25-06-2020

Wiring ,Cabling , IR Testing Megger.

in Solar Plants
• of The device enable us to measure electrical leakage in wire, results
are very reliable as we shall be passing electric current through device
while we are testing. The equipment basically uses for verifying the
BY electrical insulation level of any device such as motors, cables,
generators, windings, etc
Piyush Kumar Singh • Megohmmeter (famous as Megger*) is an electrical instrument used to
Dy.Director//NPTI//NANGAL measure the electrical resistance of insulators. Very often a megger is
used to check the insulation of cable jackets, motors, and other high
voltage (HV) equipment to ensure the safety of equipment.
• During its working, the object under test is connected with the probes
(terminals) of megger and voltages are generated, usually, these
voltages are between 1kV – 5kV. The resistance of the object is
measured, A high resistance value such as 50 MΩ or higher indicates
that object is properly insulated. A small value or zero indicates that
object is not safe and it is short

Pre-Insulated Terminals
Ring Terminals
FEATURES

■■ Pre-insulated halogen free ring type terminal with funnel entry

Part number Colour Hole Size Conductor Size
POWER CABLE
RF-M Red 3, 3.5, 4, 5, 6, 8, 10, 12mm 0.25-1.5mm2

BF-M Blue 3, 3.5, 4, 5, 6, 8, 10, 12mm 1.5-2.5mm2

GF-M Ye llow 3.5, 4, 5, 6, 8, 10, 12mm 4-6mm2

Butt Connectors
FEATURES

■■ Pre-insulated straight connectors with funnel entry

Part Colour Conductor Size number

PL03-M Red 0.25-1.5mm2

PL06-M Blue 1.5-2.5mm2

PL1-M Ye llow 4-6mm2

Pin Terminals
FEATURES

■■ Pre insulated halogen free pin type terminal with funnel entry
Part number Colour Pin Length Conductor Size

RF-P Red 8, 10, 12mm 0.25-1.5mm2

BF-P Blue 8, 10, 12mm 1.5-2.5mm2

GF-P Ye llow 10, 12, 14mm 4-6mm2

Cable Lugs & Connectors
Blade Terminals
FEATURES

■■ Pre insulated halogen free blade type terminal with funnel entry
Part number Colour Blade Length Conductor Size

RF-PP Red 13, 17mm 0.25-1.5mm2

BF-PP Blue 13, 17mm 1.5-2.5mm2

GF-PP Ye llow 13, 17mm 4-6mm2

Also available in this range are Fork terminals, maleand female disconnect andend sleeves.

20 www.jointingtech.co.uk

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 25-06-2020

POWER CABLE POWER CABLE

• A power cable is an assembly of two or
more electrical conductors, usually held
together with an overall sheath. The
assembly is used for transmission &
distribution of electrical power. Power
cables may be installed as
permanent wiring within
• buildings,
• buried in the ground,
• Run through trench or duct,
• run overhead, or exposed.

POWER CABLE WHY POWER CABLES?

• In very congested areas where the overhead

system of bare conductors for transmission &
distribution of electrical power becomes
impracticable on account of safety
regulations.
• The type of cable to be used at a particular
location is determined by the mechanical
considerations and the voltage at which it is
required to operate.

POWER CABLES POWER CABLE

• Usually the operating voltage decides the • Flexible power cables are used for
type of insulation & cable. portable devices, mobile tools and
machinery.
• The various type of cables depending upon
the voltage for which they are designed are • Modern power cables come in a variety
as under: of sizes, materials, and types, each
1. Low Tension – up to 1,100 V particularly adapted to its uses.
2. High Tension – up to 11 kV • Large single insulated conductors are
also sometimes called power cables.
3. Medium High Tension – up to 33 kV
4. Extra High Tension – up to 400 kV

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 25-06-2020

POWER CABLE POWER CABLE

The construction and material are determined
• Cables consist of three major by three main factors:
components: • Working voltage: determining the thickness of
1. Conductor, the insulation;
2. Insulation, • Current-carrying capacity: determining the
cross-sectional size of the conductor(s);
3. Protective Jacket
• Environmental conditions: such as
The makeup of individual cables varies temperature, water, chemical or sunlight
according to application. exposure and mechanical impact,
determining the form and composition of the
outer cable jacket.

