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Aluminum Rods Bare Conductors And CablesUniversal Cable (M) Berhad, incorporated in 1967 has grown steadily to become the country’s single largest cable manufacturer today since its 1990 merger with
Through its far sighted planning and unceasing product and service innovation,
cable and wire products.
domestic and export markets to aluminium rods and high voltage cable, UCMB has achieved a distinguished reputation as a leading supplier of power and telecommunication cables to major corporations both local and foreign.
most advanced facilities for manufacturing aluminium and aluminium alloy rods
The aluminium and aluminium alloy rods manufactured today for the wire and
standards.
This catalogue serves as a guide to UCMB’s manufacturing processes and standards in the manufacture of aluminium rod, conductor and cables.
7
CONTENTS
Page
INTRODUCTION......................................................................................................................................... 1
ALL ALUMINIUM CONDUCTORS ( AAC )BS 215, Part 1 .......................................................................................................................................................10
..................................................................................................................................................................11
..........................................................................................................................................................11
...............................................................................................................................................13
..............................................................................................................................................................13
ALL ALUMINIUM ALLOY CONDUCTORS ( AAAC )..............................................................................................................................................15
..................................................................................................................................................................15
...............................................................................................................................................16
..........................................................................................................................................................17
ALUMINIUM CONDUCTORS STEEL REINFORCED ( ACSR )BS 215, Part 2 .......................................................................................................................................................19
..................................................................................................................................................................19
..........................................................................................................................................................20
..............................................................................................................................................................22
............................................................................................................................................................23
PVC COVERED ALUMINIUM CONDUCTORS...............................................................................................................................
ALUMINIUM 1350 AND ALUMINIUM ALLOY RODSChemical composition........................................................................................................................................25
Mechanical and electrical properties...............................................................................................................25
Diameter tolerance.............................................................................................................................................25
APPENDIX : TECHNICAL DATAProperties of aluminium, aluminium alloy and copper ................................................................................26
Comparison of aluminium and copper conductors.....................................................................................27
...................................................................
Current rating calculation for bare conductor .............................................................................................29
Wire gauges ..........................................................................................................................................................32
Common conversion factor ..............................................................................................................................
.....................................................................................................................35
Publications referred to......................................................................................................................................36
This trend is due to their excellent overall properties. Principally these are listed as:
1. Conductivity
2. Strength
3. Workability
4. Light Weight
5. Corrosion resistanceMost industrial, marine and chemical atmospheres cause corrosion.
6. Compatibility with insulation
clean stripping.
and distribution. The major areas dominated by aluminium and aluminium alloy conductors are non-insulated overhead power transmission, insulated overhead power transmission and non overhead power distribution.
alloy conductors offer good conductivity, light weight, excellent resistance to corrosion, good bending properties, greater tensile strength than copper and excellent compatibility with most common insulation used by the wire and cable industry.
heavy current installations) where weight and ease of handling are important factors.
ALUMINIUM CONDUCTORS
9
wire) to wire stranding from a large diameter of redraw aluminium and aluminium alloy rods.
annealing and heat-treating.
distribution cables where the characteristics of aluminium are of importance.
10
ALL ALUMINIUM CONDUCTORS ( AAC )( BS 215, Part 1 )
Code name area
Construction,
diameter
Calculatedarea
overalldiameter
weight
Calculatedbreaking
load
CalculatedDC resistance
at 20°C
Hard-drawn copper
mm² mm² mm mm²
Midge 22 23.3 3.99 1.227
50 9.30 33.2
60 63.6 10.2 9.90
Wasp 100 106 13.2 290 16.00 0.2702 66.6
Hornet 150 16.3 99.3
Chafer 200 213
Cockroach 250 266 21.1 731 167
300 323 23.3 203
Centipede 26.5 63.10 261
ALL ALUMINIUM CONDUCTORS ( AAC )
show some typical stranding patterns.
