CABLES AND WIRES

Cable Standards and Certificates

noreply@blogger.com (INDER KUMAR TIWARI) — Mon, 03 Mar 2025 11:36:00 +0000

Standards in the cables

Cable standards are most important criteria which decide thickness of insulation, armouring and test passed by the cables almost every country have its own standard for wire and cable.

Some of important standards are:-
IS:-Indian Standards published by Bureau of India Standard(BIS)
An "ISI certification" for industrial cables refers to a mark indicating that the cable complies with Indian standards set by the Bureau of Indian Standards (BIS), signifying its quality and safety for use within India.

ISI Mark for PVC insulated cables
Manufacturers need to comply with the requirements of IS 694:2010 to be eligible for the ISI Mark on their PVC insulated cables.

BS:-British standards
One of popular BS Standard is "BS 7846" is a British Standard that defines the requirements for specific types of electrical cables designed for use in situations where fire resistance is critical.

EN:-European standards
One of popular EN Standard is "EN 50618" is a European standard that used for ensuring the quality and safety of cables used in solar energy applications.

IEC:-International Electrotechnical Commission
One of popular IEC Standard is "IEC 60502" in RS-485 cables tell us regarding cable construction, such as shielding and jacketing materials where electromagnetic interference (EMI) is a concern.

UL:-USA standards
Underwriters Laboratories (UL) was originally created for the United States. UL interestingly is one of the most popular around the world, as they have locations in 46 different countries.

Similarly other countries also have there Standards such as
VDE:-Verband De Elektrotechnik (German standards)
NF:-France standards
JIS:-Japanese standards

Apart from this every industries and needs specific approvals and certificates that vary based on an application's geographical location.
example:-
On the base of location
"CE certificates" in cables
The CE marking is a symbol that indicates a product complies with the European Union's (EU) health, safety, and environmental protection standards.
on the base of industries
"TIA/EIA-568:"
This is a telecommunications cabling standard developed by the Telecommunications Industry Association (TIA). It establishes guidelines for structured cabling systems in commercial buildings.
TIA/EIA-568-B.2-1:(printed on cat-6)
In essence, it relates to Category 6 (CAT6) cabling specifications. CAT6 provides enhanced performance compared to earlier categories like CAT5e, with stricter specifications for crosstalk and system noise.

ISO certifications(manufacturing of Industrial cables)

# ISO stands for the International Organization for Standardization. This is a non-governmental organization that develops and publishes international standards.
# ISO certifications are extremely valuable and often essential, especially in manufacturing of Industrial cables.
# The purpose of ISO certification is to help organizations(Company) meet international standards for quality, safety, and efficiency.

ISO 9001:2015
INDICATES QUALITY MANAGEMENT SYSTEMS

ISO 14001: 2015
INDICATES ENVIRONMENTAL SYSTEM MANAGEMENT

ISO 45001:2018
INDICATES SAFETY MANAGEMENT SYSTEM

ISO 8000:2014
INDICATES SOCIAL ACCOUNTABILITY

ISO 26000:2010
INDICATES GUIDELINES ON SOCIAL RESPONSE.

Various Tests on the Cables
Flammability test.
Flex test.
Wrapping Test (for AI Wires).
Heat Shock Test.
Insulation Resistance Test.
HV Test (at Room Temperature).
Conductor Resistance.
Oxygen Index Test.
Smoke Density Rating.
Hot Deformation.
Spark Test.
Shrinkage Test.
Annealing Test (for Copper Wires)
Tensile Test (for AI Wires).

Measurements of diameter of a wire and cable

For measurements of diameter of a wire and cable we most commonly used Micrometer(or screw gauge) and calipers

Caliper
Caliper is used to measure the overall diameters of the cable.

Micrometer( or screw gauge)
Micrometer( or screw gauge) is used for measuring the diameter of thin wires (or strand of wire).

Bond

noreply@blogger.com (INDER KUMAR TIWARI) — Sun, 04 Jul 2021 09:42:00 +0000

Bond

A bond is simply a loan taken by a company from the public.
We can say that bonds are debt securities issued by corporations, governments, or other organizations and sold to investors.

Face value:-Face value is equal to bond's price when its first issued.
or we can say that actual value of bond.

Coupon rate:-Rate of interest paid by bond issuers on the bond's face value.
In simple language we can say it rate of interest on face value.

Note:-Purchase price of a bond on secondary market can be go up or down depend on market current interest rate, financial situation of company, Credit rating etc. But actual value of bond is its face value.

redemption date:- The bond issuer will repay the original sum loaned at the bond's maturity date this data is known as redemption date.

Type of risk in bond:-
It has low liquidity, therefore it is not easy to sell before its maturity date.
Credit Risk(Defailt risk):-if we do not get our face value.
Interest rate risk:-if interest rate goes up in future in that case also we get less interset.

Types of bond
Very safe
Government bond(GS)
e.g:-832GS2032[ 8.32%(interest in a year)------Government Security-----2032(Bond muturity year) ]
e.g:-915GS2024 [ 9.15%(interest in a year)------Government Security-----2024(Bond muturity year) ]
State Development Loans(SDL)

safe
public sector undertaking company such as NHAI(National Highways Authority of India)
Corporate Bonds(By major company e.g:-Tata)

Note:-bonds also store in demat account.

some website are avilable for bond study such as
1-thefixedincome.com
2-goldenpi.com

Sovereign Gold Bond(SGB)

SGB are government securities denominated in gram of gold. These bond are issued by Reserve Bank on behalf of Goverment of india.
when we are buying an Sovereign Gold Bond(SGB) we should remember that every Sovereign Gold bond have an face value, interest rate and interest date, maturity date(redemption date).

Face value:-value at the time of first buying and interest always pay on face value therefore more the face value greater is the interest.
NOTE:- In case of Sovereign Gold Bond(SGB) the maturity value depends on current value of gold and interest rate is 2.5% normally.

some website are avilable for Sovereign Gold bond study such as
1-moneyseth.com

Stock Market

noreply@blogger.com (INDER KUMAR TIWARI) — Tue, 13 Apr 2021 14:50:00 +0000

Stock Market

Stock Market(or Stock Exchange) is a market where a deal is made between buyers and sellers of the shares. In India NSE(National Stock Exchange) and BSE(Bombay Stock Exchange) are two main stock exchanges, Nifty and Sensex are there index
Index in stock Exchange
BSE(Bombay Stock Exchange)-->Sensex(here are more company)
But Sensex mainly take data of 30 companys.
NSE(National Stock Exchange)-->Nifty(here are less company)
Similarly Nifty mainly take data of 50 companys.
NOTE:-These company are not fiexed these are change such as in 2016 PNB Bank and Vedanta in nifty, but due to there poor performance they are repalce by Aurobindo pharma and Eicher Motors.

Type of profit in Stock Exchange

In stock markets you get profit by 2 ways
1-Dividend
When a company shares some of its profit with the shareholders, its called dividend. But its is not compulsory for the company to provide dividend to its shareholders, Company provide divident or not it is completely depends on its Bord of directors of the company. Usually small companies do not provide dividends.
2-Capital Appreciation
Capital appreciation means when the value of the share rises, investment value also rises.Let we purchase a share in 1000 rupess and after 2 year its price will be 1600. then 600 hike is called capital appreciation.
NOTE:-If company grow then its share price also increase this is main source of income in share market.

Type of selling and buying in Stock Exchange

In Stock market there are mainly two type of selling and buying. 1-Trading when we holding the shares for a Short term it is known as trading. For trading we need techanical analysis of a share.

Intraday trading:-We have to sell the intraday shares same day and if we do not do it then broker do this.
Scalp trading:-holding the shares for a second or a munite
Swing trading:-holding the shares few days to a weeks
Position trading:-holding the shares for few a months

2-Investing
holding the shares atlest a year. For Investing we need Fundamental analysis of a share. In investing we always take deliver of share
NOTE:-In India share settlement done according to T+2 Cycle, that means when we buy a share that is Transaction day and after that day it will take 2 days to reflect in our Demat account. if we taken it delivery.

What we need to start investing in share market?

First we need a demat account(open by CDSL and NSDL) and a trading account(open by Brokers such as Zerodha, Upstox,etc). In Demat accout we put our deliver share By the the help of trading account we can buy and sell.In Stock market timing:-9:15Am to 3:30Pm(open for normal work) and 9:00Am to 9:15Am(only open for After Market Order).

How can we Analysis share?

For Analysis of a share we must know
First of all we have to understand company busness model
for example:-Domino's in delivery business, But some people think that it is in Pizza businees.
Second we have to understand some technical term such as
vol-->volume-->It means number of shear trade within a day that is known as it volume.
Bid price--> price offer by buyer.
offer price--> price offer by seller.
VWAP(volume weighted average price)-->Average price of share at present day.
L/U price band-->lower and upper control limit Price band-->It is used to control the sudden change in price, if share goes up and down then this then trading of that share will stop for that day.

Balance sheet of a company

Balance sheet of a company[(profit and loss statement) or (cashflow statement)] are know as financial statement of the company.
It is basically 2 type:-
1-Consolidated financial statement
In Consolidated financial statement we have financial statement of parent company and its child company(subsidiaries company, Associate companies, joint ventures). By the help of Consolidated financial statement we know about financial condition of parent company as well as its child company.
2-Standalone financial statement As name suggest Standalone means only that companies(parent company).
Note:-In most of financial app we get only Standalone financial statement. But on Money control website we get both Consolidated financial statement and Standalone financial statement