POWER CABLE POWER CABLE

Cables for direct burial or for exposed • Power cables use stranded copper or
installations may also include metal aluminum conductors, although small power
armour in the form of wires spiraled cables may use solid conductors. The cable
around the cable, or a corrugated tape may include non-insulated conductors used
for the circuit neutral or for ground (earth)
wrapped around it. The armour may be connection.
made of steel or aluminum, and • The overall assembly may be round or flat.
although connected to earth ground is Non-conducting filler strands may be added
not intended to carry current during to the assembly to maintain its shape. The
cables may have a plastic or metal sheath
normal operation. enclosing all the conductors.

POWER CABLE POWER CABLE

• The materials for the sheath will be • Cables intended for underground use
selected for resistance to water, or direct burial in earth will have heavy
oil, sunlight, underground plastic or metal, most
often lead sheaths or may require
conditions, chemical vapors, special direct-buried construction.
impact, or high temperatures. When cables are exposed to
Cable materials may be specified mechanical impact damage, they may
not to produce large amounts of protected with flexible steel tape or wire
smoke if burnt. armor, which may also be covered by a
water resistant jacket.

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 25-06-2020

POWER CABLES SELECTION OF POWER CABLES

Power cables are generally selected

considering the application. However,
following factors are important for selection
of suitable cable construction required to
transport electrical energy from one end to
the other.
Maximum operating voltage
Insulation level
Power Cables (3 / 3½ / 4 / 5 CORE up to 630 SQ. MM
AND 3.8 / 6.6 kV) and SINGLE CORE up to 1000 SQ. Frequency
MM as per IS:1554 (Part-I) / IS:7098 (Part-I) / BS / IEC
Load to be carried

SELECTION OF POWER CABLES PVC CABLES

PVC insulated LT Heavy Duty cables
Possible overloading duration & magnitude are made as per IS-1554 (Part I) 1988.
Route length and voltage drop The cables are suitable for use on AC
Mode of installation considering installation single phase or three phase (earthed or
environment such as ambient & ground unearthed) systems for rated voltage up
temperature, chemical & physical properties to and including 1100 volts. These
of the soil cables can be used on DC systems for
Flame retardant properties rated voltage up to and including 1500
Plant safety requirements volts to earth.

PVC CABLES PVC CABLES

CONDUCTOR: • CONDUCTOR CONSTRUCTION
The most acceptable metals for conductors The most economical construction for conductor is
are copper and aluminium due to their higher solid conductor i.e. conductor is made of one single
wire. As the area of conductor increase, solid
conductivity and ductility. conductor becomes more stiff and hence difficult to
As copper has got higher affinity for sulphur, handle. In this case stranded construction is adopted.
it corrodes in the atmosphere where sulphur Here the conductor is made of number of strands.
fumes are present. In these conditions tinned The strands are arranged in spiral layers in
1+6+12+18+…….. formations. This construction
copper should be used. Aluminium oxide film provides more flexibility. Where crimping of lugs are
which is always present on Aluminium required, the conductor has to be of stranded
conductor surface acts as barrier and it construction only.
protects the aluminium conductor from Formula for total number of strands = 1+3n(n+1)
corrosion in fumes laden atmosphere. where n is no. of layers

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 25-06-2020

PVC CABLES PVC CABLES

• CONDUCTOR CONSTRUCTION • INSULATION
To economize in insulating material, weight • The PVC covering over conductor is called insulation
and overall diameter, shaped conductors are and is provided by extrusion process only. The
employed in bigger sized cables. Here the insulated conductor is called core.
stranded conductor is shaped in to a segment • IS-1554 permits two types of PVC insulation as
of a circle so that when all the cores are laid, follows :
they form a complete circle.
• 1) Insulation with TYPE A PVC compound as per I.S.
IS-1554 permits solid conductor construction 5831 which is suitable for 70 deg.C continuous
up to 10 sq. mm in Aluminium and up to 6 sq. operation.
mm in copper. It permits the use of shaped • 2) Insulation with TYPE C PVC compound as per I.S.
conductors for sizes from 16 sq. mm 5831 which is suitable for 85 deg.C continuous
onwards. operation.

PVC CABLES
PVC CABLES
• a) EXTRUDED INNER SHEATH: Here the
• INNER SHEATH: inner sheath is provided by extrusion of
Thermoplastic over the laid up cores. This
• Inner sheath is provided over the laid up type of the inner sheath is generally provided
cores. It is provided to give circular in cables having round cores i.e in control
shape to the cable and it provides cables and in power cables up to 10 sq. mm
size. This type of the inner sheath also acts
bedding for the armouring. as a water barrier between cores and outer
• I.S. 1554 permits following two methods sheath. In case of a puncture in the outer
of applying the inner sheath of any sheath the water can not reach to the cores
and hence we recommend that cables for
thermoplastic material i.e. PVC, outdoor underground uses should have
Polyethylene, etc. extruded inner sheath.

