POWER CABLE

MANUAL
3RD EDITION
POWER CABLE
MANUAL
3RD EDITION

Edited by
Thomas P. Arnold
Manager of Power Cable Technology

and

C. David Mercier
Applications Engineering Manager

Southwire Company
One Southwire Drive
Carrollton, Georgia 30119, USA
800.444.1700
 Southwire Company
One Southwire Drive
Carrollton, Georgia 30119

© 2005 Southwire Company. All rights reserved.

Printed in the United States of America.

Hypalon is a registered trademark of E.I. DuPont DeNemours & Company.

National Electrical Code and NEC are registered trademarks of the
National Fire Protection Association.

Materials on pages 2-12 and 7-32 and the tables of electrical characteristics of cable
systems on pages 6-31 through 6-49 are reprinted with permission from NFPA 70-2005,
the National Electric Code, © 2005 National Fire Protection Association, Quincy,
Massachusetts 02269. This reprinted material is not the complete and official position
of the National Fire Protection Association on the referenced subject, which is repre-
sented only by the standard in its entirety.

This publication is a collection of items of general information related to the subject of power cable. It is not intend-
ed to be nor should it be used as authority for design, construction, or use of power cable. The design, construction,
and use of power cable should only be undertaken by competent professionals in light of currently accepted design
and engineering practices.

While great care has been employed to ensure that the tables and formulas contained herein are free of errors,
absolutely no warranties, either expressed or implied, are made as to the accuracy or completeness of any such
tables and formulas contained herein.

Those preparing and/or contributing to this publication specifically disclaim any warranty of any kind, either
expressed or implied. The warranties of merchantability and fitness for a particular purpose are hereby specifically
disclaimed by Southwire and all other parties involved in the creation, production, or delivery of this publication.

Neither Southwire nor anyone else who has been involved in the creation, production, or delivery of this publication
shall be liable for any direct, indirect, consequential, or incidental damages arising out of the use, the results of the
use, or inability to use such publication, even if Southwire has been advised of the possibility of such damages or
claim. Some states do not allow the exclusion or limitation for consequential incidental damages, so the above limi-
tation may not apply to you.
FOREWORD
Welcome to the third edition of the Southwire Company Power Cable Manual. Since
we first published this manual in 1991, we had distributed more than 20,000 copies
within the wire and cable industry. Your response to the first and second editions was
very encouraging. We greatly appreciate all of your positive reviews and helpful
suggestions. We are pleased to be able to make available a third edition providing
valuable information in addressing your technical questions.
Our objective at Southwire is to be your primary source for wire and cable products and
technical information. In addition to this manual, you may find valuable resources to aid
in answering your technical questions at www.southwire.com. Included is extensive
information on Southwire products and services, detailed technical information, copies of
our industry technical papers, product catalog, and monthly newsletters: Power Cable
Update and T&D Update.

USING THIS MANUAL

The Southwire Power Cable Manual provides engineering and installation information
for extruded dielectric power cable systems. The manual covers copper and aluminum
conductors from No. 14 AWG through 1000 kcmil, insulated for operation from 600
volts through 35 kilovolts. Although this manual includes specific recommendations in
certain sections, it is impossible to cover all possible design, installation, and operating
situations for every application. Please use the information in this manual as general
guidelines only.
We kept the contents as concise as possible while providing the basics of power cable
system engineering and installation. This manual is intended for users who have an
understanding of the engineering fundamentals of power cable systems. For additional
details and assistance, consult the reference publications listed at the end of the manual
or contact Southwire.
This manual includes many tables, equations, and related data for the convenience of
the user. Southwire’s Product Catalog, available at www.southwire.com, provides
additional data on cable weights, dimensions, and specifications to be used in concert
with this manual.
This manual is not a complete representation of the full range of wire and cable products
offered by Southwire. For information on any of your wire and cable needs, please
contact your local Southwire representative.
We welcome your suggestions on the third edition so that we can make future
editions more relevant, more current, and easier to use. We are constantly expanding
our technical resources and encourage you to send the enclosed response card or
comments via e-mail to talktous@southwire.com. Updates to the manual can be found
in the Technical Libraries section of Southwire’s web site at www.southwire.com.
REFERENCE ORGANIZATIONS
Below is a listing of organizations whose codes, standards, and technical papers are referenced
in this manual.

Association of Edison Illuminating Companies (AEIC)

600 North 18th Street
Birmingham, AL 35291-0992
www.aeic.org

The Aluminum Association

900 19th Street,N.W.
Washington, DC 20006
www.aluminum.org

American National Standards Institute (ANSI)

25 West 43rd Street, 4th floor
New York, NY 10036
www.ansi.org

American Society for Testing and Materials (ASTM)

100 Barr Harbor Drive
West Conshohocken, PA 19428-2959
Philadelphia, PA 19103
www.astm.org

Canadian Standards Association (CSA)

5060 Spectrum Way
Mississauga, Ontario, Canada L4W 5N6
www.csa.ca

Electric Power Research Institute (EPRI)

3412 Hillview Avenue
Palo Alto, CA 94303
www.epri.com

Insulated Cable Engineers Association (ICEA)

P.O. Box 1568
Carrollton, GA 30112
www.icea.org

Institute of Electrical and Electronics Engineers (IEEE)

3 Park Avenue, 17th Floor
New York, NY 10016-5997
(National Electric Safety Code)
www.ieee.org

National Electrical Manufacturers Association (NEMA)

1300 North 17th Street, Suite 1847
Rosslyn, VA 22209
www.nema.org

National Fire Protection Association (NFPA)

Batterymarch Park
Quincy, MA 02669
(National Electrical Code)
www.nfpa.org

Underwriters Laboratories, Inc. (UL)

333 Pfingsten Road
Northbrook, IL 60062
www.ul.com
TABLE OF CONTENTS

1. BASICS OF INSULATED POWER CABLE CONSTRUCTION 1-1

NONSHIELDED CABLE 1-1

Construction 1-1
Dielectric Field 1-2
SHIELDED CABLE 1-3
Construction 1-3
Dielectric Field 1-4
ADVANTAGES OF SHIELDED CABLE 1-5

2. CONDUCTORS 2-1

SIZE AND AREA RELATIONSHIPS 2-1

CONDUCTOR CHARACTERISTICS 2-3
Copper and Aluminum Properties 2-3
Conductor Diameters 2-4
Conductor Weights 2-6
Breaking Strengths 2-10
COPPER 2-11
Tempers 2-12
ALUMINUM 2-12
Alloys 2-12
Tempers 2-12
STRAND BLOCK 2-13
RESISTANCE TABULATIONS 2-13
Resistivity and Conductivity 2-13
DC Resistance Versus Cross-Sectional Area 2-14
Resistance at Other Temperatures 2-16
AC to DC Ratios 2-17

3. INSULATIONS 3-1

TYPES 3-1
Polyethylene 3-1
Cross-linked Polyethylene 3-1
Ethylene-Propylene Rubber 3-2
Polyvinyl Chloride 3-3
Chlorosulfonated Polyethylene 3-3
Non-Halogen Ethylene Copolymers 3-3
 INSULATION PROPERTIES 3-4
WALL THICKNESSES 3-5
ICEA Insulated Cables 3-5
NEC/UL-Listed Cables 3-5

4. SHIELDING OR SCREENING 4-1

CONDUCTOR SHIELD 4-1

INSULATION SHIELD 4-1
Materials 4-1
Voltage Parameters 4-2
Requirements for Use 4-2
GROUNDING OF INSULATION SHIELD 4-2
Single-Point Grounding 4-3
Multiple-Point Grounding 4-3

5. JACKETING, SHEATHING, AND ARMORING 5-1

GENERAL 5-1
NONMETALLIC JACKETS 5-1
METALLIC SHEATHS 5-2
Lead Sheathing 5-2
Aluminum Sheathing 5-3
ARMORING 5-3
Gas/Vaportight Continuously Corrugated 5-3
Interlocked 5-3
Flat Metal Tapes 5-4
Round Wire 5-4
SPECIAL JACKET OR SHEATH COMBINATIONS 5-4
Teck Cable 5-4

6. ELECTRICAL CHARACTERISTICS OF CABLE SYSTEMS 6-1

BASIC POWER SYSTEM REVIEW 6-1

DC Circuits 6-1
Single-Phase AC Circuits 6-1
Polyphase AC Circuits 6-2
VOLTAGE RATING 6-3
General System Categories 6-3
Voltage Potentials 6-4
FORMULAS AND RELATED INFORMATION 6-4
Inductance 6-4
Inductive Reactance 6-5
Dielectric Constant 6-6
 Capacitance 6-6
Capacitive Reactance 6-6
Charging Current 6-7
Total Reactance 6-7
Impedance 6-7
Insulation Resistance and IR Constant 6-7
Power Factor 6-8
Cable System Impedance at Power Frequencies 6-9
Ampere Determination From Power Ratings 6-10
Breakdown Strength 6-10
Voltage Stress 6-10
VOLTAGE DROP (REGULATION) 6-11
Equations for Basic AC and DC Power Systems 6-12
Typical Calculation 6-13
SHORT CIRCUIT CURRENTS 6-14
Conductor Formula 6-14
Metallic Shield Formula 6-21
Typical Calculation 6-22
SHIELD VOLTAGES, CURRENTS, AND LOSSES FOR SINGLE
CONDUCTOR CABLES 6-23
Multiple-Point Grounded Shields 6-23
Single-Point Grounded Shields 6-24
Reduced Concentric Neutral Shield Wires 6-25
AMPACITY 6-26
Formula 6-26
Ampacity Tables 6-30
SEQUENCE IMPEDANCE 6-50
Symmetrical Components 6-50
Effect of Variables 6-51
SEQUENCE IMPEDANCE EQUATIONS 6-54
Tape Shielded Medium Voltage Cables 6-54
Wire Shielded and Concentric Neutral Medium Voltage Cable 6-55
Variables for Sequence Impedance Equations 6-58
Typical Calculation 6-62

7. CABLE INSTALLATION 7-1

GENERAL FIELD PRACTICES 7-1

Introduction 7-1
Preplanning 7-1
Low Ambient Temperature 7-2
Equipment 7-2
Training Radius 7-4
Handling and Storage Guidelines 7-5
 Dynamometer Corrections 7-7
Diameters of Nonjacketed Cable Assemblies 7-8
Pull Boxes 7-8
Cable Lubrication Selection 7-9
INSTALLATION IN CONDUIT 7-10
Allowable Tension on Pulling Device 7-10
Maximum Tension on Cable Conductors 7-10
Equations for Pulling Tension 7-13
Coefficient of Friction 7-14
Configuration 7-15
Weight Correction Factor 7-15
Sidewall Pressure 7-16
Clearance 7-17
Jamming 7-17
Conduit Fill 7-18
Calculation Procedure 7-19
INSTALLATION IN CABLE TRAY 7-20
Rollers and Sheaves 7-20
Pulling Tensions 7-21
TYPICAL CALCULATION FOR CABLES IN CONDUIT 7-23
CABLES BURIED DIRECTLY IN EARTH 7-28
Depth of Burial 7-28
Trenching 7-28
Plowing 7-29
Supplemental Information 7-29
AERIAL INSTALLATION 7-29
Sag and Tension 7-29
Ice and Wind Loading 7-30
Additional Information 7-31
CABLES UNDER VERTICAL TENSION 7-31
ICEA Support Requirements 7-31
NEC Support Requirements 7-32
FIELD REMOVAL OF MOISTURE FROM POWER CABLES 7-33
Required Materials 7-33
General Purging Process 7-33
Purging Cable Conductors 7-34
Purging Cable Shield 7-35
Cable on Reels 7-35

8. DESIGN AND INSTALLATION OF CABLE ACCESSORIES 8-1

GENERAL 8-1
CABLE ACCESSORIES 8-1
Design Concepts 8-1
 Basis of Electrical Design 8-2
Design Testing 8-3
Terminations of Nonshielded Cables 8-3
Terminations of Shielded Cables 8-3
Splices of Nonshielded Cables 8-6
Splices of Shielded Cables 8-6
FIELD INSTALLATION 8-9
Cable Component Identification 8-9
Cleanliness 8-10
Cable End Preparation 8-10
Conductor Connections 8-11
Dielectric System Materials 8-12
CABLE END PREPARATION TOOLS 8-13
HARDWARE FOR INTERLOCKED ARMOR CABLES 8-14
CABLE ACCESSORIES MANUFACTURERS 8-14

9. FIELD TESTING 9-1

SAFETY 9-1
PREPARATION FOR TESTING 9-1
CONDUCTING TEST 9-2
CONCLUSION OF TESTING 9-2
FIELD ACCEPTANCE TESTS 9-2
Cable System Integrity 9-2
Low Potential Testing of Dielectric 9-3
High Potential DC Testing of Dielectric 9-4

APPENDIX A-1

CAPACITY AND DRUM DIAMETER OF REELS A-1

Reel Capacity Equation A-1
Approximate Reel Capacity Equation A-2
Minimum Drum Diameter A-2
TABULATIONS OF EQUIVALENTS A-3
Nominal Conductor Area A-3
Conversion Factors A-4
Temperature Equivalents A-5
Metric Unit Multiples A-5
SYMBOLS A-6
Greek Alphabet A-6
Typical Symbol Usage A-7
REFERENCE PUBLICATIONS A-8
INDEX A-11
 BASICS OF INSULATED
POWER CABLE
CONSTRUCTION
An insulated power cable appears to be a relatively simple electrical device. In fact, this
cable is an electrically sophisticated system of components. To understand it, let us
examine its components and basics of operation. For simplicity, the following discussion
will be confined to single-conductor cables. However, these fundamentals also apply to
multiple-conductor cables.

NONSHIELDED CABLE

Construction
Two basic components comprise a nonshielded cable: the conductor and the electrical
insulation sometimes referred to as the dielectric. A third component used in some
cable designs is an outer jacket. (See Figure 1-1.)

Figure 1-1
Construction of Low Voltage Nonshielded Cable

Conductor
The conductor can be copper or aluminum with either a solid or stranded cross section.
The primary benefit of stranded conductors is improved flexibility. Stranded conductors
can also be compressed, compacted, or segmented to achieve desired flexibility,
diameter, and load current density. For the same cross-sectional area of a conductor,
the diameter differs among solid and the various types of stranded conductors. This
consideration is important in the selection of connectors and in methods of splicing
and terminating.
Chapter 2 presents details of conductors and their characteristics.

SOUTHWIRE 1-1
CHAPTER 1

Electrical Insulation or Dielectric

The electrical insulation must provide adequate physical protection and electrical
insulation between the energized conductor and the nearest electrical ground to
prevent electrical breakdown. For low-voltage cables, 600 volts and below, the insulation
thickness required to provide the necessary physical protection against damage is more
than adequate to provide the necessary dielectric strength.

Jacket
For special applications, a jacket is applied over the insulation. Several materials are
available for use as jackets to provide the necessary chemical, physical, or thermal
protection required by the application.

Dielectric Field
Another consideration in the design and application of cables is the dielectric field. In
all electrical cables, irrespective of their voltage ratings, a dielectric field is present
when the conductor is energized. This dielectric field is typically represented by electrostatic
flux lines and equipotential lines between the conductor and electrical ground.
When a conductor is energized, electrostatic lines of flux are created within the dielectric.
The density of these flux lines is dependent upon the magnitude of the potential dif-
ference between the conductor and electrical ground.
The distance between the equipotential lines represents a voltage differential in the
insulation. For a given voltage differential, these lines are closer together nearer the
conductor.
Figure 1-2 represents the electrical field of a nonshielded cable in contact with a
ground plane. It does not take into account the difference in the dielectric constants of
the insulation and the surrounding air.

Figure 1-2
Dielectric Field of Low-Voltage Nonshielded Cable
In Contact with Electrical Ground

Observe that the electrostatic flux lines are crowded in the insulation area closest to
the ground. Also, the equipotential lines are eccentric in their relationship to the
conductor and cable dielectric surface. This distortion of the fields is acceptable if the
dielectric strength of the cable insulation is adequate to resist the concentration of the
dielectric stresses. Low-voltage nonshielded cables are designed to meet this requirement.

1-2 SOUTHWIRE
 BASICS OF INSULATED POWER CABLE CONSTRUCTION

SHIELDED CABLE

Construction
A fundamental difference between nonshielded and shielded cable is the inclusion of
conducting components in the cable system. The basic components of a shielded cable
are shown in Figure 1-3.

Figure 1-3
Construction of Shielded Power Cable

Conductor
The conductors used in shielded cables are comparable to those used in nonshielded cables.

Conductor Shield or Screen

The conductor shield is usually a semiconducting material applied over the conductor
circumference to smooth out the conductor contours. Because of the presence of the
shield, the resulting dielectric field lines will not be distorted by the shape of the outer
strands or other conductor contours. This layer also provides a smooth and compatible
surface for the application of the insulation, and may also be used to facilitate splicing
and terminating the cable.
Chapter 4 presents detailed requirements and materials for the conductor shield.

Electrical Insulation or Dielectric

The differences between insulation for shielded and nonshielded cables include material,
process technology, and testing. The insulation thickness is primarily influenced by the
operating voltage.
Chapter 3 provides information on insulating materials and their capabilities, proper-
ties, and applicable specifications.

SOUTHWIRE 1-3
CHAPTER 1

Insulated Shield or Screen

The insulation shield or screen is a two-part system composed of an auxiliary and a
primary shield.

An auxiliary shield is usually a semiconducting nonmetallic material over the

dielectric circumference. It must be smooth, compatible with the insulation, and
exhibit an acceptably low voltage drop through its thickness. A commonly used
auxiliary shield consists of an extruded semiconducting layer partially bonded to
the insulation.
A primary shield is a metallic shield (wire or tape) over the circumference of the
auxiliary shield. It must be capable of conducting the summation of “leakage”
currents to the nearest ground with an acceptable voltage drop. In some cases
it must also be capable of conducting fault currents.

The primary shield by itself, without an intervening auxiliary shield, cannot

achieve acceptable physical contact with the dielectric surface. A relatively resilient
auxiliary shield is necessary to eliminate arcing between the dielectric surface and
the primary shield. Chapter 4 presents detailed requirements and materials for the
primary shield.

Jackets/Sheaths/Armors
The cable may have components to provide environmental protection over the insulation
shielding system. This material can be an extruded jacket of synthetic material, metal
sheath/wires, armoring, or a combination of these types of materials. Chapter 5 presents
a description of the types of materials, their characteristics, and applications used for
this purpose.

Dielectric Field
The insulation shield should be effectively at ground potential, resulting in no distor-
tion of the electrostatic flux or equipotential lines. Electrostatic flux lines are spaced
symmetrically and perpendicular to equipotential lines. The equipotential lines are
concentric and parallel with respect to each other, the conductor shield, and the insulation
shield. The presence of the shielding results in field lines as depicted in Figure 1-4.

Figure 1-4
Dielectric Field of Shielded Power Cable

In a shielded cable, all the voltage difference between the conductor and electrical
ground is contained within the cable. For nonshielded cable, the voltage difference
between conductor and electrical ground is divided between the cable dielectric and
any intervening air or other materials.

1-4 SOUTHWIRE
 BASICS OF INSULATED POWER CABLE CONSTRUCTION

In Figure 1-4, the field lines are closer to each other near the conductor shield as
compared to the insulation shield. The radial stresses or voltage gradients increase near
the conductor.

ADVANTAGES OF SHIELDED CABLE

Electrical insulation surrounding a conductor creates a capacitor when the conductor is

electrically energized. Thus, all insulated conductors are capacitors.
In the majority of nonshielded cable systems, the cable surface makes intermittent
contact with an electrical ground. Where intimate contact with this ground is not
made, the intervening air spaces also act primarily as capacitors in ac circuits and as
resistors in dc circuits. This forms a series circuit of cable dielectric and air dielectric.
The voltage across this series circuit varies along the length of the cable dependent
upon the voltage across the air gap. The cable surface becomes a floating voltage point
in a voltage divider. This floating-point voltage can vary considerably, dependent upon
the cable design and the characteristics of the air gap. If the voltage is high enough,
the cable surface can experience detrimental surface tracking or arcing discharges to
electrical ground. The cable surface can also become potentially hazardous, causing an
electrical shock if contacted by field personnel.
Shielding the cable dielectric surface and grounding this shielding eliminates tracking
and arcing discharges. Grounding the shield prevents the accumulation of an electrical
potential on the surface of the cable that could be hazardous to individuals coming
into contact with the cable surface. Industry standards and requirements define when
shielded cables must or should be used. This subject is discussed in more detail in
Chapter 4.
Service performance of nonshielded cables systems, within their design limits, is generally
considered acceptable. In addition to operating voltage limitations, inherent physical
size limitations would be encountered if attempting to design and construct nonshielded
cable systems for voltages that typically use shielded cable systems.

