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CONTENTS Page Introduction... 1 Customer Service... Product Range... Specification and Construction... 5 Salient Features of Ducab s Design... 6 Installation and Electrical Data... 617 XLPE Insulated s to BS 567: Technical Data Tables... 18 600/1000V rated, Copper and Aluminium Conductors... 188 Single Core s... 1819 Two Core s... 01 Three Core s... Four Core s... 5 Four Core s with Reduced Neutral Conductors... 67 Three and Four Core Armoured s... 8 1900/V rated, Armoured Copper Conductors... 9 XLPE insulated Lead Sheathed Armoured s to BS 567... 0 Advantages of XLPE Insulated s... LSZH s... XLPE Voltage Drop Data for partial loads... 5 Components Reference Chart... 6 Ducab is listed in the following publication issued by the Department of Trade and Industry ofthe United Kingdom. THE DTI QA REGISTER PRODUCTS AND SERVICES LIST Only those companies whose quality system is assessed and certified by U.K. accredited certification bodies appear in the above publication.
INTRODUCTION Established in 1979, Ducab is the leading cable manufacturing company in the region and is equally owned by the Governments of Dubai and Abu Dhabi. Ducab has three major manufacturing facilities that support it's continuous growth, one in Jebel Ali and two in Abu Dhabi Industrial City. DucabHV, inaugurated in November 011, is a joint venture between Ducab, ADWEA and DEWA offering High Voltage cable systems up to 00 kv. DucabHV will sell cable systems in the voltage range 66kV (66,000 Volts) to 00kV (00,000 Volts) covering the highest voltage currently used in the GCC. To meet the growing demand of customers around the region and the world, Ducab continues to expand its worldclass facilities across the Middle East, North Africa, Europe and India. Ducab prides itself on setting and maintaining the highest quality standards of power cables. Experienced and highly skilled employees operate stateoftheart equipment, and conduct extensive testing at every phase of production. When it comes to advanced cable solutions, Ducab continues its status as the superbrand across the world in 0 countries. Ducab product range covers High Voltage cables up to 00kV, Ducab Powerplus Medium Voltage cables up to kv, Control & Auxiliary, Wiring and LeadSheathed cables, Ducab SmokemasterLow Smoke Zero Halogen s, and Ducab Flam (Fire Resistance cables), Ducab s Flexible cables, Instrumentation and Pilot cables, components and cable accessories, Installation of cables, as well as Copper rod manufactured in Ducab s own Copper rod plant. This catalogue provides working information on Low Voltage power cables. Separate catalogues are available for the remaining range of Ducab s. ORDERING ADVICE Due to the wide range of cables in the catalogue, it is advisable, when ordering, to provide as much information as possible. Please use the following table as a guide: 1. standard / specification number.. Voltage designation.. Number of cores.. Conductor size. 5. Colour of outer sheath. 6. Length of cables required and individual drum lengths.* 7. Any other special requirement, e.g. special PVC sheath material, drum weight limitation, etc. * s are normally supplied in lengths of 100 metres, 0 metres and 1000 metres depending on size. Other lengths can be supplied if required. TECHNICAL ADVISORY SERVICE For any specialist advice and assistance on the entire Ducab product range contact the Technical Department, Dubai Company (Private) Limited, P. O. Box 1159, Dubai, U. A. E., Tel: 971 815 8888, Fax: 971 815 8111. 1
CUSTOMER SERVICE Ducab is the premier cable manufacturer in the United Arab Emirates and, since 1979, has been meeting the requirements of customers throughout the GCC, Middle East and Asian markets. Ducab cables are preferred for the following reasons: PRODUCT QUALITY Ducab is coitted to supplying its customers with the highest quality of product and of service. Ducab s cables have been type approved by recognized certifying bodies such as BASEC UK (British Approval Service for s), Lloyd s Register of the UK, KEMA Netherland, LPCB UK ( Loss Prevention Certification Board), ESMA (Emirates Authority for standardization and Metrology). They fully conform to BS, IEC other international and national specifications. In addition, Ducab was presented with the Dubai Quality Award 199, for the best local industrial company of the year. Ducab won Dubai Quality Gold Category award twice, in 1998 and in 0. The Gold Award rewards the most distinguished companies which are judged to be world class and Ducab is the only manufacturing company in the region to win such acclaim. Ducab has won the Sheikh Mohaed Bin Rashid Al Maktoum (MRM) Business Excellence Award in manufacturing category in 009. Recognizing quality products and services, Ducab has also won the Superbrand award for years consecutively from 009. RELIABILITY Specifying the right cable for a particular application is the first step. The key to reliability however, is in the manufacturing process. The cable must be free from material and manufacturing defects, and weaknesses that will be revealed in service. Ducab constantly monitors its manufacturing processes and operates stringent quality assurance procedures to give long term reliability. This is of vital significance where cables are to be installed in locations where future access would be difficult and this is where Ducab s reputation and resources give peace of mind. PERFORMANCE Optimum cable performance can be provided only by a company such as Ducab, with access to the latest developments in materials technology. In addition, Ducab s knowledge of application requirements throughout the Middle and Far East is an assurance of high performance. Our experienced Technical Staff can provide guidance on cable selection and installation and can ensure that you get the right cable for the job. HEALTH & SAFETY MANAGEMENT SYSTEM CERTIFIED TO OHSAS 18001 Ducab is able to maintain a close watch on world developments in cable technology and regulations and therefore ensure that its products are designed and constructed to be hazardfree under the prescribed conditions of use. Ducab uses only tried and tested materials and processes in full compliance with all relevant British and International Standards. Our cables are therefore manufactured for safe use without risk to health on the understanding that users will exercise the same degree of care in their selection and application. Safety is an important issue for Ducab, and the strictest standards are adhered to throughout the company. Ducab is proud of its safety record and has been awarded RoSPA (Royal Society for the Prevention of Accidents) Gold Awards for safety from 1991 to 1999. From 000 onward, Ducab was awarded the prestigious President s Award for Health and
Safety which is a recognition of Ducab winning 10 consecutive annual Gold awards and acknowledges Ducab s total coitment to health and safety. In 00, Ducab was declared the joint winner of the Manufacturing Industry Sector Award from RoSPA. Ducab is the first organisation in the Middle East to receive accreditation to OHSAS 18001 by BASEC (British Approvals Service for s). Certification to OHSAS 18001 provides a recognisable Occupational Health and Safety Management standard against which an organisation s management systems can be assessed and certified. Based on the structure of OHSAS 18001, the standard requires continual improvement in health and safety related activities. QUALITY MANAGEMENT SYSTEM CERTIFIED TO ISO 9001 Ducab s Quality Management System conforms to the ISO 9001 International Quality System Standard and is certified by BASEC (British Approvals Service for s), a specialist certifying body for cables who are an internationally recognised quality authority accredited in the UK and throughout the world. Certification to the ISO 9001 International standard demonstrates that Ducab has drawn up written procedures to ensure full compliance with all requirements of the standard and that these procedures are followed by every department in the company, thus ensuring that goods leaving Ducab s factory are of the highest quality and meet each customer s requirements in every respect. Ducab is particularly proud to have achieved certification to the stringent ISO 9001 standard as it is an independent conformation that the company designs, manufactures and tests cables consistently to accepted standards. ISO 9001 is widely used throughout Europe, and is therefore a reassurance to Ducab s customers that the products and service supplied by the company are equal to the best in the world. ENVIRONMENTAL MANAGEMENT SYSTEM CERTIFIED TO ISO 1001 Ducab s Environmental Management System conforms to the ISO 1001 International Environmental Management Standard and is certified by BASEC who are an internationally recognised certifying authority accredited in the UK and throughout Europe. Certification to the ISO 1001 International standard shows that Ducab has a well defined structure and established working practices aimed at limiting its impact on the environment. Measurement and monitoring of effects, issuing work instructions, training of personnel and taking corrective actions are all essential elements to limiting the impact on the environment. Ducab has set improvement targets to reduce the significant environmental impacts associated with its activities. Ducab is proud to be the first cable manufacturer in the region to achieve certification to ISO 1001 and this certification along with its quality, business success and safety record demonstrates that Ducab is a world class organisation and can hold its head up to any business counity throughout the world. BASEC CERTIFICATION Ducab is also proud to hold a Process capability certification issued by BASEC (British Approvals Service for s) for several cables in its product range. DUCAB SHAREEK Ducab s customer satisfaction prograe is designed to ensure that customers receive a consistently high level of service from Ducab s dedicated staff.