PVC CABLES PVC CABLES

• ARMOURING
• b) TAPPED INNER SHEATH: Here the inner
sheath is provided by wrapping a • In case of armoured cables, generally
galvanized steel wire/strip armouring is
thermoplastic tape over the laid up cores. It is provided over the inner sheath in multi-
generally employed in cables having sector core cables and over the insulation in
shaped cored i.e. multi core cables of 16 sq. single core cables. It provides
mm and above. This method saves a process mechanical protection to inside cores and
and hence manufacturers always provide this it carries earth return current in case of a
type of inners heath unless the purchase short circuit of a core with armour.
specifications ask for extruded inner sheath.

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 25-06-2020

PVC CABLES PVC CABLES

• As per I.S. 1554 (Part I) 1988, round wire • OUTER SHEATH
armouring is provided in cable, where • The PVC covering on armouring in case
calculated diameter under armour is upto of armoured cables and over the inner
13 mm. Above this the armouring is sheath in case of unarmoured cables is
called outer sheath.
either with round wire or strip of size 4
mm x 0.80 mm. As strip construction is • I.S. 1554 specifies nominal and minimum
thicknesses of outer sheath for
economical, the manufacturers always unarmoured cables and only minimum
provide steel strip armouring unless wire thickness of outer sheath for armoured
armouring is specially specified. cables.

PVC CABLES PVC CABLES

• It permits the following types of outer • PVC has got fire retardant properties due to
sheath PVC compounds: its halogen content. The fire in the cable gets
• 1) Outer sheath with type ST1 PVC extinguished immediately on removal of the
compound as per IS-5831, which is fire source.
suitable for 70 deg.C continuous
operation. • In the modern Power, Chemical, Fertilizer and
Cement Plants many PVC cables are
• 2) Outer sheath with Type ST2 PVC
compound as per IS-5831, which is bunched in the cable shaft or on cable trays.
suitable for 85 deg.C continuous In case of fire in these cables, the fire
operation. becomes self sustaining.

PVC CABLES PVC CABLES

• Moreover, due to the burning of PVC a dense • To overcome these deficiencies FRLS i.e.
corrosive smoke is emitted which makes fire Fire Retardant Low Smoke PVC was
developed.
fighting very difficult, due to poor visibility and
toxic nature of the smoke. HCL content of the • If required, we can provide Fire Retardant
Low Smoke (FRLS) PVC Inner sheath and /
smoke, not only damages other costly
or outer sheath. This PVC compound, apart
equipment lying nearby, but also penetrates from meeting the requirements of Type ST2
the RCC and corrodes the steel as per IS-5831, has got better fire retardant
reinforcement. Due to this there is an properties and it emits lower smoke and acid
extensive damage to the property. fumes when it catches fire.

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 25-06-2020

CONTROL CABLES COLOUR CODING

The following colour code is used for identification:
• Single Core : Red, Black, Yellow, Blue or natural
• Two Cores : Red and Black
• Three Cores : Red, Yellow and Blue
• Three & Half : Red, Yellow, Blue and Reduced
neutral Black
• Four Core : Red, Yellow, Blue and Black
• Five Core : Red, Yellow, Blue, Black, and Grey
• Six Cores : Two adjacent cores. Blue and Yellow
Control Cables (any size and any no. of Cores) (Counting and direction core) and remaining
as per IS:1554 (Part-I) / IS:7098 (Part-I) / BS / IEC Grey in each layer OR by printing numbers on
each core

XLPE CABLES XLPE CABLES

• CROSS-LINKED POLYETHYLENE (XLPE): • By means of process similar to the vulcanization of
XLPE means cross-linked polyethylene or rubber the polyethylene molecules can be cross-
vulcanized polyethylene. The basic material is linked. The process of cross-linking or vulcanization
low density polyethylene. Polyethylene is a consists of producing chemical bonds at interval
between the long molecular chain to give a “ladder”
thermoplastic material consisting of long effect which prevents slippage between molecules.
chain of hydrocarbon molecules. At elevated As a result of cross-linking the material becomes heat
temperatures these molecules tend to move resistant and does not soften at higher temperatures.
relative to one another so that the material Further it has better resistance to stress cracking and
becomes increasingly deformable and will good resistance to ageing in hot air. With the change
eventually melt at the temperature around of structure there is no adverse effect on electrical
properties.
110oC.