SOUTHWIRE 1-5
 CONDUCTORS
Conductor selection is contingent upon a number of considerations, including requirements
of ampacity, voltage regulation, materials characteristics, flexibility, geometric shape,
and economics. The most commonly used metals for conductors in power cables are
copper and aluminum. These conductor materials may be solid or stranded.

SIZE AND AREA RELATIONSHIPS

A conductor’s size is usually specified based on the conductor’s cross-sectional area.

Standard practice in the United States is to identify conductor size by the American
Wire Gage (AWG) and by thousand circular mils (kcmil) for conductor sizes larger than
4/0 AWG. International practice is usually square millimeters (mm2). For standard
conductors, the area is based on the sum of the area of individual strands.
The American Wire Gage, also known as the Brown & Sharpe gage, was developed in
1857 by J.R. Brown. The gage is formed by the specification of two diameters with a
specific number of intermediate diameters formed by a geometric progression. The
largest AWG size is a 0000 (4/0) gage defined as 0.4600 inches in diameter. The smallest
diameter is 0.0050 inches for a 36 gage. Between these two diameters are 38 AWG sizes.
Thus, the ratio of any diameter to the next greater diameter is given by the expression:

Standard practice in the United States for wire sizes larger than 4/0 AWG is to designate
the size by the cross-sectional area in kcmil (formerly, MCM). One cmil is defined as the
area of a circle having a diameter of one mil. To determine the cmil area of a solid
conductor, square the diameter in mils.

Example:
8 AWG solid diameter = 0.1285 inches = 128.5 mils
cmil = (128.5)2 = 16,512

Conductor size conversions can be accomplished by the following relationships.

where: 25.4mm = 1 inch

SOUTHWIRE 2-1
CHAPTER 2

Stranded conductors provide desired properties of flexibility but with some increase in
overall diameter. Diameters of stranded conductors vary depending upon constructions.
These constructions include concentric round, compressed, compact, and compact sector
as shown in Figure 2-1.

Figure 2-1
Comparative Sizes and Shapes of 61 Strand Conductors

The stranding of conductors is the formation of solid individual wire strands into a
composite construction to achieve a specified cross-sectional area. The number of
strands is usually based on a geometric progression of single strand layers (1, 6, 12, 18,
etc.). The stranded constructions can be conventional concentric or unidirectional
concentric stranding as shown in Figure 2-2.

Figure 2-2
Concentric Stranding Constructions

2-2 SOUTHWIRE
 CONDUCTORS

Unilay Stranded Conductors

The 19-wire combination unilay stranded construction has an outer diameter equal to
the compressed stranded equivalent conductor. This construction is depicted in Figure
2-3 as presented in ASTM volume 2.03, Standards B 786 and B 787. Note the interstices
of the outer strand layer are partially occupied by strands of a lesser diameter.
Compressed unilay stranding is about three percent smaller in diameter than an equivalent
compressed conductor made with traditional reverse-lay techniques. This construction is
shown in Figure 2-3 and is specified in ASTM volume 2.03, Standards B 8 and B 231. In
this construction, one or more of the layers may consist of shaped strands and may also
be compressed overall. The diameter of compressed unilay is included in Table 2-2.

Figure 2-3
Unilay Stranded Constructions

CONDUCTOR CHARACTERISTICS

Copper and Aluminum Properties

Table 2-1 provides pertinent mechanical, physical, and electrical properties of copper
and aluminum conductor materials.

TABLE 2-1
PROPERTIES OF COPPER AND ALUMINUM
Copper Aluminum
Hard-Drawn One-Half Hard
Property Unit Annealed 1350 8000
Volume electrical conductivity
at 20°C %IACS 100.00 61.2 61.0
Density at 20°C grams/cm3 8.890 2.705 2.710
lb/in3 0.32117 0.0975 0.0980
Weight Resistivity at 20°C ohms·lb/mil2 875.20 434.81 436.23
ohms·g/m2 0.153280 0.076149 0.076399
Volume Resistivity at 20°C ohms·cmil/ft 10.371 16.946 17.002
at 25°C ohms-cmil/ft 10.571 17.291 17.348
at 20°C ohms·mm2/m 0.017241 0.028172 0.028265
at 20°C microhms·cm 1.7241 2.8172 2.8265
Temperature coefficient of
resistance at 20°C °C 0.00393 0.00404 0.00403
at 25°C °C 0.00385 0.00396 0.00395
Melting Point °C 1083 652-657
°F 1981.4 1205-1215
Temperature Coefficient of /°C 17.0 x 10-6 23.0 x 10-6
linear expansion /°F 9.4 x 10-6 12.8 x 10-6

SOUTHWIRE 2-3
CHAPTER 2

Conductor Diameters
Table 2-2 provides nominal diameters of both cooper and aluminum conductors from
14 AWG through 1000 kcmil having solid and stranded constructions.1 For diameters in
millimeters, multiply the tabulated dimensions by 25.4 (see next page).

TABLE 2-2
DIAMETERS FOR COPPER AND ALUMINUM CONDUCTORS
Nominal Diameters (in)
Conductor Size Concentric Lay Stranded
Reverse
AWG kcmil Solid Compact Concentric Unilay Combination Class B Class C
Compressed Compressed Unilay
14 4.11 0.0641 - 0.071 - 0.071 0.073 0.074
12 6.53 0.0808 - 0.089 - 0.090 0.092 0.093
10 10.38 0.1019 - 0.113 - 0.113 0.116 0.117
8 16.51 0.1285 0.134 0.142 - 0.143 0.146 0.148
6 26.24 0.1620 0.169 0.178 - 0.179 0.184 0.186
4 41.74 0.2043 0.213 0.225 - 0.226 0.232 0.234
3 52.62 0.2294 0.238 0.252 - 0.254 0.260 0.263
2 66.36 0.2576 0.268 0.283 - 0.286 0.292 0.296
1 83.69 0.2893 0.299 0.322 0.313 0.321 0.332 0.333
1/0 105.6 0.3249 0.336 0.362 0.352 0.360 0.373 0.374
2/0 133.1 0.3648 0.376 0.405 0.395 0.404 0.419 0.420
3/0 167.8 0.4096 0.423 0.456 0.443 0.454 0.470 0.471
4/0 211.6 0.4600 0.475 0.512 0.498 0.510 0.528 0.529
250 0.5000 0.520 0.558 0.542 0.554 0.575 0.576
300 0.5477 0.570 0.611 0.594 0.607 0.630 0.631
350 0.5916 0.616 0.661 0.641 0.656 0.681 0.681
400 0.6325 0.659 0.706 0.685 0.701 0.728 0.729
450 0.6708 0.700 0.749 0.727 0.744 0.772 0.773
500 0.7071 0.736 0.789 0.766 0.784 0.813 0.815
550 0.7416 0.775 0.829 0.804 - 0.855 0.855
600 0.7746 0.813 0.866 0.840 - 0.893 0.893
650 0.8062 0.845 0.901 0.874 - 0.929 0.930
700 0.8367 0.877 0.935 0.907 - 0.964 0.965
750 0.8660 0.908 0.968 0.939 - 0.998 0.999
800 0.8944 0.938 1.000 0.969 - 1.031 1.032
900 0.9487 0.999 1.060 1.028 - 1.093 1.093
1000 1.0000 1.060 1.117 1.084 - 1.152 1.153
Compact and compressed nominal diameters based on concentric lay stranded Class B construction.
Diameters are based on ASTM specifications.

1
ASTM Standards, volume 02.03 Electrical Conductors, B 231-99, B 496-01, and B 787-01.

2-4 SOUTHWIRE
 CONDUCTORS

METRIC TABLE 2-2

DIAMETERS FOR COPPER AND ALUMINUM CONDUCTORS
Nominal Diameters (mm)
Conductor Size Concentric Lay Stranded
Reverse
AWG mm2 Solid Compact Concentric Unilay Combination Class B Class C
or kcmil Compressed Compressed Unilay
14 2.08 1.63 - 1.80 - 1.80 1.84 1.87
12 3.31 2.05 - 2.26 - 2.29 2.32 2.35
10 5.26 2.588 - 2.87 - 2.87 2.95 2.97
8 8.37 3.264 3.404 3.61 - 3.63 3.71 3.76
6 13.30 4.115 4.293 4.52 - 4.55 4.67 4.72
4 21.15 5.189 5.410 5.72 - 5.74 5.89 5.94
3 26.66 5.827 6.045 6.40 - 6.45 6.60 6.68
2 33.63 6.543 6.807 7.19 - 7.26 7.42 7.52
1 42.41 7.348 7.595 8.18 7.95 8.15 8.43 8.46
1/0 53.49 8.252 8.534 9.19 8.94 9.14 9.47 9.50
2/0 67.42 9.266 9.550 10.3 10.03 10.3 10.6 10.7
3/0 85.03 10.40 10.74 11.6 11.25 11.5 11.9 12.0
4/0 107.2 11.68 12.07 13.0 12.65 13.0 13.4 13.4
250 126.6 12.70 13.21 14.2 13.77 14.1 14.6 14.6
300 152.0 13.91 14.48 15.5 15.09 15.4 16.0 16.0
350 177.4 15.03 15.65 16.8 16.28 16.7 17.3 17.3
400 202.7 16.07 16.74 17.9 17.40 17.8 18.5 18.5
450 228.0 17.04 17.78 19.0 18.47 18.9 19.6 19.6
500 253.4 17.96 18.69 20.0 19.46 19.9 20.7 20.7
550 278.7 18.84 19.69 21.1 20.42 - 21.7 21.7
600 304.0 19.67 20.65 22.0 21.34 - 22.7 22.7
650 329.4 20.48 21.46 22.9 22.20 - 23.6 23.6
700 354.7 21.25 22.28 23.7 23.04 - 24.5 24.5
750 380.0 22.00 23.06 24.6 23.85 - 25.3 25.4
800 405.4 22.72 23.83 25.4 24.61 - 26.2 26.2
900 456.1 24.10 25.37 26.9 26.11 - 27.8 27.8
1000 506.7 25.40 26.92 28.4 27.53 - 29.3 29.3

SOUTHWIRE 2-5
CHAPTER 2

Conductor Weights

Solid Conductors
Table 2-3 provides diameters and weights of solid copper and aluminum conductors
through 1000 kcmil.
TABLE 2-3
SOLID ALUMINUM AND COPPER AREA, DIAMETER, AND WEIGHT
Size Cross-Sectional Area
AWG or Diameter Copper Aluminum
kcmil Cmil sq. in. inch lbs/1000 ft lbs/1000 ft
14 4,110 0.00323 0.0641 12.4 3.78
12 6,530 0.00513 0.0808 19.8 6.01
10 10,380 0.00816 0.1019 31.43 9.56
8 16,510 0.01297 0.1285 49.98 15.17
7 20,820 0.01635 0.1443 63.03 19.13
6 26,240 0.02061 0.1620 79.44 24.12
5 33,090 0.02599 0.1819 100.2 30.40
4 41,740 0.03278 0.2043 126.3 38.35
3 52,620 0.04133 0.2294 159.3 48.36
2 66,360 0.05212 0.2576 200.9 60.98
1 83,690 0.06573 0.2893 253.3 76.91
1/0 105,600 0.08291 0.3249 319.6 97.00
2/0 133,100 0.1045 0.3648 402.9 122.3
3/0 167,800 0.1318 0.4096 507.9 154.2
4/0 211,600 0.1662 0.4600 640.5 194.4
250 250,000 0.1963 0.5000 - 229.7
300 300,000 0.2356 0.5477 - 275.7
350 350,000 0.2749 0.5916 - 321.6
400 400,000 0.3142 0.6325 - 367.6
450 450,000 0.3534 0.6708 - 413.5
500 500,000 0.3927 0.7071 - 459.4
550 550,000 0.4320 0.7416 - 505.4
600 600,000 0.4712 0.7746 - 551.3
650 650,000 0.5105 0.8062 - 597.3
700 700,000 0.5498 0.8367 - 643.3
750 750,000 0.5890 0.8660 - 689.1
800 800,000 0.8944 0.8944 - 735.1
900 900,000 0.9487 0.9487 - 827.1
1000 1,000,000 1.0000 1.0000 - 918.9
Weights are based on ASTM Volume 2.03 Specifications B 8, B 609, and B 231.

2-6 SOUTHWIRE
 CONDUCTORS

METRIC TABLE 2-3

SOLID ALUMINUM AND COPPER AREA, DIAMETER, AND WEIGHT
Size Cross-Sectional Area Diameter Copper Aluminum
AWG or kcmil mm2 mm kg/km kg/km
14 2.08 1.628 18.5 5.6
12 3.31 2.052 29.4 8.9
10 5.26 2.588 46.8 14.2
8 8.67 3.264 74.4 22.6
7 10.55 3.665 93.8 28.5
6 13.30 4.115 118.2 35.9
5 16.77 4.620 149.1 45.2
4 21.15 5.189 188.0 57.1
3 26.67 5.827 237.1 72.0
2 33.62 6.543 299.0 90.8
1 42.41 7.348 377.0 114.5
1/0 53.49 8.252 475.6 144.4
2/0 67.43 9.266 599.6 182.0
3/0 85.01 10.40 755.9 229.5
4/0 107.2 11.68 953.2 289.3
250 126.7 12.70 - 341.8
300 152.0 13.91 - 410.3
350 177.3 15.03 - 478.6
400 202.7 16.07 - 547.1
450 228.0 17.04 - 615.4
500 253.3 17.96 - 683.7
550 278.7 18.84 - 752.1
600 304.0 19.67 - 820.4
650 329.4 20.48 - 888.9
700 354.7 21.25 - 957.4
750 380.0 22.00 - 1026
800 405.4 22.72 - 1094
900 456.1 24.10 - 1231
1000 506.7 25.40 - 1368
Weights are based on ASTM Volume 2.03 Specifications B 8, B 609, and B 231.

SOUTHWIRE 2-7
CHAPTER 2

Class B and C Stranded Conductors

Table 2-4 provides diameters and weights of Class B and C stranded copper and
aluminum conductors. Class B stranding is recommended for power cable use. Class C
stranding is recommended for use where power cable conductors require greater
flexibility than Class B stranded conductors.

TABLE 2-4
CONCENTRIC STRANDED ALUMINUM AND COPPER CONDUCTOR
DIAMETER AND WEIGHT
Size Class B Class C Weight
Nominal Nominal
AWG Number Diameter Outside Number Diameter Outside Copper Aluminum
or kcmil of Strands of Strand Diameter of Strands of Strand Diameter lbs/1000 ft lbs/1000 ft
(mils) (in) (mils) (in)
14 7 24.2 0.0726 19 14.7 0.074 12.68 3.86
12 7 30.5 0.0915 19 18.5 0.093 20.16 6.13
10 7 38.5 0.116 19 23.4 0.117 32.06 9.75
8 7 48.6 0.146 19 29.5 0.148 50.97 15.5
7 7 54.5 0.164 19 33.1 0.166 64.28 19.5
6 7 61.2 0.184 19 37.2 0.186 81.05 24.6
5 7 68.8 0.206 19 41.7 0.209 102.2 31.0
4 7 77.2 0.232 19 46.9 0.235 128.9 39.1
3 7 86.7 0.260 19 52.6 0.263 162.5 49.3
2 7 97.4 0.292 19 59.1 0.296 204.9 62.2
1 19 66.4 0.332 37 47.6 0.333 258.4 78.4
1/0 19 74.5 0.373 37 53.4 0.374 325.8 98.9
2/0 19 83.7 0.419 37 60.0 0.420 410.9 124.8
3/0 19 94.0 0.470 37 67.3 0.471 518.1 157.2
4/0 19 105.5 0.528 37 75.6 0.529 653.3 198.4
250 37 82.2 0.575 61 64.0 0.576 771.9 234.3
300 37 90.0 0.630 61 70.1 0.631 926.3 281.4
350 37 97.3 0.681 61 75.7 0.681 1081 327.9
400 37 104.0 0.728 61 81.0 0.729 1235 375.7
450 37 110.3 0.772 61 85.9 0.773 1389 421.8
500 37 116.2 0.813 61 90.5 0.815 1544 468.3
550 61 95.0 0.855 91 77.7 0.855 1698 516.2
600 61 99.2 0.893 91 81.2 0.893 1883 562.0
650 61 103.2 0.929 91 84.5 0.930 2007 609.8
700 61 107.1 0.964 91 87.7 0.965 2161 655.8
750 61 110.9 0.998 91 90.8 0.999 2316 703.2
800 61 114.5 1.031 91 93.8 1.032 2470 750.7
900 61 121.5 1.094 91 99.4 1.093 2779 844.0
1000 61 128.0 1.152 91 104.8 1.153 3088 936.8
Weights and diameters are based on ASTM Volume 2.03 Sections B 8 and B 231.

2-8 SOUTHWIRE
 CONDUCTORS

METRIC TABLE 2-4

CONCENTRIC STRANDED ALUMINUM AND COPPER CONDUCTOR
DIAMETER AND WEIGHT
Size Area Class B Class C Weight
Number Diameter Nominal Number Diameter Nominal
AWG of of Outside of of Outside Copper Aluminum
or kcmil mm2 Strands Strand Diameter Strands Strand Diameter kg/km kg/km
(mm) (mm) (mm) (mm)
14 2.08 7 615 1.84 19 373 1.87 18.87 5.74
12 3.31 7 775 2.32 19 470 2.35 30.00 9.12
10 5.26 7 978 2.95 19 594 2.97 47.71 14.5
8 8.67 7 1234 3.71 19 749 3.76 75.85 23.1
7 10.55 7 1384 4.17 19 841 4.22 95.66 29.0
6 13.30 7 1554 4.67 19 945 4.72 120.6 35.7
5 16.77 7 1748 5.23 19 1059 5.31 152.1 46.1
4 21.15 7 1961 5.89 19 1191 5.97 191.8 58.2
3 26.67 7 2202 6.60 19 1336 6.68 241.8 73.4
2 33.62 7 2474 7.42 19 1501 7.52 304.9 92.3
1 42.41 19 1687 8.43 37 1209 8.46 384.6 116.7
1/0 53.49 19 1892 9.47 37 1356 9.50 484.9 147.2
2/0 67.43 19 2126 10.6 37 1524 10.7 611.5 185.7
3/0 85.01 19 2388 11.9 37 1709 12.0 771.0 233.9
4/0 107.2 19 2680 13.4 37 1920 13.4 972.2 295.3
250 126.7 37 2088 14.6 61 1626 14.6 1149 348.7
300 152.0 37 2286 16.0 61 1781 16.0 1379 418.8
350 177.3 37 2471 17.3 61 1923 17.3 1609 488.0
400 202.7 37 2642 18.5 61 2057 18.5 1838 559.1
450 228.0 37 2802 19.6 61 2182 19.6 2067 627.7
500 253.3 37 2951 20.7 61 2299 20.7 2298 696.9
550 278.7 61 2413 21.7 91 1974 21.7 2527 768.2
600 304.0 61 2520 22.7 91 2062 22.7 2758 836.4
650 329.4 61 2621 23.6 91 2146 23.6 2987 907.5
700 354.7 61 2720 24.5 91 2228 24.5 3216 976.0
750 380.0 61 2817 25.3 91 2306 25.4 3447 1047
800 405.4 61 2908 26.19 91 2383 26.21 3676 1117
900 456.1 61 3086 27.79 91 2525 27.76 4136 1256
1000 506.7 61 3251 29.26 91 2662 29.29 4596 1394
Weights and diameters are based on ASTM Volume 2.03 Sections B 8 and B 231.
Diameters in millimeters are obtained by multiplying values in inches by 25.4.
Weights in kilograms are obtained by multiplying values in pounds per 1000 feet by 1.4882.

SOUTHWIRE 2-9
CHAPTER 2

Breaking Strengths
Table 2-5 provides breaking strengths for copper and aluminum stranded conductors.

