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Insulation

P.V.C. Insulation

P.V.C. as per IEC 60502 & B.S. 6746 is clean , easy to handle material with good electrical characteristics and resistance to water, oil, and chemicals together with inherent toughness and flexibility over a wide temperature range. P.V.C. cables are easy to handle joints, terminates and have an outstanding record of trouble free service.
P.V.C. is inherently flame retardant and is suitable for max. operating temp of 70 °C. All of the cables in this publication meet the requirement of IEC-332

Fillers
Non-hygrosopic polyproplyne filler are included between laid up cores as standard.

Binding Tape
A separate tape of polyproplene tape is applied over the laid up cores where necessary.

Over Sheath
The standard sheath of all cables is an extruded layer of black P.V.C. , the extruded surface of which is embossed with voltage rating and cable size.
The nominal thickness of the non-metallic sheath shall be calculated by the following formula:

Thickness = 0.035 D + 1 mm

(D = the fictitious diameter immediately under the sheath)

For unarmoured cables, the normal sheath thickness shall not be less than 1.4 mm for single core cable and 1.8 mm for multicore cable (that for voltage rate 600 – 1000 volt)

Core Identification
Core identification is by colour as follows (unless otherwise agreed).

Number of Cores	1	2	3	3 ½	4
Core Colours	Black or Red	Red, Black	Red, Yellow, Blue	Red, Yellow, Blue, & Black	Red, Yellow, Blue, Black

Black identifies the neutral conductor and the other colours identify the phase conductor in two, three, three & half and four core cables.

MAXIMUM D.C. RESISTANCE OF COPPER CONDUCTORS AT 20°C FOR PERMANENT INSTALLATION CABLES ACCORDING TO IEC 228

	Group 1
	Circular Copper Conductors
Nominal Cross Section	Minimum No. of wires in conductor	Single-core cables		Multi-core cables
		Plain wires	Metal –coated wires	Plain wires	Metal –coated wires
Mm 2		W /km	W /km	W /km	W /km
1	1	17.7	17.9	18.1	18.2
1.5	1	11.9	12.0	12.1	12.2
2.5	1	7.14	7.21	7.28	7.35
4	1	4.47	4.51	4.56	4.60
6	1	2.97	3.00	3.03	3.06
10	1	1.77	1.79	1.81	1.83
16	1	1.12	1.13	1.14	1.15
25	1	0.708	0.715	0.722	0.729
35	1	0.519	0.524	0.529	0.535
50	7	0.358	0.361	0.365	0.368
70
95
120	19	0.148	0.149	0.151	0.152
150	19	0.117	0.119	0.120	0.121

	Group 2
	Circular or Sector Shaped Conductors
Nominal Cross Section	Minimum No. of wires in conductor		Single-core cables		Multi-core cables
	For circular copper conductor	For compact circular or sector-shaped conductors	Plain wires	Metal –coated wires	Plain wires	Metal –coated wires
Mm 2			W /km	W /km	W /km	W /km
1	7	-	20.8	21.2	21.2	21.6
1.5	7	-	13.3	13.6	13.6	13.8
2.5	7	-	7.27	7.41	7.41	7.56
4	7	-	4.52	4.60	4.61	4.70
6	7	-	3.02	3.05	3.08	3.11
10	7	6	1.79	1.81	1.83	1.84
16	7	6	1.13	1.14	1.15	1.16
25	7	6	0.712	0.719	0.727	0.734
35	7	6	0.514	0.519	0.524	0.529
50	19	15	0.379	0.383	0.387	0.391
70	19	15	0.262	0.265	0.268	0.270
95	19	15	0.189	0.191	0.193	0.195
120	37	30	0.150	0.151	0.153	0.154
150	37	30	0.122	0.123	0.124	0.126

	Group 3
	Circular Copper Conductors
Nominal Cross Section	Minimum No. of wires in conductor	Single-core cables		Multi-core cables
		Plain wires	Metal –coated wires	Plain wires	Metal –coated wires
Mm 2		W /km	W /km	W /km	W /km
1
1.5
2.5
4
6
10	12	1.76	1.78	1.79	1.81
16	19	1.11	1.12	1.13	1.14
25	19	0.660	0.666	0.673	0.679
35	19	0.514	0.519	0.524	0.529
50	27	0.361	0.365	0.369	0.372
70	37	0.264	0.266	0.269	0.272
95	37	0.195	0.197	0.199	0.201
120	61	0.146	0.148	0.149	0.151
150	61	0.118	0.119	0.121	0.122