XLPE CABLES XLPE CABLES

ADVANTAGES OF XPLE CABLES OVER PVC ADVANTAGES OF XPLE CABLES OVER
CABLES PVC CABLES
(A) TECHNICAL: (B) COMMERCIAL:
1.Higher current rating, higher short Circuit Rating
2.Higher insulation resistance - 1000 times more than
1.Lower laying cost because of comparatively
PVC cables smaller diameter of cable and lighter weight
3.Better Resistance to Surge currents 2.Requiring less size of cable trays / supports
4.Low Dielectric Losses 3.One size lower cable can be used as
5.Better resistance to chemicals and corrosion compared to PVC insulated cable.
6.Longer Service life 4.Density of XLPE is lower than PVC.
7.Comparatively higher cable operating temperature 5.For longer cable length voltage drop shall
90°C and short circuit temperature 250°C.
be considerably low.

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 25-06-2020

CABLE CODE CABLE CODE

The following codes are used for designating the cables as per
IS:1554/ Part-I / 1988 / IS:7098-Part:I • YWY means Copper conductor, PVC insulated, round
CONSTITUENT CODE LETTER wire armoured and PVC sheathed cable.
• COPPER CONDUCTOR -
• ALUMINIUM CONDUCTOR A • AYFY means Aluminium conductor, PVC insulated,
• PVC INSULATION Y steel strip armoured and PVC sheathed cable.
• XLPE INSULATION 2X
• STEEL ROUND WIRE ARMOUR W
• FOR EXAMPLE
• STEEL FLAT STRIP ARMOUR F • 3 Core x 2.50 sq. mm YWY : Plain Copper conductor,
• STEEL DOUBLE ROUND WIRE ARMOUR WW PVC insulated, laid up, Inner sheathed, G.I. wire
• STEEL DOUBLE FLAT STRIP ARMOUR FF armoured and PVC sheathed cable having 3 cores of
• NON MAGNETIC (AI) ROUND WIRE ARMOUR Wa
2.50 sq. mm conductor size.
• NON MAGNETIC (AI) FLAT STRIP ARMOUR Fa
• PVC OUTER SHEATH Y

CABLE CODE POWER CABLE

• 4 core x 4.0 sq. mm AYWY: Aluminium
conductor, PVC insulated, laid up, inner • The best way to check the length of the
sheathed, G.I. wire armoured and PVC supplied cable is by resistance method.
sheathed cable having 4 cores of 4.0 sq. mm Take the resistance of the full drum and
conductor size. divide the reading by the resistance of 1
mtr. length.
• 3 ½ core x 50 sq. mm AYFY: Aluminium
conductor, PVC insulated, laid up, inner • To decide the size of the conductor,
sheathed, Steel strip armoured and PVC particularly that of the sector shaped
sheathed cable having 3 cores of 50 sq. mm conductor, we recommend the following
and 1 core of 25 sq. mm conductor size. method:

POWER CABLE POWER CABLE

• HANDLING AND LAYING OF CABLES
• Cables are costly capital items. They are arteries and
• Take weight of a small conductor veins of the plant and any blockade in the same will
piece and measure its weight in paralyze the complete plant. Unfortunately very little
grams. Then find out the weight of attention is paid in handling and installing the Cables.
the conductor in gms per meter Generally the work is entrusted to unskilled labourers
length. Divide it by 2.7 in case of and they may damage the cable in handling and
Aluminium and by 8.9 in case of laying. This damage may not be noticed while
charging the cable but when water comes in to contact
copper. It will give the area of the with this Cable, it shows a fault. In this case the blame
conductor in sq. mm. comes on cables.

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 25-06-2020

POWER CABLE POWER CABLE

• Therefore, special attention should be paid in handling
and laying the cables. If they are laid properly, they • The wood of the drum deteriorates fast
will give trouble free service for years to come.
if the drums are kept in sunlight or in
• Some recommendations about the handling and
laying of CABLES : moist atmosphere. The drums should be
• If possible the cables should be unloaded by a crane stored in covered godown having a
or a fork lift. If the same is not available, the drums
should be rolled down from the truck to a inclined concrete flooring.
plane or should be dropped from the truck on scrap • On receipt of the drums, the cables
truck tyres or on sand. In the last case the cable drum
may get damaged, if proper care is not taken. should be meggered with a 500/1000
volts megger.