Voltage range: /1kV and /. kv 1) Armoured/unarmoured XLPE insulated cables ) Lead sheathed cables ) Copper or Aluminium PE tape (with drain wire) shielded PRODUCT RANGE CABLE TYPES CABLE SIZES Single core up to and including 1000 core up to and including core up to and including 00 core up to and including 0 5 core up to and including SPECIFICATION BS 567...for XLPE insulated armoured cables BS 7889...for XLPE insulated single core unarmoured cables IEC 60 (Part 1)...for XLPE insulated single/multicore armoured/unarmoured cables Any other International Specification as per VDE/DIN, GOST and as per customer's specifications. SPECIFICATION AND CONSTRUCTION CONDUCTORS It is the current carrying component of the cable. Material Plain, stranded, compacted copper as per BS 660/IEC: 608 Aluminium, stranded, compacted s INSULATION The rated voltage level of the cable depends on the dielectric strength and thickness of the insulation. Material Crosslinked polyethylene (XLPE) Type GP8 as per BS 7655:Section 1.. Colour Masterbatch Ultraviolet (UV) resistant polyethylene masterbatch is used for colouring of insulation. This protects the insulation from deterioration when exposed to continuous sunlight. CORE IDENTIFICATION Core identification is by colour as follows (unless otherwise agreed): No. of cores Core Colours 1 Red or Black Red and Black Red, Yellow and Blue Red, Yellow, Blue and Black 5 Red, Yellow, Blue, Black and Green/Yellow * s to new colour scheme of BS ٥٤٦٧ eg. Blue, Brown, Black, Grey could also be supplied on special request FILLERS For providing circular shape to the cable, nonhygroscopic compatible fillers (wherever necessary) are included between laid up cores.
METALLIC SCREEN If required by the customer screening may be provided for electrical shielding. Material Copper tape / Copper laminate / Aluminium laminate Aluminium PE tape along with tinned copper drain wire (for providing screen continuity). Note: Special constructions other than stated above may be provided on request. BARRIER TAPE Material Polypropylene/PETP tape is used as a barrier tape over the laid up cores. Functions Holds the cores together and prevents them from opening out. Works as a separator between different polymers used in a cable. BEDDING Extruded bedding serves as a bedding for the armour and as a protection for the laidup cores. Material Extruded PVC Type 9 Compound as per BS 7655. Reduced propagation flame retardant (RPLHCL)/RP PVC Compound for reduced flame propagation characteristics. Smokemaster Low Smoke & Zero Halogen and fume for installations where fire hazards exist. ARMOUR Armour provides mechanical protection to the cable. It also serves as an Earth Continuity Conductor (ECC). One layer of round wire is applied helically over the bedding. Material Galvanised round steel wire (GSW). Galvanised round steel wire (GSW) along with tinned copper wires (TCW) for maintaining specified conductivity of armour (if required by the customer). Aluminium round wire armour (AWA) is generally used for single core ac circuits as aluminium is a nonmagnetic material and this will reduce losses due to armour. Note: Aluminium glands should be used in conjunction with cables having aluminium wire armour. OVERSHEATH FINISH Following types of materials may be specified for oversheathing. General Purpose: Extruded PVC Type 9 Compound as per BS 7655. Medium Density Polythylene (MDPE): Offers higher protection from water ingress and mechanical abrasion. Anti Termite: Termite resistance can be built in both types described above by compounding with proper additives. Reduced Propagation (RP): Retards propagation of flame in fire situation. (Oxygen Index 0) Reduced Propagation and Low Acid Fumes (RPLHCL): Retards propagation of flames and gives low emission of hydrochloric acid fumes. (OI 0 & acid gas emission is less than 18%) Smokemaster Low Smoke & Fume (LSZH): Smokemaster cables are ideal for installations where the dense black smoke generated by PVC cables in a fire are a danger to people. Smokemaster is characterised by the features as Oxygen Index greater than 5, acidgas liberation almost nil (<%) and smoke density within controllable limit of 0% smoke density. Smokemaster cables are offered to BS 67. 5
SALIENT FEATURES OF DUCAB CABLE DESIGN (1) XLPE insulation Ultraviolet (UV) colour masterbatch Ultraviolet (UV) resistant polyethylene masterbatch is used for colouring of insulation. This protects the insulation from deterioration when exposed to continuous sunlight. () Polypropylene/PETP tape over the laid up cores Acts as a separator between different polymers used in a cable. () Fillers For ensuring proper circular shape to the cable, nonhygroscopic compatible fillers (wherever necessary) are included between laid up cores. () Special requirements Ducab cables can be custom designed to incorporate special requirements of the client as follows: (a) (b) (c) (d) (e) (f) Screening: Copper tape or Aluminium PE tape (along with tinned copper drain wire) can be used for shielding purposes. Tinned copper wire can be used along with galvanised round steel wires to maintain specified armour conductivity requirements. Reduced propagating flame retardant bedding (RPLHCL/RP) and outersheath material can be offered to meet reduced flame propagation characteristics and low hydrogen acid gas emission. with bedding and outersheath material of special LSZH (low Smoke and Zero Halogen) compound can be offered for installations where fire and its associated problems the emission of smoke and toxic fumes offer a serious potential threat. (For details on LSZH cables refer page ) In water logged areas or where the cables are required to be abrasion resistant, cable with medium density polyethylene (MDPE) can be offered. For protection from insects, antitermite protection can be added to the outersheath. (5) Fire test requirement s sheathed with general purpose PVC Type 9 meet fire test requirement of IEC 601. s with varying fire performance requirements are manufactured by Ducab. The details on this are provided on request. INSTALLATION Whichever form of is used, XLPE insulated cables are simple to handle, install and joint. All the cables described in this publication can be used indoors or outdoors, but some reservations are necessary concerning cables for direct burial in the ground or for use in sustained wet conditions as follows: (i) Unarmoured cables are not generally recoended for laying directly in the ground. (ii) s laid directly in the ground, particularly in sustained wet conditions, should have extruded bedding and preferably MDPE Medium Density Polyethylene as the outersheath material. Other important factors to be taken into account are: SHEATH DAMAGE Care should be taken to ensure that the oversheath is not damaged during installation. This is especially important where aluminium wire armour is used, as ingress of moisture could lead to corrosion or ultimate loss of earth continuity. 6
