Electrical Installation

Lecturer: Mr. Keemal Ali

Handout #2 Unit 202

Electrical Cables
A cable is defined as a length of insulated conductor solid or stranded or of two or more such
conductors, each provided with its own insulation which are laid up or fixed together. Cables
form the necessary connections between the machine which generates electricity and the
apparatus which uses it. They comprise of a wide range of sizes and types. The necessary
requirements of a cable are that it should conduct electricity efficiently, cheaply and safely. To
this end it should not be too small as to have a large internal voltage drop. It should not be too
big sp as to cost too much originally. Its insulation should be such as to prevent leakage of
current in unwanted directions and thus to minimize the risk of fire and shock.

A cable has 3 main parts: the conductor, insulation and mechanical protection.

Conductor materials
Copper and Aluminum are the materials used as conductors in power and lighting cables. Copper
has lower resistivity than Aluminum. This means that copper conductors has a smaller cross
section area and takes up less space than Aluminum for the same current carrying capacity. On
the other hand, Aluminum has about 1/3 the weight of copper and so will have an advantage in
some circumstances.
Copper conductors maybe annealed or hard drawn. Annealed copper conductors are
comparatively soft and pliable and are most suitable for indoor and outdoor wires and cables laid
or fixed in position. Hard drawn copper conductors, which have a very high tensile strength, are
used as overhead wires in some instances, mainly in the bare form.

Stranding of conductors
Conductors were often stranded to make cables more flexible. A set number of strands are used
in cables: 1, 3, 7, 19, 37, 61, 91, and 127.
Each layer of strands is spiraled onto the cable in the opposite direction to the previous layer.
This system increases the flexibility of the completed cable and also minimizes the danger of
‘bird caging’ or the opening up of the strands under a bending or turning force.

Flexible Cables & Flexible cords.

The IEE regulations define a flexible cable as: “A cable consisting of one or more cores, each
containing a group of wires, the diameters of the wires and the construction of the cable being
such as to afford flexibility.”
A flexible cord is defined as: “A flexible cable in which the cross section area of each
conductor, does not exceed4 mm2.”

Construction of cables
A cable usually derives it name from the type of insulation used.
1) Polyvinyl chloride (PVC) cables: this is termed a thermoplastic cable as the insulation is
formed from a synthetic resin which softens when heated. The process of manufacture is as
follows:
a) The PVC is extruded (extrusion) onto the conductor by passing them through a die into which
soft PVC is formed.
b) The formed cable is then passed through a tough of cold water to harden the plastic insulation.
Electrical Installation
Lecturer: Mr. Keemal Ali
Handout #2 Unit 202

2) Multi-cored cables: this cable is made up of two or more insulated conductors. Multi-cored
cables are sheathed in a protective covering, for example, tough rubber for tough rubber sheathed
cables (TRS) and PVC for plastic cables.

3) Tough Rubber Sheathed (TRS) cables: this is made up of specially toughened rubber which
is resistant to acids and alkaline. Specially constructed TRS, which has been reinforced with tape
and external braiding, is used in farm yards.

Comparison of TRS & PVC cables

TRS PVC
Affected by oil and water Largely unaffected by oil, water and corrosive
chemicals.
More flexible Hardens at low temperatures and softens at
high temperatures.
Must be protected against direct sunlight Does not support combustion.

The maximum operating temperature for both rubber and PVC insulated cable is 45℃

City and guilds colour coding

Colour identification of cores of non-flexible cables and bare conductors for fixed wiring.

Function Colour identification

Protective (including earthing conductor) Green and yellow
Phase of ac single phase circuit (Red or Yellow or Blue)
Phase R of a 3 phase circuit Red
Phase B of a 3 phase circuit Blue
Phase Y of a 3 phase circuit Yellow
Positive of dc 2 wire circuit Red
Neutral of dc 2 wire circuit Black
Middle wire of dc 3 wire circuit Blue

Colour Identification of cores of flexible cords and cables

No. of cores Function of cores Colour identification

1 Phase Brown
Neutral Blue
Protective Green and yellow
2 Phase Brown
Neutral Blue
3 Phase Brown
Neutral Blue
Protective Green and yellow
4 Phase Brown or Black
Electrical Installation
Lecturer: Mr. Keemal Ali
Handout #2 Unit 202

Neutral Blue
Protective Green or yellow

Armored cables
This cable is used where there is a likelihood of mechanical damage to conductors or insulation,
for example, underground cable runs. There are two main types of armored cables:
1) Lead covered paper insulated steel wire or steel tape, armored cables (PILCSWA)
2) PVC armored cables.

The diagram above shows a PILCSWA armored cable.

Voltage drop across a cable

The voltage drop across a cable maybe determined by three main factors:
1) The MVA rating of the cable: this is the millivolt ampere rating of the cable. It tells the
amount of current and voltage a cable can handle (measured in mVA)
2) The load current: this is the amount of current supplied to the cable. (measured in amperes)
3) Length: this is the length of the cable measured in meters.

Voltage drop = (mVA x load current x length of cable) ÷ 1000

Example: A 35 m length of cable has a quoted voltage drop of 11mv/A/m. When the cale carries
a current of 16A find the voltage drop.

Length = 35m load current = 16A MVA = 11mV/A/m.

Voltage drop = (MVA x load current x length of cable) ÷ 1000

( 11 x 16 x 35 ) ÷ 1000
= 6.16v