Cables
The cable that is used for the transmission and distribution of electrical power is known as the electrical power cable. It is used for the transmission of high voltages in places where overhead lines are impractical to use.
The power cable is made of three main components, namely, conductor, dielectric, and sheath. The conducting path for the current in the cable is provided by the conductor. The insulation or dielectric withstands the service voltage and isolates the live conductor with other objects. The sheath does not allow the moistures to enter and protects the cables from all external influences like chemical or electrochemical attacks and fire.
Advantages of Cables
Reliability
Cables are generally known for their reliability in transmitting data or power. They provide a stable connection that is less prone to interference compared to wireless transmissions.
Security
Wired connections are typically more secure than wireless connections because they are harder to intercept or hack into.
Speed
Cables can provide faster data transfer speeds compared to wireless connections, especially in situations where large amounts of data need to be transferred quickly.
Stability
Cables offer a stable connection with consistent performance, making them suitable for applications where a consistent and uninterrupted connection is crucial.
Cost-effective
Cables are often more cost-effective than wireless solutions, especially for stationary devices where the cost of cable installation can be justified by the reliability and performance benefits.
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![LMR400 Coaxial Cable]()
LMR400 Coaxial CableRead MoreLMR400 coax cable is only one of a large number of radio frequency coaxial cable types specifically stocked to be ready for quick shipment. LMR-400 coax cable is manufactured in a flexible design and
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![LMR600 Coaxial Cable]()
LMR600 Coaxial CableRead MoreLMR600 coax cable is one of a large number of radio frequency coaxial cable types specifically stocked to be ready for fast shipment. Raygnal LMR600 coax cable is offered in a flexible design and has
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Ribbon electric cables
It consists of multiple insulated wires running parallel with one another and is used for transmission of multiple data simultaneously. For example, this is used to connect the cpu with the motherboard and is generally used for the interconnection of networking devices.
Shielded cables
It consists of 1 or 2 insulated wires which are covered by a woven braided shield or aluminium mylar foil for better signal transmission and removing irregularities in the frequency of power and external interference in radio. These cables transmit high voltage electric current and are protected by a shield.
Twisted pair cables
It has two or more insulated copper wires which are twisted with each other and are colour-coded. These types of wires are usually used in telephone cables and the resistance to external interference can be measured by the number of wires.
Coaxial cables
This consists of solid copper or steel conductor plated with copper which is enclosed in the metallic braid and metallic tape. This is entirely covered with an insulated protective outer jacket. These types of cables are used for computer networking and audio-video networking.
Fibre optics cable
There are these types of cables which transport optical data signals from an attached light source to the receiving device. We are pretty much aware of what is optical fibre and its uses in a wide variety of applications.
Residential applications
In residential settings, common power cables include low voltage cables for general wiring, flexible cables for appliances, and armoured cables for outdoor installations.
Commercial applications
Commercial buildings often use medium voltage cables for distribution, flexible cables for office equipment, and insulated cables for lighting and hvac systems.
Industrial applications
Industrial environments require robust cables such as armoured cables for machinery, medium voltage cables for distribution, and submersible cables for wet areas. Industrial power cables must withstand harsh conditions, provide high performance, and ensure the safety and reliability of critical operations.
Components of Cables
Conductor
The conducting part is used to transmit electricity. Extensively used conductors are copper and aluminum.
Insulator
To keep the conductors separated from each other and prevent unintended paths for current flow (e.g. short circuit), the wires are shielded with insulating materials. Various synthetic polymers are used for this purpose.
Sheath
It is yet another layer to give protection to the wires from chemical reactions with the atmosphere. A common material for the sheath is PVC (polyvinyl chloride).
Material of Cables
Aluminum
Conductors made from aluminum are lightweight, affordable, and able be used in a diverse range of applications. Although aluminum is less expensive than copper or metal alloys, aluminum is also less conductive.