Technical term we get from Balance sheet of a company

Mkt. Cap
Market capitalization tell us about total value of the company.
Book value
Book value is Actual value of share. Book value of a share effectively indicates a company net asset value(total assets-total liabilities)
NOTE:-But by book value we can not calculate intangible assets such as brand value, goodwill, intellectual property etc. Therefore by the help of book value we are not able to calculate IT company.
P/B ratio
P/B ratio tell us that compare to book value how much value invester are paying.
P/B ratio=(market price per share)/(book value per share)
P/B ratio also help us to tell that stock us under price or over price.
NOTE:-It also do not work on intangible assets therefore by P/B ratio work only on manufacturing companies, automobile, asset-heavy companies.
EPS(Earning per shares)
total profit of company=10,000
Number of shares=2,000
EPS=10,000/2,000
EPS=5
so company is getting 5 rupees from a shares
More that value of EPS better for shares holder as its shares value is more.
As EPS is given by company of every Quarter(4 months) and TTM( Tralling twelve Months that means EPS of 12 months).
NOTE:-But EPS value is compare in same sector of company. second thing EPS do not consider debt of company.
price to earning ratio(P/E)
price to earning ratio=(price of 1 share in the stock market)/EPS(Earning per shares)
price to earning ratio=100/5=20
from this price to earning ratio we know that for 1 ruppes earning of company invester is paying 20 rupees.
some point to remember
Normally if P/E is low then it is good for us But if company is growing very fast then its Earning per shares(EPS) also increase very fast therefore mostly such company have very high P/E ratio. So if EPS is growing very fast then do not think to much about P/E ratio there P/E ratio may be 60 to 70 also because of there growth record.
price to earning ratio do not work very correctly on Real Estate company Let's suppose if in a year 2000 Real Estate company sell 100 flat then its P/E ratio go very down. But in next year 2001 company sell only 1 flat its P/E ratio increase slightly. Therefore in such company(Real Estate company,Mines and Mineral company) we see P/B ratio.
If company take large amount of debt in that case also P/E ratio goes down as EPS increase.
Normally According to Financial advisors
if price to earning ratio is between 13 to 20 that is consider as good
if price to earning ratio is more than 20 then then there will be 2 reason
1-company share is over price
2-invester thinking that company future is very good.
Normally, if price to earning ratio is less than 13
1-company share is under price
2-invester thinking that company future is not good.
Note:- Some sector have low price to earning ratio for example diamond and fertilizer industry. But some sector have high price to earning ratio for example IT and Pharmaceutical industry. Therefore by using price to earning ratio we can compare 2 company of same sector.
Industry p/E
Industry P/E means Average sum of P/E ratio of full industry that sector such full IT and Pharmaceutical industry
Beta
Beta is used to know that how much share follow the market.
If beta
1=exactly behave just like market
0.5 to 1=follow market trand but low volatile share
More than 1 that means more volatile
Negative:-just opposite to behavior of market
Face value
First time when a company issue the share to promoter against there equity capital(amount) that is known as face value. Face value of share does not change with time it is fixed untill share do not split.
Dividend
Dividend is always given on face value of share. Whenever a company decide to give dividend. They also decide Record date(The date at which you must have company share for getting divident)
Deliverables.
Deliverables means how many share are purchase for delivery.
Deliverables=(Delivery shares/total volume)X100

Enterprise value

Enterprise value=(market capitalization+debt)-(cash)

Negative of Enterprise value means company have more cash as compare to company value

ROE

If company buy 10 product at the price of 10 ruppess and sell in 20 ruppess then there

1-margin=50%

2-Return on equity(ROE)=(Total income/total investment)x100

ROE=(100/100)*100

ROE=100%

Factor affecting share price

Quarter results of company:-it is one of most important factor, if quater result of company is not good in that case generally the share price of the company is go down.
Inside trading:-inside trading means, trading by the person who is working in that company. As they get news of company decision more early then anyone else.
Government policy:-goverment policy also affect the share price of the company.
promoter holding:-If promoter holding is decreasing in a company generally it will be a bad news for the comapany.
Developing and adapting new technology:-If company is not adapting new technology it may be hazardous for the company. We have many examle who do not adapting new technology such as Nokia mobile, kodak camera.
Other factor:-Future prospects of the company, Top management of a company.

HSN Code

noreply@blogger.com (INDER KUMAR TIWARI) — Thu, 01 Apr 2021 08:43:00 +0000

HSN Code

HSN stands for ‘Harmonized System Nomenclature.’HSN is a list of commodity. By the help of HSN Code we are able to identify an commodity internationally. As we know that name of a commodity is change from one country to another country. Therefore we use HSN as this is fixed for every item, it does not change.
HSN Code is developed by The WCO (World Customs Organization).It contains 21 sections, with 99 chapters, about 1,244 headings and 5,244 subheadings.

HSN Code Chapter 85

Electrical Machinery and Equipment and its Parts, Television and Sound Recorders and Reproducers and its Parts, and Accessories of Such Articles.

HSN Code Heading

01-->Electric motors and generators. Full code:-8501

HSN Code Heading

44-->Insulated wire, cable, and other insulated electric conductors, etc.
Full code:-8544(In most of cable this is sufficient)

HSN Code sub-heading

60-->other Electric Conductors, For a voltae exceeding 1000V
Full code:-854460

HSN Code Tarrif item

Rubber insulated->30
Full code:-85446030

HSN Code Tarrif item

other electric conductor that are paper, plastic and rubber insulated->90
Full code:-85446090

Discount Calculator

noreply@blogger.com (INDER KUMAR TIWARI) — Mon, 01 Mar 2021 02:58:00 +0000

Discount Calculator

Amount

Discount

CAMERA

noreply@blogger.com (INDER KUMAR TIWARI) — Wed, 04 Nov 2020 01:24:00 +0000

Camera

Camera have 2 main function

1-detection-->The range upto which we can detect the object that it is animal, human, car etc.
2-Identification-->The range upto which we can Identify the object that it is which type animal or name of human or car number etc. The identification range is always less than detection range for example if identification range is 6 meter then detection range may be upto 50 meter

Camera specification

Lens mount
Viewing angle->Viewing angle may be 50 degree,180 degree,360 degree
Effective pixels
IR LEDs-e.g-30 IR LEDs
Frame rates-e.g 1 Mega pixels 30 frames per second(fps)
Image output:-1280*720p

video Compression

H.264 video encoding:-if we use this encoding with 2 Mega pixels camera which is working 24 hours the amount of data around 32GB(approximately) will be generated H.265 video encoding:-if we use this encoding with 2 Mega pixels camera which is working 24 hours the amount of data around 24GB(approximately) will be generated

Image sensor(CCD and CMOS)

CCD and CMOS sensor are made of photosites that is commanly known as Pixels.In both sensor the process are: Light is convert into Charge->In this way charge is Accumulated->This charge is transfer and convert into voltage and then we amplify that voltage CCD(Charge Coupled Device)

Typical Voltage:7V to 10 V(More power consumption)
processing speed:-less
Noise:-less
Dynamic range:-high
when we required high dynamic range and low noise then we use CCD e.g:-space application

CMOS(Complementary Metal Oxide Semiconductor)

Typical Voltage:3.3V to 5 V(less power consumption)
processing speed:-high
Noise:-high
Dynamic range:-low
when we need fast processing speed and low power consumption then we use CMOS sensor e.g:-mobile phone

CCTV(Closed Circuit Television)

Different type of camera
1-analog camera
2-IP camera

Dome shaped camera->These type of camera are mostly install indoor
Bullet camera->These type of camera are mostly install outdoor.They are water and dust resistance
Varifocal camera->A varifocal lens camera is a camera with variable focal length.In a varifocal camera you can adjust focal length of camera or do zoom
PTZ(Pan-tilt-Zoom) camera->A PTZ Camera is a camera with mechanical parts,which allow the camera and lens to move

pan->panning means moving in parallel (or horizontally)
tile->rotates up and down in vertical plane
Zoom->zoom means moves so that something seem much closer or further away

Analog CCTV

camera->DVR->LCD | DC Power supply of 12 volt In Analog CCTV we use BNC connector BNC connector full form:-Bayonet(indicate its shape) Neill(Electrical enginerr Paul Neill) concelman(Electrical enginerr Carl Concelman)

DVR(Digital Video Recoder)

DVR is a analog system
In case of DVR for video we use Co-Axial cable and connector BNC connector.But we can also use CAT6 cable with Video Balun.
In case of DVR for video we use Co-Axial cable and connector BNC connector.But we can also use CAT6 cable with Video Balun.
full form of Balun(BALance to UNbalanced) is a electrical device that converts a balance signal into an unbalanced signal. Video balun also known as UTP baluns.In video balun balance signal(on Balun+ and Balun-) and an unbalanced signal(BNC connector).

Specification of DVR

Channel->It may be 4 channel or 8 channel or 32 channel. Number of channel = maximun number of camera we can connect
Quality of image can be capture->It may be 720p or it may be 1080p or it may be 1080p HDCVI(High Definition Composite Video Interface)
support memory->it may be upto 4TB or 6TB
port->HDMI OR VGI
USB Ports->Port for mouse or Port for external backup hard drive.It may be USB 2.0 or USB 3.0(high speed data transfer)
Warranty period

Two types of co-axial cable are used in case of DVR (1) 3+1 CCTV Cable – A 3+1 CCTV cable have 1 Video Cable and 3 other cables which is used for power, and audio. (2) 4+1 CCTV Cable –In 4+1 CCTV Cable there is 1 Video Cable and 4 other cable which can be used in power, audio and fourth one can be used for controlling PTZ cameras.

IP CCTV

camera->POE Switch->NVR->LCD POE(Power Over Ethernet) Switch POE(Power Over Ethernet) Switch is a network switch that has power over Ethernet.If we have POE switch and POE camera in that case we does not need to give power separately to our camera.The power from switch to camera goes through POE switch and it also work as switch.

NVR(Network Video Recoder)

NVR is a digital system
In case of NVR for video we use Ethernet cable.Which is a CAT6 cable with RJ45 connector
Specification of NVR are also same as DVR.But in NVR camera is first connecter to IP switches then from IP switch we connect NVR

Surveillance hard drive

In both DVR and NVR we install a hard drive for storing data of CCTV.In DVR and NVR we does not use normal hard drive we use surveillance hard drive surveillance hard drive has more perfomance and it can work 24 house.It is specially design for Surveillance.

conductor insulation

noreply@blogger.com (INDER KUMAR TIWARI) — Sun, 25 Oct 2020 17:16:00 +0000

Conductor insulation Property

conductor insulation property

What are the main property of insulating material?

1-Insulator material must have high insulation resistance to avoid leakage current.

Insulation Resistance

As conductor of the wire are at higher potential and outer side of wire insulation material at lower potential due to this there are chance of current flow from higher to lower potential.
But we do not want that current will flow through the insulator because if there is very small flow of current it cause power losses and potential drop, therefore we use the material which have very high resistance as an insulator.
NOTE:-Megger is an insulation tester which is used to measure insulation resistance of the cable which is generally in mega-ohm(M&#8486).

2-Insulator material must have high dielectric strength.

Dielectric Strength

The dielectric strength is the maximum electric field strength that it(insulator) can withstand without experiencing failure of its insulating properties.
or
Dielectric Strength of an insulator is the maximum strength of field(i.e Electrical field), it can withstand without becoming a conductor.
if electric field is above the Dielectric Strength then breakdown occur and insulator behave just like an conductor.