POWER CABLE PVC CABLE

I.S. 1554 does not mention the minimum megger values of the PVC cables. The Table

• Please note that megger value decreases below gives the minimum megger values of the PVC cables as per B.S. 6346-1989

with increase in the length, temperature and MINIMUM INSULATION RESISTANCE VALUES

size of the cables. NOMINAL CROSS SECTIONAL AREA OF

CONDUCTOR SQ.MM
INSULATION RESISTANCE IN MEGA OHM/
KILOMETRE AT 20 DEG.C 650/1100 VOLTS

• Before meggering, both the ends of the 1.50 10

2.50 9
cables should be opened out and cleaned to 4.00 8

remove dust or metal particles. After the test, 6.00 7

the core should be shorted to discharge the 10.00

16.00
7
6
cable, otherwise charged cores may give a 25.00 5

shock to a person who may handle it 35.00 5

50.00 5
subsequently. 70.00 5
95.00 & above 5

PVC CABLE PVC CABLE

• As PVC cables have got higher capacitance, while • When laying the cables the drums must be rotated in
meggering, a high charging current will flow initially the direction marked on the drums.
and hence the megger will show a lesser reading. As
per International specifications the reading after one • If they are rotated in the reverse direction, the
minute of continuous meggering should be taken. winding will become loose.
• It is observed that some electricians check the cables • Always use jacks to raise the cable drum and then
by giving one phase to one of the cores of the cable pull the cable from the drum. It is observed that some
and check the other cores by a tester for a possible times due to non availability of jacks, people turn the
leakage. cable drum on flange side and then unwind the cable.
• This is a wrong method as other cores will show an This gives one twist to the cable per turn unwound
induced voltage when tested with a tester due to and due to this the armour comes out damaging the
capacitance between the cores, which is quite high in outer sheath and forms a bulge.
case of PVC cables. Capacitance also increases with
increase in temperature, length and size of the cable.

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 25-06-2020

PVC CABLE PVC CABLE

• When cables are laid in ground, sand bedding
• Where the cables are crossing the roads, the
same should be laid in concrete ducts. Care must be provided below the cable and it
should be taken to see that the sharp edges should also be covered by sand and over the
of concrete ducts do not damage the cables sand a brick layer should be provided.
when the same are being pulled. Rollers must • Sharp bends should be avoided while laying
be provided when longer lengths are being the cables. We recommend a minimum
laid, to avoid any damage to the sheath. bending radius of 12 x D Cables. (D is the
• The cables with extruded inner sheath must overall diameter of the cable).
be used when the same are laid in ground.

HT CABLES
• For circuits operating at or above 2,000
volts between conductors, a conductive
shield may surround each insulated
conductor. This equalizes electrical
stress on the cable insulation. The
individual conductor shields of a cable
are connected to earth ground at the
ends of the cable, and at locations along
the length if voltage rise
A high voltage cable designed for 400 kV. Large center conductor carries
during faults would be dangerous.
the current, smaller conductors on the outside act as a shield to equalize
the voltage stress in the thick polyethylene insulation layer.

HT CABLES HT CABLES
• Cables for power distribution of 10kV or • Modern high voltage cables use polymers or
higher may be insulated with oil and polyethylene, including (XLPE) for insulation.
paper, and are run in a rigid steel pipe, They require special techniques for jointing and
semi-rigid aluminum or lead sheath. For terminating.
higher voltages the oil may be kept • Many multi-conductor cables have a bare or
under pressure to prevent formation of insulated grounding or bonding wire which is for
voids that would allow partial- connection to earth ground. The grounding
discharges within the cable insulation. conductor connects equipment enclosures to
ground for protection from electric shock.

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 25-06-2020

INDIAN STANDARDS
HT CABLES
• Electrical power cables are often IS-1554 Part-1 PVC insulated Cables
IS-5831:1984 PVC insulation & sheath of
installed in raceways, electric cables
including electrical conduit and cable IS-7098 Part-1 Cross linked polyethylene (XLPE)
insulated PVC sheathed cables (for
trays, which may contain one or more working voltage upto & including
conductors. 1100 V)

• A hybrid cable can include conductors IS-10810:1984 Methods of test for cables
for control signals or may also
include optical fibers for data.

