Cable Designers guide: Conductor selection

In case you've missed our over view about cable designing (Cable Designers guide: Conductor selection) you could check it out here. Through this email we will further go into more detail regarding cable designing and talk about selection of copper conductors.

Copper conductor used in cables industry usually complies with the following standards:

1. IS 8130
2. HD 383
3. IEC 60228

Factors to be considered while deciding the size of the conductor 

1. Current carrying capacity 
2. Distance - If current/ signal needs to pass a long distance from one end to the other end distance plays an important role in deciding the size of the conductor. Because longer the length higher the voltage drop. You could find a voltage drop calculator here. 

Factors considered while selecting the type of conductor 

Type 1: Usually used for solid applications. Can be used only in circular form

Type 2: Can be used for solid or moderate flexing applications. Shaped conductor can be used when the conductor size is above 16 sqmm

Type 5 & 6: Used for high flexing applications. 

To inform you a little bit more about the difference between the types of conductor copper conductor of area 1.5 sq.mm. is taken as reference:

Particulars	Type 1	Type 2	Type 5
No of strands	1 strand (Solid)	3 strands	No of strands depend on size of each strand.  Max diameter of strand 0.26 mm
Resistance	12.1 Ω	12.1 Ω	13.1 Ω
Flexibility	Poor	Good	Excellent
Diameter	Smallest final size of conductor compared to other types	Slightly bigger diameter than Type 1	Biggest final size diameter of conductor

Ease of installation	Poor	Good	Good
Flexing life	Poor	Good	Excellent

Copper coating selection guide

Coating material

Properties

Peak Temperature

Tin	Protects conductor from insulation (e.g silicon rubber) Eliminates problems of soldering Prevents oxidisation of copper at high temperature	150 ° c
Silver	Higher conductivity & temp higher than silver Not good where high flexing is required It is electro positive to copper so in case electrolytic corrosion happens copper will protect it	200 ° c
Nickel	High temp coating Electrolytic corrosion does not happen at elevated temperatures Can be soldered ready but requires higher temperatures	300 ° c
Gold	Specialize applications, aerospace, music etc	----

*Next newsletter in the pipeline for Cable Guide Series: Instrumentation Cables (Monthly Series)
*Next newsletter in the pipeline for Cable Design Guide Series: Insulation Material Selection (Monthly Series) - Stay tuned

For feedback & cable requirements please free to get in touch. 

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