3-Insulator material must have low relative permittivity(dielectric constant)

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Relative permittivity(dielectric constant)

Relative permittivity (dielectric constant) describes the ability to polarize a material subjected to an electrical field.
As dielectric constant is about energy storage in the form of polarize molecule. A lower dielectric constant means less energy is stored in the insulation and reduced capacitance between conductors within a cable which help in reducing signal distortion and losses. That result in Improved Signal Propagation.
Dielectric materials can absorb some of the energy of an electrical signal, leading to signal loss. A lower dielectric constant generally means less energy absorption and, therefore, lower signal loss.
The speed of signal propagation is inversely related to the square root of the dielectric constant. Therefore, a lower constant means a higher propagation speed.

It is normally indicated by Er(Relative permittivity).
The large the dielectric constant, more charge can be stored and as the value of dielectric increase its capacitance also increase.
NOTE:-XLPE have 2.2 dielectric constant at 1kHZ where as dielectric constant of EPR is between 2.8 to 3.2. A lower dielectric constant in cable insulation offers several advantages, particularly in high-frequency applications.

Dielectric constant and dielectric strength completely different from each other as dielectric constant is about energy storage, while dielectric strength is about resistance to electrical breakdown. Dielectric constant and dielectric strength has not direct relationship between them.

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4-Insulator material must be Non-hygroscopic.
Non-hygroscopic material having little or no tendency to absorb moisture.

5-Good mechanical strength

6-Non-inflammable:-not catching fire easily.

7-The cost of insulator should be economically

8-Oil Resistance:-If we are going to use our cable in chemical processing industry,food beverage industry,automative assemblies utilizing various cleaning solvents in that case our cable must be oil resistance.

NOTE:-We use some standards and specifications for insulation material such as For PVC power cables we use IS:5831 and for XLPE power cables we use IS:7098 and for Rubber-based power cables, we use IS:9968 and other relevant specifications. There are some international standards also which form by International Electro-technical Commission's(IEC) such as IEC 60228 for EPR Cables

Which material is used to insulate cables?

Mainly most of our insulation material are polymer of plastic and we can divide plastic into 2 type.
1-Thermoplastic:-A Thermoplastic is a material that softens when heated and becomes firm when cooled
e.g:-PVC, PUR, TPE
2-Thermoset plastics:-Thermoset plastics always remain in a permanent solid state.
e.g:-XLPE, EPR, Silicone Rubber

We have lage number of different types of insulation material some of them are very popular such as polyvinyl chloride(PVC), Cross-linked polyethylene(XLPE),EPR(Ethylene Propylene Rubber).

Polyvinyl chloride(PVC)

PVC is world third-most widely use synthetic plastic polymer because of Cheap, Durable, Widely available. The maximum operating temperature for PVC is 70°C for general-purpose 85°C for heat-resisting purpose.

Short circuit temperature for PVC

160 for 5 second

PVC Disadvantages
Highest dielectric losses, Melts at high temperatures(as it is a thermoplastic), Contains halogens.

Cross-linked polyethylene(XLPE)

The Cross-linked polyethylene(XLPE) are ideal for transmission and distribution of power most of HT and LT cables are insulated by XLPE because of Low dielectric losses, Improved material properties at high temperatures. The maximum operating temperature for XLPE 90°C.

Short circuit temperature for XLPE

250 for 5 second

XLPE Disadvantages
Does not melt but thermal expansion occurs, Medium sensitivity to water treeing (although some XLPE polymers are water-tree resistant) and not very flexible.

EPR(Ethylene Propylene Rubber)

EPR is also a very popular material in cable industries because of excellent flexibility, Reduced thermal expansion (relative to XLPE), Low sensitivity to water treeing etc. The maximum operating temperature for EPR 90°C. It is also know as Tough Rubber Sheathed(T.R.S) cable.
EPR Disadvantages
Medium-High dielectric losses, Requires inorganic filler/additive

Silicone Rubber

Silicone insulated cables have an outstanding thermal range of -90°C to 200°C+. This temperature range demonstrates it's greater resistance to heat than PVC insulated cables. Silicone test leads offer superior flexibility and softest surface than the PVC alternative.

PUR Cable(Polyurethane Cables)

PUR cables has very good mechanical characteristics property such as high abrasion resistance, tear resistance and this has toughness for cable jacketing. Cable with PUR installation is harder to strip.

In machining applications PUR becomes the cable to use owing to its better resistance to cutting and hydraulic oils, therefore PUR cables are very well suited for flexible applications in robotics, machine tools and metal cutting manufacturing.

Polyurethanes displayed excellent antibacterial, Polyurethane limits the growth of bacteria and microbes which makes the sheathing material particularly to use in the food & beverage industry, clean rooms, and complying with the hygiene requirements of production lines.

PUR cables can operate between -40°C and +125°C.

But Polyurethanes(PUR) insulation is very costly and mostly used as a jacketing material instead of insulation.

Thermo-Plastic Elastomers(TPE)

Thermoplastic elastomers (TPE), also known as thermoplastic rubbers.

TPE cables are resistant to inorganic oils, organics oils, heat resistance, flame resistance, moisture resistance and deep-freeze applications better than PUR.

But the cost of TPU cables is relatively high. TPE is eco-friendly and non-toxic recyclable plastics.

TPE is often used in more robust applications that feature fast movements such as conveyor systems and crane systems,materials handling or low temperature applications.

As TPE is also a thermoplastic so it melt down at high temperature.

Polypropylene(PP)

Polypropylene (PP) insulation generally has a lower dielectric constant. This is a significant advantage at high frequencies.
A lower dielectric constant means less energy is stored in the insulation, and a lower dissipation factor means less energy is lost as heat. This makes PP more efficient for high-frequency signals.
PP generally has a higher melting point, more flexible, good chemical resistance, less dense (Lighter weigh) than PVC. Generally lower cost than PVC
Polypropylene (PP) also has a higher dielectric strength, and a lower dissipation factor compared to PVC.
PP also often has better temperature resistance than standard PVC, which can be important in high-frequency applications where heat generation might be a concern.

Polypropylene (PP) insulation good high frequencies but it catch fire very easily.

Foam Polyethylene(FPE)

The foaming process introduces air into the polyethylene, and air has a very low dielectric constant. So due to foaming process results in an insulation material with a lower dielectric constant compared to solid polyethylene.

A lower dielectric constant is beneficial because it can reduce signal loss, especially at higher frequencies.

This characteristic makes FPE insulation particularly useful in applications involving high-frequency signals, such as:

* Coaxial cables (like those used for cable television or internet).

* Data transmission cables.

* Other communication cables.

How Foam Polyethylene(FPE) also reduce capacitance of cables ?

As Low dielectric constant of the insulation, resulting in less ability for the cable to store an electrical charge, which is what capacitance is.

Therefore, using FPE insulation is a common technique to minimize capacitance, particularly in applications where high-frequency signal transmission is crucial.

Electron Beam Cross Linked (EBXL) Cables

The Electron Beam Cross Linked (EBXL) Cables are the Cables in which cross-links between the molecules is formed by the help of E-Beam Technology E-Beam Technology
In E-Beam Technology we use electron-beam accelerator with variable energy 1 to 3 MeV and power of 100 KW. This electron accelerator give us a number of high energy electron and when our polymer(made of hydrocarbon) is exposed on the beam of high energy electron the weak bond between hydrogen and carbon is break and strong bond between carbon and carbon remain unaffected. These free hydrogen ion react with each other and form a cross-links between the molecules.
This cross-linking makes the polymer dimensionally more stable. Therefore it improve thermal, chemical, barrier, impact wear and other mechanical properties. As a result we get cables with the advantages of increased life, higher temperature withstand capability, higher current carrying capacity, improved physical properties with reduced thicknesses in these cables.
It is also better than conventional method of cross-linking based on thermally induced chemical reaction(or chemical cross-linking). Which is carried out at high temperature due to which there is some degradation of polymer. Whereas E-beam cross-linking carry out at room temperture by the help of electron-beam accelerator within few second.

Feature of Electron Beam Cross Linked (EBXL)

EBXL is environment friendly and very reliable.
current carrying capacity to more than double.
Increase in Abrasion resistant
Increased the life of cable more than 50 years.
Cross-linked cables have already been adopted in all critical applications such as railways, defense, solar power, nuclear power, Marine and Automobile.

Why high voltage is used for power transmission?

As when current flow through a wire there is some losses such as copper losses.

power loss( or Copper losses)=I2R.

When voltage increase current in line goes down and voltage drop also goes down. Therefore we use high voltage for power transmission.

CABLE POWDER

In the manufacturing of cables different types powder are used such as:-
Talcum powder
It is used where low current is supplying for example in our Computer power supply cable. It protect internal wire to attached each other and jacket of the cable
Magnesium Oxide
It is mostly used. It is used where high current is flowing and cable temperature is high as magnesium Oxide reduce the temperature of the cable. It also work as very good insulator. magnesium Oxide also have fire resistant property. Magnesium Oxide also provide additional flexibility to our cable.
Swellable Powder
It Block water and protects our cable from moisture.
Chalk Powder
It have very good fire resistance property.

INSULATION AND SHEATHING

For Insulation and sheathing we mostly follow stranded IS:5831-1984 (and it also written as "PVC Type 'ST2' as per IS:5831/84")

Insulation Material

PVC Type A-------------General purpose insulation for conductor temp. 70°C under 3.3 KV.
PVC Type B-------------Insulation for conductor temp. 70°C and voltage upto 3.3KV and above.
PVC Type C-------------Heat Resistance Insulation for conductor temperature 85°C and 105°C and voltage upto 1100V.
PVC Type D-------------Flexible insulation for conductor temp. 70°C and voltage up to 3.3KV.
XLPE----------90°C.
Rubber-EPR IE-1----------90°C.
EPR MV-105---------------105°C.

Silicon Rubber--------------150°C.
Teflon------------------------450°C.

sheathing Material

PVC Type ST1:-General purpose sheath for conductor temperature 70°C.
PVC Type ST2:-Heat Resisting sheath for cables with maximum conductor temperature 90°C.
FR PVC Type ST2:-Additional property fire resisting, and Anti-Rodent.
FRLS PVC Type ST2:-Additional property fire Retardant low smoke sheath.
PVC Type ST3:-General purpose flexible sheath for conductor temperature 70°C.
ST7:-ST7 is used for PE (PE types HDPE, LDPE and MDPE).
ST8:-It is halogen free (or LSZH) with maximum conductor temperature 90°C.