19(1+6+12)7(1+6)
11
ALL ALUMINIUM CONDUCTORS ( AAC / 1350 ) ( AS 1531 )
Code name
Construction,
diameter
Calculatedsectional
areaoverall
diameterweight
Calculatedminimum
breaking load
CalculatedDC resistance
at 20°C
Hard-drawn copper
mm² mm mm²
7.50 5.71 21.6113 6.72 26.2
9.00 135 0.579 31.1Mars 77.3 11.3 211 0.370Mercury 111 13.5 16.9Moon 339 0.232
16.3 99.3Orion 17.5 503 0.157 115Pluto 210 576 31.9 0.137 132Saturn 262 21.0 721 0.110 165Sirius 307 193Taurus 337 51.3 212Triton 26.3 1,120 62.2 0.0706 257Uranus 506 29.3 75.2 0.0572Ursula 31.5 1,620 369Venus 97.2
ALL ALUMINIUM CONDUCTORS ( AAC ) ( ASTM B 231 )
Code name
Hard-drawn copper Stranding
class *
Construction,
diameter
Calculatedarea diameter
Standardweight
Calculatedbreaking strength
CalculatedDC resistance at 20°C
mm² mm Kg
Peachbell
PansyPoppy
PhloxOxlip
ValerianDaisy
PeonyTulipDaffodil
CannaGoldentuftCosmos
SyringaZinnaHyacinth
DahliaMistletoeMeadowsweet
OrchidHeucheraVerbena
6
2
1
250
250
300
350
397.5
500500
556.5556.5600
636650700700
6
321
157.2
157.2
220
250
300
300
350350377
21.133.5
53.5
107127
126135135
152171
201
253253
303
322330
355
9.3610.5
13.3
15.1
16.016.917.3
19.620.1
20.220.620.7
22.6
23.323.6
37
92
117
296
372372
696
779
909975976
399611
901
1,3721,735
2,110
2,257
3,2223,5713,775
3,965
5,2695,651
2.151.37
0.6790.539
0.2130.213
0.1900.1690.162
0.1260.120
0.120
0.1020.1020.0951
12
ALL ALUMINIUM CONDUCTORS ( AAC )( ASTM B 231 )
Code name
Hard-drawn copper
area
Strandingclass *
Construction,
diameter
Calculatedarea diameter
Standardweight
Calculatedbreaking strength
CalculatedDC
resistance at 20°C
mm² mm Kg
Violet
Petunia
Cattail
CoskscombSnapdragonMagnolia GoldenrodHawkweedCamellia
Bluebell
Marigold Hawthorn
Columbine
CarnationGladiolusCoreopsis JessamineCowslipSagebrush
BitterrootTrilliumBluebonnet
715.5715.5750
750795795
900900
1,0001,000
1,033.51,033.51,113
1,192.51,2721,351
1,510.51,590
1,7502,0002,250
2,5002,7503,0003,500
500500
566566600
600629629
650650700
750
900950
1,000
1,1011,260
1,5701,730
2,200
362362
506
525525
725767
1,016
1,2671,3961,5171,776
25.3
26.026.1
27.7
29.329.3
30.9
32.033.0
35.036.036.9
50.7
997
1,1071,110
1,2551,2601,332
1,552
1,6631,777
1,9972,111
3,523
6,156
6,510
6,9797,223
7,6507,7767,990
9,53310,01110,620
11,61112,199
20,91522,72526,607
0.07960.07960.0757
0.07570.07170.0716
0.06330.06300.0596
0.0595
0.0570
0.0511
0.0376
0.0325
0.0256
0.0230
0.01920.0165
13
ALL ALUMINIUM CONDUCTORS ( AAC )( DIN 48201, Part 5 )
area
Construction,
diameter
Calculatedarea
overalldiameter
Standardweight
Calculatedbreakingstrength
CalculatedDC resistance
at 20°C
Hard-drawncopper
mm² mm² mm Kg mm²
162535
505070
95120150
300
500625
1000
15.9
93.3117
299
500626
1,000
5.16.37.5
9.09.010.5
12.5
17.520.322.5
26.029.132.6
36.9
66.3
135133
256322
500670
1,105
1,733
2,2202,767
290
590
1,155
1,5991,916
3,115
7,6169,716
12,076
0.5950
0.1960
0.11910.09650
0.07221
0.03611
10.015.221.6
31.1
73.692.5
153
251
629
ALL ALUMINIUM CONDUCTORS ( AAC ) ( JIS C 3109 )
area
Construction,
diameter
Calculatedarea
overalldiameter
Standardweight
Minimumbreaking
load
CalculatedDC resistance
at 20°C
Hard-drawncopper
mm² mm² mm Kgf mm²
30
55
95150200
300
510660
1,260
29.137.256.3
97.0153
239
513656
1,261
6.9
9.6
12.616.0
20.0
25.9
33.3
79.5102
265
560
655
1,097
2,716
79.5102
265
560
655
1,097
2,716
0.7690.507
0.295
0.1200.09690.0726
0.0563
0.02970.0230
61.096.2
150
250
323
531
615793
ALL ALUMINIUM ALLOY CONDUCTORS ( AAAC )
1. Strength
2. Weight
3. Corrosion resistance
areas.