MAXIMUM D.C. RESISTANCE OF COPPER CONDUCTORS AT 20°C FOR FLEXIBLE CABLES ACCORDING TO IEC 228

	Group 4
Nominal Cross Section	Maximum diameter of wires in conductor	Single-core cables		Multi-core cables
		Plain wires	Metal –coated wires	Plain wires	Metal –coated wires
Mm 2	Mm	W /km	W /km	W /km	W /km
0.5	0.31	37.7	38.8	39.6	40.7
0.75	0.31	24.0	24.7	25.2	25.9
1	0.31	18.8	19.4	19.8	20.4
1.5	0.41	12.1	12.4	12.7	13.0
2.5	0.41	7.28	7.42	7.64	7.79
4	0.51	4.66	4.75	4.89	4.99
6	0.51	3.10	3.17	3.26	3.32
10	0.51	1.90	1.94	2.00	2.04
16	0.61	1.16	1.18	1.21	1.24
25	0.61	0.770	0.785	0.809	0.824
35	0.68	0.524	0.535	0.550	0.561
50	0.68	0.357	0.364	0.375	0.382
70	0.68	0.268	0.273	0.281	0.286

	Group 5
Nominal Cross Section	Maximum diameter of wires in conductor	Single-core cables		Multi-core cables
		Plain wires	Metal –coated wires	Plain wires	Metal –coated wires
Mm 2	mm	W /km	W /km	W /km	W /km
0.5	0.21	37.1	38.2	39.0	40.1
0.75	0.21	24.7	25.4	26.0	26.7
1	0.21	18.5	19.1	19.5	20.0
1.5	0.26	12.7	13.0	13.3	13.7
2.5	0.26	7.60	7.82	7.98	8.21
4	0.31	4.71	4.85	4.95	5.09
6	0.31	3.14	3.23	3.30	3.39
10	0.41	1.82	1.85	1.91	1.95
16	0.41	1.16	1.18	1.21	1.24
25	0.41	0.743	0.757	0.780	0.795
35	0.41	0.527	0.538	0.554	0.565
50	0.41	0.368	0.375	0.386	0.393
70	0.51	0.259	0.264	0.272	0.277

	Group 6
Nominal Cross Section	Maximum diameter of wires in conductor	Single-core cables		Multi-core cables
		Plain wires	Metal –coated wires	Plain wires	Metal –coated wires
Mm 2	mm	W /km	W /km	W /km	W /km
0.5	0.16	37.7	38.8	39.6	40.7
0.75	0.16	25.1	25.8	26.4	27.1
1	0.16	18.8	19.4	19.8	20.4
1.5	0.16	12.4	12.8	13.0	13.4
2.5	0.16	7.54	7.76	7.91	8.14
4	0.16	4.63	4.76	4.86	5.00
6	0.21	3.14	3.23	3.30	3.39
10	0.21	1.83	1.88	1.92	1.98
16	0.21	1.16	1.19	1.21	1.25
25	0.21	0.758	0.780	0.796	0.819
35	0.21	0.536	0.552	0.563	0.579
50	0.31	0.376	0.387	0.395	0.406
70	0.31	0.264	0.272	0.277	0.285

MAXIMUM D.C. RESISTANCE OF ALUMINUM CONDUCTORS AT 20°C FOR PERMANENT INSTALLATION CABLES ACCORDING TO IEC 228

	Group 1			Group 2				Group 3
	Circular Conductors			Circular or Sector Shaped Conductors				Circular Conductors
Nominal Cross Section	Minimum No. of wires in conductor	Single-core cables	Multi-core cables	Minimum No. of wires in conductor		Single-core cables	Multi-core cables	Minimum No. of wires in conductor	Single-core cables	Multi-core cables
				For circular aluminum conductors	For compact circular or sector-shaped conductors
Mm 2		W /km	W /km			W /km	W /km		W /km	W /km
1	1	29.3	29.9	7	-	34.8	35.4
1.5	1	19.7	20.0	7	-	22.2	22.7
2.5	1	11.8	12.0	7	-	12.1	12.4
4	1	7.39	7.54	7	-	7.55	7.701
6	1	4.91	5.01	7	-	4.99	5.09
10	1	2.94	3.00	7	1	2.96	3.02	12	2.91	2.97
16	1	1.85	1.89	7	1	1.87	1.91	19	1.84	1.88
25	1	1.17	1.20	7	1	1.18	1.20	19	1.09	1.11
35	1	0.859	0.876	7	6	0.851	0.868	19	0.850	0.867
50	7	0.592	0.604	19	6	0.628	0.641	27	0.598	0.610
70				19	15	0.435	0.443	37	0.437	0.445
95				19	15	0.313	0.320	37	0.323	0.329
120	19	0.245	0.250	37	15	0.248	0.253	61	0.242	0.247
150	19	0.194	0.198	37	15	0.202	0.206	61	0.196	0.200