TABLE 2-5
RATED STRENGTH AND CONCENTRIC LAY CLASS B COPPER
AND ALUMINUM CONDUCTORS IN POUNDS
Copper Aluminum
Size Number Soft-Drawn 1350 8000 Series
AWG of Hard-Drawn Medium-Hard Annealed Hard-Drawn One-Half Hard
or kcmil Strands Minimum Minimum Maximum Minimum Minimum
14 7 - - - - -
12 7 - - - - -
10 7 - - - - -
8 7 777 611 499 - 187
6 7 1288 959 794 563 297
4 7 1938 1505 1262 881 472
3 7 2433 1885 1592 1090 595
2 7 3045 2361 2007 1350 750
1 19 3899 3037 2531 1640 916
1/0 19 4901 3805 3191 2160 1160
2/0 19 6152 4765 4024 2670 1460
3/0 19 7698 5970 5074 3310 1840
4/0 19 9617 7479 6149 4020 2320
250 37 11560 8652 7559 4910 2680
300 37 13870 10740 9071 5890 3210
350 37 16060 12450 10580 6760 3750
400 37 18320 14140 11620 7440 4290
450 37 20450 15900 13080 8200 4820
500 37 22510 17550 14530 9110 5360
550 61 25230 19570 16630 10500 5830
600 61 27530 21350 18140 11500 6360
650 61 29770 22970 18890 11900 6890
700 61 31820 24740 20340 12900 7420
750 61 34090 26510 21790 13500 7950
800 61 36360 28270 23250 14400 8480
900 61 40520 31590 26150 15900 9540
1000 61 45030 35100 29060 17700 10600

Rated strengths are based on ASTM Volume 2.03.

2-10 SOUTHWIRE
 CONDUCTORS

METRIC TABLE 2-5

RATED STRENGTH OF CONCENTRIC LAY CLASS B COPPER
AND ALUMINUM CONDUCTORS IN KILOGRAMS (FORCE)
Copper Aluminum
Size Number Soft-Drawn 1350 8000 Series
AWG of Hard-Drawn Medium-Hard Annealed Hard-Drawn One-Half Hard
or kcmil Strands Minimum Minimum Maximum Minimum Minimum
14 7 - - - - -
12 7 - - - - -
10 7 - - - - -
8 7 353 277 226 - 85
6 7 584 435 360 255 135
4 7 879 683 572 400 214
3 7 1104 855 722 494 270
2 7 1381 1071 910 612 340
1 19 1769 1378 1148 744 415
1/0 19 2223 1726 1447 980 526
2/0 19 2791 2161 1825 1211 662
3/0 19 3492 2708 2302 1501 835
4/0 19 4362 3392 2789 1823 1052
250 37 5244 4061 3429 2227 1216
300 37 6291 4872 4115 2672 1456
350 37 7285 5647 4799 3066 1701
400 37 8310 6414 5271 3375 1946
450 37 9276 7212 5933 3719 2186
500 37 10210 7961 6591 4132 2431
550 61 11444 8877 7543 4763 2644
600 61 12488 9684 8228 5216 2885
650 61 13504 10419 8568 5398 3125
700 61 14433 11222 9226 5851 3366
750 61 15463 12025 9884 6124 3606
800 61 16493 12823 10546 6532 3847
900 61 18380 14329 11862 7212 4327
1000 61 20425 15921 13182 8029 4808
Rated strengths are based on ASTM Volume 2.03.
Rated strengths are obtained by multiplying breaking strength in lbs. by 0.45360

COPPER

Drawing copper rod into a wire results in the work hardening of the finished wire. This
causes a soft temper rod to become a higher temper wire. It may be desirable to use a
conductor of softer temper in a cable construction. This property can be achieved by an
annealing process during or after wire drawing or stranding.
Annealing consists of heating the conductor to the elevated temperatures for specific
time periods. Annealing is usually done in an oven or by inline annealers installed on
the drawing machines.
The coating or tinning of the conductor strands may be employed for protection of the
strands against possible incompatibility with other materials. The conductive coating
increases the dc resistance of the stranded conductor.

SOUTHWIRE 2-11
CHAPTER 2

Tempers
Copper is available in three tempers based on ASTM2. These tempers are soft or
annealed, medium-hard-drawn, and hard-drawn. Soft or annealed is the most commonly
used temper for insulated conductors because of its flexibility. Medium-hard-drawn and
hard-drawn tempers are most often used in overhead applications because of their
higher breaking strengths.

ALUMINUM

Like copper, aluminum rod hardens when drawn into wire. Annealing may be used to
reduce the temper.

Alloys
1350 (formerly EC grade) and 8000 series aluminum alloys are manufactured to meet
the chemical and physical requirements of ASTM Standards B 233 and B 800, respectively.3
1350 is primarily used by utilities for overhead and underground cables.
8000 series alloy is designed for cables that are required to meet UL specifications.
The 2005 NEC® mandates the use of 8000 series aluminum alloys as follows:4

310-14. Aluminum Conductor Material. Solid aluminum conductors 8, 10, and 12

AWG shall be made of an AA-8000 series electrical grade aluminum alloy
conductor material. Stranded aluminum conductors 8 AWG through 1000 kcmil
marked as Type RHH, RHW, XHHW, THW, THHW, THWN, THHN, service-entrance
Type SE Style U and SE Style R shall be made of an AA-8000 series electrical
grade aluminum alloy conductor material.*

Tempers
Based on ASTM, 1350 aluminum can be provided in five tempers as shown in the
following table. The overlapping values show that the same conductor may meet the
temper requirements of two classifications.5

1350 Aluminum Tempers PSI x 103 MPa

Full Soft (H-O) 8.5 to 14.0 59 to 97
1/4 Hard (H-12 or H-22) 12.0 to 17.0 83 to 117
1/2 Hard (H-14 or H-24) 15.0 to 20.0 103 to 138
3/4 Hard (H-16 or H-26) 17.0 to 22.0 117 to 152
Full Hard (H-19) 22.5 to 29.0 155 to 200
Tempers in megapascals (MPa) are obtained by multiplying pounds per square inch (PSI) by 0.006895.

*Reprinted with permission from NFPA 70-2005, the National Electric Code®, Copyright 2005, National Fire Protection Association,
Quincy, MA 02269. This reprinted material is not the complete and official position of the National Fire Protection Association on the
referenced subject which is represented only by the standard in its entirety.
2
ASTM Standards, volume 02.03 Electrical Conductors, B 1-01, B 2-00, and B 3-01.
3
ASTM Standards, volume 02.03 Electrical Conductors, B 233-03 and B 800-00.
4
National Electrical Code (NEC), 2005, NFPA 70.
5
ASTM Standards, volume 02.03, B 233-03.

2-12 SOUTHWIRE
 CONDUCTORS

Three-quarter and full-hard are the most common tempers of 1350 used for insulated
conductors. 1350 full-hard-drawn temper is most often used in overhead applications
because of its higher breaking strengths.
One-half hard is the most often used temper when using an 8000 series alloy for
insulated conductors due to its flexibility.

STRAND BLOCK

Water blocked stranded conductors are used to reduce the possibility of premature
insulation failure caused by water treeing. This blocking compound prevents moisture
migration along the conductor strands.6

RESISTANCE TABULATIONS

Resistivity and Conductivity

Conductivity is typically specified in percent. This percent is based on an International
Annealed Copper Standard (IACS). This standard was established in 1913 by the
International Electrotechnical Commission, specifying the resistance of a copper wire
one meter long that weighs one gram. This standard resistance is designated as having
100% conductivity. The conductivity of aluminum is 61% or higher compared to
annealed copper of the same cross-sectional area (neglecting stranding and skin
effects). It is common to use 61% conductivity for aluminum in power cable applica-
tions; utilities use 61.2% for 1350 as specified by ASTM.

The dc resistance per unit length of a conductor can be calculated from:

R = (2-1)

where: = 1.02 for class B and C stranded conductors,

and 1 for solid conductors
= volume resistivity in ohms-cmil/foot
= 10.575 for uncoated copper at 25°C
= 17.345 for aluminum at 25°C (61% conductivity)
= cross-sectional area of conductor in cmil

6
ICEA T-31-610-1994, “Walter Penetration Reference Test, Sealed Conductor.”

SOUTHWIRE 2-13
CHAPTER 2

DC Resistance Versus Cross-Sectional Area

Table 2-6 provides dc resistance in ohms per 1000 feet for conductors from 14 AWG
through 1000 kcmil.

TABLE 2-6
DC RESISTANCE IN OHMS PER 1000 FEET AT 25°C
Size Solid Concentric Lay Stranded
AWG Copper Aluminum Copper Aluminum
or kcmil Uncoated Coated Uncoated Coated
Class B, C Class B Class C Class B, C
14 2.57 2.67 4.22 2.63 2.79 2.83 4.31
12 1.62 1.68 2.66 1.66 1.72 1.75 2.70
10 1.02 1.06 1.67 1.04 1.08 1.08 1.70
8 0.640 0.659 1.05 0.652 0.678 0.678 1.07
6 0.403 0.414 0.661 0.411 0.427 0.427 0.675
4 0.253 0.261 0.415 0.258 0.269 0.269 0.424
3 0.201 0.207 0.329 0.205 0.213 0.213 0.336
2 0.159 0.164 0.261 0.162 0.169 0.169 0.265
1 0.126 0.130 0.207 0.129 0.134 0.134 0.211
1/0 0.100 0.102 0.164 0.102 0.106 0.106 0.168
2/0 0.0794 0.0813 0.130 0.0810 0.0842 0.0842 0.133
3/0 0.0630 0.0645 0.103 0.0642 0.0667 0.0669 0.105
4/0 0.0500 0.0511 0.0819 0.0510 0.0524 0.0530 0.0836
250 - - 0.0694 0.0431 0.0148 0.0448 0.0707
300 - - 0.0578 0.0360 0.0374 0.0374 0.0590
350 - - 0.0495 0.0308 0.0320 0.0320 0.0505
400 - - 0.0433 0.0269 0.0277 0.0280 0.0442
450 - - 0.0385 0.0240 0.0246 0.0249 0.0393
500 - - 0.0347 0.0216 0.0222 0.0224 0.0354
550 - - - 0.0196 0.0204 0.0204 0.0321
600 - - - 0.0180 0.0187 0.0187 0.0295
650 - - - 0.0166 0.0171 0.0172 0.0272
700 - - - 0.0154 0.0159 0.0160 0.0253
750 - - - 0.0144 0.0148 0.0149 0.0236
800 - - - 0.0135 0.0139 0.0140 0.0221
900 - - - 0.0120 0.0123 0.0126 0.0196
1000 - - - 0.0108 0.0111 0.0111 0.0177

Resistance taken from ICEA S-95-658/NEMA WC70. Table 2-4.

Concentric lay stranded includes compressed and compact conductors.

2-14 SOUTHWIRE
 CONDUCTORS

METRIC TABLE 2-6

DC RESISTANCE IN OHMS PER KILOMETER AT 25°C
Size Solid Concentric Lay Stranded
AWG Copper Aluminum Copper Aluminum
or kcmil Uncoated Coated Uncoated Coated
Class B, C Class B Class C Class B, C
14 8.43 8.76 13.84 8.63 9.15 9.28 14.11
12 5.31 5.51 8.72 5.44 5.64 5.74 8.92
10 3.35 3.48 5.48 3.41 3.54 3.54 5.58
8 2.10 2.16 3.44 2.14 2.22 2.22 3.51
6 1.32 1.36 2.17 1.35 1.40 1.40 2.21
4 0.830 0.856 1.36 0.846 0.882 0.882 1.39
3 0.659 0.679 1.08 0.672 0.699 0.699 1.10
2 0.522 0.538 0.856 0.531 0.554 0.554 0.872
1 0.413 0.426 0.679 0.423 0.440 0.440 0.692
1/0 0.328 0.335 0.538 0.335 0.348 0.348 0.551
2/0 0.260 0.267 0.426 0.266 0.276 0.276 0.436
3/0 0.207 0.212 0.338 0.211 0.219 0.219 0.344
4/0 0.164 0.168 0.269 0.167 0.172 0.174 0.274
250 - - 0.228 0.141 0.049 0.147 0.232
300 - - 0.190 0.118 0.123 0.123 0.194
350 - - 0.162 0.101 0.105 0.105 0.166
400 - - 0.142 0.0882 0.0909 0.0918 0.145
450 - - 0.126 0.0787 0.0807 0.0817 0.129
500 - - 0.114 0.0708 0.0728 0.0735 0.116
550 - - - 0.0643 0.0669 0.0669 0.105
600 - - - 0.0590 0.0613 0.0613 0.0968
650 - - - 0.0544 0.0561 0.0564 0.0892
700 - - - 0.0505 0.0522 0.0525 0.0830
750 - - - 0.0472 0.0485 0.0489 0.0774
800 - - - 0.0443 0.0456 0.0459 0.0725
900 - - - 0.0394 0.0403 0.0413 0.0643
1000 - - - 0.0354 0.0364 0.0364 0.0581

Resistance taken from ICEA S-95-658/NEMA WC70. Table 2-4.

Concentric lay stranded includes compressed and compact conductors.
Resistance values in ohms per kilometer are obtained by multiplying ohms per 1000 feet by 3.28

SOUTHWIRE 2-15
CHAPTER 2

Resistance at Other Temperatures

The values of Table 2-6 require a correction factor to obtain the resistance at temperatures
other than 25°C. The change in resistance is linear over the temperature range normally
encountered in power cable applications.
The basic relationship between the resistance and temperature of conductors is as follows:

(2-2)

where: = resistance at temperature T2

= resistance at initial or reference temperature T1
= temperature coefficient of resistance corresponding to T1 and the
metal having resistance R1
= temperature at which the resistance R2 is desired
= initial or reference temperature

For Copper (Annealed): = 0.00385 at 25°C.

For Aluminum (61% Conductivity): = 0.00395 at 25°C.

Equation (2-2) can be developed into the following:

For Copper:
(2-3)

For Aluminum:
(2-4)

Typical Calculations
Resistance at 90°C
1/0 AWG Copper, Class B Stranding, Uncoated

= 0.102 ohms/1000 feet from Table 2-6

= temperature at which resistance R2 is desired
= reference temperature of Table 2-6

2-16 SOUTHWIRE
 CONDUCTORS

Using equation (2-3):

1/0 AWG Aluminum, Class B Stranding

= 0.168 ohms/1000 feet from Table 2-6
= temperature at which resistance R2 is desired
= reference temperature of Table 2-6

Using equation (2-4):

AC to DC Ratios
The dc resistance values must be corrected for ac operating frequencies. The correction
ratio, including skin and proximity effect, is dependant upon whether cables are in air
or conduit. Correction ratios vary for the following configurations: (1) for single
conductor cables whether the conduit is metallic or nonmetallic and if the sheaths
insulate the metallic shields from metallic conduit, (2) for single conductor cables in
separate nonmetallic ducts, and (3) for multiconductor cables whether they are
nonmetallic-sheathed or not and if they are in air or nonmetallic conduits.
For 60-hertz operation, the ICEA Project 359 Committee Report presents detailed
tabulations and calculation references.7 Table 2-7 presents typical ac/dc resistance ratios
presented in the Project 359 report.

7
“Committee Report on AC/DC Resistance Ratios at 60 Cycles,” ICEA Project 359, June 1958, reprinted 1973.

SOUTHWIRE 2-17
CHAPTER 2

TABLE 2-7
AC/DC RESISTANCE RATIOS AT 60 CYCLES AND 65°C
NONSHIELDED, NONLEADED, 600 VOLT CABLE
THREE SINGLE CABLES INSTALLED IN TRIANGULAR OR CRADLE
FORMATION
NONMETALLIC CONDUIT
or
“IN AIR” (In Contact) MAGNETIC CONDUIT
AC/DC RATIO AC/DC RATIO
(1) (2) (3) (4)
Size Triangular or Triangular or Triangular Cradle
AWG or kcmil Cradle “At Cdr” Cradle “At Cdr” “At Conduit” “At Conduit”
COPPER CONDUCTORS
1 1.01* 1.01* 1.01* 1.01*
1/0 1.01* 1.01* 1.01 1.01
2/0 1.01* 1.01 1.01 1.01
3/0 1.01 1.01 1.01 1.02
4/0 1.01 1.02 1.02 1.03
250 1.01 1.02 1.03 1.04
300 1.02 1.03 1.05 1.05
350 1.03 1.05 1.06 1.07
400 1.04 1.06 1.08 1.09
500 1.06 1.10 1.13 1.14
600 1.08 1.14 1.17 1.19
700 1.11 1.19 1.23 1.25
750 1.13 1.22 1.26 1.29
800 1.15 1.25 1.30 1.32
900 1.19 1.31 1.37 1.40
1000 1.22 1.38 1.44 1.47
ALUMINUM CONDUCTORS
1 1.01* 1.01* 1.01* 1.01*
1/0 1.01* 1.01* 1.01* 1.01*
2/0 1.01* 1.01* 1.01* 1.01
3/0 1.01* 1.01* 1.01 1.01
4/0 1.01* 1.01 1.01 1.01
250 1.01 1.01 1.01 1.02
300 1.01 1.01 1.02 1.02
350 1.01 1.02 1.03 1.03
400 1.01 1.02 1.03 1.04
500 1.02 1.04 1.05 1.06
600 1.03 1.05 1.07 1.08
700 1.05 1.08 1.10 1.11
750 1.05 1.09 1.11 1.13
800 1.06 1.10 1.13 1.14
900 1.07 1.13 1.16 1.18
1000 1.09 1.16 1.20 1.22
NOTES:
1.01 with an asterisk(*) indicates that inductive effect is less than 1%.
The “At Cdr” ratios of column (1) allow for “In Air” Conductor Skin-Proximity only. The “At Cdr” ratios of column (2)
allow for Conductor Skin-Proximity Effect in Magnetic (Steel) Conduit. The “At Conduit” ratios in columns (3) and (4)
allow for the combined effect of Conductor Skin-Proximity Effect, in Magnetic (Steel) Conduit, and Conduit Loss
Effect. The ratios indicated above are applicable for cables with rubber, rubber-like, and thermoplastic insulations.
Above ratios based on the following constructional details:
Conductor
Concentric Round Diameters from AEIC
Insulation Thickness
1 through 4/0 AWG 78 mils
250 through 500 kcmil 94 mils
600 through 1000 kcmil 109 mils
Diameter-Inches
Conduit Dimension Nominal Inside
1 through 3/0 AWG 2.0 2.07
4/0 AWG Through 250 kcmil 2.5 2.47
300 through 500 kcmil 3.0 3.07
600 through 700 kcmil 3.5 3.55
750 through 1000 kcmil 4.0 4.03

2-18 SOUTHWIRE
 CONDUCTORS

For frequencies other than 60 hertz, a correction factor8 (x) is provided by:

(2-5)

where: = frequency in hertz

= conductor resistance, dc, at operating
temperature in ohms/1000 feet

Table 2-8 derived from the National Bureau of Standards Bulletin 169, provides the
factors for a skin effect ratio of R/Ro as a function of a correction factor (x) where Ro is
the dc resistance and R is the ac resistance. Thus, to determine conductor resistance at
a frequency other than 60 hertz, calculate the correction factor from equation (2-5).
Using Table 2-8, enter the calculated correction factor to determine the R/Ro ratio.
Use this ratio to multiply the dc resistance of the conductor to obtain the resistance
at frequency (f).

8
1957 EEI UGSRB.

