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Wire and Cable Construction: The Basics
• Conductor – Allows for flow of current
Wire Cable
• Insulation – High resistivity/Low conductivity
• Jacket – provides protection for cable core
1X8AWG CABLE
CROSS-SECTION
Conductor
Insulation
Jacket
4X14AWG CABLE
CROSS-SECTION
Conductors
Insulation
Jacket
Conductors
• Many types
• Copper
• Aluminum
• Copper-Clad Aluminum or Copper-Clad Steel (mainly coaxial cable)
• Solid
• Stranded: ASTM B8 (Classes AA, A, B, C, D), Others
• Uncoated, or Coated to protect, improve conductivity – Tin, Lead, Nickel,
Silver
• Cross-Sectional Area in AWG or mm2 (or kcmil or MCM for large
conductors)
Insulation
• Prevents loss of current and directs its flow – critical for safety
• Usually Polymeric or rubber/polymer blend
• Many types – Thermoplastics and Thermosets - EP (Ethylene
Propylene), PE (Polyethylene), PVC (Polyvinyl Chloride), PTFE
(Polytetrafluoroethylene), etc.
• Tables in UL1581 (Reference Standard) provide summary of types
and physical property (tensile and elongation) requirements
• Will break down and conduct at some voltage level – thus voltage
ratings for cables (Dielectric Voltage Withstand Testing)
Jacket
• Provides protection for the components found within the cable
during installation and use
• Can provide mechanical, chemical, weather (UV) and in some cases
flame resistance
• Usually polymeric or rubber/polymer blend
• Many types – as with insulation
Other Components
• Armor – for additional mechanical protection
• Shield - to prevent external noise from disrupting the cable signals
and to prevent energy in the cable core from causing external
interference
• Braid - on power cables to reduce hazard from insulation leakage,
ensure voltage stresses are held within the insulation
• Fillers – to round out shape of cable
• Rip Cords – To assist with jacket removal
• Strength members – to add tensile strength to overall cable
FIBER OPTIC CABLE
Rip Cord
Optical Fiber
“Loose” Buffer Tube
Central Strength Member
Inner Jacket
Outer Jacket
Why Do We Need Cable Markings?
• Many different cable types and uses
• Variations in materials and constructions to optimize wire or cable
for use in specific installations
• Markings allow the designer, installer, and inspector (AHJ) to
determine at a glance the relevant characteristics of a cable and
confirm that it’s appropriate for the installation
What Determines the Marking Information?
• The Standard!
• WC standards are written for specific uses/applications
• The standard the wire or cable was evaluated to has specific
requirements for markings
• These are based on the constructional and test requirements in the
standard
• These markings need to be placed on the actual wire or cable
and/or the spool or reel or package
What Parameters Do the Markings Tell Us About?
Very Important:
• Voltage Rating
• Insulation Temperature Rating
• Manufacturer
• Conductor Gauge Size
• Flammability Rating
• Evaluation by a Third-Party Lab (ETL, UL, CSA)
What Parameters Do The Markings Tell Us About?
Additional Capabilities:
• Low Temperature Use (usually -40°C)
• Sunlight Resistance, Wet Rating, Direct Burial in earth
• Oil and Gasoline Resistance
Other Capabilities:
• Cable Tray, Exposed Run (-ER), Submersible Pump Cable
• For Communications Cable: Data Transmission Performance
(Category Cables, i.e. ‘CAT6’, ‘CAT5E’, etc.)
How Many Markings Are There?
• Many!
• Markings are dependent on the WC Standard used, and there are
many WC Standards
• Difficult to Cover Them All
• We’ll choose those that cover some of the most common markings:
UL758, UL83, UL44, UL62, UL444, UL1651, UL1063
Recognition versus Listing
• A recognized component is intended to be used within an end
product that will have its own evaluation
• The performance capabilities of a recognized component are
generally limited, so the evaluation for recognition is also more
limited
• Conditions of acceptability in the evaluation report constrain how
the recognized component may be used
• Examples: Switches, relays, motors
Listed Products
• A listed product is a complete product or system, that can function
on its own.
• Safety listings are based on full evaluations to safety standards
Recognized versus Listed Wire and Cable
• With regard to safety, almost all wire and cable is listed
• Most notable exception: UL recognizes Appliance Wiring to UL758
• Intertek lists all wire and cable, including AWM: no recognition
• Verified programs also exist for performance verification; mainly for
data and communications cable to verify transmission performance
UL 758: Appliance Wiring Material (AWM)
• Covers both single insulated conductors (wires) and multi-conductor
cable, with or without optical fiber
• From Scope of UL758: AWM covered are only “for use as factory-installed
wiring either within the overall enclosure of appliances and other
equipment (internal wiring) or as external interconnecting cable for
appliances (external wiring) or for further processing as components in
multi-conductor cables.”
