technical information hanbook wire and cable

A comparison is shown below: SolidFigure 2.8–Comparative Sizes and Shapes of 1,000 kcmil Conductors In a concentric stranded conductor, each individual wire is round and considerable spa

P r o d u c t s T e c h n o l o g y S e r v i c e s D e l i v e r e d G l o b a l l y

Technical Information Handbook

Wire and Cable

informed purchasing decisions around technology, applications and relevant standards Throughout the world, we provide innovative supply chain management solutions to reduce our customers’ total cost

of production and implementation.

Copyright by Anixter 2301 Patriot Blvd Glenview, Illinois 60026

No part of the publication may be reproduced without express permission of Anixter

Anixter Inc does not manufacture the items described in this publication All applicable warranties are provided by the manufacturers Purchasers are requested to determine directly from the manufacturers the applicable product warranties and limitations Data and suggestions made in the publication are not to be construed as recommendations or authorizations to use any products in violation of any government law or regulation relating to any material or its use

All due concern has been devoted to accuracy, but Anixter cannot

be responsible for errors, omissions or obsolescence All data herein are subject to change without notice

P r o d u c t s T e c h n o l o g y S e r v i c e s D e l i v e r e d G l o b a l l y

Technical Information HandbookWire and CableFifth Edition Copyright © 2013

The following registered trademarks appear in this handbook:

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Information in this handbook has been drawn from many publications of the leading wire and cable companies in the industry and authoritative sources in their latest available editions Some of these include:

• American Society for Testing and Materials (ASTM)

• Canadian Standards Association (CSA)

• Institute of Electrical and Electronics Engineers (IEEE)

• Insulated Cable Engineers Association (ICEA)

• International Electrotechnical Commission (IEC)

• National Electrical Manufacturers Association (NEMA)

• National Fire Protection Association (NFPA)

• Naval Ship Engineering Center (NAVSEC)

• Telecommunications Industry Association (TIA)

• Underwriters Laboratories (UL).

Note: National Electrical Code (NEC) is a registered trademark of the National Fire Protection Association, Quincy, MA The term, National Electrical Code, as used herein, means the triennial publication constituting the National Electrical Code and is used with permission

of the National Fire Protection Association.

The Anixter Wire and Cable Technical Handbook is an easily accessible collection of engineering and technical information about electrical and electronic cable and their related products Primarily intended for individuals who design, specify or troubleshoot wire and cable systems, the Anixter Wire and Cable Technical Information Handbook contains information about topics such as:

• Basic principles of electricity

• Conductor, insulation and jacket materials along with their electrical and mechanical properties

• Cable types, selection criteria and application guidelines for electrical and optical wire and cable

• Installation and testing guidelines and recommendations

• Application tips for cable accessories such as connectors, lugs and terminations

• Packaging, handling and shipping guidelines

• References to hundreds of key domestic and international wire and cable standards

• Conversion tables (e.g., AWG to mm2) and basic engineering equations used in the industry

The information contained in this handbook will assist engineers and individuals in designing and constructing safe, reliable, cost-effective and environmentally responsible electrical and communications networks.

Anixter wishes to acknowledge the contributions of the many individuals who assisted in the preparation of this edition of the handbook Anixter especially wants to recognize the efforts of Deborah Altman, Dana Anderson, Harmony Merwitz, Eric Bulington, Mark Fordham, Jeff Gronemeyer,

Andy Jimenez, Jason Kreke, Jonathan Meyer, Nader Moubed, Ania Ross, Eric Wall and Bill Wilkens

Anixter hopes it has succeeded in making this handbook the best in the industry and welcomes your comments and suggestions for improvements

in future editions If you are interested in downloading the PDF version of this book, please visit anixter.com.

About Anixter

Anixter is a leading global supplier of communications and security products, electrical and electronic wire and cable, fasteners and other small components We help our customers specify solutions and make informed purchasing decisions around technology, applications and relevant standards Throughout the world, we provide innovative supply chain management solutions to reduce our customers’ total cost of production and implementation

trademarks and reference information ii

6.10 Shipboard Cables (MIL-DTL-24643, MIL-DTL-24640 and MIL-DTL-915) 81

8 installation and testing 103

17.2 Circular Measurements – Diameter, Circumference and Area 244

18.3 Resistance, Inductance and Capacitance in AC Circuits 253

18.7 Determination of Largest Possible Conductor in Cable Interstices 255

1.1 eLeCtriCity

Electricity, simply put, is the flow of electric current along a conductor This electric current takes the form of free electrons that transfer from one atom

to the next Thus, the more free electrons a material has, the better it conducts There are three primary electrical parameters: the volt, the ampere and the ohm.