Examples

For better understanding have to observe some of the data from datasheets of the cable
50 x 3.5 Core Alum. Armd

Voltage Grade V:-1100V
Conductor material:-H2/H4 Grade Aluminium as per Class 2 of IS: 8130/84,latest
Insulation:-XLPE as per IS 7098(Pt-1)/88
Inner Sheath:-Wrapping of Tapes
Outer Sheath:-PVC Type 'ST2' as per IS:5831/84
Max. conductor temp. under normal operating conditions: 90°C, [short circuit temp.=250°C]

1.5 x 3 Core Cu Armd Str. Cond. Frls Cable

Voltage Grade V:-1100V
Conductor material:-Plain annealed Copper as per Class 2 of IS:8130/84
Insulation:-XLPE as per IS 7098(Pt-1)/88
Inner Sheath:-Extruded PVC Type ST2 as per IS:5831/84
Outer Sheath:-Extruded FR-LSH PVC Type ST2 as per IS:5831/84
Max. conductor temp. under normal operating conditions: 90°C, [short circuit temp.=250°C]

1.5 x 1 P Overall Shielded Armd Frls Cable Red

Voltage Grade V:-300/500V
Conductor material:-Plain Stranded Copper as per IS: 8130
Insulation:-PVC Type A
Inner Sheath:-Extruded PVC Type ST1 as per IS:5831
Outer Sheath:-Extruded FRLS PVC Type ST1 as per IS:5831
Max. conductor temp. under normal operating conditions:70°C, [short circuit temp.=160°C]

1.5 x 4 Core Cu Braided Flex Cable Black

Rated Voltage:-1100V
Conductor material:-Plain annealed high conductivity Flexible copper conductor as per Class 5 of IS 8130/2013 latest
Insulation:-PVC Type A
Sheath:-Extruded FRLS PVC Type ST1 as per IS:5831/84
Max. conductor temp. under normal operating conditions:70°C, [short circuit temp.=160°C]

0.5 x 2 Core Cu Flex PVC Cable Black

Rated Voltage:-1100V
Conductor material:-Plain annealed high conductivity Flexible copper conductor as per Class 5 of IS 8130/2013 latest
Insulation:-PVC Type 'D'
Sheath:-Extruded PVC Type 'ST3' as per IS:5831/84
Max. conductor temp. under normal operating conditions:70°C, [short circuit temp.=160°C]

1.5mmX2core FS(EPR-LSZH-LSZH) ARMD CABLE

Voltage Grade V:-1100V
Conductor material:-Annealed Tinned Class -2 Copper to IEC 60228
Insulation:-EPR as per IEC 60502-1
Inner Sheath:-Extruded LSZH Type ST8 as per IEC 60502-1
Outer Sheath:-Extruded LSZH Type ST8 as per IEC 60502-1
Max. conductor temp. under normal operating conditions: 90°C, [short circuit temp.=250°C]
Fire Performance Circuit integrity test:-IEC 60331 (750°C for 90minutes) and Glass mica Tapes to meet the fire resistance requirements

EXTRUSION

Extrusion is a process where molten polymer is forced through a die to produce a components of a fixed cross-sectional area such as tubes and pipes. The product which are formed by help of Extrusion process are known as extruded product. The Crosshead Extrusion process is widely used to coat wire and cable with a polymer.

Cable sizing

noreply@blogger.com (INDER KUMAR TIWARI) — Sat, 03 Oct 2020 00:20:00 +0000

Cable sizing

For cable sizing we should know
1-SHORT CIRCUIT CRITERIA
Cable Short circuit capacity should be higher than system Short circuit capacity. It is also known as minimum cross-section requirement that can withstand with fault current.
2-AMPACITY RATING
Cable is having base current carrying capacity based on its cross-section area (square mm). But based on installations there are some de-rating factor that affect its current carrying capacity of the cable. So After applying de-rating factor on the cable the current which we get that is known as ampacity rating of cable. Ampacity rating of cable must be higher than Full load current of the load.
3-VOLTAGE DROP CRITERIA
Cable voltage drop should be less than defined voltage drop

SHORT CIRCUIT CRITERIA

1-short circuit criteria (It is also known as minimum cross-section requirement)
Area required=(I √t)/k sq mm
here
I= fault current in Ampere
t= time for which cable must withstand with fault current
K= Constant which depend on cable conductor material and insulation material
generally value of k are

K	Cu	Al
Xlpe	143.08	94.48
PVC	115	76.03

Note:- PVC can withstand at 70°C whereas XLPE can withstand at 90°C. As XLPE insulated cable can withstand at 90°C therefore it can carry more current.

Now Let suppose we have a LT motor which operate at 415 Volt and its fault current=50KA and we need to find a cable size for this
Now first we need to find fault time
Generally motor operate by instantaneous relay which have fault clearing time=0.05second and breaker operating time=0.06second.
So total Fault time= Fault clearing time+ Breaker operating time=0.05+0.06=0.11
and some additional margin=0.09
Now,
total time=total Fault time + additional margin time=0.11+0.09=0.2sec
let suppose we using Cupper cable with XLPE Cable where k=143.08

Area required=(I √t)/k sq mm
=50,000*√0.2/143.08
=156.28 Sq mm
Nearest size around this is 185 Sq mm

AMPACITY RATING

Cable is having base current carrying capacity based on its cross-section area (Sqmm). But based on installations there are some de-rating factor that affect its current carrying capacity of the cable. So After applying de-rating factor on the cable the current which we get that is known as ampacity rating of cable.

For understanding ampacity we take an example, let we have a 3-phase motor which operate at 415V and 80KW power, who has power factor (P.F)=0.8,demand factor=1.

Now first we need find full load current for our system.
First Method
As we know P=√3*VICosθ
I=P/VCosθ
I=1.73X80,000X415X0.8
I=139
So for running this motor we need a cable which as easily withstand with 84.5A
therefore 84.5A=Full load current

2nd Method
Consume Load=Total load*Demand factor=80*1=80KW
In KVA=KW/Power factor =80/0.8=100KVA
Full load current=(KVA*1000)/(1.732*Voltage)=(100.1000)/(1.732*415)=139.12A

Once we have full load current, now we need to find de-rating factor(K). Since atmospheric condition always effect the current carrying capacity of a cable.

De-rating Factor (K) Concept

As when we can see manufacture datasheet the current carrying capacity is generally given at 40°C. But generally we have to consider Ambient temperature is around 50°C for New Delhi summer condition and at 50°C the current carrying capacity of cable is decrease.
Similarly there are several factors which affect the current carrying capacity.

1)Temperature
2)Cable laying(Where we are laying the cable)
In ground (Depth and thermal resistance of soil)
In open air
In Duct(It is a type of pipe or closed table try)
3)Distance between the cables.(As distance between the cable decrease the mutual inductance increase).It is also known as Cable distance Correction
4)Number of cable are grouping together(grouping factor)-->As sometimes we use cable tray in which as number of cable are group together.

So, Generally we have 7 de-rating factors such as, Air temperature(K1), Ground Temperature(K2), Soil Thermal resistance(k3), Soil correction(K4), Cable depth(K5), Cable distance Correction(K6), Cable grouping(K7)
Soil Thermal resistance(k3)->if we measure it, if or someone tell us about it. Only then we include its value it. The common value of resistivity are 1, 1.5, 2, 2.5 and 3. The corresponding value for these resistivity are given in Kelvin meters per watt( K m /W) or degree Celsius centimeter per watt (°C.cm/W).
Soil correction(K4)-->The value for soil correction is almost fixed such as, Very Wet Soil(K4=1.21), Wet Soil(K4=1.13), Damp Soil(K4=1.05), Dry Soil(K4=1), Very Dry soil(K4=0.86)

Now let consider our cable is 1 meter inside the ground and ground temperature is 35°C where Damp soil is present.
First we need Calculate the Value of "K"

De-rating factor(K)
K=K2(Rating factors from manufacture datasheet ground temperature=0.96)Xk4(for Damp soil k4=1.05)xK5(from datasheet inside depths of 1050mm=1.05 meter and rating value=0.96)Xk6(K6=1 as there is only one cable we are using and there is no other cable is present there) K=0.96X1.05X0.96X1=0.9776
total de-rating factor(K)=0.9776
As we get value of K, Now we need to divide value of full load current by K and result will be our needed amperes in the cable according to datasheet of manufacture
=full load current(139)/k(0.9776)
=142 Amps

So we need a cable which can carry more than 142 Amps in datasheet of manufacture.
In manufacture datasheet 70mmX3.5core XLPE insulated aluminium armoured can carry 164 ampere current inside the ground so it is sufficient according to our requirement.

Now we check the total current carrying capacity of 70mmX3.5core XLPE insulated aluminium armoured cable after de-rating factor=164X0.97=159.08Amps
So, ampacity of 70mmX3.5core XLPE insulated aluminium armoured cable=159.08Amps

As this cable is sufficient for our current requirement therefore now we will need to check its voltage drop.

VOLTAGE DROP

First Method
Lets we take length=200 meter and voltage=415
Now As we know the size of our cable that is 70mmX3.5core we can easily find resistance=0.568 and reactance=0.0742 of cable from manufacturer datasheet

For 3 phase Voltage drop=[1.732*Current*(Resistance* Cosθ+ Reactance* Sinθ)*Cable Length]/[line voltage * No of run * 1000(for Km) ]
=1.732*current*(R Cosθ + j Sinθ)*Length*100/[line voltage * No of run * 1000(for Km) ]

=[1.732 * I * (0.568*P.F+0.0742* Sinθ)*200]/[415X1X1000]
Sinθ=√(1-cosθ^2)
   =√(1-0.8^2)
   =√(1-0.64)
   =√(0.36)
Sinθ=0.6

V.D ratio=[1.732X 139 X (0.56X0.8+0.074*0.6)X200]/[415X1X1000]=57.129/1000=0.0571
for convert it into percentage=V.D ratioX100
=0.0571X100
=5.71%
Note:-The NEC recommends that the maximum combined voltage drop for both feeder and branch circuit should not exceed 5%.
so we need to increase the size of cable now we take 95mm cable where R=0.410 and X=0.0725
Ampacity of 95mm=197*0.97=191.09A
V.D ratio=[1.732* 139 *(0.41*0.8+0.0725*0.6)*200]/[415*1*1000]=43.102/1000=0.0431
for convert it into percentage=V.D ratio*100
0.0431*100
4.31%

2nd Method
From Datasheet aluminium armoured XLPE Insulated the approx Voltage Drop
70mm=0.99Mv/amp/mtr
95mm=0.72Mv/amp/mtr

voltage drop=[ (milli-volt drop/A/M)*full load current in Ampere* Length in meter ]/1000(to convert mill-volt into volt)
V_d=(0.99*139*200)/1000=27,522/1000=27.522
Voltage drop after 200 meter=27.522

Now we calculate 5% of our applied voltage=Voltage*5%
=415V*5/100
=2075/100=20.75
As for 5% maximum voltage drop=20.75V, But in 70mm for 200 meter the voltage drop=27.522V. It is greater than 5%. Therefore we go for next size that is 95mm

for 95mmX3.5core
V_d=(0.72*139*200)/1000=20.01
As 20.01 is less than 20.75 therefore 20.01 is acceptable for our cable.
Therefore we use 95mmX3.5core XLPE insulated Aluminium Armoured cable.