Copper
Copper conductors can transfer electricity efficiently and are both inexpensive and versatile. Bare copper is most often used, but copper conductors can also be tinned or silver-coated to improve performance.
Steel
Steel is also a common conductor material choice. However, steel isn't as common as aluminum or copper because steel doesn't conduct electricity as well. Common steel conductor applications are utilizing copper-clad steel for grounding conductors or for when an application needs wiring with exceptional mechanical strength.
High-strength metal alloys
High-strength alloys are common conductor materials made from one or more metallic elements. They are generally stronger combined than when compared to the elements used alone. High-strength alloy conductors are generally silver-plated or nickel-plated.
Common types of conductor coatings
Conductors can be coated with other metals to improve electrical performance and other characteristics.
Silver-plated conductors
Although silver is the most conductive metal, it is very expensive and is rarely used to construct an entire conductor. A much more common design are silver-plated conductors. Silver-plating enhances conductivity and widens the wire's operating temperature range. A silver-plated wire can usually perform from temperatures of -65°c to 200°c, making this coating is a common choice for many aerospace applications.
Nickel-plated conductors
A coating of nickel can be applied to a conductor to increase corrosion resistance and to expand the operating temperature range of a wire or cable. If the nickel is thick, a wire may be able to withstand temperatures of up to 750°c. Nickel-plating also adds a layer of mechanical toughness for cables that must withstand extreme conditions.
Wrap your cables carefully
One of the most common causes of cable damage is over-bending and twisting. When cables are bent or twisted beyond their intended capacity, it can lead to kinks, breaks, and frayed wires, compromising their performance and longevity. To prevent damage, handle cables with care and avoid excessive bending or twisting, especially near the connectors where they are most vulnerable.
To protect the wires inside the cable jacket it's important to wrap cables with care when not in use. Don't wrap them around your hand, arm or wrist as this increases the chance of breaking or damaging the protective jacket or the wires inside. Instead, wrap the cable in a loose loop while holding it in one hand. This can help to extend the lifespan of the cable.
Don't get them tangled
As tempting as it is to just shove your cables into the nearest bag when you're finished with them, try to keep them organised and stored neatly. Braided cables can help to reduce tangling, but it's always a good idea to keep them neat and tidy. Nobody wants to spend ages untangling cables!
Clutter and tangled cables not only look unsightly but can also increase the risk of damage and wear. To keep your cables in good condition, invest in cable organizers, clips, or ties to keep them neat and organized. Avoid tightly coiling or knotting cables, as this can cause strain on the wires and weaken the insulation over time.
Don't stress them
Even when in use, cables can get damaged. They are most likely to start showing issues at either end, as the connecting points are subjected to the most stress. Yanking cables or bending the connectors can cause damage over time, so try not to leave them kinked or pressed up against something when in use.
Pulling on cables or exerting excessive tension can weaken the connections and cause damage to the cable itself. When unplugging devices, grasp the connector rather than pulling on the cable itself. Similarly, avoid placing heavy objects on top of cables or running them through tight spaces where they may be subjected to constant tension or pressure.
When not in use, store cables in a cool, dry place away from dust, dirt, and potential hazards. Consider investing in cable organizers or storage solutions to keep cables neatly coiled and protected from damage.
Process of Cables
Stranding
After the conductors are manufactured, they undergo stranding, where multiple conductors are twisted together according to the cable's design requirements. Stranding provides flexibility, durability, and reduces electromagnetic interference. The stranding process can vary depending on the cable type, with different stranding patterns and lay lengths employed to meet specific performance characteristics.
Insulation
Once the conductors are stranded, they proceed to the insulation stage. Insulation involves the application of a protective layer over the conductor surface to prevent electrical leakage and external interference. Various insulation materials are used, including polyethylene (PE), polyvinyl chloride (PVC), or cross-linked polyethylene (XLPE). The insulation thickness is carefully controlled to meet safety and performance standards.