4. Surface hardness
and radio interference is a major consideration.
5. Termination
6. AC Resistance
conductor.
19(1+6+12)7(1+6)
15
ALL ALUMINIUM ALLOY CONDUCTORS ( AAAC )( BS 3242 / MS 1143 )
Codename
aluminiumarea
Construction,
diameter
Sectionalarea
overalldiameter
weight
Calculatedbreaking
load
CalculatedDC resistance
at 20°C
mm² mm² mm
Cedar
Oak
Upas
2530
50100150
175300
30.135.5
59.9119
211362
7.07.6
9.9
97131
325
997
33.3050.65
59.10101.5
0.2769
0.09155
ALL ALUMINIUM ALLOY CONDUCTORS ( AAAC / 1120 )( AS 1531 )
Codename
Construction,
diameter
Sectionalarea
Calculated
aluminium areaoverall
diameterweight
Calculatedbreaking
load
CalculatedDC resistance
at 20°C
mm² mm² mm
ChlorineChromium
HeliumHydrogen
Krypton
Oxygen
PhosphorusSeleniumSiliconSulphur
77.3111
210
262307337
506
39.7
73.7106
150173199
291320
555636
7.5
9.0
11.313.5
16.317.5
21.0
26.329.331.5
113135
211
339
503576
721
1,120
1,620
9.91
17.6
27.1
62.2
73.6
93.1
127
0.7130.599
0.2660.239
0.163
0.0973
0.07310.05920.0511
16
ALL ALUMINIUM ALLOY CONDUCTORS ( AAAC / 6201 )( AS 1531 )
Codename
Construction,
diameter
Sectionalarea
Calculated
aluminium areaoverall
diameterweight
Calculatedbreaking
load
CalculatedDC resistance
at 20°C
mm² mm² mm
DiamondDolomite
GarnetJadeJasper
OpalPatronitePearl
SapphireSpinelTantalum
77.3111
210
262307337
506
29.3
106
155
221260
7.5
9.0
11.313.5
16.317.5
21.0
26.329.331.5
113135
211
339
503576
721
1,120
1,620
11.613.9
21.731.2
51.3
73.5
115135156179
0.9670.7990.671
0.212
0.159
0.1090.0991
0.06620.0572
ALL ALUMINIUM ALLOY CONDUCTORS ( AAAC ) ( DIN 48201, Part 6 )
area
Construction,
diameter
Calculatedarea
overalldiameter
Standardweight
Calculatedbreakingstrength
CalculatedDC resistance
at 20°C
mm² mm² mm Kg
162535
505070
95120150
300
500625
1000
15.9
93.3117
299
500626
1,000
5.16.37.5
9.09.010.5
12.5
15.7
17.520.222.5
26.029.132.6
36.9
135133
257322
501671
1,106
1,735
2,2222,770
691979
1,377
2,6573,333
6,909
2.0911.3700.9669
0.69050.5073
0.1120
0.067090.05367
0.03362
17
ALL ALUMINIUM ALLOY CONDUCTORS ( AAAC ) ( ASTM B 399 )
Codename
Strandingclass *
Construction,
diameterdiameter
Standard weight
Calculatedbreakingstrength
Calculated DCresistance at
20°C
KCM mm² mm Kg
ButteCanton
CairoDarien
Greeley
123.3
195.7
559.5
927.2
15.5
39.3
62.5
99.2
125
200
236
331
375
5.0
10.111.3
16.3
19.9
23.6
25.1
172217
551
652
913
1,0331,295
503
1,270
6,011
9,955
11,020
2.161.36
0.536
0.337
0.211
0.101
0.0713
ALUMINIUM CONDUCTORS STEEL REINFORCED ( ACSR )
stranding patterns..