SOUTHWIRE 2-19
CHAPTER 2

TABLE 2-8
RESISTANCE RATIO DUE TO SKIN EFFECT
x R/R0 x R/R0

0.0 1.00000 6.6 2.60V313

0.1 1.00000 6.8 2.67312
0.2 1.00001 7.0 2.74319
0.3 1.00004 7.2 2.81334
0.4 1.00013 7.4 2.88355
0.5 1.00032 7.6 2.95380
0.6 1.00067 7.8 3.02411
0.7 1.00124 8.0 3.09445
0.8 1.00212 8.2 3.16480
0.9 1.00340 8.4 3.23518
1.0 1.00519 8.6 3.30557
1.1 1.00758 8.8 3.37597
1.2 1.01071 9.0 3.44638
1.3 1.01470 9.2 3.51680
1.4 1.01969 9.4 3.58723
1.5 1.02582 9.6 3.65766
1.6 1.03323 9.8 3.72812
1.7 1.04205 10.0 3.79857
1.8 1.05240 10.5 3.97477
1.9 1.06440 11.0 4.15100
2.0 1.07816 11.5 4.32727
2.1 1.09375 12.0 4.50358
2.2 1.11126 12.5 4.67993
2.3 1.13069 13.0 4.85631
2.4 1.15207 13.5 5.03272
2.5 1.17538 14.0 5.20915
2.6 1.20056 14.5 5.38560
2.7 1.22753 15.0 5.56208
2.8 1.25620 16.0 5.91509
2.9 1.28644 17.0 6.26817
3.0 1.31809 18.0 6.62129
3.1 1.35102 19.0 6.97446
3.2 1.38504 20.0 7.32767
3.3 1.41999 21.0 7.68091
3.4 1.45570 22.0 8.03418
3.5 1.49202 23.0 8.38748
3.6 1.52879 24.0 8.74079
3.7 1.56587 25.0 9.09412
3.8 1.60314 26.0 9.44748
3.9 1.64051 28.0 10.15422
4.0 1.67787 30.0 10.86101
4.1 1.71516 32.0 11.56785
4.2 1.75233 34.0 12.27471
4.3 1.78933 36.0 12.98160
4.4 1.82614 38.0 13.68852
4.5 1.86275 40.0 14.39545
4.6 1.89914 42.0 15.10240
4.7 1.93533 44.0 15.80936
4.8 1.97131 46.0 16.51634
4.9 2.00710 48.0 17.22333
5.0 2.04272 50.0 17.93032
5.2 2.11353 60.0 21.46541
5.4 2.18389 70.0 25.00063
5.6 2.25393 80.0 28.53593
5.8 2.32380 90.0 32.07127
6.0 2.39359 100.0 35.60666
6.2 2.46338
6.4 2.53321

2-20 SOUTHWIRE
 CONDUCTORS

Examples
-Given 1000 kcmil copper, uncoated Class B strand
-From Table 2-6, Rdc= 0.0108 ohms per 1000 ft.
-Find resistance at 50 and 400 hertz

For 50 Hz
Using equation (2-5):

From Table 2-8, x = 1.88 (by interpolation) R/Ro= 1.0620

For 400 Hz
Using equation (2-5):

From Table 2-8, x = 5.33 (by interpolation) R/Ro = 2.159

SOUTHWIRE 2-21
 INSULATIONS

TYPES

Many insulations are used in producing the various cables used to deliver electric power.
Extruded insulations used for wire and cable are classified as either thermoplastic or
thermoset material. Thermoplastic materials tend to lose their form upon subsequent
heating, while thermosetting materials tend to maintain their form. These insulations
range from thermoplastic polyvinyl chloride (PVC) to thermoset cross-linked polyethylene
and synthetic rubber compounds.

Polyethylene
Polyethylene (PE) is a long chain hydrocarbon thermoplastic material that is produced
by the polymerization of ethylene gas under high or low pressure. PE is popular
because of its relatively low price, processability, resistance to chemicals and moisture,
electrical properties, and low temperature flexibility. PE is produced in low, linear low,
medium, and high densities. As the density increases, so does the hardness, yield
strength, stiffness, and heat and chemical resistance.
If PE cables are exposed to sunlight, carbon black or a suitable inhibitor is added to
screen out ultraviolet (UV) radiation. UV radiation can degrade both physical and
electrical properties. PE’s electrical properties are excellent. Typical values for a natural,
unfilled insulation compound include a volume resistivity of greater than 1016 ohm-cm,
a dielectric constant of 2.3, a dissipation factor of 0.0002, and water absorption of less
than 0.1%. A disadvantage of PE is that, like most plastics, it is susceptible to degrada-
tion by corona discharges. PE also may experience degradation from treeing when it is
subjected to high electrical stress. Corona discharges and treeing may lead to premature
cable failure.

Cross-linked Polyethylene
Cross-linked polyethylene (XLPE) is a thermoset material normally produced by
compounding polyethylene or a copolymer of ethylene and vinyl acetate (EVA) with a
cross-linking agent, usually an organic peroxide. The individual molecules of polyethylene
join together during a curing process to form an interconnected network. The terms
“cure” and “vulcanize” are often similarly used to designate cross-linking.
While the use of peroxide as the cross-linking agent means that only low-density
polyethylene or EVA can be cross-linked, silane cross-linking technology allows the
cross-linking of all densities of polyethylene. Cables produced with cross-linked
polyethylene can operate at higher temperatures than cables produced with thermo-
plastic or noncross-linked polyethylene.
Cross-linking also significantly improves the physical properties of the polyethylene.
Additives tend to reduce the electrical properties of the insulation. For this reason, the
EVA copolymer is used only for low voltage applications. For medium voltage applications,
cross-linked polyethylene fares well because the dielectric strength of the unfilled
cross-linked polyethylene is about the same as that of thermoplastic polyethylene.
Impulse strengths of 2700 V/mil are common.

SOUTHWIRE 3-1
CHAPTER 3

For low voltage applications, the addition of fillers—in particular, medium thermal
carbon black—provides increases in tensile strength and hardness. It also provides the
necessary ultraviolet protection for outdoor applications without the use of a jacket.
The EVA copolymer is well suited to accepting up to a 30% loading of medium thermal
carbon black. Between 2% and 3% of very small particle size furnace carbon black can
be incorporated into the polyethylene if sunlight resistance is required without
significantly reducing the electrical properties.
XLPE-insulated cables may be operated continuously at a conductor temperature of
90°C and intermittently at 130°C during emergency conditions. Based on cable
construction, XLPE-insulated cables may be used for conductor temperatures up to
105°C continuously or 140°C during emergency conditions. XLPE has good low temperature
properties, shows increased resistance to corona when compared with thermoplastic
polyethylene, and has good impact, abrasion, and environmental stress crack resistance.
Medium voltage tree-retardant XLPE insulation compounds are also available. There
are two processes for imparting tree resistance to the compound. One involves additives
and the other involves copolymer technology. Additives tend to reduce the electrical
properties of the polyethylene insulation and one finds slightly lower values of dielectric
strength and slightly higher values of the dissipation factor when comparing the tree
retardant insulations to the standard materials. Medium voltage XLPE insulation is not
flame retardant. For low voltage applications, the compounding of halogen or non-
halogen flame retardants into the insulation achieves the required level of flame retardance.

Ethylene-Propylene Rubber
Ethylene-propylene rubber (EPR) is a thermoset material synthesized from ethylene,
propylene, and in many instances a third monomer. If only ethylene and propylene are
used, the polymer may be referred to as EPM. If three monomers are used, the resulting
polymer is called EPDM. However, in general usage, the term EPR is meant to cover
either polymer. EPR is the predominant insulation for industrial power cable from 5 to 35 kV.
While XLPE is considered a highly crystalline material, EPR ranges from amorphous to
semicrystalline. This range accounts for EPR’s increased flexibility when compared to XLPE.
Peroxide is the predominant cross-linking agent for EPR compounds. However, work
has been done on the use of silane cross-linking systems. Slower cure sulfur cross-linking
systems may be used only if the polymer is EPDM. While XLPE is mainly used as an
unfilled insulation, EPR has filler content that can be 50% or more. The filler is typically
a treated clay or silicate.
EPR may be used for conductor temperatures up to 90°C continuously or 130°C during
emergency conditions. Based on cable construction, EPR-insulated cables may also be
used for conductor temperatures up to 105°C continuously or 140°C during emergency
conditions. Good elastomeric properties along with good ozone, environmental, and
low temperature resistance are characteristic of EPR insulation compounds. For medium
voltage applications, electrical properties consisting of a volume resistivity of 1016 ohm-cm,
a dissipation factor of 0.008, a dielectric constant of 3.2, and an impulse strength of
1500 V/mil are typical. In order to achieve flame retardance, the addition of halogen or
non-halogen flame retardants via compounding is required. Medium voltage insulations
are generally not flame retardant; however, the overall cable may be.

3-2 SOUTHWIRE
 INSULATIONS

Polyvinyl Chloride
Polyvinyl chloride (PVC), also called vinyl, is a thermoplastic material introduced in 1932.
Since then, PVC has become widely used on wire and cable rated at 1000 volts or less.
Vinyl compounds are mechanical mixtures of PVC resin, plasticizers, fillers, stabilizers, and
modifiers. The quantity and type of each determines the final properties of the compound.
PVC compounds can be formulated to provide a broad range of electrical, physical, and
chemical characteristics. However, in achieving superiority in one property, the other
properties are usually compromised. The goal is to optimize the critical property or
properties without allowing the secondary properties to fall below acceptable levels.
PVC has high dielectric strength and good insulation resistance. It is inherently tough
and resistant to flame, moisture, and abrasion. Resistance to ozone, acids, alkalies, alcohols,
and most solvents is also adequate. Compounding can impart resistance to oils and
gasoline. Based on specific formulation, temperature ratings range from 60°C to 105°C.
Disadvantages of PVC include a relatively high dielectric constant and dissipation factor.
Plasticizer loss through evaporation or leeching eventually may cause embrittlement
and cracking. PVC compounds significantly stiffen as temperatures decline, and are not
generally recommended for uses which require flexing below –10°C. However, special
formulations have been developed that will allow flexing to –40°C.

Chlorosulfonated Polyethylene
Chlorosulfonated polyethylene (CSP) is a thermoset material commonly referred to by
DuPont’s trade name of Hypalon®. Several abbreviations are used for this material.
ASTM, in D 1418, refers to it as CSM and UL uses the letters CP. In this section, we will
refer to it by the commonly used letters of CSP.
DuPont began initial work on CSP in the early 1940s. Commercial insulation compounds
appeared a few years later. CSP is made by adding chloride and sulfonyl groups to
polyethylene. This modification changes the stiff plastic into a rubbery polymer that can
be cross-linked in a variety of ways. Organic peroxides and sulfur systems are the most
common methods of obtaining the cross-linking.
Like PVC and XLPE, CSP is a mechanical mixture of ingredients that may contain polymer,
fillers, modifiers and cross-linking agents. The quantity and type of each ingredient
affects the final physical and electrical properties of the insulation. Because CSP contains
a halogen, it is inherently flame retardant. The typical CSP compound is rated for 90°C
operation and has excellent mechanical properties such as tensile strength and abrasion
resistance. In addition, it has good weather, oil, chemical, and fluid resistance.

Non-Halogen Ethylene Copolymers

Non-halogen ethylene copolymers combine attributes of polyethylene and polypropylene
to produce insulating and jacketing compounds with superior fire performance. Unlike
many other ethylene copolymers, these compounds do not include chemicals from the
halogen group of elements, such as fluorine, chlorine, bromine, and iodine. Compounds
made with halogens are more likely to give off toxic or acid by-products when burned.
Non-halogen ethylene copolymers are the result of many years of research. They are
generally more expensive than materials such as PVC and XLPE. Manufacturers generally
do not reveal the formulas or processes they use to make non-halogen ethylene
copolymer insulations.
These compounds feature good fire performance characteristics: low smoke production,
delayed ignition, and little or no production of toxic by-products or acid gases.

SOUTHWIRE 3-3
CHAPTER 3

The fire retardant system for these copolymers is not the same as for PVC or XLPE.
Non-halogen ethylene copolymers include hydrated minerals that release water when
exposed to elevated temperatures. The water cools the burning mass to a point below
its combustion temperature, extinguishing the flame. The emission from the flaming
material is steam, not the black smoke produced by burning conventional materials.
These characteristics improve the potential of escape from fires and lower the likelihood
of equipment damage due to smoke. Because non-halogen ethylene copolymer
products are more expensive, they are primarily used for installations in which the benefit
of the additional fire performance outweighs the cost, such as computer rooms.
In properties other than fire performance, non-halogen ethylene copolymers perform
much like PVC or XLPE. In terms of performance criteria such as flexibility, a user would
be unlikely to notice any difference in non-halogen ethylene copolymers versus other
materials. However, in terms of electrical characteristics, non-halogen ethylene
copolymers do exhibit one key difference: These materials are required to provide
electrical resistance 10 times greater than PVC to ensure the integrity of the compound.

INSULATION PROPERTIES

TABLE 3-1
INSULATION PROPERTIES
Units PVC HMWPEA LLDPEA HDPEA XLPEB MVXLPE EPR CSP LSZH
Service Temperature (Max) °C 105 75 75 75 90 90 90 90 90
Tensile Strength PSI 3000 2100 2250 4000 2400 2400 1400 1700 1800
Elongation % 300 650 650 800 350 550 300 500 200
Specific Gravity 1.32 0.93 0.93 0.96 1.07 0.92 1.19 1.54 1.5

Abrasion Resistance Relc Good Good Good Good Good Good Fair Good Good
Ozone Resistance Relc Good Good Good Good Good Good Good Good Good
Flame Resistance Relc Fair Poor Poor Poor Poor Poor Poor Good Good
Flexibility Relc Fair Poor Poor Poor Poor Poor Good Good Poor

Dielectric Constant 3.4 2.6 2.5 2.5 5.0 2.3 2.5 6.0 4.0
Dissipation Factor 0.1 0.005 0.003 0.001 0.006 0.0003 0.005 0.06 0.003
Insulation ResistanceD IR K 2000 50000 50000 50000 10000 20000 20000 1000 10000
Volume resistivity (Min) ohm-cm 1E + 14 1E +16 1E +16 1E +16 1E +16 1E +16 1E +15 1E +14 1E +16
Dielectric Strength (ac) V/mil 500 500 500 500 390 1000 900 500 500

Acid Resistance Relc Good Good Good Good Good Good Good Good Good
Alkali Resistance Relc Good Good Good Good Good Good Good Good Good
Organic Solvent Resistance Relc Fair Poor Fair Fair Fair Fair Fair Good Fair
Hydraulic Fluid Resistance Relc Good Poor Fair Fair Fair Good Good Good Fair
Motor/Crude Oil Resistance Relc Good Fair Good Good Poor Fair Poor Good Poor
Gasoline/Kerosene Resistance Relc Good Fair Good Good Poor Fair Poor Fair Poor
Alcohol Resistance Relc Fair Fair Good Good Poor Fair Good Good Poor

(A) Black pigmented insulation. HMWPE - High Molecular Weight Polyethylene

(B) Typical carbon black filled 600 volt insulation. LLDPE - Linear Low Density Polyethylene
(C) Rel = Relative performance among materials listed. HDPE - High Density Polyethylene
(D) Minimum ICEA values. MVXLPE - Medium Voltage Cross-linked Polyethylene
Values are typical unless otherwise indicated. LSZH - Low Smoke Zero Halogen

3-4 SOUTHWIRE
 INSULATIONS

WALL THICKNESSES

ICEA Insulated Cables

TABLE 3-2
ICEA NONSHIELDED INSULATION THICKNESSES RATED 0 – 2000 VOLTS
Rated Circuit Conductor Insulation Thickness
Voltage, Size,
Phase-to-Phase, AWG or Column A Column B
Volts kcmil mils mm mils mm
0-600 14-9 45 1.14 30 0.76
8-2 60 1.52 45 1.14
1-4/0 80 2.03 55 1.40
225-500 95 2.41 65 1.65
525-1000 110 2.79 80 2.03

601-2000 14-9 60 1.52 45 1.14

8-2 70 1.78 55 1.40
1-4/0 90 2.29 65 1.65
225-500 100 2.67 75 1.90
525-1000 120 3.05 90 2.29
This information was taken from ICEA Standard S-95-658.
Column A thickness (2000 volts or less) apply to single-conductor power cables for general application when a carbon-black-
pigmented insulation is used without a further covering.
Column B thicknesses (2000 volts or less) apply to multiple-conductor cables with an outer covering and to single-conductor
cables with an outer covering. The Column B thicknesses are considered adequate for electrical purposes and may be
specified for single-conductor cables with a carbon-black pigmented insulation without further covering for applications
where installation and service conditions are such that the additional thicness for mechanical protection is not considered
necessary for satisfactory operation.

NEC/UL Listed Cables

TABLE 3-3
THICKNESS OF INSULATION AND JACKET FOR NONSHIELDED CABLES
RATED 2001 – 5000 VOLTS
Dry Locations, Single Conductor Wet or Dry Locations
Without Jacket With Jacket Single Conductor Multiconductor
Conductor Size Insulation Insulation Jacket Insulation Jacket Insulation
(AWG or kcmil) (mils) (mils) (mils) (mils) (mils) (mils)
8 110 90 30 125 80 90
6 110 90 30 125 80 90
4-2 110 90 45 125 80 90
1-2/0 110 90 45 125 80 90
3/0-4/0 110 90 65 125 95 90
213-500 120 90 65 140 110 90
501-750 130 90 65 155 125 90
751-1000 130 90 65 155 125 90

This information was taken from the 2005 NEC. The 2005 NEC requires cables to be shielded for systems operating
above 2400 Volts.

SOUTHWIRE 3-5
CHAPTER 3

TABLE 3-4
THICKNESS OF INSULATION FOR SHIELDED CABLES
RATED 2,001 – 15,000 VOLTS
5,001 – 8,000 Volts 8,001 – 5,000 Volts
Conductor Size 2,001 – 5,000 Volts 100% 133% 173% 100% 133% 173%
(AWG or kcmil) Level Level Level Level Level Level
mils mils mils mils mils mils mils
8 90 -- -- -- -- -- --
6-4 90 115 140 175 -- -- --
2 90 115 140 175 175 220 260
1 90 115 140 175 175 220 260
1/0-2000 90 115 140 175 175 220 260

THICKNESS OF INSULATION FOR SHIELDED CABLES

RATED 15,001 – 35,000 VOLTS
15,001 – 25,000 Volts 25,001 – 28,000 Volts 28,001 – 35,000 Volts
Conductor Size 100% 133% 173% 100% 133% 173% 100% 133% 173%
(AWG or kcmil) Level Level Level Level Level Level Level Level Level
mils mils mils mils mils mils mils mils mils
8 -- -- -- -- -- -- -- -- --
6-4 -- -- -- -- -- -- -- -- --
2 -- -- -- -- -- -- -- -- --
1 260 320 420 280 345 445 -- -- --
1/0-2000 260 320 420 280 345 445 345 420 580
This information was taken from the 2005 NEC.

The selection of the cable insulation level to be used in a particular installation is made
on the basis of the applicable phase-to-phase voltage of the circuit and of the general
system category (expressed as a percent insulation level) as outlined below:

100 Percent Insulation Level — Cables in this category shall be permitted to be

applied where the system is provided with relay protection such that ground
faults will be cleared as rapidly as possible but, in any case, within 1 minute.
While these cables are applicable to the great majority of cable installations
that are on grounded systems, they shall be permitted to be used on other systems
for which the application of cables is acceptable, provided that the above clearing
requirements are met in completely de-energizing the faulted section.

133 Percent Insulation Level — This insulation level corresponds to that formerly
designated for ungrounded systems. Cables in this category shall be permitted
to be applied in situations where the clearing-time requirements of the 100
percent level category cannot be met, and yet there is adequate assurance that
the faulted section will be de-energized in a time not exceeding 1 hour. Also,
they shall be permitted to be used in 100 percent insulation level applications
where additional insulation is desirable.

3-6 SOUTHWIRE
 INSULATIONS

173 Percent Insulation Level — Cables in this category shall be permitted to be

applied under the following conditions.
(1) in industrial establishments where the conditions of maintenance and
supervision ensure that only qualified persons service the installation
(2) where the fault clearing time requirements of the 133 percent level
category cannot be met
(3) where an orderly shutdown is essential to protect equipment and
personnel, and
(4) there is adequate assurance that the faulted section will be de-energized
in an orderly shutdown
Also, cables with this insulation thickness shall be permitted to be used in 100 or
133 percent insulation level applications where additional insulation strength is
desirable.

SOUTHWIRE 3-7
 SHIELDING OR SCREENING
Shielding (also referred to as screening) of medium and high voltage power cables uses
stress control layers to achieve symmetrical dielectric fields within the cable structure
(see Chapter 1). For some voltage levels, shielding may be applied over the conductor.
At most higher voltage levels, it is applied over the conductor and the insulation. This
construction results in the confinement of all the voltage gradients to within the cable
structure if the shield over the insulation is at essentially ground potential.

CONDUCTOR SHIELD

The conductor shield is a layer of semiconducting material used to shield out the surface
irregularities of the conductor. A conductor shield is usually required on conductors
that are to be insulated for rated operation over 2kV. This stress control layer is
compatible with the conductor and the cable insulation. Applicable industry specifications
define the characteristics of the conductor shield.1

INSULATION SHIELD

As discussed in Chapter 1, the insulation shield consists of two components. These

components are the auxiliary shield and the primary shield, both functioning as stress
control layers in concert with each other.

Materials
The auxiliary shield is an extrudable semiconducting polymer. It can also serve as a
jacketing function as discussed in Chapter 5.
The primary shield may consist of metal tape, drain wires, or concentric neutral (CN)
wires. These are usually copper and may be coated or uncoated. Some primary shields
may consist of a combination of drain wires and a collector tape, which is smaller than
a normal shielding tape.
Concentric neutral wires serve a two-fold purpose. They function as the metallic
component of the insulation shield and as a conductor for the neutral return current.
Their cross-sectional area must be sized in order to function as the neutral conductor.
Chapter 6 has information concerning fault currents in primary shields.