1.2 the VoLt

The pressure that is put on free electrons that causes them to flow is known as electromotive force (EMF) The volt is the unit of pressure, i.e., the volt

is the amount of electromotive force required to push a current of one ampere through a conductor with a resistance of one ohm.

1.3 the AMPere

The ampere defines the flow rate of electric current For instance, when one coulomb (or 6 x 1018 electrons) flows past a given point on a conductor

in one second, it is defined as a current of one ampere.

1.4 the ohM

The ohm is the unit of resistance in a conductor Three things determine the amount of resistance in a conductor: its size, its material, e.g., copper

or aluminum, and its temperature A conductor’s resistance increases as its length increases or diameter decreases The more conductive the

materials used, the lower the conductor resistance becomes Conversely, a rise in temperature will generally increase resistance in a conductor.

1.7 eLeCtriCAL systeMs

1.7.1 Medium Voltage

The most widely used medium voltage (2.4 to 35 kV) alternating current (AC) electrical distribution systems in North America are illustrated below:

Figure 1.1 – Three phase wye

(star), three wire Figure 1.3 – Three phase star, four wire, grounded neutral

Figure 1.4 – Three phase wye (star),

three wire, grounded neutral

Figure 1.2 – Three phase delta, three wire

Typical low voltage systems (0-2,000 V) are illustrated below:

Figure 1.5 – Three phase delta, four wire, grounded neutral

1.7.2 Low Voltage

Typical low-voltage systems (0 to 2,000 V) are illustrated below:

Figure 1.1 – Three phase wye

(star), three wire Figure 1.3 – Three phase star, four wire, grounded neutral

Figure 1.4 – Three phase wye (star),

three wire, grounded neutral

Figure 1.2 – Three phase delta, three wire

Typical low voltage systems (0-2,000 V) are illustrated below:

Figure 1.5 – Three phase delta, four wire, grounded neutral

2.6.1 Stranding, Diameter, Area and DC Resistance (32 through 4/0 AWG) 26

2.6.2 Stranding, Diameter, Area, DC Resistance and Weight (20 AWG through 2,000 kcmil) 28

2 ConduCtors

The conductor is the metallic component of cables through which electrical power or electrical signals are transmitted Conductor size is usually specified

by American Wire Gauge (AWG), circular mil area or in square millimeters.

AWG

The American Wire Gauge (sometimes called Brown and Sharpe or B and S.) is used almost exclusively in the USA for copper and aluminum wire The Birmingham Wire Gauge (BWG) is used for steel armor wire.

The diameters according to the AWG are defined as follows: The diameter of size 4/0 (sometimes written 0000) equals 0.4600 inch and that of size

#36 equals 0.0050 inch; the intermediate sizes are found by geometric progression That is, the ratio of the diameter of one size to that of the next smaller size (larger gauge number) is:

square Millimeters

Metric sizes are given in terms of square millimeters (mm2).

Conductor Characteristics

Relative electrical and thermal conductivities of common metal conductors are as follows:

table 2.1–relative electrical and thermal Conductivities of Common Conductor Materials

Metal relative electrical Conductivity at 20°C relative thermal Conductivity at 20°C

2.1 strAnd tyPes

2.1.1 Concentric strand

A concentric stranded conductor consists of a central wire or core surrounded by one or more layers

of helically laid wires Each layer after the first has six more wires than the preceding layer Except in

compact stranding, each layer is usually applied in a direction opposite to that of the layer under it.

If the core is a single wire and if it and all of the outer strands have the same diameter, the first layer

will contain six wires; the second, twelve; the third, eighteen; etc

Figure 2.1–Concentric Strand

2.1.2 bunch strand

The term bunch stranding is applied to a collection of strands twisted together in the same direction

without regard to the geometric arrangement.

Figure 2.2–Bunch Strand

2.1.3 rope strand

A rope stranded conductor is a concentric stranded conductor each of whose component strands is

itself stranded A rope stranded conductor is described by giving the number of groups laid together

to form the rope and the number of wires in each group.

Figure 2.3–Rope Strand

2.1.4 sector Conductor

A sector conductor is a stranded conductor whose cross-section is approximately the shape of

a sector of a circle A multiple conductor insulated cable with sector conductors has a smaller

diameter than the corresponding cable with round conductors.