6+1 6+7(1+6) 12+7(1+6)
26(10+16)+7(1+6)
72(9+15+21+27)+7(1+6)
19
ALUMINIUM CONDUCTORS STEEL REINFORCED ( ACSR )( BS 215, 2 )
Codename
aluminiumarea
Construction,Cross-sectional area
overalldiameter
weight
Calculatedbreaking
load
CalculatedDC
resistanceat 20°C
Steel Total
mm² mm² mm² mm
GopherWeasel
SkunkHorse
DogWolfDingo
CaracalPanther
JaguarBatang *Zebra
2530
506070
100150150
175175200
200300
26.2531.61
63.2273.37
105.0
212.1
210.6323.0
30.62
61.70100.1116.2
167.5
226.2
261.5
222.3
7.779.00
10.0512.9513.95
16.75
19.53
21.00
19.30
106
172
726506
6711,0101,621
9.61
15.20
61.20
32.7069.2035.70
92.25
69.67131.9
1.0930.90770.6766
0.3936
0.2733
0.15760.15630.1363
0.1367
ALUMINIUM CONDUCTORS STEEL REINFORCED ( ACSR )( AS 3607 )
Codename
Construction, Calculated
aluminium area
Cross - Sectional
areaoverall
diameterweight
Calculatedminimum
breaking load
Calculated DC resistance at
20°CSteel
mm² mm² mm
BananaCherryGrape
MangoOrangeOlive
PawpawPeach
29.035.1
65.2105
207
373
936
77.31
261.5306.9356.0
506.0
672.0
7.50
9.00
11.3
17.5
21.0
27.029.331.5
119
171
677
973
1,320
1,6901,960
3,660
10.512.6
22.7
63.5
105122
119137159
292
0.975
0.677
0.2710.196
0.1360.1160.100
0.0557
0.0303
Standard High - Strength Conductor
Quince
SultanaWalnut
31.577.31
5.37.59.011.3
95195
12.7 3.251.59
0.573
20
ALUMINIUM CONDUCTORS STEEL REINFORCED ( ACSR )( ASTM B 232 )
Codename
Hard-drawncopper
area
Construction,Calculated area
overalldiameter
Standardweight
Calculatedbreaking
load
CalculatedDC
resistanceat 20°CSteel Steel
mm² mm² mm kgf
Turkey *Swan *Swanate
Sparrow *Sparate *
Quail *Pigeon *
Penguin *Waxwing *Partridge *
OstrichWidgeon
Oriole *Chickadee *Brant *
Pelican *
Hawk *Hen *
6
221
300.0
397.5397.5
397.5397.5
66
3
21
250250
250250300
300300300
13.30
33.59
53.5267.33
107.2135.0
152.2170.2170.6
170.5200.9201.6
201.3200.9
2.223.535.35
5.60
7.07
11.22
17.97.522.0
9.5
11.226.1
32.7
13.5
39.256.3
6.366.53
9.00
10.111.3
15.516.3
17.3
19.6
19.9
20.7
21.5
100
136159171
216272
615
690
762
772
915976
1,110
1,070
1,291
1,617
3,001
3,1135,111
3,926
9,2295,335
10,772
2.161.351.36
0.676
0.536
0.337
0.215
0.1900.1690.170
0.170
0.119
0.1200.1200.120
Osprey *Parakeet *Dove *
Peacock
WoodduckTealSwift
Kingbird *
Grosbeak *
Scoter
GannetStiltStarling
CootCuckoo *
Drake *Tern *CondorMallard
556.5556.5556.5
556.5605.0605.0
605.0605.0636.0
636.0636.0636.0
636.0636.0666.6
666.6715.5715.5
715.5795.0795.0
795.0795.0795.0795.0
350350350
350
500500
500500500500
306.1
307.1307.1323.0
323.0323.1
322.6322.6337.3
363.3361.9
362.1
15.736.6
71.669.69.0
17.9
52.5
75.373.5
59.1
11.252.2
52.2
23.223.6
25.325.223.7
23.9
25.2
25.925.9
26.326.7
27.7
27.027.729.0
900
1,1591,236
960
1,0301,2221,302
1,276
1,3661,372
1,651
1,522
1,6271,3351,522
6,2199,005
11,030
13,131
7,11210,306
10,759
11,96011,561
15,673
12,630
10,01712,756
0.1020.1030.103
0.103
0.0900
0.09000.0900
0.0797
0.07170.0720
0.07200.07170.07200.0719
21
ALUMINIUM CONDUCTORS STEEL REINFORCED ( ACSR )( ASTM B 232 )
Codename
Hard-drawncopper
area
Construction,Calculated area
overalldiameter
Standardweight
Calculatedbreaking
load
CalculatedDC
resistanceat 20°C
Steel Steel
mm² mm² mm kgf
CanaryCatbird
Cardinal *Tanager OrtolanCurlewBluejay *
BuntingGrackle
SkylarkBittern *Pheasant * DipperMartinBobolink * Plover *