MINIMUM INSTALLATION RADIUS should not be bent during installation to a radius smaller than that recoended below. Wherever possible larger installation radii should be used. Table 1 Type of Overall Diameter (D) Minimum internal radius of bend Circular copper s armoured or unarmoured Shaped copper or aluminium s, armoured or unarmoured Any Any 6D 8D For lead sheathed cables Any 1D CONNECTORS The use of compression type connectors is recoended for XLPE insulated cables since the use of soldered connectors would limit the maximum short circuit temperature of the cable to 160 C (and consequently reduce the final short circuit current by approximately 0%). OVERHEAD TERMINATIONS Ultra violet resistant sleeving or taping should be provided on XLPE insulated cores to avoid degradation due to exposure to solar rays. ARMOURED SINGLE CORE CABLES FOR AC OPERATION The current rating provided for single core cables is based on armour bonded / earthed at both ends. Armour bonding at both ends results in circulating current in the armour. Higher current rating may be achieved in case the armour is bonded / earthed at single end. However single end bonding results in an induced voltage at the unearthed end of the armour. The magnitude of induced voltage is directly proportional to the current through the and length of the cable. At times the magitude of induced voltage could pose potential risk if no limiting device is connected at the open end. For this purpose sheath voltage limiters are in use. Ducab strongly recoends use of an insulated adopter in the cable gland, while terminating single core cables for AC operation. Single core cables for AC operation should not pass through steel conduit or steel gland plate, as it produces a heating effect. CABLE SUPPORT SPACING As per IEE Wiring Regulations where the cable is not continuously supported it shall be supported by suitable means at appropriate intervals in such a manner that the cable does not suffer damage by its own weight. 7
CURRENT RATINGS Current ratings for XLPE insulated cables for ground and duct installation are derived from the latest issue of ERA Report 690 Part 5 which is based upon IEC Publication 6087. The ratings for In Air installation are taken from IEE Wiring Regulations. All the ratings given are for single circuits installed thermally independent of other circuits or any other heat source and on the basis of the standard conditions of installation given in relevant Tables between 17 to. For other ambient or ground temperatures, depth of laying, soil thermal resistivity, the rating must be multiplied by relevant rating factors in Tables to 6 and 8 to 1. It should be noted that if XLPE insulated cables, are subjected to operating temperatures appreciably higher than the 90 C permissible for continuous operation, the insulation will undergo premature ageing thus affecting the normal life of the cable. However, limiting maximum temperature to 1 C during overloads with duration not exceeding hours on any one occasion, or a maximum of 100 hours in any 1 consecutive months, or a total of 0 hours in the cable s lifetime, would be tenable. IEE WIRING REGULATIONS REQUIREMENT FOR CABLES The IEE Wiring Regulations for installation and selection of cables cannot be approached in isolation from the other equipment in the installation. In particular the devices providing protection against overload, short circuit, shock by indirect contact and overheating of protective s during an earth fault, affect the selection of cables. CROSS SECTIONAL AREAS OF PROTECTIVE CONDUCTORS (Clause 5 of the 16th Edition of IEE Wiring Regulations) Regulation 5 explains how the cross sectional area of the circuit protective should be calculated to avoid it overheating during a fault to earth. Again the area required depends on the characteristics of the device providing protection against short circuit. The steel wire armour of standard cables to BS 567 (XLPE) and BS 66 (PVC) provides the required area, or more, when the protective device is one of the standard fuses or MCB s with a rating not higher than the current rating of the cable (assuming disconnection within 5 seconds). For the most of the cables the armour is still adequate when the fuse rating is one or two steps, or even more, above the current rating of the cable, the margins being greater for the small sizes and core cables than for the larger sizes and two core cables. VOLTAGE DROP Voltage drop is normally only of importance for cables of voltage rating 600/1000V or below. If the installation is to be incompliance with Regulation 55 of the 16th Edition of the IEE Wiring Regulations, it is stipulated that the voltage drop within the installation does not exceed a value appropriate to the safe functioning of the associated equipment in normal service. The requirement is deemed to be satisfied if the drop in voltage from the origin of the installation (usually supply terminals) and the fixed current using equipment does not exceed per cent of the nominal voltage of the supply, disregarding starting conditions. (Note: Diversity can be taken into account when calculating voltage drop). Since the actual power factor of the load is often not known, the most practical approach to the question of voltage drop is to assume the worst conditions i.e. where the phase angle of the load is equal to that of the cable. The voltage drop values in the tables have been based on this assumption. For sizes up to and including the figures provided apply with sufficient accuracy where the power factor lies between lagging and, and for large cables 8
where the power factor of the load does not exceed 0.8 lagging. Where the phase angles of the loads fall outside this range, the voltage drop deduced from the tables may be unduly conservative and more exact methods of calculation should be employed. The values of voltage drop for 600/1000 V rated cables are given in the current rating tables. In those cases where the actual current differs greatly from the tabulated current rating, the results obtained from the tables are only approximate; for a more accurate assessment, allowance should be made for the change in resistance with operating temperature. Refer to page 5 and Table 1 for details. It should also be ensured that the cable size ultimately selected is capable of carrying the required current under the site conditions of installation. Values of voltage drop are tabulated for a current of one ampere for a 1 metre run, i.e. for a distance of 1 metre along the route taken by the cables, and represent the effect of the voltage drop in all the circuit s. For balanced three phase ac circuits, the values relate to the line voltage. For any given run the values need to be multiplied by the length of the run (in metres) and by the current (in amperes) that the cables are to carry. Examples: Consider a route of 00 metres of Core armoured cable to be installed in air and to carry 100 amperes load per phase, with the supply voltage being 15 volts, three phase Hz and the cable to be Copper XLPE/SWA/ PVC. Using the Tables: Let Vd be the voltage drop in volts. Vd = x I x L 1000 or = Vd x 1000 I x L where I = Current in amperes L = Route length in metres = Approximate volt drop/ampere/metre Assume maximum permissible volt drop = per cent of 15 volts = 16.6 volts Substitute for current, route length and maximum permissible volt drop then = 16.6 x 1000 00 x 100 = 0.8 Select a cable from the relevant Current Rating Table 6 such that the value from the voltage drop column is equal to or less than the 0.8 calculated, ensuring that it will carry the current. It will be seen that this value is giving a cable size of. However, 100 Amp load could be less than 80% current carrying capacity of cable, in which case of cable will suffice. Note: Please refer to pages 8 and 5 for additional information on voltage drop. 9
RATING FACTORS Where the conditions of installation differ from those defined in the current rating tables, the following rating factors may be used for cables size selection. (Reference ERA report) CABLES LAID DIRECTLY IN GROUND Ratings for cables installed directly in the ground are based on values of soil temperature and soil thermal resistivity which are generally representative of conditions in the United Kingdom. Rating factors to take account of variation in ground temperatures are given in Table. Where conditions of operation can be fairly accurately estimated and knowledge of the soil along the route is available, it is possible to determine the ratings more precisely by the use of the soil thermal resistivity factors, grouping factors, and factors for the depths of laying given in Tables to 6. RATING FACTORS FOR GROUND TEMPERATURE Table Ground temperature 15 C 0 C 5 C 0 C 5 C 0 C 5 C Type Rating factor XLPE Insulated 0.97 0.9 0.89 0.86 0.8 0.76 RATING FACTORS FOR VARIATION IN THERMAL RESISTIVITY OF SOIL (AVERAGE VALUES) Table Size of cables Soil thermal resistivity in C m/w 0.8 0.9 1.5.0 Single core cables Up to 1.16 1.1 7 0.91 0.81 0.7 6 From to 1.17 1.1 7 0.91 0.80 0.7 6 From 00 to 1000 1.17 1.1 7 0.91 0.80 0.7 6 Multicore cables Up to 16 From 5 to From to 0 1.1 1.1 1.15 8 1.10 1.10 1. 1. 7 0.9 0.9 0.9 0.8 0.8 0.81 0.77 0.75 0.7 0.7 9 7 10
