are very large. The only difference here is that we are in

another measurement standard, that's all. The single definition one has to remember is that

there are 25.4 millimeters in an inch.

Calculating a Stranded Conductor Cross-Sectional Area in Square Millimeters.

Once again, lets use our 19 strand 4/0 conductor in Figure 2. All of the strands have a diameter

"d" of 0.1055 inches or 0.1055 x 25.4 = 2.6797 or 2.68 mm and the overall diameter of the

stranded conductor is is 5 x 2.6797 = 13.3985 or 13.40 mm. Likewise the cross-sectional area of

a single strand is given by the equation (/4)(d)2 or 0.7854 x 2.67972=5.6412 or 5.64 square

millimeters (mm2). Finally, the cross-sectional area of the conductor is 19 x 5.6412 or 107.18

mm2. It's just that simple.

Before we get into this, we must first define some more properties of stranded conductors and

cables.

Pitch

Regardless of how a stranded conductor is twisted, there are two basic definitions which

deal with the repetitive nature of the twist. The first is the length of pitch and the second is

the direction of pitch.

The "length of pitch" is that axial length along a conductor or a cable needed to make one

complete rotation (3600)of the hellically applied or helically laid components of that wire or

cable. For this reason it is also sometimes referred to as the "length of lay".

The "direction of pitch" or "direction of lay" is the direction of the helix described in the length

of pitch definition. It is referred to as right or left and can be very easily determined by

looking along the axis of the wire or cable and noting the direction that the helix "drops" as

the helix "moves" away from your eye. If it "drops" to your left it is a left pitch or lay and if it

"drops" to your right it is a right pitch or lay.

In Figures 1 and 2, we noted there was a central strand with one or more layers of strand applied

helically about that central strand. Concentrically stranded conductors are one of the original

strand designs and all have the following basic properties. The direction of pitch is reversed on

each layer and the length of pitch is also different on each layer. The direction of pitch on the

outer layer is always left in the United States and Canada.

Although the design of the conductor is very stable, it is slow and expensive to manufacture.

Table 2 shows how concentric strand conductors are assembled.

Layer Number (N)

Center = 0

1

2

3

4

5

6

7

8

Layer Strands

1

6

12

18

24

30

36

42

48

1

7

19

37

61

91

127

169

217

S=3N2+3N+1

Table 2

It is also very easy to determine from Table 2 that the outside diameter of the concentrically

stranded conductor is OD= d(1+2N)

The American Society for Testing Materials (ASTM) specifies the construction of concentrically

stranded conductors but before we look at those tables, we need a few more definitions to cover

rope lay designs.

A rope lay conductor is a concentrically stranded conductor in which the individual strands

making up the conductor are in reality sub-assemblies of already concentrically stranded or

bunched conductors. The outer layer normally has a left pitch.

A bunched conductor is a stranded conductor in which the individual strands making up the

conductor are twisted or "bunched" together into an open helix with a left pitch. There are no

formally defined layers in a bunched conductor.

We now have enough information to actually design electrical conductors but as you know,

things are never quite that simple. There are published standards for both the solid and stranded

conductor diameters. There are also standards for the many different stranded conductor

designs and for the conductor materials themselves. The Part 2 of this paper takes us into that

world of specifications.

About the

Author

professionally registered in the Province of Ontario. For more than 30 years he

practiced plant and process engineering in multinational wire and cable

companies. His expertise is in the manufacture of telephone cable, optical fiber

cable, data cable, instrument cable, building wire, and low, medium, high and,

extra-high voltage power cable. He is the only engineer in the Western

Hemisphere to have constructed a complete extra-high voltage MDCV

(Mitsubishi Dainichi Continuous Vulcanizing) extrusion line, a horizontal

machine capable of manufacturing 400,000+ volt polyethylene insulated power

cable. The machinery for this project came from the six different countries and

all were integrated on-site with a plc-based, DC drive distributed control

system.

For the past few years he has been the owner and principal employee of

Stewart-Hay Associates. Mr. Stewart-Hay holds patents in both the United

States and Canada and is a lifetime member of the Wire Association

International, Inc.

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