Parrot
Chukar
BluebirdKiwiThrasher
900.0900.0
1,033.5
1,033.51,033.51,113.0
1,113.01,192.51,192.5
1,272.01,272.01,272.0
1,351.01,351.0
1,510.01,510.0
1,590.01,590.0
2,156.02,167.02,312.0
566566600
600600650
650650700
700750750
900
900950950
1,0001,0001,119
1,3561,362
523.9522.5565.5
565.0
725.3
726.9
766.1
903.2
1,0931,1001,171
31.759.113.5
33.5
36.367.7
71.6
76.9
17.9
50.1
97.0
55.6
73.5
29.529.0
29.6
30.1
31.632.0
32.933.1
33.5
35.1
35.236.236.2
37.237.2
39.3
1,5091,726
1,602
1,553
1,976
2,133
1,9192,133
2,263
2,529
2,670
3,736
3,759
15,3629,670
12,57516,56613,536
17,757
19,011
11,950
16,39521,02117,392
22,277
23,151
0.06360.06350.0595
0.0599
0.0551
0.0553
0.0512
0.0515
0.0399
0.0379
0.03590.03610.0322
0.02660.0265
22
ALUMINIUM CONDUCTORS STEEL REINFORCED / HIGH STRENGTH (ACSR/HS) ( ASTM B 232 )
Codename
Hard-drawncopper
area
Construction,Calculated area
overalldiameter
Standardweight
Calculatedbreaking
load
CalculatedDC
resistance at 20°CSteel Steel
mm² mm² mm kgf
GrousePetrelMinorca
GuineaDotterel
DorkingBrahmaCochin
159.0176.9
203.2211.3
50.3
69.7
100.0111.2
120.0
51.6156.11
96.51
107.0
30.1032.73
52.15
56.30
9.3211.712.2
13.5
16.0
16.9
222379
500590656
1,005
2,5915,096
9,233
0.7112
0.5163
0.3605
0.3002
0.2707
ALUMINIUM CONDUCTORS STEEL REINFORCED ( ACSR )( JIS C 3110 )
sectionalarea
diameterCalculated
cross-sectional area overalldiameter
weight
Minimumtensileload
CalculatedDC resistance
at 20°CSteel Steel
mm² mm² mm² mm Kgf
2532
95120160
200
330
520*610
31.957.7
159.3
519.5
5.39.6
15.929.137.2
59.3
67.367.3
56.3
6.9
10.5
13.516.1
20.3
25.3
31.2
101129233
733
9121,1101,320
1,6731,9692,3202,700
907
10,21010,950
13,91015,600
1.15
0.3010.233
0.120
0.07020.0559
0.0356
23
ALUMINIUM CONDUCTORS STEEL REINFORCED ( ACSR )( DIN 48204 )
sectionalarea
Steel Totalsectional
area
Overalldiameter weight
Calculatedbreaking
load
CalculatedDC resistance
at 20°CConstruction Construction
mm² mm² mm² mm² mm Kg
15.323.9
51.2
69.9
96.5
105.7121.6122.1
127.9
209.1212.1
230.9
263.7
339.3
510.5
561.7
571.2653.5
2.5
5.7
31.7
15.356.3
75.5
71.3
39.5
39.5
56.3
39.563.6
71.3
39.5
27.9
75.756.3
109.7
157.7173.1211.9
213.6
261.6
260.7
369.1
553.9
621.0611.2
610.7
1,090.9
11.29.611.7
11.713.616.0
17.515.5
16.117.1
19.020.321.0
21.021.9
25.0
27.026.7
30.629.9
30.7
32.2
32.2
36.0
6297
372196
712
901
591605
1,002
1,2361,160
1,653
1,561
1,636
1,7702,092
2,1632,570
593920
1,295
1,752
10,012
5,902
6,761
10,71910,129
12,333
13,900
12,25915,59112,272
13,70217,077
22,223
0.6573
0.2992
0.2736
0.22590.1939
0.1571
0.1363
0.0757
0.0666
0.0590
0.05660.0526
0.0506
0.0277
PVC - COVERED ALUMINIUM CONDUCTORS( BS 6485 and BS 215, Part 1 )
aluminiumwire
Construction,
diameterdiameter ofconductor
CalculatedDC resistance
at 20°Cbreaking
load
diameter of covered conductor
mass of coveredconductor
mm² mm mm
225060*100150*200250*
9.3010.2013.1716.25
21.10
1.227
0.2702
3.99
9.9016.0025.70
11.713.016.019.721.7
100220270
610760970
PVC - COVERED ALUMINIUM CONDUCTORS
The PVC - covered conductors have been developed primarily to give protection to telecommunication lines which are crossed by power lines and to give protection to the public from low voltage lines in case of accidental contact for short periods.