• AWM is intended for factory-install in other listed products, not field
wiring
• AWM cannot be installed in buildings or used as NEC-type cabling
• The end-product the AWM is used with is evaluated (listed) separately
UL 758: Appliance Wiring Material
• Many different types/constructions of AWM
• UL has assigned “style numbers” to distinguish the various types of
AWM
• A given style number is generally produced by many manufacturers
• All style numbers divided into sections from 1 through 5
UL 758: Appliance Wiring Material
Style sections 1 through 5 are defined by:
• Whether the AWM is single conductor wire or multi-conductor
cable
• Whether insulation and jacket compound is thermoplastic or
thermoset
• Thermoplastic – can be repeatedly heated and resoftened
• Thermoset – once cured, cannot be resoftened
UL 758: Appliance Wiring Material
From UL.com:
UL 758: Appliance Wiring Material
• UL has organized all of the AWM styles within its UL.iQ family of
databases
• iq.ul.com
• Select the Appliance Wiring Material Database
UL 758: Appliance Wiring Material
• AWM Database on UL’s Website:
UL 758: Appliance Wiring Material
UL’s AWM database can be searched based on:
• Style attributes (voltage rating, temperature rating, insulation type,
etc.): Returns styles that meet the criteria
• Manufacturers: Returns list of companies that produce that style
• UL E-File Number: Returns list of styles covered under that file
number
• Style Page: Returns page documenting features of that style
• Updates: Returns style sheets that have been updated
UL 758: Appliance Wiring Material
UL 758: Appliance Wiring Material
• Testing and constructional requirements for AWM types are defined
in UL 758 Tables 3.1 to 3.9.
• These are the “roadmaps” for AWM
• Optional tests/ratings are defined in Table 3.9: Flammability, crush,
sunlight resistance, oil and gasoline resistance, wet ratings
• Optional ratings may be important depending on the environment
the AWM is being used in
UL 758: Appliance Wiring Material
• Markings: UL 758 Section 50 (AWM) and Section 51 (Tag, Reel or
Carton)
• Standard does not require marking of the AWM itself
• If the AWM is marked: minimum of ‘AWM’, an identifier for the
manufacturer (either name, symbol or file number) and, if multiple
factories, a marking to identify the manufacturing facility
• Markings for gauge size, number of conductors, etc., are acceptable
if not confusing/misleading
• If an AWM Cable contains a conductive polymeric shield this shall
also be marked on the jacket
UL 758: Appliance Wiring Material
• Tag, Reel or Carton: Many Markings Requirements
• ‘AWM’, intended use of the AWM (internal or external, end-product
name, exposure to gasoline, oil or sunlight), temperature rating,
minimum voltage rating
• Manufacturer name or symbol, distinctive manufacturing location
marking, size and number of conductors (see exceptions in
standard)
• Conductor material, insulation and jacket materials and
thicknesses, month and year of manufacture
• Refer to standard for others
UL 83: Thermoplastic-Insulated Wires and Cables
• Harmonized with CSA C22.2 No. 75, NMX-J-010-ANCE (Mexico)
• Scope covers single-conductor thermoplastic-insulated wire and
cable with 600V rating; certain types have jackets as well
• Thermoplastics can be repeatedly softened by heat, reshaped, and
hardened by cooling
• Standard is written for PVC insulation; other thermoplastics
acceptable if they meet the constructional and test requirements of
the standard
UL 83: Thermoplastic-Insulated Wires and Cables
• General Purpose Wire aka Building Wire
• Covered under NEC Article 310, ‘Conductors for General Wiring’
• Uses defined in the NEC
UL 83: Thermoplastic-Insulated Wires and Cables
• This standard uses ‘Wire Type Designations’ to identify the wire and
define the construction and conditions of use
• These designations follow a specific convention, with letters and
numbers identifying characteristics of the wire or cable
• The designation thus defines some of the attributes of the wire, and
how it can be used
UL 83: Thermoplastic-Insulated Wires and Cables
• T = Thermoplastic Insulation
• R = Thermoset Insulation (UL 44)
• X = Cross-linked polymeric insulation (UL 44)
• H = 75°C Temperature Rating (If no ‘H’ then temp. rating is 60°C)