3rd Method
All cable has a resistance that is given as ohms per metre – “W/m”. Some manufacturers give this figure, however others give the voltage drop expressed as “mV/A/m” ) milli-Volts per Amp per metre .

Lets, We have a 1.0 mm² cable connected to a battery that is at 12 metres distance and that needs to supply two light bulbs that have a total load of 50 watts at 12 volts,Now we need to find the voltage drop?
Let suppose that manufacturer give us cable resistance 0.038 W/m.
As we know that,V=IR.Therefore first we need to find out current
And, we know, P / V = I
50 watts / 12 volts = 4.17 Amps
V_d=IR*length
V_d=4.17A x (12m x 0.038W/m) = 1.901 V

COATING OF COPPER WIRE

noreply@blogger.com (INDER KUMAR TIWARI) — Sun, 16 Aug 2020 16:49:00 +0000

COATING OF COPPER

Sometimes bare copper is not enough to fulfill our requirement in that case we need to do coating of copper by other material. copper are mostly coated with tin(Sn),nickel,silver(Ag)

Tin-Copper

Tin is most common coating for the copper and copper alloys as cost of tin is low. Tin coating improve water resistance,chemical resistance,life time of wire,temperature range, and because solder is composed primarily of tin,tinned wire is easy to solder. But Tin has low conductivity, Therefore when tin plated over copper, it forms an inter-metallic layer which will increase resistance of wire. Tin coated wire can work upto 150°C

NOTE:-Bare Copper wire is known as Annealed Bare Copper(ABC) wire whereas Tinned Copper wire is known as Annealed Tinned Copper(ATC) wire

Nickel-Copper

Nickel is a much harder metal than any other common plating material therefore it provide excellent resistance to high temperature. It provide good corrosion resistance. But as the Melting point of nickel is greater than copper therefore soldering of a nickel plated wire is not easy and as conductivity of nickel is relatively Therefore when nickel plated over copper then there is increase resistance of wire. Nickel coated wire can work upto 300°C

Silver-Copper

Silver offers extremely high conductivity and reduce the resistance of wire. Silver coating wire is best for high frequency application because the skin effect will result in increased current flow through the silver layer. Silver coating wire will also work -65°C to 750°C.

RUBBER CABLE

noreply@blogger.com (INDER KUMAR TIWARI) — Sun, 02 Aug 2020 12:55:00 +0000

What is a Rubber Cable?

Rubber cable is a rubber sheathed cable, as the name suggests is a variety of rubber is used for insulation in a cable. Commonly used material for rubber cable are EPR (Ethylene Propylene Rubber), Silicon Rubber, PCP (PolyCloroPhospat), etc. Rubber cable also known as Elastomeric Cables and TRS(Tough Rubber Sheathed) Cables.

What are the benefits of Rubber insulated cables over PVC?

PVC flexible cables can resist only weak to light mechanical stress, which makes them unsuitable for industrial and heavy-duty use. Therefore we use Rubber cable, Rubber flexible cables can also be used in heavy duty applications as these cables have a thick coating of rubber compounds which acts as the load bearing member when high stress is incident on it.
Rubber flexible have excellent flexibility in temperature range. But, PVC is a synthetic material that’s less flexible. Therefore, PVC cables are less durable and strong than the rubber ones.
Rubber cables has better Abrasion resistant. It have good resistance to chemical, oil, grease and acid.

What are the applications of Rubber cable?

Rubber cables used as heavy duty welding cable. It also use in turbine system for transport electricity from the generator to transformer. It also used at Textile Machines, Electrical Machines, EOT(Electric overhead traveling) Cranes, in Construction equipments, in Steel Mills, in Wind Power Mills, etc.

Gallery

noreply@blogger.com (INDER KUMAR TIWARI) — Thu, 25 Jun 2020 10:39:00 +0000

OUR PRODUCT

noreply@blogger.com (INDER KUMAR TIWARI) — Mon, 22 Jun 2020 01:36:00 +0000

Paradise Speciality Cables Private Limited

We are the channel partner of Polycab, Belden, Agilon Cables. We have all different types of cables and wires.

1 / 4

Optical fiber

2 / 4

FR/FRLS

3 / 4

Cables

4 / 4

Armoured cable

For Downloading Polycab List price link are given bellow

Armoured LP(Power Control Cable)

CLICK HERE

Multi-core LP(Light Duty Cables)

CLICK HERE

Cat-6,telephone,speaker and co-axial LP

CLICK HERE

Cables Ready Stock with Paradise Speciality Cables Private Limited
Instrumentation Cables-Pair/Triad, Shielded Cables, Industrial Braided Cables, Fire Survival Cables, Fiber Optic Cables, Solar DC Cables, RS-485 Cables, Audio-Video Cables, Rubber Cables, Thermocouple & Compensating Cables, High Temperature Cables, Profibus Cables, Fieldbus Cables, Ethernet Cables, Custom Cables as per client’s specification

INDUSTRIAL AUTOMATION CABLE

noreply@blogger.com (INDER KUMAR TIWARI) — Sun, 21 Jun 2020 04:18:00 +0000

Automation is widely used in manufacturing industries for packaging, food and beverage processing, automotive and other production lines. As there are different types of protocols are used in it. Therefore there is also requirements of different types of cables for them.

RS-485 CABLE

Is Modbus same as rs485?

The RS-485 is a serial data transmission standard widely used in industries. The Modbus is a protocol commonly used when we implementing RS-485 communication.

RS-485 Max speed

RS-485 is a serial communications in which the data transmission speed can be up to 10Mbps.
The RS-485 can handle up to 32 device in this way RS-485 really allowed full automation possible with its ability to connect up to 32 device in a system.

RS-485 Cable

RS-485 have good susceptibility to noise as compare to RS-232 and shielding of RS-485 cable increase its susceptibility to the noise. Maximum Cable length for RS-485 is 1200 meters.
In case of RS-485 cable we use twisted pair cable(which reduce cross-talk and electromagnetic induction).
In case of RS-485 cable we try to make capacitance of wire is very Low(nf).
For half duplex communication we use single pair RS-485 cable, But if we need full-duplex communication in that case we use 2 pair RS-485 Cable.

RS-485 type OF CABLE

Armoured RS-485.

Usually Galvanized Steel Wire are use for armouring.

Unarmoured RS-485.

We also called it flexible RS-485.

Difference between standard and protocol?

Standard

Standard are guidelines to be followed when a new design is to be formulated. We can also says that a standard is something that is widely adopted.
For example:-
1-RS-485 is a standard defining the electrical characteristics of drivers and receivers for use in serial communications system.
Although RS-485 define signal level, speed, format of data. But data transmission are not specified by RS-485.
2-802.3u standards for fast ethernet. So if anyone were to design a hardware or software related to fast ethernet, they would have to follow those specifications.

Protocol

Protocol are set of rules for having a conversation between two computers to convery a specific set of information. It is an agreement between the communication parties on how the communication is to proceed.
For example:-
TCP/IP is a protocol which decide number of bits used for communication , size of data chunks, addressing format, etc.

Profibus (Process Field Bus)

Profibus is a serial communication standard with Multi-Master(or multi-vendor) System responsible for providing the communication between the field sensors and the control system or the controllers. It was developed in 1989, specifically for industrial automation and promoted by Siemens and widespread all over Europe. PROFIBUS use in high speed synchronised servo application(robotic and NC Machine). It also used to operates even in hazardous environment.
In Profibus there are 2 very popular communication profiles Profibus DP and Profibus PA.

Profibus DP(Decentralized peripheral)

In profibus DP we use a DP(Decentralized peripheral) and connect all peripheral(or I/O modules, sensors or transducers ) from it and from this DP we connect our PLC. Currently, 90 percent of the applications involving slaves PROFIBUS utilize the PROFIBUS DP. Profibus DP general designed for internal use.
Profibus DP cable is mostly voilet in color. But also uses 2-core RS-485 screened twisted pair wiring.

Profibus PA(process Automation)

But if we wants more economical structure then we need to use profibus PA where we use single profibus PA Bus to connect all the peripheral and this bus is connected to segment Coupler(or Converter). This segment Coupler(or Converter) is connected to PLC. The PROFIBUS-PA is the PROFIBUS solution that meets the requirements for process automation by connecting automation and process control systems with field equipment process control, such as pressure and temperature transmitters, converters, positioners, etc. In profibus PA two wire carrying both power and data.

Profinet(process Field net)

Profinet is newer protocol that was devloped in 2003 for Real-time Ethernet for industrial Automation. Which follow TCP/UDP Or IP protocol. Profinet is used for High speed operation. It's response time is less than 1 millisecond. So it is ideal for High speed application. Profinet use same physical connection as standard ethernet therefore it is very fast.
Profinet device have 3 different types of address IP ADDRESS, MAC address and a device name.
Profinet cable are mostly green in colour and contain robust shielding. But in some cases we can also use 4-core ethernet screened twisted pair cable also.

Ethernet Cables

We have 3 types of ethernet cables coaxial,twisted pair, optical fiber. But LAN twisted pair cable is most popular out of them. Twisted-pair cable can be used as networking cable or telephone cable. It has two type UTP and STP.

What is the difference between UTP and STP cable?

UTP (Unshielded twisted pair) is a cable with wires that are twisted together to reduce noise and crosstalk, but due to no shielding it can be affected by external interference (or noise). Whereas shielded twisted pair(STP) cables are the cables that can protect us from external as we as internal interference(or noise).

It is further divide into Category in short we call then "Cat"
Now-a-days the wire which we are using in Twisted pair mostly comes in 4 pair e.g:-Cat 5E,Cat 6 and Cat 6A

Cat 5E

It supports data transfer speeds up to 1 Gbps with 100MHz Bandwidth. It used mainly used in home for creating local area network. It can be used upto 100 metre.

Cat 6

It supports data transfer speeds up to 10 Gbps with 250 MHz Bandwidth with even less (or no) crosstalk interference, due to the cable's improved insulation. Cat 6 is not prefer to use above 55 metre(for ideal performance).

