Wiktor Wise
Electric cables are used for transmitting electrical energy and come in a variety of types, sizes, and installation methods. One of the most fundamental ratings assigned to an electric cable is its voltage rating, which is the reference voltage that defines the electrical tests the cable is designed for. Cables are categorized as low voltage (up to 750-1000 V) or medium voltage (1 kV to 36 kV) and are used in a range of applications, from domestic wiring to industrial power installations. Power, data, and control cables must comply with international standards to ensure safety and reliability, encompassing factors such as electrical conductivity, mechanical strength, and resistance to environmental factors. Cable manufacturing and usage standards vary by region, with organizations such as the International Electromechanical Commission (IEC) and British Standard (BS) providing guidelines. Installation processes for medium-voltage power cables can be complex, requiring specialized equipment and skilled personnel to ensure safe and effective energy transmission.
| Characteristics | Values |
|---|---|
| Cable type | Power, data, control, instrumentation, low voltage, medium voltage, high voltage, etc. |
| Cable standards | DIN, NBN, NF, SS, VDE, IEC, EN, SEMKO, SAA, OVE, CEBEC, SEV, NEMA, NEC, UL |
| Cable markings | Temperature ratings or codes, voltage ratings, manufacturer's name, National Test Agency symbol |
| Cable materials | Copper, aluminium, thermoplastic, thermoset, PVC, rubber, XLPE, HEPR |
| Cable applications | Indoor, outdoor, industrial, commercial, residential, special installations |
| Cable destinations | North America, Europe, Asia, South America, Germany, Austria, Belgium, Switzerland, etc. |
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What You'll Learn
Cable voltage and temperature ratings
One of the most fundamental ratings assigned to an electric cable is its voltage rating. The rated voltage of a cable is the reference voltage for which the cable is designed and which defines the electrical tests. The rated voltage of a cable is normally expressed by the combination of two values, Uo/U, expressed in volts. Uo is the Root Mean Squared (r.m.s) value between any insulated conductor and ‘earth’ (the metal covering on the cable or the surrounding medium). U is the r.m.s value between any two-phase conductors of a multicore cable or of a system of single-core cables.
There is a third designated term, Um, which is used in some cable standards, defined as the ‘highest system voltage’ for which the cable and its accessories are designed. In an alternating current system, the rated voltage of a cable should be at least equal to the nominal voltage of the system for which it is intended. Different countries and regions have different amperage and voltage requirements, and these factors will affect the size and type of cable needed to supply safe electrical power. For example, in North America, circuit voltage is usually 120V or 240V, using 15A for non-industrial needs. For industrial needs, typical requirements would be 120V, 120/208V or 120/240V using 20A or less. In the European market, non-industrial needs are usually 230V using 16A or less, whereas industrial needs could be 230 or 400V using 32A or less.
The temperature rating of the cable is the rating marked on the cable or implied by the conductor type in the cable. This indicates the minimum temperature rating, and the cable is suitable for use at higher temperatures if marked on the cable or cord. The higher temperatures (above 60°C) only apply to dry applications. Cable for indoor applications is typically rated for at least 60°C, as typical indoor room temperatures range from 20°C to 30°C, and properly operating equipment may generate an additional 30°C. If the product is a heating appliance, a rubber jacketed cable or a special heater type cable is recommended. Outdoor and industrial ambient temperatures and equipment usually have higher extremes, and the cable may need to be rated from -50°C up to 105°C.
All Thermoplastic and Thermoset materials used to make cables will slowly age and deteriorate over time; the rate of deterioration will accelerate as the temperature increases (Arrhenius Law). Therefore, it is common to state a temperature at which the material will continue to operate normally and give an acceptable life; for electric cables, this is known as the “continuous conductor operating temperature” rating.
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Cable standards and certifications
UL Standards and Certification
Underwriters Laboratories (UL) is a well-recognised organisation that sets safety standards for wires and cables in the United States. UL Listed wire and cable products are commonly used in residential, commercial, and industrial buildings. UL also has recognised components, such as the UL AWM (Appliance Wiring Material) style, which can be used for internal and external wiring. UL certification is essential for cables to meet the National Electric Code (NEC) requirements.