INDIAN STANDARDS Indian Standards

IS-6474:1984 Polyethylene insulation & • IS- 7098 Part-1 Cross linked polyethylene insulated
PVC sheathed cables (for working
sheath of electric cables voltage upto & including 1100 V)
IS-8130:1984 Conductors for insulated • IS 1554 Part-1 PVC insulated Cables
electric cables and flexible cords • IS- 6474: 1984 Polyethylene insulation & sheath of
IS-3975:1988 Mild steel wires, formed wires and electric cables.
tapes for armouring of cables • IS- 5831: 1984 PVC insulation & sheath of electric
cables.
• IS- 10810: 1984 Methods of test for cables.
• IS- 8130: 1984 Conductors for insulated electric
cables and flexible cords.
• IS- 3975: 1988 Mild steel wires, formed wires and
tapes for armouring of cables.

International Standards International Standards

• IEC 228 Conductors of insulated cables. Guide to the • IEC 885 Pts 1 through 3 Electric test methods for electric
dimensional limits of circular conductors. cables.
• IEC 331 Fire resisting characteristics of electric • IEC 304 Standard colours for insulation for
cables. low frequency cables and wires.
• IEC 332 - 3 Tests on electric cables under fire conditions. • IEC 227 01-1 through 6 PVC insulated cables of rated
Part 3: Tests on bunched wires or cables. voltages up to and including
• IEC 502 Extruded solid dielectric insulated power 450/750 V.
cables for rated voltages from 1kV to 30 kV. • IEC 1034 Pts 1 & 2 Measurement of smoke density of
• IEC 754 - 1 Test on gases evolved during combustion of electric cables burning under
materials from cables. Part 1: Determination defined conditions.
of the amount of halogen acid gas evolved • IEC 28 International Standard of
during combustion of polymeric material Resistance for Copper
taken from cables. • IEC 60840 Tests on extruded power cables
• IEC 811 Pts 1 through 5 Common test methods for insulating • IEC 60502-1 Power cable with extruded
and sheathing materials of electric insulation.
cables.

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 25-06-2020

STANDARD TECHNICAL REQUIREMENT STANDARD TECHNICAL REQUIREMENT

• FOR XLPE HT POWER CABLE

• For 33 kV and 11 kV cables, conductor screen and
• All cables should be suitable for high ambient, high insulation screen both should be extruded, semi-
humid tropical Indian Climatic conditions. Cables conducting compound and shall be applied along with
should be designed to withstand the mechanical, XLPE insulation in a single operation by triple
electrical and thermal stresses under the unforeseen extrusion process. Method of curing for 33 kV cable
steady state and transient conditions and should be should be "Dry curing/ gas curing " only, whereas for
suitable for proposed method of installation. 11kV and 3.3 kV cables it should be "Dry curing/ gas
curing / Steam curing".
• Conductor should be of uniform, of good quality, free
• Cable should be provided with copper metallic screen
from defects Aluminium copper. suitable for carrying earth fault current as stipulated in
• Insulation should be Cross Linked Polyethylene Clause-1.2 of Section 1. For single core armoured
(XLPE) . cables the armouring shall constitute the metallic part
of the screening.

STANDARD TECHNICAL REQUIREMENT STANDARD TECHNICAL REQUIREMENT

• Inner sheath - All armoured and multi-core un- • FRLS Properties - All cable shall be Flame Retardant,
armoured cables shall have distinct extruded inner Low Smoke (FRLS) type. Outer sheath shall have the
PVC sheath of black colour. following properties –
• Armouring - Material for armour for Single Core Cable • Acid Gas Generation – Max 20% ( as per IEC 754-1)
should be Aluminium wire. For Multi-core cable it
should be GS wire/flat. Armouring should be as per • Smoke density rating: 60% (As per ASTM D 2843)
relevant IS and it shall have minimum 90% coverage. • Flammability test - As per Swedish chimney test F3
• Outer Sheath – It should be of black colour PVC (type as per SEN 4241475
ST2 as per IS 5831) with Cable size and Voltage • As per IEC 332 part-3 (Category B) Minimum bending
grade embossed on it. Sequential marking should be
at every 1 (one ) meter distance. Word "FRLS" shall radius shall be 10 D
also be embossed on it at every 5 (Five ) meter
distance.