Cat 6A

It supports upto 10 Gbps internet speed with Bandwidth 500mhz. It Used mainly used in IP CAMERA. It can be used upto 100 metre

Note:-Cat6 and above it prefer for Concealed wiring(Inside Wall).

KNX

KNX is a standard which is used for smart home automation and building control. It is an open standard for commercial and domestic building automation. By the help of KNX we can easly manage lighting, audio, video, security systems, sensors, etc.
The main advantage of KNX, KNX is not based on a specific hardware platform and a network can be controlled by anything from an 8-bit microcontroller to a PC as we needed and according to network demands.
KNX evolved from three earlier standards; European Home Systems(EHS) Protocol , BatiBUS, and EIB(European Installation Bus or it also known as Instabus).

In case of KNX system we mostly used a twisted pairs of solid conductor wire which is green in color and all the devices are connected for it. This is also known as KNX bus.

Fire Survival Cable

noreply@blogger.com (INDER KUMAR TIWARI) — Sun, 14 Jun 2020 15:23:00 +0000

Fire Survival Cable (or Fire Resistant Cable)

For fire survival mostly 1.5mmX2core cable is use. These cable are designed to sustain with high temperatures. These cables mostly used Glass mica tapes to meet the fire resistance requirements which is wrapped over the conductor.
some common property of these cables are normally operate up to 90°C with Maximum conductor temperature at the termination of short circuit up to 250°C.

Oxygen Index[or limiting oxygen index(LOI) or Critical oxygen index]

Oxygen index is a parameter the that suggest us about flammability of a substance. As higher the hydrogen to carbon ratio in the polymer, the greater is the tendency to burning. therefore, if oxygen index is higher then material do not burn easily(or less flammable). As air contains approximately 21% oxygen therefore it is stated that if oxygen index of the material is greater than 26% in that case material will be self extinguishing.

Why high oxygen index is good for wire insulation?

Most of our Polymers used in cable industries are derived from ethylene(C₂H₄) such as Ethyelne propylene Rubber(EPR), cross-linked polyethylene, vinyl chloride(C₂H₃Cl),etc.

As Ethylene is highly flammable,But most of our material are derived from this therefore when we are making a substance from it we try to add other substance that increase the intermolecular force, In this way we increase the Ignition temperature(burning temperature). The second way is to decrease the concentration of ethylene. In this earlier we increase the concentration of halogen gases. But as we all know that halogen is very toxic for us therefore as we release that then we chose second option that is increasing the concentration of oxygen.
NOTE:-Oxygen is oxidizer enabling other substances to oxidize(or burn). But Pure oxygen does not "Burn"

In India polycab is one of the company which make different types of Fire Survival Cable.

What are different types of fire survival cables?

1.5 x 2 C Unarmd(Cross Linkable LSZH-LSZH)

Type of cable:-Cross Linkable LSZH insulation Outer sheath and Extruded LSZH inner sheath
Colour of outer sheath:-RED
Core Identification:-Red, Black
Fire Performance Circuit intigrity test:- 950°C for 3 Hrs.
Material:-Plain annealed Copper Class 2
Material of Drain Wire/CPC:- Stranded ATC(1.5 Sq.mm)
As it has LSZH material therefore it HCL content in this cable is as low as 0.5% and toxic index less than 5%
Printed:-300/500 V

1.5 x 2 C Armd(FRLSH-FRLSH-XLPE)

Type of cable:-Armoured, FRLSH(Type ST2 as per IS:5831/84) Outer sheath and inner sheath(Bedding) and XLPE(as per IS 7098) inner insulation
Colour of outer sheath:-RED
Core Identification:-Red,Black
Fire Performance Circuit intigrity test:-750°C for 90 Min.
Material:-Plain annealed Copper as per Class 2(as per IS:8130/2013)
Printed:-1100 Volt grade XLPE FR-LSH

1.5 x 2 C Armd(LSZH-LSZH-XLPE)

Type of cable:-Armoured, Extruded LSZH Outer sheath and inner sheath(Bedding) and XLPE inner insulation

Type of cable:-Armoured XLPE Outer sheath and LSZH inner sheath

Colour of outer sheath:-RED

Core Identification:-Blue, Brown

Fire resistant characteristic of electric cables as per IEC 60331:-(950°C for 3 Hrs.)

As it has LSZH material therefore it HCL content in this cable is as low as 0.5% and toxic index less than 5%

Material:-Plain annealed Copper Class 2 Conductor

Printed:-600/1000V

Mostly this is Available

1.5 x 2 C [LSZH-LSZH-Ethylene propylene rubber(EPR)]

Type of cable:-Armoured,Outer sheath and inner sheath(Bedding) LSZH(Type ST8 as per IEC 60502-1) and inner insulation is EPR(as per IEC 60502-1)
Colour of outer sheath:-Black
Fire Performance:-IEC 60331 (750°C for 90 minutes)
As it has LSZH material therefore it HCL content in this cable is as low as 0.5% and toxic index less than 5%.
Material:-Annealed Tinned Class -2 Copper to IEC 60228
EPR used in this cable provide it great flexibility

EPR

EPR is a generic term for a wide range of polymers based on co-polymers of ethylene and propylene. like XLPE insulation, EPR also suitable for higher voltage applications. But its dielectric properties are not as good as those of XLPE. But is also have some advantage such as extra flexibility,reduced thermal expansion and low sensitivity to water treeing

Kapton tape

Kapton tape is a specialized type of adhesive tape known for its exceptional resistance to high temperatures it has a very broad range of temperature stability. Kapton tape is typically more flexible than mica tape. If a wide operating temperature range, flexibility, and general electrical insulation are the primary concerns, Kapton tape is often preferred.

Mica tape

Mica is non-flammable and doesn't release toxic gases when exposed to fire. Mica tape is a specialized insulating material that plays a critical role in applications requiring high temperature resistance and electrical insulation. Mica tape is superior in fire resistance.If fire resistance and extreme high-temperature durability are paramount, mica tape is likely the better choice.

What is fire resistant cable used for?

fire resistant cable used for maintain integrity during the fire as it can withstand with 750 C. We commonly see it as fire alarm cable in buildings, malls and in the office.

DC Cables(or SOLAR CABLE)

noreply@blogger.com (INDER KUMAR TIWARI) — Thu, 11 Jun 2020 15:39:00 +0000

DC Cables(or SOLAR CABLE)

DC cable are used for passing DC current from source to destination.
In case of DC cable sometimes we can also use Single Strand cable, But we never prefer the use of Single Strand cable in case of AC because of Skin effect.

Skin effect

When AC current flows through a conductor then an magnetic flux induces in it and this magnetic flux is greater at the center due to which concentration of electron is increase at the outer surface of the conductor and decrease at inner surface of the conductor. As a result current flow mainly on outer surface of the conductor. Due to this effective area for current flows in our conductor decrease and this is know as skin effect.
1-Due to skin effect resistance of the conductor is increase and conductivity decrease.
2-To reduce skin effect we mostly use Multi-stranded conductor for AC current flow.
Note:-Skin effect depend on frequency if frequency increase skin effect increase and, In case of DC there is no skin effect that is a reason due to which sometime we use Single Strand conductor in case of DC and Multi-stranded conductor in case of AC. But due to flexibility issue we use and as surface area of Stranded wire is higher than original cylindrical wire. As a result extra surface area helps in flow of more currents than original cylindrical wire. Therefore Multi-stranded conductor in case of DC also. Note:-More the number of strands in the cable, the more flexible but the cost of the cable will increase

How to calculate size of cable by the number of strand in the cable?

As we know that ,Area=π*(Radius)^2
Lets we have diameter(d) of one strand=0.2mm
then,
Area=(π*d^2)/4
if diameter=0.2mm
Area of one strand=(π*d^2)/4
=(3.14*0.04)/4
=0.0314mm2
if we have number of strand=16
then, Area of cable=16*0.0314
=0.5024mm2 it is approximately 0.5mm

Similarly, 1mm wire have 32 strand of 0.2mm
As, Area of cable=32*0.0314
=1.0048mm2

SOLAR CABLE

Solar cable is a type of DC cable with double insulation mostly. This double insulation provide extra protection from temperature and UV light. solar cable can be categorize according to the temperature,operating voltage,material used and type of certification issue to the cable.
For example in India polycab company have different types of solar DC cable.

Solar dc cable specification (or solar cable types)

SOLAR DC CABLE TYPE-3

1)) Annealed Flexible Cu Conductor
2)) Non TUV Certified

3)) DC Voltage = 1.5 Kv
4)) Standard: UV resistant according to DIN 83387
5)) It is insulated with XLPE and sheathed with UV stabilized PVC ST2 compound(It is odorless non-toxic,plasticized PVC grade with calcium carbonate).

SOLAR DC CABLE TYPE-1

1)) Tinned Flexible Cu Conductor
2)) TUV Certified
3)) DC Voltage = 1.8 Kv
4)) Standard: TUV Specification-2 Pfg 1169/08.2007, Flame retardant according to IEC 60332-1-2,Halogen free according to EN 50627-2-2,Ozone resistant according EN 50396,Weather/UV resistant according to DIN 53387
5)) It is insulated and sheathed with cross linkable LSOH(low smoke zero halogen) which has UV as well as Ozone protection property.

Solar Cable Certified according to EN 50618(E Beam)

Insulation:-Cross linkable (E Beam) LSZH Insulation
Sheathed:-Cross linkable (E Beam) LSZH Sheathed Solar Cable as per EN 50618
Flame retardant,low smoke as we use Cross linkable LSZH material
Flexible Tinned Copper Conductor of class 5.
As in this E Beam is used therefore it is more flexible and we can bend it more.
Max Conductor Temperature -40°C to 120°C.
UV,ozone,temperature and hydrolysis resistance.

Shielded Cable

noreply@blogger.com (INDER KUMAR TIWARI) — Wed, 10 Jun 2020 03:27:00 +0000

Shielded Cable

What is shielded cable used for?

shielded cable is use for transferring data in the form of electronic signal.

Why we use shielded Cable?

When we are transferring data from source to destination then there is chance of distortion of data due to EM wave. To protect our data from distortion we use an extra layer of conductive material in the form of foil, braid, sprial etc. This extra conductive material layer is wrapped with our data cable and provide it protection from EM waves and EM Noise.

Is coaxial cable shielded?

yes, Coaxial Cable are also shielded but we know them by the name of "Coaxial Cable" and Coaxial Cables are mostly know as RG-6(used for cable TV in home),RG-11 and RG-59, where RG means "Radio Guide" .These cable are used for high frequency signal transmission.