1
ICEA S-93-639 (NEMA WC 74-2000): “5 - 46 kV Shielded Power Cable for Use in the Transmission & Distribution of Electric Energy.”
AEIC CS8-00 (1st edition), “Specification for Extruded Dielectric, Shielded Power Cables Rated 5 through 46kV.”

SOUTHWIRE 4-1
CHAPTER 4

Voltage Parameters
With some exceptions, an insulation shield is required by the NEC for all cables rated
above 2kV. According to ICEA, a single cable with a metallic sheath and multiple
conductor cables with metallic sheath or armor, as well as multiple conductor cables
with a discharge-resistance jacket, may operate below 5kV without an insulation shield.
ICEA and AEIC provide the required characteristics of the insulation shield.1

Requirements for Use

In addition to the voltage parameters given above for when an insulation shield must
be used, other parameters must be considered to determine when insulation shielding
is required on a cable. These requirements are presented in ICEA specifications as follows;2

1. Cable that is connected to an overhead aerial conductor.

2. When the cable length makes a transition from a conducting to a
nonconducting enclosure.
For example:
a. Conducting to nonconducting conduit
b. In nonconducting conduit that is alternately dry and wet
c. From dry earth to moist earth
3. With the use of pulling lubrications that have conductive properties
4. Where cable surface is subjected to deposits of conducting materials, such as
salts, cements, soot, etc.
5. Where there are or may be electrostatic discharges that may not be injurious
to the cable but of sufficient magnitude to create radio or television
reception interference.

GROUNDING OF INSULATION SHIELD

The grounding of the insulation shield is the electrical connection between the metallic
component of the insulation shield and the system ground. The grounding of the
insulation shield results in the symmetrical dielectric fields previously discussed. In
addition, grounding promotes personnel safety by minimizing potentials on the outer
surface of the cable and its accessories. Chapter 6 contains information on grounding
of the insulation shield.
The shielding of the cable system can be grounded by either single-point or multiple-
point methods. A single-point grounded system is frequently referred to as an open
circuit shield. Because the shield is grounded at a single point, no closed loop exists for
the flow of induced shield currents. A multiple-point grounded system is one that has
grounds at more than one point. It is frequently called a closed or short circuit shield
system.
Each arrangement has its particular advantages and disadvantages for selection.
Knowledge of the total system should be taken into account when making these
decisions. Chapter 6 and IEEE discuss this topic in more detail.3

1
ICEA S-93-639 (NEMA WC 74-2000): “5 - 46 kV Shielded Power Cable for Use in the Transmission & Distribution of Electric Energy.”
AEIC CS8-00 (1st edition), “Specification for Extruded Dielectric, Shielded Power Cables Rated 5 through 46kV.”
2
ICEA S-93-639 (NEMA WC 74-2000): “5 - 46 kV Shielded Power Cable for Use in the Transmission & Distribution of Electric Energy.”
3
ANSI/IEEE Standard 525-1992, “IEEE Guide for the Design and Installation of Cable Systems in Substations. 1992.”

4-2 SOUTHWIRE
 SHIELDING OR SCREENING

Single-Point Grounding
An ampacity improvement may be achieved if the primary shield is grounded at only
one point. Any improvement is also dependent upon conductor size, cable spacing, and
shield resistivity (see Chapter 6). The major reason for improvement is the elimination
of induced circulating currents through a shield ground-neutral loop. Current is
induced in the shield by the electromagnetic field produced by the load current in the
conductor. The shield voltage is sufficient to drive this current through any loop of
shield-ground-neutral-conductors. Opening the loop by grounding the shield at only
one point stops this circulating current flow.
Single-point grounding will result in an increasing voltage along the shield. The value
of this buildup of voltage is influenced by the electromagnetic field created by the load
current in the power conductor and the length of the shield. To keep the voltage at
the ungrounded end of the shield to the recommended maximum level of 25 volts, it
may be necessary to ground the shield at the midsection of the cable route. When
using the midsection grounding method, the cable length to achieve a 25 volt buildup
is double that if the shield were grounded at only one end.
To keep shield potentials to desirable voltage levels, it may be necessary to install
shield interrupters to create shield sections, which then are grounded at only one end.
This “interrupts” the shield to ground circulating current because of the “open” in the
shield-ground-neutral loop.
Shield interrupts require the construction of unconnected, overlapping cable insulation
shields. Splices provide convenient opportunity for either the placement of shield
interrupts or the incorporation of a shield interrupt into the design and installation.

Multiple-Point Grounding
To keep shield potentials at a minimum, it is common practice to ground insulation
shields at readily accessible locations, such as at every splice and termination. It must be
recognized that multiple-point grounding creates shield-to-ground circulating currents
and may have an adverse effect upon cable ampacity. This effect is also dependent
upon conductor size, cable spacing, current loading of cable conductor, and shield
resistivity. For more details, refer to Chapter 6.

SOUTHWIRE 4-3
 JACKETING, SHEATHING,
AND ARMORING

GENERAL

Jackets, also called sheaths, serve several purposes. For example, they provide mechanical,
thermal, chemical, and environmental protection to the insulated conductors they
enclose. They may act as electrical insulation when used over shields or armor. They
ease installation and routing concerns by enclosing multiple insulated conductors. They
may also protect the characteristics of the underlying insulation. For example, a thin
nylon jacket over PVC enhances the abrasion and fluid resistance of a 600V cable.
Sheathing may also include various forms of metallic armoring, tapes, or wires to
enhance the physical properties of the cable and to provide a built-in protective
electrically grounded conduit for the insulated conductors. The term “sheathing” is
typically used to identify tubular metallic coverings.
Armoring is primarily used to protect the cable mechanically and adds strength to the
cable. Hazards to the cable include penetration by sharp objects, crushing forces, and
damage from gnawing animals or boring insects. High pulling or application tensions
such as submarine, riser, and down-hole installations also may cause damage.
The distinctions between jackets, sheaths, armoring, and shields are sometimes
obscure. For example, an overall welded metal covering usually referred to as a sheath
may act as armor and a shield. If it is performing as a jacket, it keeps out water and
other contaminates. The covering could be acting as armor because it provides
mechanical protection to the insulated conductors. It also performs the function of a
shield because it may carry short circuit return currents, help eliminate electrical
interference problems, or “shield” the cable from damage caused by lightning strikes.

NONMETALLIC JACKETS

Commonly used jacketing materials include extrusions of PE, PVC, Nylon, CPE (chlorinated
polyethylene), non-halogen, and CSP (Hypalon®). PVC, Nylon, PE, and CPE are applied
using thermoplastic extrusion lines that heat the material to the melting point and
form it over the core. The material is then cooled, usually in a water trough, and
wound onto a reel. CSP differs because it is a thermoset material. Some heat is used to
soften the material so that it can be formed around the core. It is then necessary to
cross-link the material to obtain its full properties. The terms “cure” and “vulcanize”
are often similarly used to designate crosslinking.
These materials conform to one or more of the standards issued by AEIC, ASTM, CSA,
ICEA, IEEE, NEMA, and UL as directed by specific requirements and applications.
Properties for Low Smoke Zero Halogen (LSZH) jackets are found in ICEA.1

1
ICEA T-33-655-1994, “Low-Smoke, Halogen-Free (LSHF) Polymeric Cable Jackets.”

SOUTHWIRE 5-1
CHAPTER 5

TABLE 5-1
JACKET PROPERTY COMPARISON
Units PVC PE Nylon CSP CPE LSZH
Continuous Service Temp. of Conductors °C 90 75 90 90 90 90
Installation Temp. (Min) °C -10 -40 -10 -20 -40 -20

Tensile Strength (Min) PSI 1500 1400 7900 1200 1560 1400
Elongation (Min) % 100 350 40 200 420 100
Specific Gravity 1.43 0.93 1.13 1.54 1.28 1.5
Flexibility RelA Fair Poor Poor Good Fair Fair

Abrasion Resistance RelA Good Good Good Good Good Good

Ozone Resistance RelA Good Good Good Good Good Good
Flame Resistance RelA Fair Poor Poor Good Good Good
Moisture Resistance RelA Good Good Poor Good Good Good

Acid Resistance RelA Good Good Poor Good Good Good

Alkali Resistance RelA Good Good Good Good Good Good
Organic Solvent Resistance RelA Fair Fair Good Good Good Fair
Hydraulic Fluid Resistance RelA Good Poor Good Good Good Good

Motor/Crude Oils RelA Good Fair Good Good Good Good

Gasoline/Kerosene RelA Good Poor Good Good Good Good
Alcohol RelA Fair Fair Good Good Good Good
Hydrocarbons (Halogenated) RelA Poor Poor Fair Fair Poor Poor
( ) Relative performance among materials listed.
A

Results are typical unless otherwise indicated.

METALLIC SHEATHS

Typical requirements for lead and aluminum sheaths are specified by ICEA and IEEE.2

Lead Sheathing
Lead is one of the oldest sheathing materials used on power cables, dating back in the
early 1900s. In the sheathing operation, molten lead is fed into a cylinder. After a partial
cooling, a hydraulic piston forces the lead through an annular die, forming it tightly
around the cable. A significant advantage of this process is that the lead can be
applied to the cable at a relatively low temperature and pressure. Use of lead sheaths
has proven to be a very effective moisture barrier contributing to the long-term
reliability of cable systems.
A disadvantage of lead sheaths is that they add a great deal of weight to the cable.
Lead sheaths also pose environmental concerns. They are prone to deformation under
continuous load conditions due to the creep characteristics of the material. Also,
lead sheaths are susceptible to failure from metal fatigue caused by mechanical
vibration or thermal cycling.

2
ICEA S-93-639 (NEMA WC 74-2000): “5 - 46 kV Shielded Power Cable for Use in the Transmission & Distribution of Electric Energy”, and
IEEE Standard 635-2003, “IEEE Guide for Selection and Design of Aluminum Sheaths for Power Cables.”

5-2 SOUTHWIRE
 JACKETING, SHEATHING, AND ARMORING

Aluminum Sheathing
Aluminum sheathing began to appear in the late 1940s. Aluminum is attractive because
it is much lighter than lead and has good mechanical properties. Aluminum sheaths
may be applied using an extrusion process similar to that used for lead. Aluminum
requires significantly higher extrusion temperatures: 450°C compared to 200°C for lead.
An aluminum sheath may also be applied by longitudinally bending a relatively thick
metal tape around the core. This tape is then welded and die formed or drawn down
to the proper diameter. Corrugations may then be formed into the metal tube for
improved bending characteristics.

ARMORING

Typical requirements for continuously corrugated, interlocked, flat tape, and round wire
armoring, including required beddings and coverings, appear in ICEA specifications.3

Gas/Vaportight Continuously Corrugated

Gas/Vaportight continuously corrugated metal armor is formed by a flat metal tape
that is longitudinally folded around the cable core, seam welded, and corrugated. It
can also be manufactured by extruding over the cable core an aluminum tube that is
then corrugated. An outer protective jacket, such as PVC, is often used.
The advantage of continuously corrugated armored cable is the sheath is impervious to
water and is gas/vaportight. Applications include use as an alternative to traditional
conduit systems, aerial installations, direct burial, concrete-encased installations, open
trays, troughs, or continuous rigid cable supports. It is approved for Classes I and II,
Division 2 and Class III, Divisions 1 and 2 hazardous locations covered under NEC
Articles 501, 502, 503, and 505. Continuously corrugated aluminum armor can be used
in Class I Division 1 locations if it is jacketed, has appropriate grounding conductors,
and is listed for use in Class I and II, Division 1 locations.

Interlocked
Interlocked armor is produced by taking a flat metal tape, preforming it into an
approximate “S” shape, and then helically wrapping it around a cable core so that the
formed edges lock together. The two most commonly used materials are steel and
aluminum. An outer protective jacket, such as PVC, is often used.
Advantages of this type of armored cable include considerable flexibility and relative
ease of termination of the armor. A disadvantage is that interlocked armor is not suitable
for uses where high longitudinal loads are placed on the armor. Applications include
commercial or industrial power, control, and lighting circuits that are installed in conduits,
ducts, troughs, and raceways or are suspended from aerial messengers. Although
interlocked armor provides excellent mechanical protection and flexibility, it should not
be considered as a moisture barrier.

3
ICEA S-93-639 (NEMA WC 74-2000): “5 - 46 kV Shielded Power Cable for Use in the Transmission & Distribution of Electric Energy.”
Other standards also apply.

SOUTHWIRE 5-3
CHAPTER 5

Flat Metal Tapes

A flat metal tape is helically wrapped around the cable core. The most commonly used
materials are steel, copper, and bronze. The tape is typically protected by an outer
covering. Applications include commercial or industrial installations that are installed in
conduit, ducts, troughs, and raceways or are suspended from aerial messengers.

Round Wire
Individual wires of relatively small diameter are helically wrapped over the core.
Galvanized steel is typically used for protection. An overall extruded thermoplastic
jacket may be used for protection. Applications include submarine, borehole, dredge,
shaft, and vertical riser cables.

SPECIAL JACKET OR SHEATH COMBINATIONS

Teck Cable
To meet CSA or Ontario Hydro requirements, a double jacketed/interlocked armor
design is used. The Canadian terminology refers to this construction as “Teck Cable.”
Typically, an extruded PVC jacket is used over the armor. In this special version, an
additional PVC jacket is applied over the cable core under the armor. This jacket
provides the cable with an extra measure of protection against thermal degradation,
mechanical damage, and fluid penetration. In addition, the fully jacketed core can be
easily routed and terminated beyond the point where the armor is terminated.

5-4 SOUTHWIRE
 ELECTRICAL CHARACTERISTICS
OF CABLES AND CABLE SYSTEM

BASIC POWER SYSTEM REVIEW

DC Circuits
The following circuit diagrams represent selected dc and ac power systems. These
diagrams will help in understanding the information presented in this section.

Figure 6-1
DC Two-Wire Circuit

Figure 6-2
DC Three-Wire Circuit

Single-Phase AC Circuits

Figure 6-3
AC Single-Phase, Two-Wire Circuit
10
SOUTHWIRE 6-1
CHAPTER 6

Polyphase AC Circuits
Polyphase systems merit additional discussion because they are the most common and
are somewhat more complex than dc or single-phase ac systems.

Three-Phase Circuits

Figure 6-4
AC Three-Phase, Y (Wye) Circuit

Figure 6-5
AC Three-Phase, ∆ (Delta) Circuit

Rotating alternating current generators are typically designed with three armature
windings that are spaced 120 physical degrees apart and therefore generate sine wave
outputs that are 120 electrical degrees apart. The outputs are connected in a delta (∆)
or wye (Y) configuration. In a Y configuration, the common or neutral point may have a
neutral conductor attached. This neutral conductor may be grounded or ungrounded.
With both type circuits, the line voltages and currents are equal when a balanced load is
used. A balanced load means that the load is designed to be symmetrical electrically or
that diverse, but equal loads are placed on each line, therefore drawing equal currents
from each phase.

SOUTHWIRE 6-2
 ELECTRICAL CHARACTERISTICS

Two- and Four-Phase Circuits

Figure 6-6
AC Two-Phase, Four- or Five-Wire Circuit

These four- or five-wire circuits are variations of the three-phase circuits previously
discussed. Typically, the armature windings and resulting outputs are 90 degrees apart.
Other configurations can include three-wire, two-phase; four-wire, two-phase; and four-
wire with two isolated phases. Eliminating winding A and D in Figure 6-6 would illustrate
a three-wire, two-phase circuit.
Advantages of the polyphase circuits include increased generator output, reduced load
losses, and constant power output with balanced loads.

VOLTAGE RATING

The voltage rating of a cable is based, in part, on the thickness of the insulation and
the type of electrical system to which it is connected. Information on insulation thickness
can be found in Chapter 3.

Below are general system categories as defined by the NEC.1

General System Categories

The selection of the cable insulation level to be used in a particular installation is made
on the basis of the applicable phase-to-phase voltage of the circuit and of the general
system category (expressed as a percent insulation level) as outlined below:

100 Percent Insulation Level - Cables in this category shall be permitted to be applied
where the system is provided with relay protection such that ground faults will be
cleared as rapidly as possible but, in any case, within 1 minute. While these cables are
applicable to the great majority of cable installations that are on grounded systems,
they shall be permitted to be used on other systems for which the application of cables
is acceptable, provided that the above clearing requirements are met in completely
de-energizing the faulted section.

133 Percent Insulation Level - This insulation level corresponds to that formerly desig-
nated for ungrounded systems. Cables in this category shall be permitted to be applied
in situations where the clearing-time requirements of the 100 percent level category
cannot be met, and yet there is adequate assurance that the faulted section will be
de-energized in a time not exceeding 1 hour. Also, they shall be permitted to be used
in 100 percent insulation level applications where additional insulation is desirable.
1
National Electrical Code (NEC), 2005, NFPA 70.

SOUTHWIRE 6-3
CHAPTER 6

173 Percent Insulation Level - Cables in this category shall be permitted to be applied
under the following conditions.
1) In industrial establishments where the conditions of maintenance and supervision
ensure that only qualified persons service the installation
2) where the fault clearing time requirements of the 133 percent level category
cannot be met
3) where an orderly shutdown is essential to protect equipment and personnel, and
4) there is adequate assurance that the faulted section will be de-energized in an
orderly shutdown
Also, cables with this insulation thickness shall be permitted to be used in 100 or 133
percent insulation level applications where additional insulation strength is desirable.

Voltage Potentials
The voltage across individual cables in a 23kV three-phase system is as follows:

Figure 6-7
Three-Phase Cable Arrangement

E (Cable A to B) = E(Line-to-Line) = 23,000 volts

E (Cable-to-Ground) = E(Line-to-Neutral) = E(Line-to-Line) ⴜ 3 = 13,200 volts

However, during a fault on one phase:

E (Cable-to-Ground) can approach E(Line-to-Line) or 23,000 volts

This illustrates why 133% and 173% level systems require increased insulation
thicknesses at certain higher voltage ratings.

FORMULAS AND RELATED INFORMATION

Inductance
This unit inductance (L) of a cable to neutral is dependent on conductor diameter and
spacing between the conductors.

(6-1)

where: s = center-to-center conductor spacing in inches

d = diameter over conductor in inches
Where the equivalent distance(s) for conductor arrangements is given by

(6-2)

SOUTHWIRE 6-4
 ELECTRICAL CHARACTERISTICS

Inductive Reactance
The inductive reactance (XL) of a cable system depends on the unit inductance, cable
length, and its operating frequency.
(6-3)

where: f = frequency in hertz

L = inductance in henries for one foot
= cable length in feet

The equivalent distance(s) for several conductor arrangements is:

For triplexed cables:

s = A
where A = B = C

Figure 6-8

For equally spaced flat cables:

s = 1.26A
where A = B

Figure 6-9

For cradled conductors:

s ⬵ 1.15A
where A = B

Figure 6-10

SOUTHWIRE 6-5
CHAPTER 6

Dielectric Constant
The terms dielectric constant, permittivity, and specific inductive capacitance (SIC) are
often used interchangeably when discussing cable characteristics. Symbols used are the
currently preferred (epsilon) and the traditional ␬ (kappa).
The dielectric constant ( ) is a specific property of an insulating material that is defined
as the ratio of the electrical capacitance of a given capacitor having specific electrode/
dielectric geometry to the capacitance of the same capacitor with air as a dielectric.

TYPICAL VALUES
Material Range Medium Voltage 600V
PVC 3.4 - 8.0 N/A 8.0
EPR 2.5 - 3.5 2.9 3.5
PE 2.5 - 2.6 N/A 2.6
XLPE 2.3 - 6.0 2.4 5.0

Capacitance
The unit capacitance (C) of a cable is dependent on the insulation’s dielectric constant
and the diameter of the conductor and the insulation.

Shielded Single Conductor

(6-4)

Twisted Pair (Mutual)

(6-5)

where: = dielectric constant of the insulation

D = diameter of insulation in inches
(under insulation shield if present)
d = diameter of conductor in inches
(over conductor shield if present)

Capacitive Reactance
The capacitive reactance (Xc) of a cable system is dependent on the unit capacitance
and length of the cable and its operating frequency.

(6-6)

where: f = frequency in hertz

C = capacitance in picofarads for one foot
= cable length in feet

SOUTHWIRE 6-6
 ELECTRICAL CHARACTERISTICS

Charging Current
The capacitance of the cable causes a current to flow from the source to ground. This
charging current (IC) is independent of the load current and is usually very small when
compared to the load current. Charging current of a cable is dependent on its operating
frequency, operating voltage, the unit capacitance, and cable length.