The PVC - covered power lines have also been found useful in corrosive atmospheres and for
exceed 650 V r.m.s. between any two conductors or 250 V r.m.s. between any conductor and earth.
25
CHEMICAL COMPOSITION
1350 6201 6101 1120
Silicon Max.
Copper Max.Manganese Max.Magnesium Max.Chromium Max.Zinc Max.Boron Max.Gallium Max.Vanadium & Titanium, total Max.Other elements, each Max.Other elements, total Max.
0.10
0.050.01
-0.010.050.050.030.020.030.1099.50
0.5 ~ 0.90.500.100.03
0.6 ~ 0.90.030.100.06
--
0.030.10
0.500.100.03
0.030.100.06
--
0.030.10
0.10
0.05 ~ 0.350.010.200.010.050.050.030.020.030.1099.20
MECHANICAL AND ELECTRICAL PROPERTIES
DesignationTensile strength Conductivity Volume resistivity
1350 - O1350 - H12 & H22
1350 - H16 & H26
6.0 ~ 9.9
11.9 ~ 15.5
61.5
61.3
620161011120
16 ~ 1916 ~ 19
5152 0.033156
0.029300
DIAMETER TOLERANCE
Deviation of mean diameter Deviation at any point
mm mm mm
9.57.6
± 0.5 ± 0.76± 0.61
ALUMINIUM 1350 AND ALUMINIUM ALLOY RODS
26
PROPERTIES OF ALUMINIUM, ALUMINIUM ALLOY AND COPPER
Characteristics UnitCopper
Hard-drawn 6201 6101 1120 Hard-drawn
2.703 2.703 2.703 2.703 2.703
Tensile strength Min. 16 Max. 9.2 16 ~ 19 16 ~ 19
m Ohm.cm 3.31 2.93 1.777
Conductivity at 20°C 61 61.5 51 52 97 100
Temperature per °C 0.00390 0.00393
expansion23 23 23 23 23 17 17
Melting Point °C 660
Mechanical properties of aluminium alloy wires as per ASTM B 398
Tensile strength ( MPa )
Over Up to and including
1.5 3.25 330 315 3.0
3.25 315 305 3.0
Mechanical properties of aluminium alloy wires as per IEC 60104
Tensile strength ( MPa )
Over Up to and including Minimum Minimum
--- 3.5 325 3.0
3.5 --- 315 3.0
APPENDIX : TECHNICAL DATA
27
Electrical properties of aluminium alloy wires as per ASTM B 398 and IEC 60104
Tolerance Conductivity
Over Up to and including ( mm )
--- 3.00 ± 0.03 52.5
3.00 --- 52.5
Mechanical and electrical properties of aluminium 1120 wires as per AS 1531
Tensile strength Conductivity
Over Up to and including ( MPa )
1.5 2.5 250 0.0293
2.5 3.25 250 1.0 0.0293
3.25 3.75 1.2 0.0293
3.75 230 1.2 0.0293
230 0.0293
COMPARISON OF ALUMINIUM AND COPPER CONDUCTORS
ParticularCopper (annealed) Take hard-drawn
Weight 30 329
61
329 30
Diameter 55
50 200
137 73
61
Diameter
Weight 50 200
Weight 237
Diameter 119
CURRENT RATING CALCULATION FOR BARE CONDUCTOR ( IEC 61597 )
The symbols used in this section :
D = conductor diameter (m)
Si = intensity of solar radiation (W/m2)Ke
RT
Nu = Nusselt number : Nu = 0.65 Re0.2 + 0.23 Re0.61s = the Stefan-Boltzmann constant (5.67 x 10-8 W.m-2.K-4)Re = the Reynolds number : Re=1.644 x 109 v D [( T1 + 0.5 ( T2 - T1 )]
-1.78
with the conductor, 0.02585 W.m-1.K-1
v = wind speed (m/s)T1 = ambient temperature (K)T2
Imax= current rating (A)
Imax = [( Prad + Pconv - Psol )/RT]1/2