Figure 2.4–Sector Conductor

2.1.5 segmental Conductor

A segmental conductor is a round, stranded conductor composed of three or four sectors

slightly insulated from one another This construction has the advantage of lower AC resistance

due to increased surface area and skin effect.

Figure 2.5–Segmental Conductor

2.1.6 Annular Conductor

An annular conductor is a round, stranded conductor whose strands are laid around a suitable core

The core is usually made wholly or mostly of nonconducting material This construction has the

advantage of lower total AC resistance for a given cross-sectional area of conducting material due

to the skin effect.

Figure 2.6–Annular Conductor

2.1.7 Compact strand

A compact stranded conductor is a round or sector conductor having all layers stranded in the same

direction and rolled to a predetermined ideal shape The finished conductor is smooth on the surface

and contains practically no interstices or air spaces This results in a smaller diameter.

Figure 2.7–Compact Conductor

2.1.8 Compressed strand

Compressed conductors are intermediate in size between standard concentric conductors and compact conductors A comparison is shown below:

SolidFigure 2.8–Comparative Sizes and Shapes of 1,000 kcmil Conductors

In a concentric stranded conductor, each individual wire is round and considerable space exists between wires In a compressed conductor, the conductor has been put through a die that “squeezes out” some of the space between wires In a compact conductor each wire is preformed into a trapezoidal shape before the wires are stranded together into a finished conductor This results in even less space between wires A compact conductor is, therefore, the smallest in diameter (except for a solid conductor, of course) Diameters for common conductor sizes are given in table 2.2

table 2.2–diameters for Copper and Aluminum Conductors

Conductor size nominal diameters (in.)

(AWG) (kcmil) solid Class b

Compact Compressed Class b Concentric Class b

2.2 CoAtinGs

There are three materials commonly used for coating a copper conductor: tin, silver and nickel.

Tin is the most common and is used for improved corrosion resistance, solderability and to reduce friction between strands in flexible cables.

Silver-plated conductors are used in high-temperature environments (150°C–200°C) It is also used for high-frequency applications where silver’s high conductivity (better than copper) and the “skin effect” work together to reduce attenuation at high frequencies.

Nickel coatings are used for conductors that operate between 200°C and 450°C At these high temperatures, copper oxidizes rapidly if not nickel plated One drawback of nickel is its poor solderability and higher electrical resistance.

2.3 tensiLe strenGth oF CoPPer Wire

table 2.3–tensile strength of Copper Wire

size soft or Annealed Medium hard drawn hard drawn

(AWG) Max breaking Load (lb.) Min breaking Load (lb.) Min breaking Load (lb.)

2.4 CoPPer strAnd ProPerties

2.4.1 strand Classes

table 2.4–strand Classes

AstM

standard Construction Class Application

B8 Concentric lay AA For bare conductors – usually used in overhead lines

A For bare conductors where greater flexibility than is afforded by Class AA

is required

B For conductors insulated with various materials such as EP, XLP, PVC, etc

This is the most common class

C For conductors where greater flexibility is required than is provided by Class B

B173 Rope lay with concentric

stranded members G Conductor constructions having a range of areas from 5,000,000 circular mils and employing 61 stranded members of 19 wires each down to No 14 AWG containing

seven stranded members stranded members of seven wires each Typical uses are for portable (flexible) conductors and similar applications

H Conductor constructions having a range of areas from 5,000,000 circular mils and

employing 91 stranded members of 19 wires each down to No 9 AWG containing

19 stranded members of seven wires each Typical uses are for rubber-jacketed cords and conductors where flexibility is required, such as for use on take-up reels, over sheaves and apparatus conductors

AstM

standard Construction Class Conductor size individual Wire size Application

(kcmil/AWG) diameter (in.) (AWG)

B172 Rope lay with

bunch stranded

members

I Up to 2,000 0.0201 24 Typical use is for special apparatus cable

K 10, 12, 14, 16, 18, 20 0.0100 30 Fixture wire, flexible cord and portable cord

L 10, 12, 14, 16, 18, 20 0.0080 32 Fixture wire and portable cord with greater

flexibility than Class K

M 14, 16, 18, 20 0.0063 34 Heater cord and light portable cord

O 16, 18, 20 0.0050 36 Heater cord with greater flexibility than

Class M

P 16, 18, 20 0.0040 38 More flexible conductors than provided in

preceding classes

table 2.5–standard nominal diameters and Cross-sectional Areas of solid Copper Wire (Continued)