PROPERTIES OF INSULATING MATERIALS

		P.V.C.	PVC – Hard Grade	PET	RUBBER	BUTYL	NEOPRENE	EPR	XLPE	PAPER INSULAT.
USE		L.T.I. – M.T.I. - SH	M.T.I	L.T.I. – M.T.I. - SH	L.T.I. – SH	L.T.I. – M.T.I.	SH.	L.T.I. – M.T.I.	L.T.I. – M.T.I. - H.T.I	L.T.I. – M.T.I. – H.T.I
SPECIFIIC GRAVITY gr/cm 3		1.35	1.35	0.92	1.2- 1.7	1.3-1.5	1.25- 1.6	1.24	0.92	1.23 –1.47
DIELECTRIC CONSTANT		4 – 6	3.6 – 4.5	2.3	6	3.5-6.5	-	2.8-3.4	2.5	3.6
BREAKDOWN VOLTAGE kv/mm		20	30	40	25	25	20	30	40	100
LOSS FACTOR at 20ºC and 50 HZ		0.1	0.1	0.001	0.1	0.03	0.03-0.15	0.02	0.004	0.005
BREAKING LOAD BARS		100-150	100 – 150	100	50	50	120-200	42-70	125	-
ELONGATION AT BREAK		150%	125%	350%	300%	300%	300%	200%	200%	-
THERMAL RESISTIVITY ºC . cm ــــــ W		700	700	400	550	550	550	600	400	600
Resistance to Outer Factors	Humidity	good	good	very good	good	very good	good	good	very good	-
	Inorganic acids of low density	good	good	good	bad	good	good	good	very good	-
	Inorganic bases of low density	excellent	excellent	good	good	good	good	good	very good	-
	Aromatic Hydrocarbons	fair	fair	good	very bad	very bad	bad	very bad	good	-
	Alyphatic Hydrocarbons	Good (in cold)	Good (in cold)	Good (in cold)	very bad	very bad	very bad	very bad	good	-
	Fire	does not transmit flame	does not transmit flame	burns	burns	burns	does not transmit flame	burns	burns	burns
POSSIBILITIES OF COLOURING		very good	very good	very good	very good	bad	good	bad	bad	poor
MAXIMUM CONTINUOUS OPERATING TEMPERATURE		70 ºC	80 ºC	70 ºC	60 ºC	85 ºC	-	90 ºC	90 ºC	80 ºC
MAXIMUM TEMPERATURE OF SHORT-CIRCUIT CONDITIONS		150 ºC	150 ºC	150 ºC	200 ºC	200 ºC	-	250 ºC	250 ºC	180 ºC
SPECIFIC RESISTIVITY OF THE INSULATION AT 20ºC W x cm		10 13	10 14	10 16	10 12	10 15	10 15	10 15	10 16	10 14

H.T.I.	= High tension insulations	L.T.I.	= Low tension insulations
M.T.I	.= Medium tension insulations	SH	= Sheathings

PLASTIC INSULATED POWER AND CONTROL CABLES ACCORDING TO GERMAN STANDARDS

Types of cables	Rated voltage KV	Voltage test KV	Specifications	Application
NYY / NAYY	0.6/1	4	VDE 0271/3.69	Indoor in ducts and in the open for power stations, industrial plants and switching stations, if mechanical damage is not to be expected.
NYFGbY NAYFGbY	0.6/1	4	VDE 0271/3.69	Underground, indoor, in ducts and in the open, where better mechanical protection is required, or for higher tensile stresses during installation and operation.
NYCY NAYCY	0.6/1	4	VDE 0271/3.69	Indoor, in ducts, in the open, underground, if mechanical damage is not expected.
NYFGbY NAYFGbY	3.5/6	11	VDE 0271/3.69	Indoor, in ducts, in the open and underground for power stations, industrial plants and switching stations.
NYSY NAYSY	3.5/6	11	VDE 0271/3.69	For indoor installations, in power and switching stations. As underground cable, for difficult installation, where the low weight is particularly advantageous.
NYHSY NAYHSY	5.8/10	17	VDE 0271/3.69
NYHFGbY NAYHFGbY	5.8/10	17	VDE 0271/3.69	For urban networks, for difficult installations and operating conditions.
NYSEY NAYSEY	5.8/10	17	VDE 0271/3.69	Indoor, in ducts, in the open and underground for power stations, industrial plants and switching stations.
YHSY AYHSY	11.6/20	31.5	CEI - VDE

N	= Conductor of copper	SE	= In the case of multi-core cables, conductive layers over the conductor and the insulation for limiting the electric field and a copper shield around each individual core
NA	= Conductor of aluminum
Y	= PVC insulation, overall sheath of PVC or bedding between shield or concentric conductor and armouring	R	= Armouring of galvanized round steel wires
H	= Conductive layers over the conductor and over the insulation for limiting the electric field	B	= Armouring of steel tapes
C	= Concentric conductor of copper	F	= Armouring of galvanized flat steel wires
S	= Shield of copper	Gb	= Helix of galvanized steel tape in any direction of lay