CSA Certification
The CSA Group, formerly known as the Canadian Standards Association, sets standards and provides certification for cables primarily in Canada. Their listing indicates that a product meets the Canadian Electric Code (CEC). CSA Certification includes flame tests like FT1 and FT4 to ensure the safety of cables in terms of flame propagation and burning.
VDE Certification
Verband der Elektrotechnik Elektronik (VDE) is the German reference for cable standards. The VDE certification process tests cables for safety and compatibility with existing electrical systems. Products bearing the VDE mark are considered reliable and safe, especially in Germany and other European countries.
IEC Standards
The International Electromechanical Commission (IEC) is the world reference for cable manufacturing and usage. Their standards provide a global framework for cable design, manufacture, testing, and installation, ensuring reliability and safety.
Country-Specific Standards
Different countries have their own standards and certifications for electrical cables. For example, Austria's OVE (Austrian Association for Electrical Technology) follows IEC standards, while Belgium's CEBEC (Belgium Electrotechnical Committee) has its own set of standards similar to IEC. Other country-specific standards include the British Standard (BS), Italy's CEI, Germany's DIN, and France's NF.
Third-Party Certifications
Third-party certifications are also common in the cable industry. Intertek's ETL certification is recognised as a Nationally Recognized Testing Laboratory (NRTL) like UL. Products can be ETL "verified" for quality and performance, ensuring they meet ANSI/TIA, ISO/IEC, EN, or IEEE performance standards.
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Cable materials and insulation
The three main insulation materials are plastic, rubber, and fluoropolymer. Polyvinyl Chloride (PVC) is a cost-effective and versatile option, widely used across various applications. It is a good insulator with a high dielectric strength, making it suitable for most electrical wiring applications. However, PVC has limitations in terms of temperature resistance and flexibility when compared to other materials.
Rubber insulation materials offer greater flexibility, especially at lower temperatures. Different types of rubber insulation include Thermoplastic Rubber (TPR), Neoprene (Polychloroprene), and Styrene Butadiene Rubber (SBR). Each type of rubber insulation offers varying levels of resistance to temperatures, abrasion, oils, solvents, and UV radiation. For instance, Neoprene exhibits superior abrasion and cut resistance, as well as resistance to oils and solvents.
Fluoropolymer insulation, such as Polyvinylidene Fluoride (PVDF), is lightweight, flexible, and flame resistant to UL 910 standards for plenum cables. It is an economical option that is commonly used in wiring applications.
Other insulation materials include Polyurethane (PUR), which is known for its toughness, flexibility, and excellent resistance to chemicals, water, and abrasion. However, PUR is flammable and has poor electrical properties, making it more suitable for jacketing than insulation. Chlorinated Polyethylene (CPE) is another insulation material with good heat, oil, and weather resistance, often serving as a lower-cost and environmentally friendly alternative to chlorosulfonated polyethylene insulation.
Ethylene Propylene Rubber (EPR) insulation is commonly used in high-voltage cables due to its excellent thermal and electrical properties. It has a wide operating temperature range, from -50° Celsius to +160° Celsius, and is resistant to heat, oxidation, water, acids, alcohol, and alkali. However, EPR is relatively soft and may require careful handling during installation.
The choice of insulation material depends on the specific application and the performance requirements of the cable. International standards, such as those set by the International Electromechanical Commission (IEC), provide guidelines for cable manufacturing and usage, ensuring safety and reliability in installations.
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Cable applications and installations
Coaxial cables, for instance, are commonly used for video and television applications, offering durability and low interference at a relatively low cost. They are often employed in commercial spaces such as office buildings, data centres, healthcare facilities, educational institutions, and retail spaces to ensure reliable connections for daily operations.