Depth of laying m RATING FACTORS FOR DEPTH OF LAYING (TO CENTRE OF CABLE OR TREFOIL GROUP OF CABLES) Up to Table 600/1000 Volt 1900/ Volt Above Up to Above to 0 0 0 0 0 0.99 0.98 0.97 0.80 0.97 0.96 0.9 0 0 0 0. 0.9 0.9 0.98 0.97 5 0.9 0.9 0.89 0.96 0. 1. 0.9 0.90 0.87 0. 0.9 5 0.9 0.89 0.86 0.9 0.91 0 0.91 0.88 0.85 0.9 0.89 0 0.90 0.87 0.8 0.91 0.88.00 or more 0.89 0.85 0.8 0.90 0.86 GROUP RATING FACTORS FOR CIRCUITS OF THREE SINGLE CORE CABLES IN TREFOIL OR LAID FLAT TOUCHING, IN HORIZONTAL FORMATION Table 5 SPACING SPACING Number of Circuits Spacing of Circuits Touching** Trefoil Laid flat 0.15 m* 0 m 5 m 0 m 0.78 0.81 0.8 0.88 0.91 0.9 600/1000 Volt cables 5 6 1 6 0. 0 0.7 8 0.79 0.7 0.7 0.8 0.81 0.79 0.87 0.85 0.85 6 7 1 0.71 0.78 0.8 0.78 0.80 0.8 0.86 0.89 0.91 1900/ Volt cables 6 9 8 0.71 5 0.77 0.7 0.80 0.77 0.8 0.80 5 5 8 1 8 0.7 0.78 6 5 8 6 0.7 0.76 * This spacing will not be possible for some of the larger diameter cables. ** For high current carrying cables (i.e. large size) it is advisable to allow spacing between circuits. Alternatively the most appropriate group rating factor must be applied when determining the cable size and required number of cables in parallel. 11
GROUP RATING FACTORS FOR MULTICORE CABLES IN HORIZONTAL FORMATION Table 6 Number of s in Group SPACING Spacing Touching* 0.15 m 0 m 5 m 0 m 600/1000 volt cables 0.81 0. 0.87 0.78 0.7 0.91 0.8 0.81 0.9 0.88 0.86 0. 0.90 0.89 5 9 0. 0.78 0.8 0.87 6 5 8 0.77 0.8 0.87 0.80 0.85 0.89 0.91 0.9 1900/0 volt cables 5 8 7 0.76 0.71 6 0.81 0.77 0.7 0.8 0.81 0.78 0.87 0.8 0.8 6 0.71 0.77 0.81 * For high current carrying cables (i.e. large size) it is advisable to allow spacing between circuits. Alternatively the most appropriate group rating factor must be applied when determining the cable size and required number of cables in parallel. CABLES INSTALLED IN DUCTS The term ducts applies to single way earthenware, fibre or ferrous pipes. RECOMMENDED DUCT DIMENSIONS AND CABLE SIZES Overall cable diameter Up to and including 65 Inside diameter 100 Duct Outside diameter 10 Table 7 Above 65 up to and including 90 15 160 Ratings for cables installed in single way ducts, underground, have been based on values of soil temperature and soil thermal resistivity which are generally representative of conditions in the United Kingdom. Rating factors to take account of variations in ground temperatures are given in Table. Where conditions of operation can be fairly accurately estimated, and knowledge of the soil along the route is available, it is possible to determine the ratings more precisely by the use of estimated maximum ground temperature, the soil thermal resistivity factors, grouping factors, and factors for the depths of laying given in Tables 8 to 11. RATING FACTORS FOR GROUND TEMPERATURE Note: Same as for direct in ground, refer to Table. 1
RATING FACTORS OF VARIATION IN THERMAL RESISTIVITY OF SOIL (AVERAGE VALUES) Table 8 Size of cable Soil thermal resistivity in C m/w 0.8 0.9 1.5.0 Single Core Up to From to From 00 to 1000 Up to 16 From 5 to From to 0 1.10 1.11 1.1 1. 1. 7 7 8 8 1. 1. 1. 1. 1. 0.9 0.9 0.9 Multicore s 0.97 0. 0. 0.86 0.85 0.8 0.9 0.90 0.88 0.80 0.79 0.78 0.88 0.85 0.8 0.76 0.75 0.7 0.86 0.81 0.78 RATING FACTORS OF DEPTH OF LAYING (TO CENTRE OF DUCT OR TREFOIL GROUP OF DUCTS) Table 9 Depth in laying 600/1000 Volt 1900/ Volt m 0 0 0.80 0 5 1. 5 0 0.00 or more Single Core Multicore Single Core Multicore 0 0.98 0. 0.9 0.91 0.89 0.88 0.87 0.86 0.85 0 0.99 0.98 0.96 0. 0.9 0.9 0.9 0.9 0.91 0 0.98 0. 0.9 0.9 0.90 0.89 0.88 0 0.99 0.97 0.96 0. 0.9 0.9 0.9 GROUP RATING FACTORS FOR SINGLE CORE CABLES IN TREFOIL SINGLE WAY DUCTS, HORIZONTAL FORMATION (AVERAGE VALUES) Table 10 Number of Circuits 600/1000 Volt s 1900/ Volt s 5 6 5 6 Spacing Touching* 5 m 0 m 0.87 0.78 0.7 0. 9 0.85 0.75 0. 7 * For high current carrying cables (i.e. large size) it is advisable to allow spacing between circuits. Alternatively the most appropriate group rating factor must be applied when determining the cable size and required number of cables in parallel. SPACING 0.91 0.8 0.81 0.79 0.78 0.88 0.80 0.77 0.7 0.7 0.9 0.87 0.85 0.8 0.8 0.90 0.8 0.80 0.78 0.76 1
GROUP RATING FACTORS FOR MULTICORE CABLES IN SINGLE WAY DUCTS, HORIZONTAL FORMATION (AVERAGE VALUES) Table 11 Number of Ducts in Ground SPACING Spacing Touching* 0 m 5 m 0 m 600/1000 volt cables 1900/0 volt cables 5 6 5 6 0.90 0.8 0.79 0.75 0.7 0.88 0.80 0.76 0.7 9 0.9 0.88 0.85 0.8 0.8 0.91 0.85 0.81 0.78 0.76 0. 0.91 0.89 0.88 0.87 0.9 0.88 0.85 0.8 0.81 0.96 0.9 0.9 0.91 0.90 0.9 0.90 0.88 0.86 0.85 * For high current carrying cables (i.e. large size) it is advisable to allow spacing between circuits. Alternatively the most appropriate group rating factor must be applied when determining the cable size and required number of cables in parallel. CABLES INSTALLED IN AIR It is anticipated that many of the in air installations will be in buildings, and the ratings are therefore given in accordance with IEE Wiring Regulations for Electrical Installations, 16th Edition. It should be noted that all ratings for cables run in free air have been based on the assumption that they are shielded from the direct rays of the sun without restriction of ventilation. The rating for cables subjected to direct sunlight should be reduced to take account of this factor and further guidance on this subject is available on request. RATING FACTORS FOR OTHER AMBIENT AIR TEMPERATURES Table 1 Air Temperature 5 C 0 C 5 C 0 C 5 C C 55 C XLPE Insulated 0.96 0.91 0.87 0.8 0.76 DEFINED CONDITIONS OF INSTALLATION The inair current ratings given in relevant Tables between 18 to are based on the installation conditions in air as follows: (a) Single core cables (1) Two single core cables are installed one above the other, fixed to the vertical surface of a wall or open cable trench, the distance between the wall and the surface of the cable being not less than 0. s are installed at a distance between centres of twice the overall diameter of the cable, i.e. D, where D = overall diameter of cable. () Three single core cables are installed in trefoil formation, fixed to the vertical surface of a wall or open cable trench, the cables touching throughout and the distance between the wall and the surface of the nearest cable being not less than 0. The cables are assumed to be remote from iron, steel or ferroconcrete, other than the cable supports. Single core armoured cables to be electrically bonded at each end of the run. 1
(b) Multicore s s of all types other than single core cables are installed singly, fixed to the vertical surface of a wall or open cable trench, the distance between the surface of the cable and the wall being not less than 0 in every instance. If it is necessary for cables to be installed at distances less than those described above, then the values tabulated under the heading Clipped direct to a surface... in the IEE Wiring Regulations should be employed. SHORT CIRCUIT RATINGS CONDUCTORS Table 1 Conductor size Short circuit ratings for 1 second in KA Aluminium Copper Conductor Conductor 0.1 1 1.5 6 8 7 6 0.86 6 0.9 1. 10 1..9 16.5.58 5.9 5.00 5. 7.15 6.58 10.01 8.9 1.59 18 17.16 1.10 1.5 17.9 6.6 6. 8.0.90 7.60 57.0 00 59. 90.09 60 75.0 1 800 9.00 0 1000 Note: For any other duration t seconds divide the given value by t The values of fault current given in the graph are based on the cable being fully loaded at the start of the short circuit ( temperature 90 C) and a final temperature of C. It should be ensured that the accessories associated with the cables are also capable of operation at these values of fault current and temperature. Note: With XLPE cables the use of soldered type connectors (instead of the compression type) is not recoended since their use in the system would limit the final temperature to 160 C (and consequently reduce the fault current rating by approximately 0 per cent). FAULT CURRENT KILOAMPERES FAULT CURRENT KILOAMPERES DURATION OF SHORT CIRCUT IN SECONDS 100 90 80 60 0 0 0 10 9 8 7 6 5 Copper Conductors Aluminium Conductors 5 5 1 16 0.1 0.7.0 DURATION OF SHORT CIRCUT IN SECONDS 15