Shielding and armor
Certain cables require shielding or armor layers for additional protection against external factors. Shielding materials, such as aluminum or copper tapes or braids, are applied to mitigate electromagnetic interference. Armor, such as steel wire or aluminum-plastic tapes, provides mechanical strength and protects against physical damage. These layers are carefully applied using specialized machinery and techniques.
Jacketing
Following insulation and shielding, cables may undergo jacketing, which involves applying an outer protective layer. The jacketing material is selected based on the cable's intended application, considering factors such as UV resistance, flame retardancy, and environmental durability. PVC, PE, or thermoplastic elastomers (TPE) are commonly used for jacketing. The outer jacket provides mechanical strength, moisture resistance, and environmental protection.
Testing and quality assurance
Throughout the production process, cables undergo rigorous testing and quality assurance procedures. This ensures that they meet industry standards and customer requirements. Various tests, including continuity, insulation resistance, mechanical performance, and electrical characteristics, are conducted. Advanced testing equipment, such as high-voltage testers and impedance analyzers, are employed to evaluate the cables' performance and reliability.
Packaging and delivery
Once the cables pass all quality tests, they are carefully packaged to ensure safe transportation and storage. Proper labeling and documentation are provided for easy identification and traceability. Cables are then delivered to customers or distributors, ready for installation in various applications such as power transmission, telecommunications, or construction projects.
5 Key Factors In Choosing The Right Cable Size
Installation method
This is the first thing we look at because how and where the cable will be installed directly affects whether a cable could be overloaded (e.g. in conduit, on cable tray, in free air, grouping, spacing, trefoil, laid flat). Generally, the more enclosed the cables are (e.g. in conduit versus. in free air), the more you may need to use a larger cable size to ensure it can withstand the current and allow proper heat dissipation.
Cable material
Cable insulation material (the extruded layer after the conductor) is important in cable sizing because it directly affects your cable’s maximum operating temperature. For your reference, we have placed common insulation materials: PVC, XLPE, and EPR in the guide.
In standard cable materials, PVC has a maximum operating temperature of 70˚C, XLPE 90 ˚C and EPR 90 ˚C. You may wonder why, for instance, we would choose PVC vs XLPE, given the lower maximum operating temperature for PVC. This relates to other material properties that work better in your installation environment. For instance, PVC is much more flexible than XLPE and may be a better choice where you would require the cable to bend in tighter spaces.
You may also choose between single-core or multi-core cables depending on the installation requirement, which would also affect the current carrying capacity of the cable. A single-core cable would be able to dissipate heat better than a multi-core cable and hence would have a higher current carrying capacity. However, you may still choose the multi-core cable as installing the required conductors at go could be easier.
Cable length
We require cable length to assess Voltage Drop, which is the loss of electrical potential along your cable run.
In Singapore, we follow the SS638 (formerly known as CP5) wiring regulations, where the voltage drop of a cable run must not exceed 4%. For instance, if a supply voltage is 415V, then the maximum permissible voltage drop cannot exceed 4% of 415V = 16.6V
The cable size and length of a cable line mainly determine the voltage drop of a circuit. The smaller the cable size or, the longer the cable length required for your circuit, the greater the voltage loss. If you find that the voltage drop of the circuit has exceeded the 4% stated, you would need to upsize your cable.
Ambient temperature
Our tables assume a standard ambient temperature of 30˚C in free air or a ground temperature of 15˚C with a depth of 0.5m. Do note that cable routing and ventilation will directly affect your ambient temperature, so it is important to consider the installation condition along the entire length of the cable laid. If there is a deviation from the standard temperature, you must apply a correction factor to the current load your cable is expected to carry. The higher your ambient temperature from the standard, the larger your cable size may be needed to carry the required load.
Number of circuits
Our tables assume that you are laying one circuit single-phase or three-phase. If you intend to group circuits in your installation, it is crucial to apply a cable grouping correction factor so that you select the appropriate cable size that would prevent overheating issues. The more circuits you intend to group, the harder the heat dissipation; hence you may need to upsize the cables accordingly.
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