Ethernet cables, including Cat 5e, Cat 6, and Cat 7, form the backbone of most network installations. Cat 5e is suitable for small to medium-sized networks, while Cat 6 and its variants are ideal for high-performance networks and data centres.
Fiber optic cables are the preferred choice for long-distance and high-speed data transfer. They excel in transmitting data over long distances with minimal loss or interference.
Installation guidelines play a vital role in ensuring safe and effective cable installations. Factors such as bend radius, tensile rating, and cable protection must be considered to comply with national and international regulations. Pre-wiring during building construction or post-wiring after completion are important considerations, especially in commercial spaces requiring seamless communication and reliability, such as healthcare facilities.
Special installations may require unique cable types, such as aluminium cables for power transmission in fixed indoor, outdoor, or underground settings. Medium-voltage cables with XLPE or HEPR insulation are designed for energy distribution in medium-voltage networks, offering safety features like being halogen-free and non-flame propagating. Copper and aluminium medium-voltage cables are recommended for environments with potential exposure to oils and hydrocarbon-type chemical agents.
It is important to note that electrical cable installations must adhere to safety regulations, such as the Electrical Equipment (Safety) Regulations 2016 in Great Britain, which aim to ensure that only safe products are placed on the market. These regulations set voltage limits and require manufacturers to demonstrate how their products meet safety objectives.
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Cable manufacturing and usage guidelines
International Standards
The IEC (International Electromechanical/Electrotechnical Commission) is the world reference for cable manufacturing and usage standards. IEC standards are recognised in many countries and cover various aspects of electrical and electronic technology, including materials, design, testing, and performance requirements.
Regional Standards
Different regions have their own specific standards for cable manufacturing and usage, often with dedicated organisations. For example, the British Standard (BS) in the UK, the European Norm (EN) in Europe, the Norme Française (NF) in France, and the Singapore Standard (SS) in Singapore.
US Standards
In the United States, several organisations play a role in setting standards and regulations for cable manufacturing and usage:
- OSHA: Sets regulations for workplace safety in the industry, covering machine safety, electrical safety, and chemical exposure.
- NEC: Provides guidelines for the installation and use of electrical equipment and systems to ensure safety.
- ASTM International: Develops standards related to wire and cable manufacturing, covering materials, product specifications, testing methods, and safety.
- ANSI: Endorses and facilitates voluntary consensus standards, enhancing the quality of US-developed products.
- UL: A not-for-profit product-safety testing and certification organisation that tests wire and cable products, ensuring they meet public safety requirements.
- NFPA: Creates standards for fire safety, including fire alarm cables.
Environmental and Safety Regulations
Manufacturers must comply with environmental regulations regarding the production and disposal of materials used in cable manufacturing to reduce environmental impact. Additionally, safety regulations are in place to protect workers from hazards, such as moving parts, electrical hazards, and noise. This includes providing safety training and ensuring compliance with machinery safety standards.
To ensure product quality and safety, regulations may specify quality control procedures and testing requirements. Independent testing and certification organisations may also be involved in verifying compliance with standards.
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Frequently asked questions
Electrical cable standards ensure the reliability and safety of the installation. They provide a set of requirements, recommendations, and procedures for the design, manufacture, testing, and installation of cables.
Some common international cable standards include the International Electromechanical Commission (IEC), European Norm (EN), Norme Française (NF), Singapore Standard (SS), and Verband der Elektrotechnik Elektronik (VDE).
Different countries and regions have varying amperage and voltage requirements. For example, North America typically uses 120V or 240V for non-industrial needs, while Europe uses 230V. The end destination determines the power needs and the type of cable required to supply safe electrical power.
Voltage rating is one of the most fundamental ratings assigned to an electric cable. It is the reference voltage for which the cable is designed and is used to define electrical tests. The rated voltage ensures the cable is suitable for the intended system.
Electrical cables can be designed for various special installations, such as temporary light garlands at trade fairs, connections for overhead cranes, and applications in drinking water areas. Other examples include flexible cables for wiring electric cabinets, control cables for fixed or mobile installations, and medium-voltage cables with special insulation.