2.4.3 Class b, C and d Copper strand

table 2.6–Class b Concentric-Lay-stranded Copper Conductors

size number of Wires diameter of each strand Weight nominal overall diameter (AWG or kcmi) (mils) (lb./1,000 ft.) (in.)

table 2.6–Class b Concentric-Lay-stranded Copper Conductors (Continued)

size number of Wires diameter of each strand Weight nominal overall diameter (AWG or kcmi) (mils) (lb./1,000 ft.) (in.)

table 2.7–Copper strand diameters

Conductor size stranding

(AWG) (kcmil) Class b Compact (in.) Class b Compressed (in.) Class b Concentric (in.) Class C Concentric (in.) Class d Concentric (in.)

table 2.7–Copper strand diameters (Continued)

Conductor size stranding

(AWG) (kcmil) Class b Compact (in.) Class b Compressed (in.) Class b Concentric (in.) Class C Concentric (in.) Class d Concentric (in.)

table 2.8–Class h rope-Lay-stranded Copper Conductors

size (AWG or kcmil) number of strands Construction nominal diameter of each strand (in.) nominal o.d (in.) nominal Weight (lb./1,000 ft.)

table 2.8–Class h rope-Lay-stranded Copper Conductors (Continued)

size (AWG or kcmil) number of strands Construction nominal diameter of each strand (in.) nominal o.d (in.) nominal Weight (lb./1,000 ft.)

2.4.5 Class i Copper

table 2.9–Class i (24 AWG strands) rope-Lay-stranded Copper Conductors

size (AWG or kcmil) Construction nominal number of strands nominal 0.d (in.) nominal Weight (lb./1,000 ft.)

2.4.6 Class K Copper

table 2.10–Class K (30 AWG strands) rope-Lay-stranded Copper Conductors

size rope-Lay with bunch stranding bunch stranding Weight (AWG or kcmil) nominal number of strands Construction strand nominal number of strands Approx o.d (in.) (lb./1,000 ft.)

2.4.7 Class M Copper

table 2.11–Class M (34 AWG strands) rope-Lay-stranded Copper Conductors

size rope-Lay with bunch stranding bunch stranding Weight (AWG or kcmil) nominal number of strands Construction strand nominal number of strands Approx o.d (in.) (lb./1,000 ft.)

2.5 ALuMinuM strAnd ProPerties

2.5.1 solid Aluminum

table 2.12–Aluminum 1350 solid round Wire

size (AWG or kcmil) diameter (mils) Cross-sectional Area (kcmils) Weight (lb./1,000 ft.)

2.5.2 Class b Aluminum

table 2.13–Class b Concentric-Lay-stranded Compressed, reverse-Lay Aluminum 1350 Conductors

size (AWG or kcmil) number of Wires diameter of each Wire (mils) nominal overall diameter (in.)

table 2.13–Class b Concentric-Lay-stranded Compressed, reverse-Lay Aluminum 1350 Conductors (Continued)

size (AWG or kcmil) number of Wires diameter of each Wire (mils) nominal overall diameter (in.)

table 2.14–Concentric-Lay-stranded Aluminum Conductors, Coated-steel reinforced (ACsr)

size stranding Weight

(AWG or kcmil) Aluminum number/diameter (in.) steel number/diameter (in.) (lb./1,000 ft.)

table 2.14–Concentric-Lay-stranded Aluminum Conductors, Coated-steel reinforced (ACsr) (Continued)

size stranding Weight

(AWG or kcmil) Aluminum number/diameter (in.) steel number/diameter (in.) (lb./1,000 ft.)

2.6 AdditionAL ConduCtor ProPerties

2.6.1 stranding, diameter, Area and dC resistance (32 through 4/0 AWG)

table 2.15–stranding, diameter, Area and dC resistance

size stranding Conductor diameter Conductor Area Copper dC resistance at 20°C (AWG) (no./AWG) (in.) (mm) (cmils) (mm 2 ) (ohms/1,000 ft.) (ohms/km)

table 2.15–stranding, diameter, Area and dC resistance (Continued)

size stranding Conductor diameter Conductor Area Copper dC resistance at 20°C (AWG) (no./AWG) (in.) (mm) (cmils) (mm 2 ) (ohms/1,000 ft.) (ohms/km)

2.6.2 stranding, diameter, Area, dC resistance and Weight (20 AWG through 2,000 kcmil)

table 2.16–Copper Conductor stranding, diameter, Area, Weight and dC resistance