SHORT CIRCUIT RATINGS ARMOUR XLPE INSULATED CABLES Area of Conductor Aluminium Wire Armour 600/1000 V ARMOUR FAULT CURRENTS TO EARTH (FOR A FAULT DURATION OF 1 SECOND) 1900/ V Steel Wire Armour Table 1 600/1000 V 1900/ V Single Core amp XLPE Single Core amp XLPE Two Core amp XLPE Three Core amp XLPE Four Core amp XLPE Four Core (reduced neutral) amp XLPE Three Core amp XLPE 16 1800 000 00 0 5 1900 800 00 00 00 5 800 00 600 00 0 000* 0* 100 0 100 900 5600 0* 500* 600 100 6000 5900 600 500* 50* 5100 5800 60 6600 6900 50* 6100 600 900 900 600 600 900 100 10000 10100 7100 7100 10100 110 10 10800 7900 7800 10 100 1800 11900 8800 80 1 1600 1900 10 00 10 00 00 00 0 1800 1 0 0 60 1500 1900 800 1 1000 00 * Based on wire diameters larger than those specified in BS 567. Refer to Table 16, and for single core cable armour wire diameter Notes: 1. The ratings given in the Table above are based on a fault duration of one second and an armour temperature rise from 80 C at coencement of the fault to a final temperature of 00 C.. The asyetrical fault rating of the smaller sizes may be decided by the short circuit capability of the rather than the armour rating. It is therefore necessary to compare the two ratings. 16
CONDUCTOR / ARMOUR RESISTANCE AND REACTANCE VALUES 600/1000 V SINGLE AND MULTICORE CABLES HAVING WIRE ARMOUR Table 15 Maximum resistance of Armour in ohms/km at 0 C Area of Conductor 16 1.15 Aluminium Conductor 10 With stranded copper 600/1000 V Copper Conductor * Single Core With stranded aluminium 600/1000 V Two core 600/ 1000 V. Three Core 600/ 1000 V. 1900/ V 0 Four Core** (equal neutral) 600/ 1000 V.10 Four Core (reduced neutral) Aluminium wire armour With stranded copper & Galvanised Steel Wire Armour 600/ 1000 V Inductive reactance (approx) per core of phase circuite in ohm/km @ Hz Single core cable Two core cable 0.081 Three & Four core cable 0.081 5 0.77 00. 0 0.0.0 0.079 0.079 5 0.868.60.0 1.80 0.10 0.077 0.077 87 1 0.75.0 0 1.80 0 0.1 0.076 0.076 68 0.75 7 0 1.80 0 0 0.10 0.075 0.075 0.19 0 7 1 1.10 1.10 1.10 0.098 0.07 0.07 0.15 5 1 0 0.76 0.76 0.96 0.096 0.07 0.07 0.1 9 0 0.78 0.71 8 0.71 0.097 0.07 0.07 0.0991 0.16 8 7 0.8 0.71 5 1 0.096 0.07 0.07 0.075 0.15 0.7 9 6 0.09 0.07 0.07 0.01 0.100 1 1 7 8 5 9 0.09 0.07 0.07 00 0. 0.0778 9 0 5 6 0.09 0.07 0.07 0 0.066 0. 0 0 0.089 60 0.08 9 0.18 0.18 0.086 800 0.01 0.067 0.1 0.1 0.08 1000 0.0176 0.091 0.1 0.1 0.08 * The values given are for plain annealed copper s. For tinned s reference should be made to BS 660. ** Multicore cables with stranded Aluminium have same Armour resistances as those with Copper s. 17
XLPE INSULATED CABLES TO BS 567 & IEC60 1 DIMENSIONS AND WEIGHTS STRANDED COPPER & ALUMINIUM CONDUCTORS SINGLE CORE CABLES *UNARMOURED AND ARMOURED, PVC SHEATHED CABLES 600/1000 V Table 16 area of Thickness of insulation Unarmoured s (approximate values) diameter overall weight Aluminium kg/km weight Copper kg/km Diameter under armour Armoured s (approximate values) Armour** wire diameter diameter overall weight Aluminium kg/km weight Copper kg/km 1. 50 1.6 *** 18. 60 800 1.1 16. 0 760 1.5 *** 560 990 1.1 18. 0 100 16. ***. 690 180 510 1 18.0 ***. 800 15 1.. 60 1560 19.8 7. 9 1900.7 760 190 0.0 1 0 7.7 9 510.6.8 180 90 1.8 1190 7. 5.6 160 580 00. 0 9 10 600 0. 8.0 1900 980 6.0. 610 5680 60..9 0 600 0.0 8.8 180 7160 800.6 7.8 810 5.8 55. 0 915 1000.8 5.0 780 1075.8 6 00 1190 * Single core unarmoured cables are as per BS 7889. ** Aluminium wire armour for AC system. *** Wire diameters are larger than those specified in BS 567. Note: s with Stranded Aluminium Conductors conform to IEC 60 1 18
area of 00 0 60 800 1000 In single Direct in way ground ducts 5 5 90 80 5 0 90 5 90 0 560 0 60 5 0 580 7 60 80 6 888 69 9 75 CURRENT RATINGS (AC) STRANDED COPPER & ALUMINIUM CONDUCTORS SINGLE CORE CABLES 600/1000 V ARMOURED PVC SHEATHED CABLES Table 17 Stranded Copper Conductors Stranded Aluminium Conductors Current Ratings D Installed in air 85 6 0 6 59 65 815 918 107 1119 11 Approximate voltage drop per ampere per metre Ground 0.87 7 9 8 1 0 0.18 0.17 0.17 0.16 Duct 0.9 0. 6 8 9 5 0 8 6 5 Air 0.87 7 9 8 1 0 0.18 0.17 0.17 0.16 Direct in ground 175 0 60 0 75 5 90 50 580 60 Current Ratings In single way ducts 180 0 60 0 65 10 55 80 510 50 D Ground Installed in air 16 07 0.98 5 0.7 9 8 7 8 91 9 65 1 50 7 65 5 71 1 801 8 Approximate voltage drop per ampere per metre Duct 0 0 0.79 6 7 9 8 8 5 Air 0.98 0.7 0 9 1 9 5 0 600/1000 V area of 00 0 60 800 1000 In single Direct in way ground ducts 0 85 5 5 85 5 5 90 0 5 580 6 6 7 80 8 960 960 1 110 1 10 UNARMOURED PVC SHEATHED CABLES Stranded Copper Conductors Current Ratings D Installed in air 09 0 85 5 511 6 1 80 96 19 11 19 Approximate voltage drop per ampere per metre Ground 0.85 1 5 6 1 6 0.19 0.17 0.16 0.15 0.15 0.1 Duct 0.9 0. 6 8 9 5 0 8 6 5 Air 0.87 1 5 7 1 6 0 0.18 0.16 0.15 0.15 0.1 Direct in ground 175 15 55 5 0 90 5 60 690 Current Ratings In single way ducts 180 0 60 5 75 0 510 5 60 Aluminium Conductors D Ground Installed in air 159 0.98 5 0.71 96 7 7 9 71 1 5 6 68 6 7 89 8 Approximate voltage drop per ampere per metre Duct 1. 1.10 0.79 6 7 9 8 8 5 Table 18 Air 1.5 0.98 0.7 9 7 9 7 0 0.19 Direct in ground Trefoil touching Single way ducts ducts touching Spacing in air As shown above (D = diameter) Non magnetic wire armour bonded at both ends Installation conditions for above ratings: Ambient air temperature:0 C Ground temperature: 15 C Depth of laying: m, Soil thermal resistivity: C m/w Maximum operating temperature at rated current is 90 C, For rating factors see Tables to 6 and 8 to 1 19
XLPE INSULATED CABLES TO BS 567 & IEC60 1 DIMENSIONS AND WEIGHTS 600/1000 V UNARMOURED AND ARMOURED, PVC SHEATHED CABLES Table 19 area of Thickness of insulation STRANDED COPPER & ALUMINIUM CONDUCTORS TWO CORE CABLES diameter overall Unarmoured s (approximate values) weight Aluminium weight Copper Diameter under armour Armoured s (approximate values) Armour wire diameter diameter overall weight Aluminium weight Copper kg/km kg/km kg/km kg/km 16* 0.7 17.0 75 15. 5 900 5* 0.9 15 18.5 5.1 915 1 5* 0.9 80 5 1.5 0 7.7 155 1710 97 1100 18.7 0 5.8 10 1800 1.1.1 690 150 1.5 0 9.0 1780 0 1.1 6.5 8 0.6 0.1 19 8. 11 610 6.8 0 6.1 0 880 1. 1 0 9.7 0 9. 0 80 5.1 1810 00. 0.7 690 590 80 500 8.1 0 9.0 80 7 1.8. 760 60. 0 5.5 5100 87 * Circular, all others are sector shaped. Note: Unarmoured cables & cables with Stranded Aluminium Conductors conform to IEC 60 1 0
CURRENT RATINGS (AC) STRANDED COPPER & ALUMINIUM CONDUCTORS TWO CORE CABLES 600/1000 V ARMOURED PVC SHEATHED CABLES Table 0 Stranded Copper Conductors Aluminium Conductors area of Direct in ground 16* 10 5* 180 5* 15 55 15 81 10 7 59 6 8 Approximate voltage drop Current Ratings per ampere per metre In single way ducts 115 15 175 10 60 1 8 560 Installed in air 115 15 188 8 91 5 0 80 50 66 7 Ground.9 1. 0.7 * Circular, all others are sector shaped Duct Air.9.9 1. 1. 0.7 0.7 Current Ratings In single Direct in way ground ducts 15 110 165 10 1 155 1 88 7 Installed in air 11 18 166 11 5 Approximate voltage drop per ampere per metre Ground.1. 1.1 0.8 Duct Air.1.1.. 1.1 1.1 0.8 0.8 UNARMOURED PVC SHEATHED CABLES 600/1000 V Table 1 Stranded Copper Conductors Aluminium Conductors area of 16* 5* 5* Direct in ground 10 180 15 55 15 80 10 7 5 61 71 Current Ratings In single way ducts 115 10 1 55 11 8 560 Installed in air 115 19 5 89 5 0 80 50 6 7 Approximate voltage drop per ampere per metre Ground.9 1. 0.7 Duct.9 1. 0.7 Direct in ground s touching Single way ducts ducts touching * Circular s, all others are sector shaped Note: (1) and above are with Dshaped () Unarmoured cables are as per IEC 60 1 Air.9 1. 0.7 Direct in ground 15 165 1 85 Current Ratings In single way ducts 1 10 1 5 Installed Ground in air 108.1 15. 16 11 57 0.8 Approximate voltage drop per ampere per metre Duct.1. 0.8 Air.1. 0.8 Installation conditions for above ratings: Ambient air temperature:0 C Ground temperature: 15 C Depth of laying: m Soil thermal resistivity: C m/w Maximum operating temperature at rated current is 90 C For rating factors see Tables to 6 and 8 to 1 1