RG-6 Armoured cable

Why we use CCS material in RG-6?

As high frequency signal travel through the Coaxial Cables therefore due to skin effect signal travel through outer surface of conductor that is way we can easily use Copper Clad Steel (CCS). As in this wire outer copper layer takes care of high frequency signal transmission & Steel takes care of the load.
CCS conductor is used for long distance transmission, as it offers high strength, economy & longer life. These cables withstand all mechanical abuses during operation and are extensively used in DTH and CATV(cable television)

Type of shielding in shielded cable

There are two different type shielding Foil Shielding and Braided Shielding.
Braided Shielding, Most commonly we can see this type of protection in the Coaxial cable, Which we are using as Television(TV) Cable. In Coaxial cable we are mostly using braided protection. But braided protection does not provide 100% coverage from EM Waves therefore foil protection is use for provide 100% coverage. For better protection from EM wave we use combination of foil and bread protection.
NOTE:-Shielded cable also known as screened cable, instrumentation cable, BMS cable.

Type of shielded cable

Flexible shielded cable(Foil Shielded).
Armoured shielded cable(Foil Shielded+Armoured).
Shielded Cable with tinned copper braiding(Braided Shielded).
Shielded cable with Aluminium Mylar tape and Drain wire(Foiled Shielded Cable)
Shielded cable with Aluminium Mylar tape, Drain wire and additional braided Shielding by tinned copper which provide 100% coverage.(Foil+Braided Shielded)

Shielded cable easily available in 2 core to 24 Core, 1 Pair to 12 Pair,1 Triad to 12 Triad and size 0.5mm to 2.5mm.

As cable come in pair and tride therefore there are two type of shielding overall Shielded and Individual +overall shielded.

NOTE:-BMS cable are in multi-colour upto 4 Core and after that they mostly available in grey with numbering.

Cost of shielded cable.

The cost of shielded cable is changing company to company, number of core ,armoured and unarmoured. The cost of 1mmX4core Flexible shielded cable is around 50 rupees per meter, But the cost of 1mmX4core armoured is around 80 rupees per meter.
Note:-whenever the number of process increase to make a cable its cost automatically increase therefore cost of shielded cable is more than normal cable

Twisting Difference between BMS and Instrumentation cable

Pair:- Two cores twisted to form a pair.

Triad:-Three cores twisted to form a Triad.

Quad:-Four cores twisted to form a Quad.

Optical Fiber

noreply@blogger.com (INDER KUMAR TIWARI) — Tue, 09 Jun 2020 09:05:00 +0000

Optical Fiber Cable(OFC)

What is the principle of optical Fibre?

In 1854, john tyndall, experiment prove that light beam can travel inside the water and can follow a specific path by using internal reflection same thing used in optical fiber. An optical fiber is a flexible, transparent fiber made by glass(silica). Optical fiber provide a medium for transmission of information in the form of light. The optical fibers basically work on the principle of total internal reflection.

Construction of optical fiber

optical fiber has 4 main component
1-Core
This is the main layer that is made up by silica(or glass) in which our light signal will travel from source to destination by the process of total internal reflection
2-Cladding
This is layer of silica(or glass) that cause necessary reflection to allow light to travel through the core of fiber.
Note:-Refractive index of cladding is less then core.
3-Coating
This is the thicker surrounds layer around the cladding. It is made up by Carbon, Polymide, Silicone etc.
4-Electo Chromium Coated Steel(ECCS) Tape
This is a steel strip which is used for optical fiber cable armouring. It has very hight tensile strength. It protect from attacks from rodents.
5-Buffer
It used to encapsulate one or more optical fiber and also providing protection from physical damage. Generally it is filled with a gel such as Synthetic Thixotropic Gel. It is mostly made up from Polybutylene terephthalate(PBT)
6-Jacket
It protect our optical fiber from external environment condition and physical damage.jacket is usually made of PolyEthylene(PE), HDPE, PVC etc.

Note:-Fiber optic cable carry a number of strands of fiber optic and these strands can be grouped as Tight buffer cable or Loose Tube buffer cable.

Tight buffer cable

A Tight buffer cable consists of one or more bundled fiber strands covered by an outer often jacket the outer jacket contain multiple layer to add structure to the cable and provide water resistance.

Loose Tube buffer cable

Loose Tube buffer cable fiber strands are contained within a buffer tubes allowing the strands to move freely while also providing additional protection for strands. The addition of buffer tubes and other protective layer causes the cable diameter to be larger and cable to less flexible.
But a Tight buffer cable is more easily damaged than loose buffer cables therefore tight buffer cable are more appropriate for indoor use and loose buffer cables for outdoor use.

Fiber optic cable types

1-single mode optical fiber(SMF)

In single mode optical fiber only one wave(light) can travel through the fiber.
It is basically used for long distance transmission of the signal.

2-Multi-mode optical fiber(MMF)

In Multi-mode optical fiber we can pass more than one light wave from source to destination at same time.
In case of Multi-Mode optical fiber the diameter of core is more then diameter of cladding.

Multi-mode fiber are two type step-index multi-mode and graded index multi-mode

Graded index multi-mode fiber

In graded index multi-mode fiber is a type of optical fiber where the refractive index is higher at the axis of the core and then it decreases gradually towards the core-cladding interface.
In graded index multi-mode fiber light travels forward in the form of sinusoidal oscillation.

Step-index multi-mode fiber

In step-index fiber a uniform refractive index exists within the core and a sharply decresed refractive index exists in the core-cladding interface.
In step-index fiber light travels forward in a zig-zag path along the axis of fiber.

Different types of optical fiber used commercially

Multimode fiber cable is prefixed with 'OM' and Single mode fiber cable is prefixed with 'OS'. Presently single mode optical fiber have 2 types:-OS1 and OS2. Whereas Multimode have 6 type:-OM1, OM2, OM3, OM4, OM4+ and OM5.
The size of fiber measure in micron(µm). It is very small unit of measurement as 1µm=1X10^-6 metre and the diameter of human hair is between 20 to 200µm. As in case of multimode fiber more than one signal can travel through fiber core, therefore multimode fiber has a much larger core size as compare to single mode.Presently multimode fiber core have two main size 50 micron and 62.5 micron(it is used in case of OM1).
Generally the size is show by the companies as 62.5/125/250(Fiber size)
Here, First set of number 62.5 refer to diameter core, second set of number 125 refer to diameter of outside of the fiber cable’s that is cladding. Third set of number 250 for coating
In companies datasheet this data is indicated as
Typical Core Diameter :-62.5 ± 2.5 µm
Cladding Diameter:-125 ± 0.7 µm
Primary Coating Diameter:-245 ± 7 µm

Types of optical fibers

Single-mode(SM) optical fiber 9/125µm

Generally yellow in colour. It also indicated as OS
It is used mainly a long distance communication upto 10Km. It has low attenuation as Compare to the multimode fiber

62.5/125µm(OM1)

Generally orange in colour
lenght-1GB upto 275meter.
Bandwidth:-200MHz(depend on quality fiber)

50/125µm(OM2)

Generally orange in colour
lenght-1GB upto 550meter
Bandwidth:-500MHz(depend on quality fiber)

50/125µm(OM3)

Generally Aqua in colour
lenght-for 1GB upto 550meter, for 10GB upto 300meter, for 40GB upto 100meter
Bandwidth:-2000MHz(depend on quality fiber)

50/125µm(OM4)

Generally Aqua in colour
lenght-for 1GB upto 550meter and for 10GB upto 400meter, for 40GB upto 150meter, for 100GB upto 150meter
Bandwidth:-4700MHz(depend on quality fiber)

50/125µm(OM4+)

Generally violet in colour
lenght-for 1GB upto 550meter, for 10GB upto 800meter, for 40GB upto 300meter, for 100GB upto 300meter
Bandwidth:-4900MHz(depend on quality fiber)

50/125µm(OM5)

Generally green in colour
lenght-for 1GB upto 550meter, for 10GB upto 400meter, for 40GB upto 150meter, for 100GB upto 150meter
It is used for Short Wavelenght Division Multiplexing(SWDM) for a wavelength of 840nm to 953nm.

NOTE:-All outdoor fiber cables are black jacketed to protect from the sun harmful ultraviolet rays

Source of transmit signal in optical fiber

For transmitting signal we use Led in OM1 and OM2 and after that from OM3 we start using LASER(Light Amplification by Stimulated Emission of Radiation) such as VCSEL(Vertical cavity surface emitting laser)

Mode Field Diameter(MFD)

Mode Field Diameter(MFD) is a measure of light intensity, MFD as the effective area of fiber in which light signal propagating. Therefore it is combination of core and a little bit part of cladding.

Why is MFD important ?

It provides information about the cable performance and the amount of signal loss while propagating in the fiber due to micro bending, splicing and impurity in fiber.
MFD information given in company datasheet
Typical Mode Field Diameter@1310nm:-9.2 ± 0.4 µm
Typical Mode Field Diameter@1550nm:-10.4 ± 0.5 µm

Type of optical fiber on the base of construction

1-uni-tube
In case of uni-tube optical fiber we do not have CSM(Central strength Member).
2-Multi-tube
CSM(Central strength Member) is a rod at the center of Multi-tube fiber, which is mostly made of Fiber Reinforced Plastic(FRP). for making FRP we used E-Glass fiber with high heat resistance, which provide excellent strength and stiffness to the cable.

Type of armouring in the cable

Multi-tube steel tape armoured cable
here armouring is done by steel wire , which provide excellent mechanical streangth. It is mostly used as cable with steel tape is light weight that steel wire
Multi-tube steel wire armoured cable
here armouring is done by steel wire , which provide excellent mechanical streangth. But its weight increase largely.
Multi-tube dielectric armoured cable
here armouring is done by dielectric(IGFR) which due of which it is suitable in the area where rodent are peresent. It is a lightweight armoured cable.
Multi-tube FRP armoured cable
here armouring is done by FRP road.

Applications of fiber optics

Simplex fiber and duplex fiber are design to use indore application such as for desktop connectivity from modem and to establish a link between electronic equipment.
Jelly filled optical fiber is designed endure outside temperature and high moisture condition.
Dry loose tube cable are offering easy handling and very good durability for a broad range of application. As these cable are also light in weight therefore these are streamline cable.
Armoured cable used for rodent protection in direct burial if you required.
Jelly filled optical fiber is designed endure outside temperature and high moisture condition.
Mostly single mode is used in telecommunication network, cable T.V(CATV) network and 5G network mainly depend on optical fiber. As optic cable transmit large amount of data at very high speed. As optical fiber use light as a signal therefore they do not affected by EM wave and it provide us high security transmission for a long distance
Multimode fiber mostly used inside data center, in a LAN(Local Area Network) and CAN(Campus Area Network). As Multimode fiber provide us greater bandwidth and speed.