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 25-06-2020

TYPE TESTS TYPE TESTS

• e. Physical tests for out sheath
• a. Tests on conductor • i. Tensile strength and elongation at break
• i. Annealing test (for copper) • ii. Ageing in air oven
• ii. Tensile tests (for aluminium) • iii. Hot test
• iii. Wrapping tests (for aluminium) • iv. Shrinkage test
• iv. Resistance test • f. Bleeding and blooming tests (for outer sheath)
• b. Tests for armouring wires/strips • g. Partial discharge test
• c. Test for thickness of insulation and sheath • h. Bending test
• d. Physical tests for insulation • i. Dielectric power factor test
• i. As a function of voltage
• i. Tensile strength and elongation at break
• ii. As a function of temperature
• ii. Ageing in air oven • j. Insulation resistance (volume receptivity) tests
• iii. Hot test • k. Heating cycle test
• iv. Shrinkage test • l. Impulse withstand test
• v. Water absorption (gravimetric) • m. High voltage test
• n. Flammability test

ACCEPTANCE TESTS Routine Tests for Cables

• a. Annealing test (for copper)
• b. Tensile test (for aluminium) • Routine tests:
• c. Wrapping tests (for aluminium)
• d. Conductor resistance test,
• The following shall constitute routine
• e. Test for thickness of insulation tests:
• f. Hot set test for insulation, • a) Conductor resistance test
• g. Tensile strength and elongation at break test for
insulation and sheath • b) Partial discharge test (for screened
• h. Partial discharge test (for screened cables only) cables only) and
• i. High voltage test and
• j. Insulation resistance (volume resistively) test
• c) High voltage tests

SMOKE DENSITY TEST ON FRLS CABLES AS PER ASTM D-2843 SMOKE DENSITY TEST ON FRLS CABLES AS PER ASTM D-2843

Sl.No. TIME OBSERVATION

SMOKE DENSITY TEST 0 0.00 1

100 1 0.25 8
3 Max. Smoke Density
2 0.50 14
90
Rating Observed (%) 44.3
LIGHT ABSORPTION IN %AGE --------->

3 0.75 22
80
72 72
68 4 1.00 28
70 64 Min. Transmission of
5 1.25 33
55 56
Light (%) 55.7
60 6 1.50 39
47 48 7 1.75 40
50 42
39 40 8 2.00 42
40 33
28 9 2.25 47
30 22 10 2.50 48
20 14 11 2.75 55
8
10 12 3.00 56
1
13 3.25 64
0
14 3.50 68
00

25

50

75

00

25

50

75

00

25

50

75

00

25

50

75

00
0.

0.

0.

0.

1.

1.

1.

1.

2.

2.

2.

2.

3.

3.

3.

3.

4.

15 3.75 72
TIME IN MINUTES ------->
16 4.00 72

708

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Oxygen & Temp. Index Test on FRLS Cable as per ASTM D-2863 Oxygen & Temp. Index Test on FRLS Cable as per ASTM D-2863

OXYGEN & TEMPERATURE INDEX

36.0%

35.0% 34.0%
Temp. (Deg.C) % Oxy. Index. Temp. Index
34.0% 33.2%
OXYGEN INDEX(%) -------->

33.0% 32.4%
31.5%
25 34.0% 420 DEG.C
32.0%

31.0%
30.0%

29.0%

28.0% 50 33.2%
27.0%
26.0%

25.0%

24.0%

23.0% 75 32.4%
22.0%

21.0%
0 25 50 75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450 475 500

TEMPERATURE IN ( Deg.C) ----->

100 31.5%

Wiring Installation – Wire Size Selection

• LSZH – Low Smoke Zero Halogen • Wire is manufactured in sizes according to a
• LSOH - Low Smoke Zero Halogen standard known as the American wire gauge
• FRLS – Flame Retardant Low Smoke (AWG). As shown in Figure 9-115, the wire
diameters become smaller as the gauge
numbers become larger. Typical wire sizes
range from a number 40 to number 0000.

• Outer Sheath Color Coding

• The color of a cable’s outer sheath tells you the gauge of the
wire inside the sheath as well as the amperage rating for the
circuit.
• WHITE = 14-gauge wire, 15-amp circuit
• YELLOW = 12-gauge wire, 20-amp circuit
• ORANGE = 10-gauge wire, 30-amp circuit
• BLACK = 8- or 6-gauge wire, 45- or 60-amp circuits. Check
sheath labeling for gauge and circuit specifics.
• GRAY = Underground cable. Since all UF (underground
feeder) cable is gray, check the