(6-7)

where: f = frequency in hertz

C = capacitance in picofarads for one foot
En = line-to-neutral voltage in volts
= cable length in feet

Total Reactance
The total cable reactance (X) is the vector sum of the inductive reactance and the
capacitive reactance of the cable.
(6-8)

Impedance
Impedance (Z) may be defined as the opposition to the flow of alternating current. The
impedance of cables is dependent upon both the resistive and reactive characteristics
of the cable.

(6-9)

where: R = ac resistance at operating temperature in ohms per foot

X = reactance in ohms per foot

Insulation Resistance and IR Constant

Insulation resistance (IR) is the ratio of an applied dc voltage to the small dc current that flows
through the insulation to ground. This dc current is commonly called the leakage current.

(6-10)

where: E = applied dc voltage n voltage in volts

IL = leakage current in amps

Insulation resistance measurements are affected by temperature and can be corrected

to a base reference temperature with temperature coefficients. The base temperature is
usually 60°F.

SOUTHWIRE 6-7
CHAPTER 6

Insulation Resistance Constant (K)

The minimum insulation resistance (IR) value for a cable can be calculated using an insulation
resistance constant (K) based on the insulation used and the applicable specification
requirements IR is inversely proportional to cable length. A 2,000 foot length of cable
has approximately one-half the IR value of a 1,000 foot length of the same cable.

(6-11)

where: K = specific insulation resistance constant at 60°F

D = diameter of insulation in inches
(under insulation shield if present)
d = diameter of conductor in inches
(over strand shield if present)

TYPICAL K VALUES
PVC 2,000
EPR 20,000
PE 50,000
XLPE 20,000

Power Factor
The power factor (pf) of a power system can be defined as the percentage of total
current flowing from the source that is used to do useful work. A power factor of 1
means that all of the current is used to do work. This represents an ideal situation from
the viewpoint of the load. The vector diagram for this would be as shown below:

where: pf = 1
␪ = 0° [The angle between E (voltage)
and I (current) vectors in degrees]

Figure 6-11

A power factor of 0 means that none of the current is used to do work. A load with a
power factor of 0 would be useless because no work would be done. However, a feeder
cable with a power factor of 0 is ideal with no lost energy dissipated into the cable.
The vector diagram would be as shown below:

where: pf = 0
␪ = 90°

Figure 6-12

SOUTHWIRE 6-8
 ELECTRICAL CHARACTERISTICS

A “practical” load has a power factor somewhere between 0 and 1. A typical value
would be 0.8. When the power factor is equal to 0.8, the angle ␪ will equal 36.9° because
the power factor is defined as cos ␪. The vector diagram would be as shown below:

where: pf = 0.8
␪ = 36.9°

Figure 6-13

A “practical” cable has a power factor of 0.1 or less. When the power factor is equal to
0.1, the angle ␪ will equal 84.3°. Because 90° would be ideal, the imperfection angle,
also referred to as the dissipation factor or tan delta (␦), is 90° minus 84.3° or 5.7°. The
vector diagram would be as shown below:

where: pf = 0.1
␪ = 84.3°

Figure 6-14

For the small angles found in modern power cables, the sin ␦, tan ␦, and cos ␪ are
essentially the same.

Cable System Impedance at Power Frequencies

The cable system impedance (Z) at power frequencies is dependent on the conductor
resistance, cable reactance, and the power factor of the load.

(6-12)

where: R = ac resistance of cable conductor at operating

temperature in ohms
X = total reactance of cable in ohms
␪ = power factor angle of load

SOUTHWIRE 6-9
CHAPTER 6

Ampere Determination From Power Ratings

DC
(6-13)

AC Single-Phase

(6-14)

AC Three-Phase

(6-15)

where: kva = apparent power in kilovoltamperes

kw = power in kilowatts
EL = line-to-line voltage
pf = power factor of load

Breakdown Strength
The electrical breakdown mechanisms of insulation systems are complex. Some of the
factors affecting breakdown voltage are the type and condition of the dielectric
material, cable design, nature and duration of applied voltage, temperature, and
mechanical stresses.
The breakdown voltage strength is defined as the average voltage at which complete electrical
failure occurs in the insulation of a given cable. A listing of typical breakdown tests follows. In
all of these tests, a sufficient number of specimens must be tested so that a statistically valid
average is obtained.
• An ac or dc fast rise test is typically done by raising the applied voltage from 0
volts at a uniform and relatively rapid rate until the insulation fails.
• An ac or dc step rise test is typically done by applying a fixed voltage to a cable for
a fixed time. The voltage is then raised in equal voltage steps and held for equal
time increments until the insulation fails.
• Impulse testing is done to approximate lightning and other surges that cables may
be subjected to in use. An impulse of a standard wave shape is used with the crest
value increased until failure.

Voltage Stress
Voltage stress is defined as the voltage across a unit thickness of insulation.

Average Stress (SA)

The average radial stress is determined by the ratio of the applied voltage to the total
insulation thickness.
(6-16)

where: E = applied voltage in volts

t = thickness of insulation in mils

SOUTHWIRE 6-10
 ELECTRICAL CHARACTERISTICS

Actual Stress (S)

The cable geometry creates a nonlinear dielectric field. This results in higher radial
stresses, or voltage gradients, near the conductor shield when compared to those near
the insulation shield.

(6-17)

where: E = voltage to ground in volts

D = diameter over insulation in mils
(under insulation shield if present)
dc = diameter of conductor in mils
(over strand shield if present)
dx = any diameter of interest between dc and D in mils
The maximum radial stress occurs when dx is equal to dc.

VOLTAGE DROP (REGULATION)

Voltage drop (Vd) is the difference in voltage between the source (Es) and the load (EL).
The feeder cable connects the load to the source and is a major consideration in the
calculations. It often happens that voltage drop, not ampacity, is the limiting factor in a
given application.
The term voltage regulation (Vr) is often used and is voltage drop expressed as a percentage
of the load voltage.

(6-18)

The following symbols are used in this section:

A, B, C, D = phase windings
ES = source voltage
EL = voltage at load
ENS = line-to-neutral voltage at source
ELS = line-to-line voltage at source
ELL = line-to-line voltage at load
EPS = phase voltage at source
EPL = phase voltage at load
Vd = voltage drop
VN = voltage drop to neutral
VL = voltage drop line-to-line
VP = voltage drop per phase
Vr = voltage regulation in percent
I = line current in amps
R = dc or ac resistance of cable conductor at operating
temperature of the cable in ohms
X = reactance of cable at power frequencies in ohms
pf = power factor of load (cos ␪)
␪ = the angle between voltage and current degrees
Z = cable impedance in ohms
= cable length in feet

SOUTHWIRE 6-11
CHAPTER 6

When calculating voltage drop for ac circuits, the complications of the cable’s ac
resistance and reactance as well as the power factor of the load must be considered.

The general equation for voltage drop (Vd) is:

(6-19)
where:
(6-20)

Because ES is known, the equation can be solved for EL. Vd can now be calculated.
However, without the use of a computer, this is a tedious process.

Where the effect of shunt capacitance is negligible, a good approximation is:

(6-21)

where Z = cable impedance:

(6-12)

therefore:
(6-22)

Equations for Basic AC and DC Power Systems

Refer to the power system discussion and circuit diagrams at the beginning of this section.

DC Two-Wire Circuit
Is defined as:

or: (6-23)

DC Three-Wire Circuit
Is defined as:

or: (6-24)

Is also defined as:

or: (6-25)

AC Single-Phase. Two-Wire Circuit

Is defined as:

or approximately:
(6-26)

SOUTHWIRE 6-12
 ELECTRICAL CHARACTERISTICS

AC Two-Phase, Four- or Five-Wire Circuit

Is defined as:

or approximately:
(6-27)

(6-28)

(6-29)

When the load is balanced, the neutral (fifth wire) carries no current; therefore, the
equations are the same.

AC Three-Phase Circuits
Is defined as:

or approximately:
(6-27)

(6-30)

Typical Calculation
What is the voltage regulation of a feeder circuit consisting of three single conductor,
600 volt cables pulled into a nonmetallic conduit with the following parameters?

Es = 440 volts, three-phase

I = 250 amps
pf (of load) = 0.8
= 750 feet
R = 0.063 x 10 –3 ohms/foot at 75°C
XL = 0.037 x 10 –3 ohms/foot

Using approximate equation (6-27):

and using equation (6-30):

SOUTHWIRE 6-13
CHAPTER 6

Voltage Regulation:
Using equation (6-18):

SHORT CIRCUIT CURRENTS

Today’s high capacity power systems require that the short circuit capabilities of system
cables be considered. Calculations can be used to determine an installed cable’s ability to
withstand various short circuit conditions or the cable size needed to withstand a given
short circuit condition.

Conductor Formula
The usual form of the equation used to calculate the conductor’s short circuit current (ISC) is
presented in ICEA for copper and aluminum conductors.2 The equations for calculating
short circuit currents for copper and aluminum conductors are presented on the following
pages. The accompanying figures graphically depict the relationship between conductor
size and short circuit current duration for copper and aluminum conductors with thermoset
or thermoplastic insulation. For these equations and curves to be valid, the conductor must
be allowed to return to or below the rated maximum operating temperature (T1) before
another short circuit is encountered.
The short circuit current equations may be simplified after designating the conductor
metal and the values of T1 and T2 as follows:

(6-31)

where: ISC = short circuit current in amps

A = conductor area in cmil
FC = conductor short circuit factor from Table 6-1
t = duration of short circuit in seconds

TABLE 6-1
CONDUCTOR SHORT CIRCUIT FACTORS, FC
Insulation Copper Aluminum
Thermoset (XLPE, EPR) 0.0678 0.0443
T1=105°C, T2=250°C

Thermoset (XLPE,EPR) 0.0719 0.0470

T1=90°C, T2=250°C

Thermoplastic (PVC, PE) 0.0529 0.0346

T1=75°C, T2=150°C

Calculation can be made for any value T1 and T2 by using (6-32) or (6-33)

2
ICEA P-32-382, “Short Circuit Characteristics of Insulated Cable” – Fourth Edition, 1999.”

SOUTHWIRE 6-14
 ELECTRICAL CHARACTERISTICS

Short Circuit Current (Thousands of Amps)

Conductor Size

Figure 6-15
Allowable Short Circuit Currents for
Copper Conductor and Thermoset Insulation

Curves based on:

(6-32)

where: ISC = short circuit current in amps

A = conductor area in cmil
t = duration of short circuit in seconds
T1 = maximum operating temperature of the conductor (105°C)
T2 = maximum short circuit temperature rating of the conductor (250°C)

SOUTHWIRE 6-15
CHAPTER 6

Short Circuit Current (Thousands of Amps)

Conductor Size

Figure 6-16
Allowable Short Circuit Currents for
Copper Conductor and Thermoset Insulation

Curves based on:

(6-32)

where: ISC = short circuit current in amps

A = conductor area in cmil
t = duration of short circuit in seconds
T1 = maximum operating temperature of the conductor (90°C)
T2 = maximum short circuit temperature rating of the conductor (250°C)

SOUTHWIRE 6-16
 ELECTRICAL CHARACTERISTICS

Short Circuit Current (Thousands of Amps)

Conductor Size

Figure 6-17
Allowable Short Circuit Currents for
Copper Conductor and Thermoplastic Insulation

Curves based on:

(6-32)

where: ISC = short circuit current in amps

A = conductor area in cmil
t = duration of short circuit in seconds
T1 = maximum operating temperature of the conductor (75°C)
T2 = maximum short circuit temperature rating of the conductor (150°C)

SOUTHWIRE 6-17
CHAPTER 6

Short Circuit Current (Thousands of Amps)

Conductor Size

Figure 6-18
Allowable Short Circuit Currents for
Aluminum Conductor and Thermoset Insulation

Curves based on:

(6-33)

where: ISC = short circuit current in amps

A = conductor area in cmil
t = duration of short circuit in seconds
T1 = maximum operating temperature of the conductor (105°C)
T2 = maximum short circuit temperature rating of the conductor (250°C)

SOUTHWIRE 6-18
 ELECTRICAL CHARACTERISTICS

Short Circuit Current (Thousands of Amps)

Conductor Size

Figure 6-19
Allowable Short Circuit Currents for
Aluminum Conductor and Thermoset Insulation

Curves based on:

(6-33)

where: ISC = short circuit current in amps

A = conductor area in cmil
t = duration of short circuit in seconds
T1 = maximum operating temperature of the conductor (90°C)
T2 = maximum short circuit temperature rating of the conductor (250°C)

SOUTHWIRE 6-19
CHAPTER 6

Short Circuit Current (Thousands of Amps)

Conductor Size

Figure 6-20
Allowable Short Circuit Currents for
Aluminum Conductor and Thermoplastic Insulation

Curves based on:

(6-33)

where: ISC = short circuit current in amps

A = conductor area in cmil
t = duration of short circuit in seconds
T1 = maximum operating temperature of the conductor (75°C)
T2 = maximum short circuit temperature rating of the conductor (150°C)

SOUTHWIRE 6-20
 ELECTRICAL CHARACTERISTICS

Metallic Shield Formula

The same general equation (6-32) may be applied to copper metallic shields. For this
equation to be valid, the shield temperature must be allowed to return to or below the
maximum rated shield temperature (T1) before another short circuit is encountered. However,
the determination of the area (A) of the shield is more involved than for a conductor.

(6-34)

where: FS = shield short circuit factor from Table 6-2

TABLE 6-2
SHIELD SHORT CIRCUIT FACTORS FS
Insulation Jacket T1 T2 FS (Copper)
Thermoplastic 200°C 0.0630
Thermoset (PVC, PE, LSZH, CPE) 85°C
(XLPE, EPR) Thermoset 350°C 0.0890
(Hypalon)
Thermoplastic Thermoplastic 70°C 200°C 0.0678
(PVC, PE) (PVC, PE, LSZH, CPE)

NOTES: (A) T1 is the shield temperature resulting from the maximum conductor operating temperature.
(B) T2 is the maximum short circuit shield temperature.
(C) T1 and T2 are from ICEA P-45-482.3
(D) Calculations can be made for any value of T1 and T2 by using equation (6-32).

Equations for Calculation of Shield Areas

The equations for calculating the area of the shield are taken from ICEA.3 For overlapped
tapes, ICEA used the concept of effective tape shield area to compensate for the contact
resistance between the tape laps that can increase the shield resistance. While in service,
the contact resistance will likely increase as the cable ages and is exposed to heat and
moisture. ICEA states that under these conditions the contact resistance may approach
infinity, where (6-35) could apply.

Helically Applied Tape Shield

Tape Overlapped
(6-35)

Tape Not Overlapped

(6-36)

Tubular Shields
(6-37)

Wire Wrap (Concentric) or Braided Shields

(6-38)

Longitudinally Applied Corrugated Tape

(6-39)

3
ICEA P-45-482, “Short Circuit Characteristics of Metallic Shields and Sheaths on Insulated Cable” – Fourth Edition, 1999.
SOUTHWIRE 6-21
CHAPTER 6

where: A = effective cross-sectional area of metallic shield in cmils

b = tape or tube thickness in mils
Dc = diameter of core over semiconducting insulation shield in mils
L = overlap of tape in percent
dm = mean diameter of shield in mils
N = number of wires
ds = diameter of wire in mils
B = tape overlap in mils
w = width of tape in mils

Typical Calculation
A given circuit has protection devices that are guaranteed to operate within 1 second
(60 Hz). What are the maximum conductor and shield short circuit currents when using
an EPR insulated 500 kcmil copper cable that has a semiconducting insulation shield
diameter of 1.305 inches, with a 5 mil, 1.5 inches wide, 1/4 (25%) overlap copper tape
shield and a PVC jacket? The continuous operating temperature of the cable is 105ºC.

Conductor Short Circuit Current

Using equation (6-34):

Shield Short Circuit Current

Using equation (6-35):

Using equation (6-34):

SOUTHWIRE 6-22
 ELECTRICAL CHARACTERISTICS

SHIELD VOLTAGES, CURRENTS, AND LOSSES

FOR SINGLE CONDUCTOR CABLES

Shields that are grounded at multiple points have circulating currents induced by the
currents of the underlying power conductors. The I2R heating losses produced by the
circulating currents have an adverse impact upon the cable ampacity. Table 6-3 provides
tabulation of formulas for various arrangements of single conductor cables.

Multiple-Point Grounded Shields

The calculation of shield resistance (RS) and mutual reactance (XM) used in Table 6-3 can
be facilitated by the following equations.4

Shield Resistance
(6-40)

where: R = Apparent resistivity of shield in ohms-circular mils per foot

at operating temperature (assumed at 50°C).
Allowance is included for tapes or wire. Typical values of
(rho) are presented in Table 6-4.
ds = mean diameter of shield in inches
t = thickness of metal tapes used for shielding in inches

Mutual Reactance
(6-41)

(6-42)

(6-43)

where: XM = mutual inductance of shield and conductor in micro-ohms/foot

a,b = correction factors for mutual inductance for various cable
arrangements found in Table 6-3. (The correction
factors for 60 Hz are a = 15.93 and b = 36.99 Ω/foot)
Ω = micro-ohm = 10–6 ohms
RS = resistance of shield in micro-ohms/foot
t = thickness of metal tapes used for shielding in inches
f = frequency in hertz
S = spacing between center of cables in inches
dS = mean diameter of shield in inches

The above equations and the equations included in Table 6-3 are only valid for cable
circuits having balanced current loadings.
For an arrangement of three single conductors in the same conduit, use arrangement II
of Table 6-3.

4
1957 EEI UGSRB. ANSI/IEEE Standard 525-1992, “IEEE Guide for the Design and Installation of Cable Systems in Substations.”

SOUTHWIRE 6-23
CHAPTER 6

TABLE 6-3
FORMULAS FOR CALCULATING INDUCED SHIELD VOLTAGES AND
SHIELD LOSSES FOR SINGLE CONDUCTOR CABLES

TABLE 6-4

APPARENT SHIELD RESISTIVITIES FOR USE WITH EQUATION (6-40)

Shield or Sheath ohm-cmil/foot
Lapped, helical, copper tape 30
Bare copper wires 10.6
Aluminum interlocked armor 28
Galvanized steel interlocked armor 70
5052 aluminum alloy 30

Single-Point Grounded Shields

The shield-to-ground voltage will increase along the length of the cable for shields
grounded at a single point. The induced shield voltages can be calculated using the
formulas given in Table 6-3.
The recommendation for cable lengths that would limit a single-point grounded shield
potential to 25 volts is given in IEEE Standard 525.5 This data is given in Table 6-5 of this
manual. Because the voltage increases in linear proportions to length, cable lengths for
other shield potentials can be easily extrapolated from the values given in Table 6-5.
Induced shield voltages are also dependent upon cable spacing and geometry. If better
precision is desired, then separate calculations should be conducted as shown in Table 6-3.

5
ANSI/IEEE Standard 525-1992, “IEEE Guide for the Design and Installation of Cable Systems in Substations.”

SOUTHWIRE 6-24
 ELECTRICAL CHARACTERISTICS

TABLE 6-5
TYPICAL LENGTHS FOR CABLES WITH SHIELDS GROUNDED AT ONE
POINT TO LIMIT SHIELD VOLTAGE TO 25V
Size One Cable Three Cables
Conductor Per Duct Per Duct
(ft) (ft)
1/0 AWG 1250 4500
2/0 AWG 1110 3970
4/0 AWG 865 3000
250 kcmil 815 2730
350 kcmil 710 2260
400 kcmil 655 2100
500 kcmil 580 1870
750 kcmil 510 1500
1000 kcmil 450 -
2000 kcmil 340 -

Reduced Concentric Neutral Shield Wires

Information on shield resistance calculations and the effect of reduced concentric neu-
tral wires is presented in ICEA.6 This information is presented in addition to ampacities
and shield losses for single conductor concentric neutral cables. Shield resistance data
for 1/3 to 1/36 reduced neutrals is given in Table 6-6. The “fractional” neutrals refer to
the approximate ratio of the shield’s resistance to the conductor’s resistance.