(a) Prad - the heat loss by radiation of the conductor ( W/m ) Prad = s D Ke ( T2
4 - T14 )
(b) Pconv - the convection heat loss ( W/m ) Pconv 2 - T1 )
(c) Psol - the solar heat gain by the conductor surface ( W/m )Psol = D Si
(d) RT
RT = f(x).RT2
ƒ(x)= 0.996 09 + 0.018 578x - 0.030 263x2 + 0.020 735x3
x =
RT2 = R20 [ 1 + ( T2 - 20 ) ]
= 0.00403 ( aluminium )= 0.00360 ( aluminium alloy )
RT2 = conductor DC resistance at temperature T2
D1 = conductor diameter in cmd1 = steel core diameter in cmFor conductor other than ACSR, d1 = 0 cm
0.01 (D1 + 2d1)
(D1 + d1)
8 . f (D1 - d1 )½
RT2 (D1 + d1 )[ ]
ACSR 30/7/2.59mm(BS 215 Part 2)
D = 18.13mm v = 1 m/sSi = 900 W/m²
= 0.5
R20
T1 = 40ºC ( 313K )T2 = 80ºC ( 353K ) Ke = 0.6
d = 7.77 mmf = 50 HzRe = 964.6
Calculation
(a) Prad = 5.67 x 10 - 353
(b) Pconv0.2 0.61
(c) Psol
T T2 T2
x = = 0.611740.01 (1.813 + 1.554 )
(1.813 + 0.777)
8 (50)(1.813 - 0.777)½
0.227 (1.813 + 0.777)[ ]
2 3
Imax = [( Prad + Pconv - Psol )/RT]1/2
max
29
CURRENT RATING CALCULATION FOR BARE CONDUCTOR
The symbols used in this section :
Id = conductor inside diameter (cm)
D = overall diameter (cm)
S = aluminium sectional area (mm )
20
a
d1 = maximum conductor d.c resistance at 100d20 = conductor d.c resistance at 20
T0
Tr
)
ƒ(x) = the skin effect constant
hw )
C.cm )
I w .Tr½[ ]
where by :
(a) Heat dissipated due to wind velocity, hw
5.72 x 10-3
(273 + T0 + 0.5Tr)0.123 D[ ]V ½
hw
(b) Heat dissipated due to radiation, hr
5.67 x 10-12 0 + Tr ) - ( 273 + T0 )
Trhw
where by :
d1 d1 d20 ( 1 + 20. T )
2 + 0.020 735x3
[ ]0.01 (D + 2d) . f (D - d)½
( D + d ) d1 (D + d)
30
CURRENT RATING CALCULATION FOR BARE CONDUCTOR
1 d1
ƒ(x)1 2 3
where by :
x = I I 2 - d2) mm2
ii) in most case the following assumption is valid :
- æ = 0.9
Dd
D = 1.2 cmd20
Conditions :
T0
Tr
æ = 0.9
31
CURRENT RATING CALCULATION FOR BARE CONDUCTOR
Calculation :
][hw = 25.72 x 10-3 0.50.123 1.2
½
hr = 25.67 x 10-12
60
d1
][x =
½
2 3
a d1
-5 -5 ohm
Then
Current Rating,
][I =
= 311.5
0.50169 x 10-5
½
32
WIRE GAUGES
Gauge system Diameter Cross-sectional areaWeight of
copperWeight ofaluminium
S.W.G. mm mil mm² CM
--
-
--
-0--1-2--3-
-5-6-7-
--9-
10-
1112--
13
-15-
16-
17
--
19-
2021
--
-
-
-
-01-2-3
-5-6-7-
-9-
1011-
12-
13--
15--
16-
17-
--
1920-
21--
13.11912.700
10.973
10.16
9.266
7.620
7.011
3.665
3.251
2.906
2.3372.3052.0532.032
1.626
1.2911.2191.150
1.016
0.9117
0.7230
516.5500
372
300
276257.6252232
212
192
176162160
116
101.992
7271.96
57.0756
36
3231.95
170.5135.2126.7109.1107.2
70.12
61.36
53.19
33.63
27.2726.6622.7721.15
16.7715.6913.3012.9710.5510.51
6.633
5.261
3.309
2.627
2.0751.650
1.3091.167
0.65670.6529
209500
169100166200
125700
95110
7069065730
52120
35300
26000
2062020110163501629012970
10570
51295027
32253217
2029
160912751257
1012
636.3
250000215300211600