• HH = 90°C Temperature Rating (for dry conditions only)
• N = Nylon Jacket
• W = Moisture/Water Resistant
• U = Underground Use
• -2 = Acceptable for use at 90°C in both dry and wet conditions
UL 83: Thermoplastic-Insulated Wires and Cables
• S = Silicone Insulation (UL 44)
• Z = Ethylene Tetrafluoroethylene Insulation
UL 83: Thermoplastic-Insulated Wires and Cables
• Constructional and Test Requirements for the various wire types are
summarized in Table C1 of Annex C
• There are many requirements, though not all apply to every wire
type
• Some tests are long term: Weather Resistance = 30 days,
Long Term Insulation Resistance = 12 weeks (minimum)
Capacitance and Relative Permittivity = 14 days
UL 83: Thermoplastic-Insulated Wires and Cables
• Examples of UL83 Wire Type Designations and their meanings:
TW = Thermoplastic Insulation, 60°C Dry/Wet Temperature Rating,
Wet Rating
THW = Thermoplastic Insulation, 75°C Dry/Wet Temperature Rating,
Wet Rating
THHN = Thermoplastic Insulation, 90°C Dry Temperature Rating,
no wet rating, Nylon Jacket
THWN-2 = Thermoplastic Insulation, 90°C Dry/Wet Temperature
Rating, Wet Rating, Nylon Jacket
UL 83: Thermoplastic-Insulated Wires and Cables
Required Markings on the Wire/Cable, From Section 6.1:
• Manufacturer’s Name or symbol
• The type designation (if the product complies with the requirements for
more than one type, all types may be shown)
• Conductor Size
• Conductor Stranding Type, if not ASTM Class B or C
• Aluminum conductors marked ‘AL’
• If compact-stranded copper conductors are used, marked ‘Compact
Copper”
• Voltage Rating
UL 83: Thermoplastic-Insulated Wires and Cables
Optional Markings on the Wire/Cable:
• Low Temperature (-40°C, if meets requirements)
• Flame Test Markings (For products that meet the appropriate
requirements, such as FT1, VW-1, FT4, etc.)
• Cable Tray Use (CT, must comply with large-scale, vertical tray flame
test)
• Weather (Sunlight) Resistance = SR, Sunlight Resistant, Sun Res
UL 83: Thermoplastic Insulated Wires and Cables
More Optional Markings on the Wire/Cable:
• Oil Resistance:
60°C Oil Resistance = PRI, OIL RESISTANT I, OIL RES I, OIL RESISTANT
75°C Oil Resistance = PRII, OIL RESISTANT II, OIL RES II
• Gasoline and Oil Resistance (To get gasoline rating, must have oil):
60°C Oil Resistance + Gasoline Resistance = GR I
75°C Oil Resistance + Gasoline Resistance = GR II
UL 83: Thermoplastic-Insulated Wire and Cable
Required Markings on Package:
• Manufacturer’s Name or Symbol
• Type Designation
• Conductor Size
• ‘AL’ if aluminum conductors
• ‘Compact’ if compact conductor stranding used, ‘Compact Copper’
if conductors are compact copper
• Voltage Rating
UL 44: Thermoset-Insulated Wires and Cables
• Harmonized with CSA C22.2 No. 38, NMX-J-451-ANCE (Mexico)
• General Purpose Wire aka Building Wire – NEC Article 310
• Covers single-conductor and multiple-conductor thermoset-
insulated wires and cables, with voltage ratings of 600V, 1000V,
2000V, and 5000V
• Thermoset compounds, once hardened, cannot be softened and
reformed (Hardening can be performed by cross-linking, denoted
XL)
• Acceptable thermoset insulation materials covered by Clause
4.2.1.2 and Table 19, and include XLPE, EP, Silicone, CPE, others
UL 44: Thermoset – Insulated Wires and Cables
• Like UL83, this standard also uses ‘Wire Type Designations’ to identify
the wire and define the construction and conditions of use
• Some UL 44-Specific Designations:
R = Thermoset Insulation
X = Cross-linked Insulation
S = Silicone Insulation (Thermoset)
75 or 90 after W indicates temp rating for both dry and wet
UL 44: Thermoset-Insulated Wires and Cables
• Examples
RHH = Thermoset Insulation, 90°C dry temperature rating, no wet
rating (600V and 2kV only)
R 90 = Thermoset Insulation, 90°C dry temperature rating, no wet
rating (600V, 1kV, 2kV, 5kV)
XHHW-2 = Cross-Linked Thermoset Insulation, 90°C Dry/Wet
Temperature Rating, Wet Rating
RWU 75 = Thermoset Insulation, wet rating, underground use,
75°C Dry/Wet
UL 44: Thermoset-Insulated Wires and Cables
• Exceptions: Sometimes, the identifying letters and numbers don’t
seem to fit
SIS = ‘Stranded Insulated Switchboard’ Wire. Not silicone insulation,
as the ‘S’ might indicate, but actually cross-linked polyethylene