TABLE 6-6
CONDUCTOR AND SHIELD RESISTANCE MICROHMS PER FOOT AND 25°C
Conductor dc
Size, Resistance Equivalent Metallic Shield Resistance for
AWG or of 15 kV Through 35 kV
kcmil Conductor 1/3 1/6 1/12 1/18 1/24 1/36
STRANDED COPPER CONDUCTORS
4/0 51.0 153.0 306.0 612.0 918.0 - -
350 30.8 92.4 184.8 369.6 554.4 - -
500 21.6 64.8 129.6 259.2 388.8 - -
750 14.4 43.2 86.4 172.8 259.2 - -
1000 10.8 - 64.8 129.6 - 259.2 388.8
STRANDED ALUMINUM CONDUCTORS
4/0 83.6 250.8 501.6 1003.0 1504.8 - -
350 50.5 151.5 303.0 606.0 909.0 - -
500 35.4 106.2 212.4 424.8 637.2 - -
750 23.6 70.8 141.6 283.2 424.8 - -
1000 17.7 - 106.2 212.4 - 424.8 637.2

6
ICEA P-53-426/NEMA WC 50-1976. “Ampacities, Including Effect of Shield Losses for Single-Conductor Solid- Dielectric Power Cable 15kV
through 69kV (Copper and Aluminum Conductors). Second Edition, Revised 1999.”

SOUTHWIRE 6-25
CHAPTER 6

AMPACITY

The variables involved when determining the ampacity of a cable may include:
• Conductor size and material
• Insulation type and thickness
• Shield type and thickness
• Armor type and thickness
• Sheath type and thickness
• Maximum conductor temperature rating
• Number of cables, ducts, conduits, etc.
• AC or dc voltage, frequency of ac voltage
• Ambient conditions:
• Temperature of surrounding environment
• Exchange rate of air
• Air pressure and humidity
• Proximity of heat sources
• Thermal resistivity of earth*

Any method used to calculate ampacities contains assumptions or procedures that might be
challenged. Two approaches are predominantly used: (1) Values from the National Electrical
Code (NEC), which are used when compliance with the NEC is required; (2) Values and
extrapolations from IEEE Standard 835, which are typically used by the electric utility industry.7
NOTE: Guidance provided in the NEC, IEEE, and by the cable manufacturer must be
consulted to ensure proper application and use of this information.

Formula

Basic Equations
The heat generated (HC) by the flow of conductor current is:
(6-44)

where: N = number of loaded conductors

I = conductor current in amps
Rac = ac resistance of conductor at the conductor operating
temperature in ohms
(See Chapter 2 for more on ac resistance.)

This formula correctly assumes that, for modern cables rated 35kV or less, the
dielectric losses are very small when compared to the conductor losses and therefore
can be ignored.
A thermal resistance of 1 ohm is defined as the path through which a heat flow of 1
watt produces a temperature difference of 1°C. A thermal resistance “circuit” can be
drawn that is analogous to an electrical circuit with series resistors, as shown in Figure 6-19.

*The determination of the thermal resistivity of earth is complex. It varies with type of soil, depth of burial, moisture content, and density.
In IEEE Standard 835 rho ( ) is used to express this parameter in units of thermal ohms per cm or ºC – cm/watt.7 IEEE Standard S-135 uses a
rho equal to 90 as a nominal value and includes tables for rho equal to 60 and 120 thermal ohms per cm. Values ranging from 60 to 300
are not usual. A lower thermal resistivity results in an increased ampacity.
7
IEEE 835/ICEA P-46-426, “IEEE-ICEA Power Cable Ampacities, Copper Conductors, Aluminum Conductors. Revised 2000.”

SOUTHWIRE 6-26
 ELECTRICAL CHARACTERISTICS

The thermal circuit for a single conductor shielded cable suspended in air may be
represented by:

Figure 6-19

RTH = Ri + RS + Rj + Re thermal ohm/foot

where: RTH = thermal resistance to air
Ri = thermal resistance of insulation
RS = thermal resistance of shield
Rj = thermal resistance of jacket
Re = thermal resistance of environment

or: (6-45)

solving for I:
(6-46)

where: TC = conductor operating temperature in °C

TA = ambient temperature in °C

Note that this calculated current should lead to an equilibrium condition so that TC will
not exceed the maximum temperature rating of the cable.

Adjustment for Other Temperature

It is often necessary to determine the ampacity at conditions other than those specified
in published tables. Any value of ampacity may be adjusted for a change in one or one
more basic parameters by using the following equations:

Copper Conductors
(6-47)

Aluminum Conductors
(6-48)

Where the primed (/) values are the revised parameters.

SOUTHWIRE 6-27
CHAPTER 6

Sample Calculation
A 90°C rated copper cable has a published ampacity of 500 amps under a given set of
conditions that include an ambient temperature (TA) of 40°C. Find the ampacity at a
conductor temperature of 80°C and ambient temperature of 50°C.
Using (6-47):

Adjustment for Emergency Overloads

The NEC does not recognize overload operation of cable conductors.
ICEA recommendations for emergency overload conditions of the cable vary according
to the cable rating. For 0 – 2kV cables, operation at the emergency overload temperature
shall not exceed 100 hours in any twelve consecutive months nor more than 500 hours
during the lifetime of the cable. For 5kV – 35kV cables, ICEA states operation at the
emergency overload temperatures shall not exceed 1500 hours cumulative during the
lifetime of the cable. Lower temperatures for emergency overload conditions may be
required because of the type of material used in the cable joints and terminations, or
because of cable environmental conditions.

Equations (6-47) and (6-48) can be developed into uprating factors for emergency
operating temperatures. These uprating factors are presented in Table 6-7.

TABLE 6-7
EMERGENCY OVERLOAD UPRATING FACTORS FOR COPPER
AND ALUMINUM CONDUCTORS
Conductor Conductor Uprating Factors for
Voltage Operating Overload Ambient Temperature*
Class Temp. Temp.
Insulation Type (kV) (°C) (°C) 20°C 30°C 40°C 50°C

Polyethylene (thermoplastic) 35 75 95 1.13 1.16 1.21 1.30

Polyethylene (cross-linked) 35 90 130 1.18 1.22 1.27 1.33

EPR rubber 35 90 130 1.18 1.22 1.27 1.33

Polyethylene (cross-linked), EPR 35 105 140 1.13 1.15 1.18 1.22

Chlorosulfonated polyethylene 0.6 75 95 1.13 1.16 1.21 1.30

Polyvinyl chloride 0.6 60 85 1.22 1.30 1.44 1.80

Polyvinyl chloride 0.6 75 95 1.13 1.16 1.21 1.30

*Ambient temperature of given ampacity.

SOUTHWIRE 6-28
 ELECTRICAL CHARACTERISTICS

Adjustments for Other Frequencies

A derating (FF) for frequencies other than 60 Hz may be determined using the ac/dc
ratio (R/R0) as presented in Chapter 2.
(6-49)

where: (R/R 0 ) = ac/dc ratio for 60 Hz

(R/R 0 ) / = ac/dc ratio for new frequency

Revised ampacity:
(6-50)

SOUTHWIRE 6-29
CHAPTER 6

Ampacity Tables
Ampacity tables from the 2005 NEC® are provided with a selection matrix to help choose the
correct table based on installation method and cable type.

1 THROUGH 2,000 VOLT COPPER AND ALUMINUM CONDUCTORS

Single Conductor Three Conductor Three-Conductor Cable
Installation Table NEC Table Table NEC Table Table NEC Table

Raceway 6-8 310.16 6-8 310.16 6-8 310.16

Direct Burial 6-9 B.310.10 6-12 B.310.9 6-15 B.310.8
Underground Duct 6-10 B.310.5 6-13 B.310.7 6-16 B.310.6
Air 6-11 310.17 6-14 310.20 6-17 B.310.3
Conduit in Air 6-8 310.16 6-8 310.16 6-18 B.310.1
Cable Tray:
Uncovered 6-111 310.171 6-111 310.171 6-8 310.16
Covered 6-112 310.172 6-112 310.172 95% x 6-8 95%x310.16
Spaced† 6-11 310.17 6-14 310.20 6-17 B.310.3

†Ladder-type tray with maintained spacing between conductors.

Tables with a “B” prefix should be used only under the supervision of a qualified engineer.
1: AWG 1/0 through 500 kcmil, 65% x Table 6-11 (NEC Table 310.17);
600 kcmil and over 75% x Table 6-11 (NEC Table 310.17).
2: AWG 1/0 through 500 kcmil, 60% x Table 6-11 (NEC Table 310.17);
600 kcmil and over, 70% x Table 6-11 (NEC Table 310.17).

2,001 THROUGH 35,000 VOLT COPPER CONDUCTORS

Single Conductor Three Conductors Three-Conductor Cable
Installation Table NEC Table Table NEC Table Table NEC Table

Direct Burial 6-19 310.81 6-21 310.85 6-25 310.83

Underground Duct 6-22 310.77 6-26 310.79
Air 6-20 310.69 6-23 310.20 6-27 310.71
Conduit in Air 6-24 310.16 6-28 310.75
Cable Tray:
Uncovered 75% x 6-20 75% x 310.69 75% x 6-20 75% x 310.69 6-28 310.75
Covered 70% x 6-20 70% x 310.69 70% x 6-20 70% x 310.69 95% x 6-28 95%x310.75
Spaced† 6-20 310.69 6-23 310.67 6-27 310.71
†Ladder-type tray with maintained spacing between conductors.

NEC REFERENCES FOR USE OF AMPACITY TABLES

Single Conductor Three Conductors Three-Conductor Cable
Installation 2,000 V 2,001 – 35,000V 0-2,000 V 2,001-35,000 V 0-2,000 V 2,001-35,000 V

Direct Burial
Underground Duct
310.15
Air
Conduit in Air
Cable Tray:
Uncovered 392.11 (B) 392.13 (B) 392.11 (B) 392.13 (B) 392.11 (A) 392.13 (A)
Covered 392.11 (B) 392.13 (B) 392.11 (B) 392.13 (B) 392.11 (A) 392.13 (A)
Spaced 392.11 (B)(3) 392.13 (B)(2) 392.11 (B)(4) 392.13 (B)(3) 392.11 (A) 392.13 (A)

SOUTHWIRE 6-30
 ELECTRICAL CHARACTERISTICS

TABLE 6-8 (NEC TABLE 310.16)

ALLOWABLE AMPACITIES OF INSULATED CONDUCTORS RATED
0 THROUGH 2000 VOLTS, 60°C TO 90°C (140°F TO 194°F)
NOT MORE THAN THREE CURRENT-CARRYING CONDUCTORS IN RACEWAY, CABLE, OR
EARTH (DIRECTLY BURIED), BASED ON AMBIENT TEMPERATURE OF 30°C (86°F)
Temperature Rating of Conductor (See Table 310.13)
60°C 75°C 90°C 60°C 75°C 90°C
(140°F) (167°F) (194°F) (140°F) (167°F) (194°F)
TYPES TYPES TYPES TYPES TYPES TYPES
TW RHW TBS, SA, TW RHW, TBS,
UF THHW SIS, FEP, UF THHW SA, SIS,
THW FEPB, MI, THW, THHN,
THWN RHH, RHW-2, THWN, THHW, Size
XHHW THHN XHHW, THW-2, (AWG or
Size USE, ZW THHW USE RHH, kcmil)
(AWG or THW-2 RHW-2,
kcmil) THWN-2 THWN-2
USE-2, XHH, USE-2, XHH,
XHHW, XHHW,
XHHW-2, XHHW-2,
ZW-2 ZW-2

COPPER ALUMINUM OR
COPPER-CLAD ALUMINUM
18 - - 14 - - - -
16 - 20 18 - - - -
14* 20 25 25 - - - -
12* 25 35 30 20 20 25 12*
10* 30 - 40 25 30 35 10*
8 40 50 55 30 40 45 8
6 55 65 75 40 50 60 6
4 70 85 95 55 65 75 4
3 85 100 110 65 75 85 3
2 95 115 130 75 90 100 2
1 110 130 150 85 100 115 1
1/0 125 150 170 100 120 135 1/0
2/0 145 175 195 115 135 150 2/0
3/0 165 200 225 130 155 175 3/0
4/0 195 230 260 150 180 205 4/0
250 215 255 290 170 205 230 250
300 240 285 320 190 230 255 300
350 260 310 350 210 250 280 350
400 280 335 380 225 270 305 400
500 320 380 430 260 310 350 500
600 355 420 475 285 340 385 600
700 385 460 520 310 375 420 700
750 400 475 535 320 385 435 750
800 410 490 555 330 395 450 800
900 435 520 585 355 425 480 900
1000 455 545 615 375 445 500 1000
1250 495 590 665 405 485 545 1250
1500 520 625 705 435 520 585 1500
1750 545 650 735 455 545 615 1750
2000 560 665 750 470 560 630 2000
Correction Factor
Ambient For ambient temperatures other than 30°C (86°F), multiply the allowable Ambient
Temp. (°C) ampacities shown above by the appropriate factor shown below. Temp. (°F)
21-25 1.08 1.05 1.04 1.08 1.05 1.04 70-77
26-30 1.00 1.00 1.00 1.00 1.00 1.00 78-86
31-35 .91 .94 .96 .91 .94 .96 87-95
36-40 .82 .88 .91 .82 .88 .91 96-104
41-45 .71 .82 .87 .71 .82 .87 105-113
46-50 .58 .75 .82 .58 .75 .82 114-122
51-55 .41 .67 .76 .41 .67 .76 123-131
56-60 - .58 .71 - .58 .71 132-140
61-70 - .33 .58 - .33 .58 141-158
71-80 - - .41 - - .41 159-176

*Unless specifically permitted elsewhere in the NEC, the overcurrent protection for conductor types shall not exceed 15
amperes for 14 AWG, 20 amperes for 12 AWG, and 30 amperes for 10 AWG copper; or 15 amperes for 12 AWG and 25
amperes for 10 AWG aluminum and copper-clad aluminum after any correction factors for ambient temperature and
number of conductors have been applied.
Reprinted with permission from NFPA 70-2005, the National Electrical Code®, copyright 2005, National Fire Protection
Association, Quincy MA 02269. This reprinted material is not the complete and official position of the National Fire
Protection Association on the referenced subject which is represented only the standard in its entirety.

SOUTHWIRE 6-31
CHAPTER 6

TABLE 6-9 (NEC TABLE B.310.10)

AMPACITIES OF THREE SINGLE INSULATED CONDUCTORS

RATED 0 THROUGH 2000 VOLTS, DIRECTLY BURIED IN EARTH BASED
ONAMBIENT EARTH TEMPERATURE OF 20°C (68°F)
100 PERCENT LOAD FACTOR, THERMAL RESISTANCE (RHO) OF 90

1 Circuit 2 Circuits 1 Circuit 2 Circuits

60°C 75°C 60°C 75°C 60°C 75°C 60°C 75°C
(140°F) (167°F) (140°F) (167°F) (140°F) (167°F) (140°F) (167°F)
Size Size
(AWG or TYPES TYPES (AWG or
kcmil) kcmil)
UF USE UF USE UF USE UF USE

COPPER ALUMINUM OR
COPPER-CLAD ALUMINUM
8 84 98 78 92 66 77 61 72 8
6 107 126 101 118 84 98 78 92 6
4 139 163 130 152 108 127 101 118 4
2 178 209 165 194 139 163 129 151 2
1 201 236 187 219 157 184 146 171 1
1/0 230 270 212 249 179 210 165 194 1/0
2/0 261 306 241 283 204 239 188 220 2/0
3/0 297 348 274 321 232 272 213 250 3/0
4/0 336 394 309 362 262 307 241 283 4/0
250 - 429 - 394 - 335 - 308 250
350 - 516 - 474 - 403 - 370 350
500 - 626 - 572 - 490 - 448 500
750 - 767 - 700 - 605 - 552 750
1000 - 887 - 808 - 706 - 642 1000
1250 - 979 - 891 - 787 - 716 1250
1500 - 1063 - 965 - 862 - 783 1500
1750 - 1133 - 1027 - 930 - 843 1750
2000 - 1195 - 1082 - 990 - 897 2000
Correction Factor
Ambient For ambient temperatures other than 20°C (68°F), multiply the Ambient
Temp. (C°) ampacities shown above by the appropriate factor shown below. Temp. (F°)
6-10 1.12 1.09 1.12 1.09 1.12 1.09 1.12 1.09 43-5
11-15 1.06 1.04 1.06 1.04 1.06 1.04 1.06 1.04 52-59
16-20 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 61-68
21-25 0.94 0.95 0.94 0.95 0.94 0.95 0.94 0.95 70-77
26-30 0.87 0.90 0.87 0.90 0.87 0.90 0.87 0.90 79-86

Reprinted with permission from NFPA 70-2005, the National Electrical Code®, copyright 2005, National Fire Protection
Association, Quincy MA 02269. This reprinted material is not the complete and official position of the National Fire
Protection Association on the referenced subject which is represented only the standard in its entirety.

SOUTHWIRE 6-32
 ELECTRICAL CHARACTERISTICS

TABLE 6-10 (NEC TABLE B.310.5)

AMPACITIES OF SINGLE INSULATED CONDUCTORS,

RATED 0 THROUGH 2000 VOLTS IN NONMAGNETIC UNDERGROUND
ELECTRICAL DUCTS (ONE CONDUCTOR PER ELECTRICAL DUCT),
BASED ON AMBIENT EARTH TEMPERATURE OF 20°C (68°F),
CONDUCTOR TEMPERATURE 75°C (167°F), 100% LOAD FACTOR,
THERMAL RESISTANCE (RHO) OF 90.
3 Electrical Ducts 6 Electrical Ducts 9 Electrical Ducts 3 Electrical Ducts 6 Electrical Ducts 9 Electrical Ducts
Size Size
(Detail 2) (Detail 3) (Detail 4) (Detail 2) (Detail 3) (Detail 4)
(AWG or (AWG or
kcmil) TYPES TYPES TYPES TYPES TYPES TYPES kcmil)
RHW, THHW RHW, THHW RHW, THHW RHW, THHW RHW, THHW RHW, THHW
THW, THWN, THW, THWN, THW, THWN, THW, THWN, THW, THWN, THW, THWN,
XHHW, USE XHHW, USE XHHW, USE XHHW, USE XHHW, USE XHHW, USE

COPPER ALUMINUM OR
COPPER-CLAD ALUMINUM
250 344 295 270 269 230 211 250
350 418 355 322 327 277 252 350
500 511 431 387 401 337 305 500
750 640 534 469 505 421 375 750
1000 745 617 533 593 491 432 1000
1250 832 686 581 668 551 478 1250
1500 907 744 619 736 604 517 1500
1750 970 793 651 796 651 550 1750
2000 1027 836 683 850 693 581 2000
Correction Factor
Ambient For ambient temperatures other than 20°C (68°F), Ambient
Temp. (C°) multiply the ampacities shown above by the appropriate factor shown below Temp. (C°)
6-10 1.09 1.09 1.09 1.09 1.09 1.09 43-50
11-15 1.04 1.04 1.04 1.04 1.04 1.04 52-59
16-20 1.00 1.00 1.00 1.00 1.00 1.00 61-68
21-25 0.95 0.95 0.95 0.95 0.95 0.95 70-77
26-30 0.90 0.90 0.90 0.90 0.90 0.90 79-86

For Ampacities based on 60 Rho, 120 Rho, and additional load factors, refer to NEC Table B.310.5
Reprinted with permission from NFPA 70-2005, the National Electrical Code®, copyright 2005, National Fire Protection
Association, Quincy MA 02269. This reprinted material is not the complete and official position of the National Fire
Protection Association on the referenced subject which is represented only the standard in its entirety.