XLPE INSULATED CABLES TO BS 567 & IEC60 1 DIMENSIONS AND WEIGHTS STRANDED COPPER & ALUMINIUM CONDUCTORS THREE CORE CABLES UNARMOURED AND ARMOURED, PVC SHEATHED CABLES 600/1000 V area of 16* 5* 5* 00 Thickness of insulation 0.7 0.9 0.9 1.1 1.1 1. 1.8 diameter overall 18.0 1.5.0.6 8.0.8 8.5.0 9.5 5.5 59. Unarmoured s (approximate values) weight Aluminium kg/km 0 610 10 11 10 7 00 660 * Circular s, all others are sector shaped. weight Copper kg/km 675 990 1 160 0 980 51 6 880 10 11575 Diameter under armour 16.0 0.0.7.0 6.0 0.0.8 6.8 1.5 6.0 51.5 56. Armoured s (approximate values) Armour wire diameter 5 diameter overall 6.7 9. 8.5. 7.0 5.5 9.8 55.1 6 66.6 Note: Unarmoured cables & cables with Stranded Aluminium Conductors conform to IEC 60 1 weight Aluminium kg/km 10 115 15 1810 0 8 660 0 51 6100 Table weight Copper kg/km 110 1710 100 10 5160 7160 8600 10755 1080 15810
600/1000 V CURRENT RATINGS (AC) STRANDED COPPER & ALUMINIUM CONDUCTORS THREE CORE CABLES ARMOURED PVC SHEATHED CABLES Stranded Copper Conductors Approximate voltage drop area of Current Ratings per ampere per metre Direct in In single Installed Ground Duct Air ground way ducts in air 16 5 5 00 115 180 15 65 15 60 60 50 590 667 9 15 175 15 60 5 80 0 5 99 11 16 197 51 5 6 56 68 78 0.9 0.9 0.9 Stranded Aluminium Conductors Current Ratings Direct in In single ground way ducts 89 7 115 9 15 110 165 15 00 165 00 75 0 10 55 10 0 60 85 50 Installed in air 7 98 15 6 18 88 56 Approximate voltage drop per ampere per metre Ground..7 1. 0.7 Table Duct..7 1. 0.7 Air..7 1. 0.7 600/1000 V UNARMOURED PVC SHEATHED CABLES Table Stranded Copper Conductors Stranded Aluminium Conductors area of 16 Current Ratings Direct in In single Installed ground way ducts in air 9 100 Approximate voltage drop per ampere per metre Ground Duct Air Current Ratings Direct in In single Installed ground way ducts in air Approximate voltage drop per ampere per metre Ground Duct Air 5 15 15 17 115 9 97.7.7.7 5 180 15 158 15 110 15 175 19 0.9 0.9 0.9 165 15 16 1. 1. 1. 65 15 6 00 165 187 15 55 98 1 7 0.7 0.7 0.7 65 6 75 5 6 0 99 10 55 65 80 56 90 7 50 0 58 15 0 09 600 0 61 65 85 71 00 675 575 71 5 5 Direct in ground s touching Single way ducts ducts touching Note: Unarmoured cables are as per IEC 60 1 Installation conditions for above ratings: Ambient air temperature:0 C Ground temperature: 15 C, Depth of laying: m Soil thermal resistivity: C m/w Maximum operating temperature at rated current is 90 C For rating factors see Tables to 6 and 8 to 1
XLPE INSULATED CABLES TO BS 567 & IEC60 1 DIMENSIONS AND WEIGHTS STRANDED COPPER & ALUMINIUM CONDUCTORS FOUR CORE CABLES UNARMOURED AND ARMOURED, PVC SHEATHED CABLES 600/1000 V Table 5 area of 16* 5 5 00 0** Thickness of insulation 0.7 0.9 0.9 1.1 1.1 1. 1.8. Unarmoured s (approximate values) diameter weight weight overall Aluminium Copper kg/km kg/km 0.0.5 6.5 5. 9.0.5 9.0 5.5 6 67.5 7. 50 6 900 110 15 1910 10 990 890 5780 780 1160 150 100 9 9 960 6160 7690 100 190 1560 19900 Diameter under armour 18.0 0.0.8 5.5 9.5.5 7.5 1.5 6.0 5 57.5 65.0 7.6 Armoured s (approximate values) Armour wire diameter 5.15.15 diameter overall. 6.1 8.6 7.7 7.1 51. 56.6 6.0 68.8 78.1 8 * Circular s, all others are sector shaped. ** as per IEC 60 1 Note: Unarmoured cables & cables with Stranded Aluminium Conductors conform to IEC 60 1 weight Aluminium kg/km 0 10 17 0 980 9 600 50 6660 77 1080 100 weight Copper kg/km 10 180 10 9 500 00 8 1010 180 1550 199 60
CURRENT RATINGS (AC) STRANDED COPPER & ALUMINIUM CONDUCTORS FOUR CORE CABLES 600/1000 V ARMOURED PVC SHEATHED CABLES Table 6 Stranded Copper Conductors Stranded Aluminium Conductors area of 16 5 5 00 0 Current Ratings Direct in In single Installed ground way ducts in air 115 180 15 65 15 60 60 50 590 667 9 15 175 15 60 5 80 0 5 6 99 11 16 197 51 5 6 56 68 78 800 Approximate voltage drop per ampere per metre Ground Duct Air 0.9 0.9 0.9 Current Ratings Direct in In single Installed ground way ducts in air 89 115 15 165 00 75 10 10 60 50 561 7 9 110 15 165 00 0 55 0 85 7 98 15 6 18 88 56 618 Approximate voltage drop per ampere per metre Ground..7 1. 0.7 Duct Air...7.7 1. 1. 0.7 0.7 600/1000 V UNARMOURED PVC SHEATHED CABLES Table 7 area of 16 5 5 00 0 Direct in ground 15 180 15 65 15 65 65 50 600 675 Stranded Copper Conductors Aluminium Conductors Current Ratings In single way ducts 9 15 15 175 15 55 0 80 0 0 575 610 Installed Ground in air 100 17 158 19 6 98 6 99 56 58 61 71 81 Approximate voltage drop per ampere per metre 0.9 Direct in ground s touching Single way ducts ducts touching Note: Unarmoured cables are as per IEC 60 1 Duct 0.9 Air 0.9 Current Ratings Direct in In single Installed Ground ground way ducts in air 89 115 15 165 00 75 10 15 65 5 565 7 9 110 15 165 1 5 55 90 0 85 7 97 16 187 7 6 7 09 71 5 66..7 1. 0.7 Approximate voltage drop per ampere per metre Duct..7 1. 0.7..7 1. 0.7 Installation conditions for above ratings: Ambient air temperature: 0 C, Ground temperature: 15 C, Depth of laying: m, Soil thermal resistivity: C m/w Maximum operating temperature at rated current is 90 C For rating factors see Tables to 6 and 8 to 1 Air 5
XLPE INSULATED CABLES TO BS 567 & IEC60 1 DIMENSIONS AND WEIGHTS STRANDED COPPER & ALUMINIUM CONDUCTORS FOUR CORE CABLES WITH REDUCED NEUTRAL CONDUCTOR 600/1000 V area of 5 5 Thickness area of of neutral insulation (phase) 16* 0.9 16* 0.9 5* 5* 1.1 UNARMOURED AND ARMOURED, PVC SHEATHED CABLES Unarmoured s (approximate values) diameter weight weight overall Aluminium Copper kg/km kg/km 1. 10. 6.1 860 1080 160 190 610 Diameter under armour 19.1.5 8.5 Armoured s (approximate values) Armour wire diameter diameter overall 6.1 7.9 6.6 weight Aluminium kg/km 1710 0 Table 8 weight Copper kg/km 17 10 7 8 1.1.8 190 0 800 910 9. 180 50 5.5 5. 0 60 * 1. 190 50 9.5.0 60 7610 7.7 60 6760.5 55. 0 9 * 5. 0 8900 5 61.1 60 1160 * 1.8 59.0 11000 55.0 66.7 1980 00 * 67.0 5560 1900 6.15 7.8 99 18 0** *. 7.0 60 17560 68.8.15 8.9 10 000 * Circular stranded s, all others are sector shaped. ** as per IEC 60 1 Note: Unarmoured cables & cables with Stranded Aluminium Conductors conform to IEC 60 1 6
CURRENT RATINGS (AC) STRANDED COPPER & ALUMINIUM CONDUCTORS FOUR CORE CABLES WITH REDUCED NEUTRAL CONDUCTOR 600/1000 V ARMOURED PVC SHEATHED CABLES Approximate voltage drop Approximate voltage drop area of area of Current Ratings Current Ratings neutral per ampere per metre per ampere per metre In single Direct in way Installed Ground Duct Air Direct in In single Installed Ground Duct Air ground ducts in air ground way ducts in air 5 16* 15 11 115 9 98.7.7.7 5 16* 180 16 15 110 5* 15 175 197 0.9 0.9 0.9 165 15 15 1. 1. 1. 5* 65 15 51 00 165 15 60 00 0.7 0.7 0.7 60 5 75 0 6 * 5 10 55 60 80 6 * 50 0 56 10 0 18 * 590 68 60 85 88 00 * 667 5 78 50 56 0 * 6 800 561 618 * Circular s, all others are sector shaped. 600/1000 V UNARMOURED PVC SHEATHED CABLES Table 0 area of area of Conductor neutral Direct in ground 5 16* 15 5 16* 180 5* 15 5* 65 15 65 * 65 * 50 * 600 00 * 675 0 * Stranded Copper Conductors Stranded Aluminium Conductors Stranded Copper Conductors Stranded Aluminium Conductors Current Ratings In single way ducts 15 15 175 15 55 0 80 0 0 575 610 Installed Ground in air 17 158 19 0.9 6 98 6 99 56 58 61 71 81 Direct in ground s touching Single way ducts ducts touching * Circular s, all others are sector shaped Note: Unarmoured cables are as per IEC 60 1 Approximate voltage drop per ampere per metre Duct 0.9 Air 0.9 Current Ratings Direct in In single Installed Ground ground way ducts in air 115 15 165 00 75 10 15 65 5 565 9 110 15 165 1 5 55 90 0 85 97 16 187 7 6 7 09 71 5 66.7 1. 0.7 Approximate voltage drop per ampere per metre Duct.7 1. 0.7 Table 9.7 1. 0.7 Installation conditions for above ratings: Ambient air temperature: 0 C Ground temperature: 15 C Depth of laying: m Soil thermal resistivity: C m/w Maximum operating temperature at rated current is 90 C For rating factors see Tables to 6 and 8 to 1 Air 7