160000
13310012110010560010500090000
6637063500
52620
33100309702625025600
16510
13090
6531
32573136
16001296
1021
151512021126969.9953.2
720.7
599.5
377.0
299.0
237.0
166.1
139.5
115.3
60.61
37.09
23.3523.33
11.63
9.226
7.207
365.0
255.3229.5
165.7
123.1
73.6371.99
57.10
35.9235.02
22.59
17.91
11.26
7.093
3.152
2.221
1.7731.763
1.397
33
WIRE GAUGES
Gauge system Diameter Cross-sectional areaWeight of
copperWeight ofaluminium
S.W.G. mm mil mm² CM
-22-
23-
--
25-
26-
27-
--
29-
30--
31-
32-
33-
-35-
36-
37--
-39-
-
-
-
-
-50
22-
23-
-2526-
27-
-29-
3031-
32-
33
-35-
36-
37-
-39-
-
-
-
-
-
-
--
---
-50-
0.7112
0.60960.5733
0.5106
0.37590.3606
0.32110.3150
0.2337
0.20190.1930
0.17270.1602
0.13210.12700.12190.1131
0.10160.1007
0.07113
0.06069
0.05023
0.03159
0.02505
25.35
22.5722
20.120
17.9
13.6
11.611.26
10.03109.2
7.957.6
6.3056
5.6155.25
3.9653.6
3.5313.2
2.2212
1.7611.6
1.397
1.2
1
0.39730.32560.2919
0.2027
0.16230.1363
0.11100.10210.09372
0.07791
0.050970.05067
0.035750.032030.02927
0.015970.013700.012670.011670.01005
0.0065670.006319
0.0050120.0039730.0031510.002919
0.002027
0.0015720.001297
0.0072970.00062160.0005067
317.3
251.6211.3199.6172.0
125.5
105.7
79.01
62.60
39.3736.3231.22
19.63
15.5715.2112.5712.35
6.159
3.072
2.0111.9321.5321.2151.1310.9635
576.0
269.0
219.0201.5
126.7116.6100.6100.0
79.7170.5663.2057.7650.13
39.7536.0031.53
25.00
19.3616.0015.7212.96
6.2195.760
3.9113.1022.560
1.951
1.2271.000
3.532
2.5952.295
1.212
0.9077
0.69260.60620.57090.5252
0.3590
0.2602
0.17910.1622
0.1126
0.07207
0.03532
0.025950.02222
0.017620.013970.01153
0.005526
1.073
0.69700.6622
0.29970.27570.2530
0.15950.1376
0.10900.09653
0.07902
0.06326
0.03700
0.031520.02713
0.021510.017730.01706
0.013530.01073
0.005351
0.0035020.0033650.0026690.0021160.00197
0.001331
COMMON CONVERSION FACTOR
Mass
11111
cwt
ibib
ton ( long )
===== 1.016
kggmkg
tonne ( metric )tonne ( metric )
0.01970.0352
220.26
1111
inftyd
mile
==== 1.6093
mmmmmmkm
0.03937
1.0936
111
in²ft²yd²
===
0.0929mm²m²m²
0.00155
1.196
Volume
111111
======
6.229
0.06135.33350.16050.03531.30791.2009
111
kgfton ( long ) f
===
kgf0.10190.10036
Pressure and Stress
1111
atmatm
bar
====
0.10131.0133
1.0197
MPabar
11111
HP.hBtuBtuBtucal
=====
0.0002931.0551107.59
BtukW.h
kJkgf.m
J
0.00393
0.009290.239
11 -6 in² = 0.5067 x 10-3mm²
35
FORMULA FOR ELECTRIC CALCULATION
To Calculate Given D.C
kW 1000 x kWV
1000 x kWV x pf
1000 x kW1.73 x V x pf
---V 1.73 x V
hpV x eff V x eff x pf 1.73 x eff x pf
Power (kW)1000kW = 1000kW = 1000kW =
---1000kW = 1000kW =
36
PUBLICATIONS REFERRED TO
and without prior notice. The information contained herein is in line with the appropriate standards and sound electrical practice -
products for a particular use, or for any errors or omissions, unintentional or otherwise.