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• Wire Color Coding

• This code is standard for all conductors. The colors you’re
most likely to find in your home are the following:
• BLACK (OR RED) = HOT. Hot wires carry current from
the panel to the device, which could be a switch, receptacle, • Joint Box or Tee or Jointing System
light fixture or appliance. There are other colors for hot
wires, but they’re much less common. • In this method of wiring, connections to appliances are
made through joints. These joints are made in joint boxes
• WHITE = NEUTRAL. Neutral wires carry the current back by means of suitable connectors or joints cutouts. This
to the panel, completing the circuit. method of wiring doesn’t consume too much cables size.
• BARE (OR GREEN) = GROUND. In the event of a • You might think because this method of wiring doesn’t
ground fault, the ground wire provides a path for the fault require too much cable it is therefore cheaper. It is of
current to return to the panel, opening the breaker or blowing course but the money you saved from buying cables will
the fuse, cutting off the flow of electricity. be used in buying joint boxes, thus equation is balanced.
This method is suitable for temporary installations and it is
cheap.

LV Lugs Cable Lugs & Connectors

LV Copper Lugs
FEATURES

■■ Designed to be crimped on to a conductor to facilitate the termination of the cable via the
lug hole
■■ Copper lugs are electrolytically tin plated to avoid oxidation
■■ Each terminal has a sight hole for visual inspection of the conductor inserted
■■ 1000V Rated
LV copper tube crimping
lugs
• Loop-in or Looping System Part number

A 03-M
Hole Size

3.5, 4, 5, 6mm
Conductor Size

1.5mm2
Partnumber

A24-M
Hole Size

8,10,12, 14,16,20mm
ConductorSize

120mm2

A 06-M 3.5, 4, 5, 6, 8mm 2.5mm2 A30-M 8,10,12, 14,16,20mm 150mm2

• This method of wiring is universally used in wiring. Lamps and other A 1-M

A 2-M

A 3-M
3.5, 4, 5, 6, 8mm

3, 4, 5, 6, 8,10mm

4, 5, 6, 8,10,12mm
4-6mm2

10mm2

16mm2
A37-M

A48-M

A60-M
8,10,12, 14,16,20mm

10,12, 14,16,20mm

10,12, 14,16,20mm
185mm2

240mm2

300mm2

appliances are connected in parallel so that each of the appliances can A 5-M

A 7-M
4, 5, 6, 8,10,12mm

5, 6, 8,10,12mm
25mm2

35mm2
A80-M

A100-M
12,16,20mm

16, 20mm
400mm2

500mm2

A 10-M 6, 8,10,12, 14,16mm 50mm2 A120-M 16, 20mm 630mm2

be controlled individually. When a connection is required at a light A 14-M

A 19-M
6, 8,10,12, 14,16mm

8,10,12, 14,16, 20mm

70mm2

95mm2
A160-M

A200-M
16, 20mm

16, 20mm
800mm2

1000mm2

or switch, the feed conductor is looped in by bringing it directly to the

LV Narrow Palm Copper Lugs
terminal and then carrying it forward again to the next point to be fed. FEATURES

• The switch and light feeds are carried round the circuit in a series of ■■ Designed to be crimped onto a conductor to facilitate the termination of the cable via the
lug hole in tight spaces and reduced space terminal blocks

loops from one point to another until the last on the circuit is reached. ■■ Copper lugs are electrolytically tin plated to avoid oxidation
■■ Each terminal has a sight hole for visual inspection of the conductor inserted
The phase or line conductors are looped either in switchboard or box LV narrow palm copper ■■ Please refer to our tooling and equipment section on page 212 for dies and tooling
■■ 1000V Rated
and neutrals are looped either in switchboard or from light or fan. Line tube crimping lugs
Part number Palm Width Hole Size ■■ Tested to BS EN 61238 Partnumber
Conductor Size PalmWidth Hole Size ConductorSize

BTN10-M 9m m 5m m 10mm2 BTN95-M 15.5mm 8mm 95mm2

or phase should never be looped from light or fan. BTN16-M

BTN25-M
9m m

9m m
5m m

5m m
16mm2

25mm2
BTN120-M

BTN150-M

BTN185-M
19mm

19mm

24.5mm
8, 10mm

8, 10mm

10mm
120mm2

150mm2

185mm2
BTN35-M 11.5mm 6m m 35mm2

BTN50-M 11.5mm 6m m 50mm2 BTN240-M 31mm 10, 12,16mm 240mm2

BTN70-M 11.5mm 6m m 70mm2 BTN300-M 31mm 10, 12mm 300mm2

www.jointingtech.co.uk 21

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