XLPE INSULATED CABLES TO BS 567 CURRENT RATINGS (AC) AND VOLT DROPS STRANDED COPPER CONDUCTORS 600/1000 V THREE AND FOUR CORE ARMOURED, PVC SHEATHED CABLES Table 1 Conductor size Current in air A Voltage drop /A/m Current in ground A Conductor size Current in air A Voltage drop /A/m Current in ground A Conductor size Current in air A Voltage drop /A/m Current in ground A 99 0 115 51 07 65 6 55 60 97 0 11 99 60 5 9.7 110 0 89 0 9 5 89. 1 0 80 5 15 6 0 16 8.9 100 10 7 5 80.5 97 1 6 5 0 90 7.1 9 5 15 5 7 75 68.7 89 1 5 0 5 55 6. 8 6 1 90 5 11 5 6 15 56 11 50 10 1.59 15 9 50 08 515 15 1.56 10 90 510 0 1.5 15 7 90 90 85 5 110 1.51 10 55 1 80 65 0 1 15 15 0 00 99 1.6 5 08 55 10 0.199 0 91 1. 115 10 0 5 75 0.197 10 8 1.1 110 190 96 0 0 0.1 85 5 16 155 15 15 10 110 100 197 190 180 175 165 155 15 15 1.15 1.15 1.1 1.11 9 8 1. 1. 0.865 0.85 0.89 0.86 0.81 0.800 0.787 0.77 0.761 180 175 1 165 160 15 10 10 15 10 00 1 190 175 165 155 5 0 5 10 80 60 15 75 65 5 5 80 66 57 5 7 7 8 0 99 9 88 8 80 77 7 60 0 0 0 80 60 85 60 5 0 15 00 68 6 580 555 50 0 65 0 90 78 715 685 655 60 585 55 0 0. 0.18 0.181 0.180 0.179 0.177 0.176 0.17 0.17 0.166 0.16 0.16 0.161 0.160 0.159 0.158 0.157 0.156 590 575 560 50 50 0 80 55 0 667 60 60 600 580 560 55 5 75 Installation conditions for above ratings: Ambient temperature: 0 C Ground Temperature: 15 C Soil Thermal resistivity: Cm/W Depth of laying: m 8
XLPE INSULATED CABLES TO BS 567 DIMENSIONS AND WEIGHTS 1900/ V ARMOURED PVC SHEATHED CABLES Table Stranded Copper Conductors Single core cables Stranded Copper Conductors Three core cables Approximate Values Approximate Values area of Thickness of insulation Diameter Armour** under armour wire diameter diameter overall weight copper kg/km 15.0 * 810 16.6 *. 10 18. *. 10 19.8 7. 1680 8.8 19.0 0.8 5.5.5 960 7.7 6.1 610 00 600 0. 6.0. 5680 60. 0.0 8.8 7160 800.6 5.8 55. 9 1000.8.8 6 11 * Circular s, all others are sector shaped area of 16* 5* 5* Thickness of insulation Diameter under armour 1.5.5 6.5 5. 8. 6.6 8.5 7.8 51. Armour wire diameter diameter overall 9...8.7 8.0 1. 5.7 8.5 5 56.9 6 weight copper kg/km 1600 0 0 00 800 60 10 8 1010 1 CURRENT RATINGS 1900/ V ARMOURED PVC SHEATHED CABLES Table Stranded Copper Conductors Single core cables Stranded Copper Conductors Three core cables area of Direct in ground In single way ducts Installed in air area of Direct in ground In single way ducts Installed in air 00 0 60 800 1000 71 66 09 60 58 589 651 789 81 880 19 6 10 76 1 6 5 55 579 6 6 689 8 85 07 6 58 6 710 808 915 100 1119 11 16 5 5 11 17 175 07 5 5 87 6 56 96 1 17 17 1 57 9 8 71 8 80 1 1 168 0 55 1 61 10 71 55 6 Direct in ground Trefoil touching Single way ducts ducts touching Spacing in air As shown above (D= diameter) *Wire diameters are larger than those specified in BS 567 **Aluminium wire armour for AC system Installation conditions for above ratings: Ambient air temperature: 0 C Ground temperature: 15 C Depth of laying: m Soil thermal resistivity: C m/w Maximum operating temperature at rated current is 90 C For rating factors see Tables to 6 and 8 to 1 9
XLPE INSULATED CABLES TO BS 567 DIMENSIONS AND WEIGHTS Lead Sheathed Armoured Power s to BS 567 and EEMUA 1 600/1000 V Table area of lead sheath thickness Approximate diameter Over lead Armour Wire Overall cable Approx. weight kg/km Single core * * * * 00 0 60 800 1000 1.1 1.1 1.1 1. 1. 1. 1.8.1 15.0 16.8 18.5.8 5.5 8.1. 7.0 0.8 7.5 5..0 0.8.6.5 6. 8.5 0.8.5 6. 1.8 6.6.8 59. 6. 1 160 0 80 80 65 180 600 8000 9 10 1500 Two core 16 5 5* 1.1 1. 1. 1. 1. 1.5 1.8 15.5 18.9 1. 19.0..8 7..7 8.9.9 5 5 1.8 5.5 9. 7..5 7.8 1.1 6. 5 56. 150 0 6 60 00 50 51 6 7710 96 11510 Three core 16 5 5 * 00 1.1 1. 1. 1. 1.5.. 16.5.0.0 6.5.5 7.8.8 8. 5. 57.8 5.0 8.6 5.0.5 9. 5.5 6 65. 71.8 17 6 0 60 560 6110 7 8980 108 10 16 1 Four core 16 5* 5 00 1. 1. 1.5.. 18.8. 6..8 7.8. 7.8 5.8 58.5 65.9 5.15 5.5 8.5 1..6.8 9.8 55.0 60.0 66.5 7 8.6 800 0 60 58 900 1180 1600 100 0 6100 * with wire armour, a deviation from BS 567. Tolerance on the above dimensions are and +. sizes marked + and higher have sector shaped s. Lead sheath thicknesses are nominal values based on EEMUA 1. For core cables, and above have Dshaped s. 0
XLPE INSULATED CABLES TO BS 567 16 DIMENSIONS AND WEIGHTS LEAD SHEATHED ARMOURED POWER CABLES TO BS 567 AND EEMUA 1 1900/ V Table 5 Approximate diameter area of lead sheath thickness 1. Over lead.9 Armour Wire Overall cable 1.8 Approx. weight kg/km 7 5 1. 6.1.9 1 5 1.5 8.6 7.6 5 * 1.5 9.8 8 Three core 1.5 1.1.7 8.0.5 5 5560 658 80 1.8 9.8 5.7 0.8 56.6 117 8.9 6. 1819. 5. 66.9 1656 * sizes and higher have sector shaped s. 1
XLPE INSULATED CABLES TO BS 567 RESISTANCE OF LEAD SHEATH AND ARMOUR LEAD SHEATHED ARMOURED POWER CABLES TO BS 567 AND EEMUA 1 1900/ V Table 6 Maximum Resistance (ohms) per 1000 metres of cable at 0 C area of 1.5 Single core Armour Lead 600/1000 V 1900/ V Two core Three core Four core Three core Lead Armour Lead Armour Armour Lead Armour Lead 8.98 6.1 8.5 5.96 7.7 5.59 7.56 5.51 7.09 5.6 6.9.8 6.7.88 6.7.81 5.1.1 6 5.85.59 5.0.1.91.0 10.91.01.71.9.10.6 16 8.1.9.10.11.6.1.6. 5 6.6.1.6.96 1.58.9 1.57 7 5 6.01 0.60 9.1 1..8 1.1 8 1.1 5. 7.19 1.88.7 6 7 1 0.8.56 1. 7 1.59 0.87 1.5 0.81.07 9.10 1.1 0 0.87 0.77 0.77.0 5 1.89 1. 1. 0.78 1.11 7 1.10.0 1.58 0. 1.1 8 0.88 1 0.8 9 1. 9 0.89 0.75 7 0.86 8 6 1 0.76 7 1 0.7 1.86 0.87 5 8 1 0 00 1.1 0.17 9 6 7 0 1.16 0.15 60 0.98 0.1 800 0.76 0.09 1000 5 0.08 Note: Single core cables with Aluminium Wire Armour and Multicore cables with Steel Wire Armour
ADVANTAGES OF XLPE INSULATED CABLES 1. Does not soften beyond the normal range of operating temperatures and is called THERMOSETTING insulation.. Due to greater capacity to withstand heat, the permissible maximum continuous operating temperature is 90 C and for momentary short circuits the permissible temperature is C.. Higher insulation strength and superior mechanical properties allow lower insulation thickness. The insulation resistance value of the cable does not appreciably change with operating temperature.. XLPE insulation dissipates heat from s much faster as its thermal resistivity is.5 C m/w. 5. Heat generation in the insulation itself is low due to very low loss angle. 6. Due to the foregoing reasons, an XLPE cable can carry 15% to 0% higher current than a PVC cable with the same size. 7. Density of XLPE is 0.9 to 0.9 gm/ml and due to lower insulation thickness, XLPE insulated cables are lighter and easier to install. 8. Jointing and terminating of XLPE insulated cables does not require any special techniques. LSZH CABLES Ducab can manufacture a dedicated cable called LSZH (Low Smoke & Zero Halogen) for installations where fire and its associated problems the emission of smoke and toxic fumes offer a serious potential threat. LSZH compound is free from halogens (fluorine, chlorine and bromine) and when tested to BS 65 Part 1 and IEC 75 Part 1 the acidic gas evolved during combustion is less than % by weight of material. Furthermore, when tested in accordance with BS 78 Method 11D, the oxygen index of both bedding and sheath will not be less than 0. These cables comply with BS 67 and also meet the requirements of IEC Part. LSZH : is slow to ignite,burns slowly and gives off reduced smoke and fumes which can kill people does not produce corrosive halogen acid gases which destroy sensitive electronic equipment helps people to escape from a fire helps them to see and to breathe for longer wins time for people to escape and for emergency services to help is essential in public buildings, transport or confined areas where larger numbers of people many of them strangers to the surroundings or infirm regularly congregate Some of the key benefits of LSZH cables are as follows:... to the Public much improved safety margins to help them survive a fire situation in enclosed areas or high population, hightech coercial offices in which they might work or visit... to the Specifier enhanced fire damage protection for both structure and sensitive electronic equipment demonstrates proper concern for public and environmental safety... to the Contractor no loss of versatility can be installed wherever conventional cables would be used and are compatible with standard accessories