ALUMINUM AND COPPER CABLE

noreply@blogger.com (INDER KUMAR TIWARI) — Sun, 07 Jun 2020 11:49:00 +0000

Electrical cable

An electrical cable is an assembly of one or more wire which are arrange side by side or in a bundled form and by the help of these cable we can transfer electric current or signal from source to destination.

Construction of cable

A cable have following main components
1-CONDUCTOR
Conductor is the main component of the cable and by the help of the conductor current will flow through the cable. Mostly two type of Cables are use in day-today life
i-Copper(Cu) cable
As Copper have low resistance and better conductivity therefore copper cable are mostly used for signal transmission and controlling the device by sending the signal that is why it is also known as Control cable.
ii-Aluminium(Al) cable
As Aluminium are lightweight and low cost therefore Aluminium is mostly used for power transmission and aluminium cable are also known as power cable.

2-INSULATION(OR DIELECTRIC)
By the help of dielectric(or insulation) we provide an isolation between the conductors within the cable. Most commonly used dielectric in cable are polyvinyl chloride(PVC), Cross-linked polyethylene(XLPE), poly chloro prene(PCP),paper, HDPE(High Density Polyethylene), etc.

3-BEDDING(or also called as inner sheath or inner jacket)

Bedding(or also called inner sheath or inner jacket)

It helps to provide circular shape to the cable and used to provide a protective boundary to inner and outer layers of the cable.

4- OUTER SHEATH
The sheath of a cable is provide outer protection to the cable by the help of which we protect our cable from external environmental condition such as moisture, external temperature, external electro-chemical attack, fire, etc. The Sheath also provide mechanical strength to the cable. Most commonly used sheath in cable are polyvinyl chloride(PVC), Cross-linked polyethylene(XLPE), Ethylene propylene Rubber(EPR)

outer covering of the cable also known as:-

Jacket:- In case of signal cable outer covering of the cable is normally called jacket of the cable.

Serving:- In case of HT cable outer covering of the cable is normally called Serving of the cable.

Outer Sheathed:-In case of LT cable outer covering of the cable is normally called Outer Sheathed of the cable.

5- SCREEN ON THE CABLE

Screen means a conducting layer on the cable, Which is used to neutralize extra electrons. In case of HT Cable metallic screen also help in increasing the heat dissipating power of the cable.

6- SEMICON(Extruded semiconducting compound) in case of HT cable

The Semicon layers prevent air-filled cavities between metal conductors and dielectric, so that electric discharges cannot arise and voltage will be uniformly distributed throughout the cables. This layer is present on the cable above 3.3KV.

Note:-Semicon is a XLPE insulating tape that has some conductive material as additive.

Mechanical protection

In some case we need to provide the mechanical protection to our cable therefore we can distinguish cable according to its protection
1-Armoured cable

Armouring as name suggests it is a protection. So, In case of Armoured cable usually Galvanised Steel is used for protection of the cable. This type cable is mostly used underground power or signal transmission because they do not bend easily.
In case of Armoured cable we are mostly do bedding. Bedding is a process of surrounding that cable by hessian cloth tape and jute, as a result cable get protection form mechanical injury due to armouring. It is just like a shock absorber.

In case of an armoured cable the outer insulation also know as serving.
NOTE:-Mostly XLPE Insulation is used in Armoured cable.

NOTE:-Generally in case of Armoured, In Aluminium armoured we get solid Aluminum conductor up to 10mm. In cupper armoured we get solid cupper up to 6mm.

Type of Armouring cable

SWA:-Steel Wire Armoured cable(W Or SWA)

Steel strip Flat armoured(F)

STA:-Steel Tape Armoured cable(STA)

Copper Tapped Armoured cable(CT)

2-flexible cable

The cable without armouring are known as flexible cable as these cable can be easily bend therefore they are used within wiring of house or company

NOTE:-In a multi-core cable the cores are identified by color-coding by using different colors on insulation or by number printing on cores

Classification of cable on the voltage

Low tension(LT)[or Low voltage]
It is used up to 1kv(1000V)
High tension(HT)[or High voltage]
It comes in range of 3.3KV to 33KV in some of the company in the India such as polycab (3.3kv, 6.6kv, 11kv, 22kv, 33kv).
In case of HT electrical distribution the system can be earthed or unearthed (if system neutral is not grounded).The selection of earthed/unearthed cable will depend on the system.

The HT cable again divide into two part

i-Earthed(E) cable
In three phase earthed system, phase to earth voltage is 1.732(√3) times less than phase to phase voltage. Therefore voltage stress on the cable to armor is 1.732(√3) times less than voltage stress between conductor to conductor.
So earthed cable stress is 1.732 times less than as compare to Unearthed(UE) cable
ii-Unearthed(UE) cable
As on unearthed cable has more stress(1.732√3 times) as compare to earth cable therefore. The unearthed cable has more insulation strength as compared to earthed cable. As a result the voltage carrying capacity of unearthed cable is more than earthed cable. The 6.6kv unearthed cable can with stand with voltage of 11kv(6.6X√3=11.4312), therefore generally people says that 6.6kv unearthed cable is equal to 11kv earthed cable.

Standards in the cables

Cable standards are most important criteria which decide thickness of insulation, armouring and test passed by the cables almost every country have its own standard for wire and cable.

IS:-Indian Standards published by Bureau of India Standard(BIS)

BS:-British standards

IEC:-International Electrotechnical Commission

EN:-European standards

VDE:-Verband De Elektrotechnik (German standards)

NF:-France standards

UL:-USA standards

JIS:-Japanese standards

Code in the cable

A2XFY

A=Aluminium

2X=xlpe insulation.

F=Steel strip Flat armoured

Y=PVC outer sheath

A2XWY

A=Aluminium

2X=xlpe insulation.

W=Round Wire armoured

Y=PVC outer sheath

Annealing process

Annealing is a heat treatment process. Annealing process increase corrosion resistance of a metal improve the electrical and thermal conductivity of a metal increasing toughness, reducing hardness and increasing the ductility and machinability of a metal.

Stain hardened(H)[ or work hardening process]

Stain hardened(H) is a process to increase the hardness and strength of metal by plastic deformation.

The first digit after the H indicates a basic operation

H1 – Strain Hardened Only.

In H1 material is strain hardened without thermal treatment.

H2 – Strain Hardened and Partially Annealed.

H3 – Strain Hardened and Stabilized by low temperature heating.

H4 – Strain Hardened and Lacquered or Painted.

In aluminium cable manufacturing we use h2, h4 grade plain aluminium conductor that possesses high tensile strength.

WIRE

noreply@blogger.com (INDER KUMAR TIWARI) — Fri, 05 Jun 2020 13:47:00 +0000

WIRE

A wire is a single rod of metal which can be used for electric power transmission(e.g:- in power line and in Domestic wiring),for signals transmission(e.g:-in telecommunication) and to bear mechanical loads(e.g:-In case of a elevator wire)
or
A wire is a single conductor. It may be with solid(Class 1), Stranded(Class 2), or flexible(class 5) conductor.

What materials are used to make wires?

For electric power transmission we use mainly two types of conductor for wire formation
1-Copper(Cu)
2-Aluminum(Al)

Copper(Cu)

It has high conductivity, high tensile strength and high cost as compare to Aluminum. Most of the signal cable are copper cable due to its good conductivity

Aluminum(Al)

It has low conductivity, low tensile strength and low cost. Aluminum is mostly use in the form of cable for power transmission due to its low cost.

physical forms of conductor

physical forms of conductor in the wire may be a solid conductor(i.e a single solid conducting wire) or it may be strand conductor(or multi-strand)
Strand meaning :-A single piece of cotton, hair, thread.
Therefore multi-strand wire are those wire in which there are multiple wire of very small diameter are present.

According to the flexibility of the wire conductors we can divided it into 4 classes

Class 1: Solid conductor

Class 2: Class 2 are stranded conductors and Class 2 conductor preferred for fixed installations such as house wiring(or building wiring) due to lower resistance, better mechanical strength and less energy losses.

Class 5: Class 5 having more strand's of thinner dia than class 2 and it is used where more flexibility is desirable.

Class 6: Extra flexible conductor Mostly used for cords and welding, etc.
So we can say that class 1 and class 2 are cables used for fixed installations, Whereas class 5 and class 6 are used where we need flexibility.

Normally our house wiring(or building wiring) is belong to class 2 and class 5

But due to thinner dia resistance of conductor increase due to which energy loss increase. This is the reason due to which for fixed installations such as house wiring(or building wiring) Class 2 is prefer over class 5.

However in case of class 5 more number of strands in a cable increase its flexibility, heat dissipation property of the cable by increasing the surface area of overall conductor in the contact of surrounding environment. So more number of strands helps to maintain operating temperature with slightly higher resistance.

Insulation

When we use wire for carrying the electric current we mostly provide an insulation the wire and there are different types of insulation which is use for a wire

PVC(Polyvinyl chloride)

PVC is mostly used for insulation of the cable because of its ease to use and widely available. It provide a better insulation but it easily catch fire and give a large amount of smoke, therefore PVC quality is improve and we get different version of PVC such as FR, FRLS, HFFR, etc.

What is the difference between FR and FRLS wires?

FLAME RETARDANT (FR)

Compared with normal PVC wire FR wire do not catch fire easily, But these wire emit smoke. As we know that in case of a fire accident a major cause of death is smoke so our scientist try our best to remove the smoke from wire therefore we have different types of wire for low smoke e.g FRLSH and FRZH

FLAME RETARDANT LOW SMOKE (FRLSH)

As compare to fire property FRLS is just like FR, But it emit low amount of smoke as compare to the FR.

Oxygen index of Normal PVC cable is about 25% while FRLS Industrial Cable have oxygen index of more than 29%(minimum)

FLAME RETARDANT ZERO HALOGEN (FRZH) / LOW SMOKE ZERO HALOGEN (LSZH) / HALOGEN FREE FLAME RETARDANT (HFFR)

It is better than FRLSH because here we get zero halogen from the smoke of LSZH as halogen is a toxic gas.

Wire gauge

Wire gauge is also a way of measurement of wire diameter.
AWG(American Wire Gauge), As the value of AWG is increase the diameter of wire is decrease. AWG comes in range of 0 to 40 normally.
10AWG=2.588mm
28AWG=0.321mm