WHICH SITUATIONS DEMAND LSZH CABLE? LSZH cables should be used in any location where the outbreak of fire would constitute an iediate threat to life and to the performance of sensitive electronic equipment. LSZH cables with their slow burning and nosmoke qualities are most essential in high population public or coercial buildings, enclosed areas such as tunnels or public transport, or places where large numbers of people, perhaps unfamiliar with their surroundings or with limited mobility, congregate for example: places which are densely occupied on a regular basis multi storey dwellings, office blocks, hotels, educational establishments, factories. places where large number of people congregate without being familiar with the layout cinemas, theatres, shopping complexes, tunnels, underground and surface passenger terminals and concourses. for housing people with limited mobility hospitals, retirement homes. places involving high security defence installations, prisons, research establishments, computer centres where operating critical processes power stations, nuclear reprocessing petrochemical installations. Note: For technical data for LSZH cables, please refer to Technical Department. XLPE CABLE DATA FOR PARTIAL LOADS For installations where XLPE insulated cables are not fully loaded and operating temperatures are below 90 C. The current ratings given in relevant tables of this publication assume that cables are fully loaded i.e. operating temperature is 90 C and resistances at this temperature have been used in the tabulated figures of volt drop per ampere per metre for various sizes of cables. In many situations the size which is ultimately chosen may not be carrying its maximum permissible current (i.e. its full rated current) and consequently it will not be operating at its maximum designed temperature. Table 1 shows the reduced voltage drop / ampere/metre/ data corresponding to reduced operating temperature due to reduced load currents. The first line is applicable to 90 C temperature. Examples are given below to illustrate situations where overdesigning can be avoided. Standard conditions in the following refer to those obtained in the United Kingdom on which the current rating /voltage drop tables are based. For situations other than standard conditions such as those in the Middle East, suitable rating factors can be applied for utilising data in Table 1 as shown in example () in the following: It should also be ensured that the cable size ultimately selected is capable of carrying the required current under site conditions of installation. Formula Vd = x I x L 1000 or = Vd x 1000 I x L where Vd = maximum acceptable volt drop (in volts) I = current per phase (in ) = appropriate volt drop (in /amp/metre) L = route length (in metres) Examples: At standard defined conditions: 1) Consider a route of metres of four core copper XLPE/SWA/PVC to be installed in air (at standard conditions) and to carry per phase at 15 volts. Maximum voltage drop to be per cent. per cent of 15 V = 1 V Substitute for current, route length and maximum volt drop = 1 x 1000 x = 89 /A/m
From Table 1, the first line of figures per size (corresponding to IEE Wiring Regulations) and giving a voltage drop value less than 89 is. By studying the table to find a voltage drop value equal to, or less than the 89 calculated, but at the same time representing the A load required, it will be seen that a voltage drop of 80 corresponds to a current of A and a reduced size of. Therefore it is possible to select a cable rather than the cable first indicated. The actual volt drop of this installation is Vd = X X 80 1000 = 10.1V ) Consider a route of 10 metres of four core copper XLPE /SWA/PVC cable to be installed partly in air, partly underground, and to carry 60 per phase at 80 V. Maximum voltage drop to be %. % of 80 V = 11. V Substitute for current, route length and maximum volt drop = 11. X 1000 60 X 10 = 7 /A/m Selecting a voltage drop corresponding to the maximum rating the size would be but selecting from Table 1 such that /A/m is equal to, or less than the 7 calculated and is capable of carrying 60 A (in ground and in air), it will be seen that this value is for a cable (instead of ). and the actual voltage drop = 60 x 10 x = 11. V 1000 (See Tables to 1 for site conditions other than standard defined conditions) Examples: At site conditions other than standard defined conditions ) Consider example (1) but at an ambient temperature of 5 C. Derating factor for this temp. = 0.87 (see Table 1). Using this factor, calculate the equivalent current at standard conditions by dividing the actual current by the derating factor. Thus equivalent current = 0.87 = 5 A and from previous example (1) the /A/m figure needs to be 89 or less. Selecting a cable from Max Rating figures as previously the cable would be. However selecting from Table 1 with a current of 5A and a volt drop of 89 (or less), gives a cable size of with a voltage drop value of 88 /A/m at 5A. (instead of the ). and the actual voltage drop = x x 88 1000 = 1 V 5
6 Go to Contents Page XLPE INSULATED CABLE TO BS 567 STRANDED COPPER CONDUCTORS Con. Area No. of cores Thread Size BW Indoor Gland Kit Reference CW Outdoor Gland Kit Reference E1W Outdoor Gland Kit Reference E1WF E.Exd Gland Kit Reference EXCEL PLUS Delugeproof Gland Reference BARRW Explosion Proof Gland Reference Telcleat Ref. 85AA Ranger Cleat Ref. 8AA Aluminium Claw & Bolt Cleat Ref. BA Easypac Resin Joint Copper Connectors Lugs 1.5 7 1 19 7 7 0 0 0 0 0 0 0 0/5 5 5 5 5 BW0SK BW0SK BW0K BW0K BW0K BW0K BW0K BW0K BW5K BW5K BW5K BW5K CW0SK CW0SK CW0K CW0K CW0K CW0K CW0K CW0K CW5K CW5K CW5K CW5K KA15 KA15 KA15 KA15 KA15 KA15 KA15 KA15 KA155 KA155 KA155 KA155 KA75 KA75 KA75 KA75 KA75 KA75 KA75 KA75 KA755 KA755 KA755 KA755 9AB5 9AB5 9AB5 9AB5 9AB5 9AB5 9AB5 9AB5 9AB55 9AB55 9AB55 9AB55 AA5 AA5 AA5 AA5 AA5 AA5 AA5 AA55 AA55 AA55 AA55 AA55 0 0 0 0 0 01 01 01 01 01 0 0 0 0 0 0 0 0 0 0 0 0 PUJ6CC PUJ6CC PUJ10CC PUJ16CC BT6C BT6C BT6C BT6C BT6C BT6C BT10C BT10C BT10C BT16C BT16C BT16C 6 10 16 0 0 0 0 5 5/ 0 BW0SK BW0SK BW0SK BW0K BW5K BW5K BWK BW0K CW0SK CW0SK CW0SK CW0K CW5K CW5K CWK CW0K KA15 KA15 KA15 KA15 KA155 KA155 KA156 KA157 KA75 KA75 KA75 KA75 KA755 KA755 KA756 KA757 9AB5 9AB5 9AB5 9AB5 9AB55 9AB55 9AB56 9AB57 AA5 AA5 AA5 AA5 AA55 AA56 AA56 AA57 7 1 19 7 7 8 0 0 0 0 0/5 5 5/ 0 BW0SK BW0SK BW0SK BW0K BW5K BW5K BWK BWK BW0K CW0SSK CW0SSK CW0SK CW0K CW5K CW5K CWK CWK CW0K KA171 KA171 KA15 KA15 KA155 KA155 KA155 KA156 KA157 KA771 KA771 KA75 KA75 KA755 KA755 KA755 KA756 KA757 9AB71 9AB71 9AB5 9AB5 9AB5 9AB55 9AB56 9AB56 9AB57 AA5 AA5 AA5 AA5 AA55 AA55 AA56 AA56 AA57 01 01 01 0 0 07 01 01 0 0 01 01 0 0 0 01 01 01 01 0 0 0 0 0 0 07 01 01 0 0 07 PUJCC PUJCC PUJCC PUJCC PUJ6CC PUJ6CC PUJ6CC PUJ16CC PUJ5CC PUJCC PUJCC PUJCC PUJ6CC PUJ6CC PUJ5CC PUJ5CC PUJ5CC BTC BTC BTC BTC BTC BTC BTC BTC BTC BTC BTC BTC BTC BTC BTC BTC BTCcontd...page 7 COMPONENTS REFERENCE CHART Table 7 600/1000V