SOUTHWIRE 6-33
CHAPTER 6

TABLE 6-11 (NEC TABLE 310.17)

ALLOWABLE AMPACITIES OF SINGLE-INSULATED CONDUCTORS,
RATED 0 THROUGH 2000 VOLTS, IN FREE AIR
BASED ON AMBIENT TEMPERATURE OF 30°C (86°F)
60°C 75°C 90°C 60°C 75°C 90°C
Size Size
(140°F) (167°F) (194°F) (140°F) (167°F) (194°F) (167°F)
(AWG or (AWG or
kcmil) TYPES TYPES TYPES TYPES TYPES TYPES kcmil)
TW RHW, THHW TBS, SA, SIS, FEP, TW RHW, THHW TBS, SA, SIS,
UF THW, THWN, FEPB, MI, RHH, UF THW, THWN, THHN, THHW,
XHHW, USE, ZW RHW-2, THHN, XHHW, USE THW-2, RHH,
THHW, THW-2, RHW-2, THWN-2
THWN-2, USE-2, USE-2, XHH,
XHH, XHHW, XHHW, XHHW-2,
XHHW-2, ZW-2 ZW-2

COPPER ALUMINUM OR
COPPER-CLAD ALUMINUM
18 - - 18 - - - -
16 - - 24 - - - -
14* 25 30 35 - - - -
12* 30 35 40 25 30 35 12*
10* 40 50 55 35 40 40 10*
8 60 70 80 45 55 60 8
6 80 95 105 60 75 80 6
4 105 125 140 80 100 110 4
3 120 145 165 95 115 130 3
2 140 170 190 110 135 150 2
1 165 195 220 130 155 175 1
1/0 195 230 260 150 180 205 1/0
2/0 225 265 300 175 210 235 2/0
3/0 260 310 350 200 240 275 3/0
4/0 300 360 405 235 280 315 4/0
250 340 405 455 265 315 355 250
300 375 445 505 290 350 395 300
350 420 505 570 330 395 445 350
400 455 545 615 355 425 480 400
500 515 620 700 405 485 545 500
600 575 690 780 455 540 615 600
700 630 755 855 500 595 675 700
750 655 785 885 515 620 700 750
800 680 815 920 535 645 725 800
900 730 870 985 580 700 785 900
1000 780 935 1055 625 750 845 1000
1250 890 1065 1200 710 855 960 1250
1500 980 1175 1325 795 950 1075 1500
1750 1070 1280 1445 875 1050 1185 1750
2000 1155 1385 1560 960 1150 1335 2000
Correction Factor
Ambient For ambient temperatures other than 20°C (68°F), Ambient
Temp. (C°) multiply the ampacities shown above by the appropriate factor shown below Temp. (C°)
21-25 1.08 1.05 1.04 1.08 1.05 1.04 70-77
26-30 1.00 1.00 1.00 1.00 1.00 1.00 78-86
31-35 0.91 0.94 0.96 0.91 0.94 0.96 87-95
36-40 0.82 0.88 0.91 0.82 0.88 0.91 96-104
41-45 0.71 0.82 0.87 0.71 0.82 0.87 105-113
46-50 0.58 0.75 0.82 0.58 0.75 0.82 114-122
51-55 0.41 0.67 0.76 0.41 0.67 0.76 123-131
56-60 - 0.58 0.71 - 0.58 0.71 132-140
61-70 - 0.33 0.58 - 0.33 0.58 141-158
71-80 - - 0.41 - - 0.41 159-176

*Unless specifically permitted elsewhere in the NEC, the overcurrent protection for conductor types shall not exceed
15 amperes for 14 AWG, 20 amperes for 12 AWG, and 30 amperes for 10 AWG copper; or 15 amperes for 12 AWG
and 25 amperes for 10 AWG aluminum and copper-clad aluminum after any correction factors for ambient tempera-
ture and number of conductors have been applied.

SOUTHWIRE 6-34
 ELECTRICAL CHARACTERISTICS

TABLE 6-12 (TABLE B.310.9)

AMPACITIES OF THREE TRIPLEXED SINGLE INSULATED CONDUCTORS

RATED 0 THROUGH 2000 VOLTS, DIRECTLY BURIED IN EARTH BASED
ON AMBIENT EARTH TEMPERATURE OF 20°C (68°F),
100% LOAD FACTOR, THERMAL RESISTANCE (RHO) OF 90

1 Circuit 2 Circuit 1 Circuit 2 Circuit

60°C 75°C 60°C 75°C 60°C 75°C 60°C 75°C
(140°F) (167°F) (140°F) (167°F) (140°F) (167°F) (140°F) (167°F)
Size Size
(AWG or TYPES TYPES (AWG or
kcmil) kcmil)
UF USE UF USE UF USE UF USE

COPPER ALUMINUM OR
COPPER-CLAD ALUMINUM
8 72 84 66 77 55 65 51 60 8
6 91 107 84 99 72 84 66 77 6
4 119 139 109 128 92 108 85 100 4
2 153 179 140 164 119 139 109 128 2
1 173 203 159 186 135 158 124 145 1
1/0 197 231 181 212 154 180 141 165 1/0
2/0 223 262 205 240 175 205 159 187 2/0
3/0 254 298 232 272 199 233 181 212 3/0
4/0 289 339 263 308 226 265 206 241 4/0
250 - 370 - 336 - 289 - 263 250
350 - 445 - 403 - 349 - 316 350
500 - 536 - 483 - 424 - 382 500
750 - 654 - 587 - 525 - 471 750
1000 - 744 - 665 - 608 - 544 1000
Correction Factor
Ambient For ambient temperatures other than 20°C (68°F), Ambient
Temp. (C°) multiply the ampacities shown above by the appropriate factor shown below Temp. (C°)

6-10 1.12 1.09 1.12 1.09 1.12 1.09 1.12 1.09 43-50
11-15 1.06 1.04 1.06 1.04 1.06 1.04 1.06 1.04 52-59
16-20 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 61-68
21-25 0.94 0.95 0.94 0.95 0.94 0.95 0.94 0.95 70-77
26-30 0.87 0.90 0.87 0.90 0.87 0.90 0.87 0.90 79-86

SOUTHWIRE 6-35
CHAPTER 6

TABLE 6-13 (NEC TABLE B.310.7)

AMPACITIES OF THREE SINGLE INSULATED CONDUCTORS

RATED 0 THROUGH 2000 VOLTS, IN UNDERGROUND ELECTRICAL
DUCTS (THREE CONDUCTORS PER ELECTRICAL DUCT), BASED ON
AMBIENT EARTH TEMPERATURE OF 20°C (68°F), CONDUCTOR
TEMPERATURE 75°C (167°F) 100% LOAD FACTOR,
THERMAL RESISTANCE (RHO) OF 90
1 Electrical Ducts 3 Electrical Ducts 6 Electrical Ducts 2 Electrical Ducts 3 Electrical Ducts 6 Electrical Ducts
Size Size
(Detail 1) (Detail 2) (Detail 3) (Detail 1) (Detail 2) (Detail 3)
(AWG or (AWG or
kcmil) TYPES TYPES TYPES TYPES TYPES TYPES kcmil)
RHW, THHW RHW, THHW RHW, THHW RHW, THHW RHW, THHW RHW, THHW
THW, THWN, THW, THWN, THW, THWN, THW, THWN, THW, THWN, THW, THWN,
XHHW, USE XHHW, USE XHHW, USE XHHW, USE XHHW, USE XHHW, USE

COPPER ALUMINUM OR
COPPER-CLAD ALUMINUM
8 58 51 44 45 40 34 8
6 77 67 56 60 52 44 6
4 100 86 73 78 67 57 4
3 116 99 83 91 77 65 3
2 132 112 93 103 87 73 2
1 153 128 106 119 100 83 1
1/0 175 146 121 136 114 94 1/0
2/0 200 166 136 156 130 106 2/0
3/0 228 189 154 178 147 121 3/0
4/0 263 215 175 205 168 137 4/0
250 290 236 192 227 185 150 250
300 321 260 210 252 204 165 300
350 351 283 228 276 222 179 350
400 376 302 243 297 238 191 400
500 427 341 273 338 270 216 500
600 468 371 296 373 296 236 600
700 509 402 319 408 321 255 700
750 529 417 330 425 334 265 750
800 544 428 338 439 344 273 800
900 575 450 355 466 365 288 900
1000 605 472 372 494 385 304 1000
Correction Factor
Ambient For ambient temperatures other than 20°C (68°F), Ambient
Temp. (C°) multiply the ampacities shown above by the appropriate factor shown below Temp. (C°)
6-10 1.09 1.09 1.09 1.09 1.09 1.09 43-50
11-15 1.04 1.04 1.04 1.04 1.04 1.04 52-59
16-20 1.00 1.00 1.00 1.00 1.00 1.00 61-68
21-25 0.95 0.95 0.95 0.95 0.95 0.95 70.77
26-30 0.90 0.90 0.90 0.90 0.90 0.90 79-86
For Ampacities based on 60 Rho, 120 Rho, and additional load factors, refer to NEC Table B.310.7

SOUTHWIRE 6-36
 ELECTRICAL CHARACTERISTICS

TABLE 6-14 (NEC TABLE 310.20)

AMPACITIES OF NOT MORE THAN THREE SINGLE INSULATED
CONDUCTORS, RATED THROUGH 2000 VOLTS, SUPPORTED ON A
MESSENGER BASED ON AMBIENT AIR TEMPERATURE OF 40°C (104°F)
75°C 90°C 75°C 90°C
Size Size
(167°F) (194°F) (167°F) (194°F) (167°F)
(AWG or (AWG or
kcmil) kcmil)
TYPES TYPES TYPES TYPES
RHW, THHW MI, RHH, RHW-2, RHW, THHW THHN, THHW,
THW, THWN, THHN, THHW, THW, THWN, THW-2, RHH,
XHHW, USE, ZW THW-2, THWN-2, XHHW RHW-2, THWN-2
USE-2, XHHW-2, USE-2, XHH, XHHW,
ZW-2 XHHW-2, ZW-2

COPPER ALUMINUM OR
COPPER-CLAD ALUMINUM
8 57 66 44 51 8
6 76 89 59 69 6
4 101 117 78 91 4
3 118 138 92 107 3
2 135 158 106 123 2
1 158 185 123 144 1
1/0 183 214 143 167 1/0
2/0 212 247 165 193 2/0
3/0 245 287 192 224 3/0
4/0 287 335 224 262 4/0
250 320 374 251 292 250
300 359 419 282 328 300
350 397 464 312 364 350
400 430 503 339 395 400
500 496 580 392 458 500
600 553 647 440 514 600
700 610 714 488 570 700
750 638 747 512 598 750
800 660 773 532 622 800
900 704 826 572 669 900
1000 748 879 612 716 1000
Correction Factor
Ambient For ambient temperatures other than 40°C (104°F), Ambient
Temp. (C°) multiply the ampacities shown above by the appropriate factor shown below Temp. (C°)
21-25 1.20 1.14 1.20 1.14 70-77
26-30 1.13 1.10 1.13 1.10 79-86
31-35 1.07 1.05 1.07 1.05 88-95
36-40 1.00 1.00 1.00 1.00 97-104
41-45 0.93 0.95 0.93 0.95 106-113
46-50 0.85 0.89 0.85 0.89 115-122
51-55 0.76 0.84 0.76 0.84 124-131
56-60 0.65 0.77 0.65 0.77 133-140
61-70 0.38 0.63 0.38 0.63 142-158
71-80 - 0.45 - 0.45 160-176

SOUTHWIRE 6-37
CHAPTER 6

TABLE 6-15 (NEC TABLE B.310.8)

AMPACITIES OF TWO OR THREE SINGLE INSULATED CONDUCTORS

RATED 0 THROUGH 2000 VOLTS, CABLED WITHIN AN OVERALL
(TWO-OR-THREE-CONDUCTOR) COVERING, DIRECTLY BURIED IN
EARTH, BASED ON AMBIENT EARTH TEMPERATURE OF 20°C (68°F)
100% LOAD FACTOR, THERMAL RESISTANCE (RHO) OF 90
1 Cable 2 Cables 1 Cable 2 Cables
60°C 75°C 60°C 75°C 60°C 75°C 60°C 75°C
(140°F) (167°F) (140°F) (167°F) (140°F) (167°F) (140°F) (167°F)
Size Size
(AWG or TYPES TYPES (AWG or
kcmil) kcmil)
UF RHW, THW, UF RHW, THW, UF RHW, THW, UF RHW, THW,
THHW, THHW, THHW, THHW,
THWN, THWN, THWN, THWN,
XHHW, USE XHHW, USE XHHW, USE XHHW, USE

COPPER ALUMINUM OR
COPPER-CLAD ALUMINUM
8 64 75 66 70 51 59 47 55 8
6 85 100 84 95 68 75 60 70 6
4 107 125 109 117 83 97 78 91 4
2 137 161 140 150 107 126 110 117 2
1 155 282 159 170 212 142 113 132 1
1/0 177 208 181 193 138 162 129 151 1/0
2/0 201 236 205 220 157 184 146 171 2/0
3/0 229 269 232 250 179 210 166 195 3/0
4/0 259 304 263 282 203 238 188 220 4/0
250 - 333 - 308 - 261 - 241 250
350 - 401 - 370 - 315 - 290 350
500 - 481 - 442 - 381 - 350 500
750 - 585 - 535 - 473 - 433 750
1000 - 657 - 600 - 545 - 497 1000
Correction Factor
Ambient For ambient temperatures other than 20°C (68°F), Ambient
Temp. (C°) multiply the ampacities shown above by the appropriate factor shown below Temp. (C°)

6-10 1.12 1.09 1.12 1.09 1.12 1.09 1.12 1.09 43-50
11-15 1.06 1.04 1.06 1.04 1.06 1.04 1.06 1.04 52-59
16-20 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 61-68
21-25 0.94 0.95 0.94 0.95 0.94 0.95 0.94 0.95 70-77
26-30 0.87 0.90 0.87 0.90 0.87 0.90 0.87 0.90 79-86

For ampacities for UF cable in underground electrical ducts, multiply the ampacities shown in the table by 0.74

SOUTHWIRE 6-38
 ELECTRICAL CHARACTERISTICS

TABLE 6-16 (NEC TABLE B.310.6)

AMPACITIES OF THREE INSULATED CONDUCTORS, RATED 0 THROUGH

2000 VOLTS, WITHIN AN OVERALL COVERING (THREE CONDUCTOR
CABLE) IN UNDERGROUND ELECTRICAL DUCTS (ONE CABLE PER
ELECTRICAL DUCT), BASED ON AMBIENT EARTH TEMPERATURE OF
20°C (68°F), CONDUCTOR TEMPERATURE 75°C (167°F) 100% LOAD
FACTOR, THERMAL RESISTANCE (RHO) OF 90
3 Electrical Ducts 6 Electrical Ducts 9 Electrical Ducts 3 Electrical Ducts 6 Electrical Ducts 9 Electrical Ducts
Size Size
(Detail 2) (Detail 3) (Detail 4) (Detail 2) (Detail 3) (Detail 4)
(AWG or (AWG or
kcmil) TYPES TYPES TYPES TYPES TYPES TYPES kcmil)
RHW, THHW RHW, THHW RHW, THHW RHW, THHW RHW, THHW RHW, THHW
THW, THWN, THW, THWN, THW, THWN, THW, THWN, THW, THWN, THW, THWN,
XHHW, USE XHHW, USE XHHW, USE XHHW, USE XHHW, USE XHHW, USE

COPPER ALUMINUM OR
COPPER-CLAD ALUMINUM
8 54 48 42 42 37 32 8
6 71 63 54 55 49 42 6
4 93 81 69 72 63 54 4
2 121 105 89 94 82 70 2
1 140 121 102 109 94 79 1
1/0 160 137 116 125 107 90 1/0
2/0 183 156 131 143 122 102 2/0
3/0 210 178 148 164 139 116 3/0
4/0 240 202 168 187 158 131 4/0
250 265 222 184 207 174 144 250
350 321 267 219 252 209 172 350
500 389 320 261 308 254 207 500
750 478 388 314 386 314 254 750
1000 539 435 351 447 361 291 1000
Correction Factor
Ambient For ambient temperatures other than 20°C (68°F), Ambient
Temp. (C°) multiply the ampacities shown above by the appropriate factor shown below Temp. (C°)
6-10 1.09 1.09 1.09 1.09 1.09 1.09 43-50
11-15 1.04 1.04 1.04 1.04 1.04 1.04 52-59
16-20 1.00 1.00 1.00 1.00 1.00 1.00 61-68
21-25 0.95 0.95 0.95 0.95 0.95 0.95 70.77
26-30 0.90 0.90 0.90 0.90 0.90 0.90 79-86

For Ampacities based on 60 Rho, 120 Rho, and additional load factors, refer to NEC Table B.310.6.

SOUTHWIRE 6-39
CHAPTER 6

TABLE 6-17 (NEC TABLE B.310.3)

AMPACITIES OF MULTICONDUCTOR CABLES WITH
NOT MORE THAN THREE INSULATED CONDUCTORS,
RATED 0 THROUGH 2000 VOLTS, IN FREE AIR,
BASED ON AMBIENT AIR TEMPERATURE OF 40°C (104°F)
(FOR TC, MC, MI, UF, AND USE CABLES)
60°C 75°C 60°C 75°C 60°C 75°C 60°C 75°C
Size (140°F) (167°F) (140°F) (167°F) (140°F) (167°F) (140°F) (167°F) Size
(AWG or (AWG or
kcmil) ALUMINUM OR kcmil)
COPPER COPPER-CLAD ALUMINUM
8 72 84 66 77 55 65 51 60 8
18 - - - 11* - - - - 18
16 - - - 16* - - - - 16
14 18* 21* 24* 25* - - - - 14
12 21* 28* 30* 32* 18* 21* 24* 25* 12
10 28* 36* 41* 43* 21* 28* 30* 32* 10
8 39 50 56 59 30 39 44 46 8
6 52 68 75 79 41 53 59 61 6
4 69 89 100 104 54 70 78 81 4
3 81 104 116 121 63 81 91 95 3
2 92 118 132 138 72 92 103 108 2
1 107 138 154 161 84 108 120 126 1
1/0 124 160 178 186 97 125 139 145 1/0
2/0 143 184 206 215 111 144 160 168 2/0
3/0 165 213 238 249 129 166 185 194 3/0
4/0 190 245 274 287 149 192 214 224 4/0
250 212 274 305 320 166 214 239 250 250
300 237 306 341 357 186 240 268 280 300
350 261 337 377 394 205 265 296 309 350
400 281 363 406 425 222 287 317 334 400
500 321 416 465 487 255 330 368 385 500
600 354 459 513 538 284 368 410 429 600
700 387 502 562 589 306 405 462 473 700
750 404 523 586 615 328 424 473 495 750
800 415 539 604 633 339 439 490 513 800
900 438 570 639 670 362 469 514 548 900
1000 461 601 674 707 385 499 558 584 1000
Correction Factor
Ambient For ambient temperatures other than 40°C (104°F), Ambient
Temp. (C°) multiply the ampacities shown above by the appropriate factor shown below Temp. (C°)
21-25 1.32 1.20 1.15 1.14 1.32 1.20 1.15 1.14 70-77
26-30 1.22 1.13 1.11 1.10 1.22 1.13 1.11 1.10 79-86
31-35 1.12 1.07 1.05 1.05 1.12 1.07 1.05 1.05 88-95
36-40 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 97-104
41-45 0.87 0.93 0.94 0.95 0.87 0.93 0.94 0.95 106-113
46-50 0.71 0.85 0.88 0.89 0.71 0.85 0.88 0.89 115-122
51-55 0.50 0.76 0.82 0.84 0.50 0.76 0.82 0.84 124-131
56-60 - 0.65 0.75 0.77 - 0.65 0.75 0.77 133-140
61-70 - 0.38 0.58 0.63 - 0.38 0.58 0.63 142-158
71-80 - - 0.33 0.44 - - 0.33 0.44 160-176

*Unless specifically permitted elsewhere in the NEC, the overcurrent protection for conductor types shall not exceed
15 amperes for 14 AWG, 20 amperes for 12 AWG, and 30 amperes for 10 AWG copper; or 15 amperes for 12 AWG
and 25 amperes for 10 AWG aluminum and copper-clad aluminum after any correction factors for ambient tempera-
ture and number of conductors have been applied.

SOUTHWIRE 6-40
 ELECTRICAL CHARACTERISTICS

TABLE 6-18 (NEC TABLE B.310.1)

AMPACITIES OF TWO OR THREE INSULATED CONDUCTORS
RATED 0 THROUGH 2000 VOLTS, WITHIN AN OVERALL COVERING
(MULTICONDUCTOR CABLE), IN A RACEWAY IN FREE AIR BASED ON
AMBIENT TEMPERATURE OF 30°C (86°F)
60°C 75°C 90°C 60°C 75°C 90°C
Size Size
(140°F) (167°F) (194°F) (140°F) (167°F) (194°F) (167°F)
(AWG or (AWG or
kcmil) TYPES TYPES TYPES TYPES TYPES TYPES kcmil)
TW RH, RHW, THHW RHH, RHW-2, TW RH, RHW, THHN, THHW,
UF THW, THWN, THHN, THHW, THHW THW-2, RHH,
XHHW, ZW THW-2, THWN-2, THW, THWN, RHW-2, THWN-2
USE-2, XHH, XHHW USE-2, XHHW,
XHHW, XHHW-2, XHHW-2,
ZW-2 ZW-2

COPPER ALUMINUM OR
COPPER-CLAD ALUMINUM
14* 16* 18* 21* - - - 14
12* 20* 24* 27* 16* 18* 21* 12
10* 27* 33* 36* 21* 25* 28* 10
8 36 43 48 28 33 37 8
6 48 58 65 38 45 51 6
4 66 79 89 51 61 69 4
3 76 90 102 59 70 79 3
2 88 105 119 69 83 93 2
1 102 121 137 80 95 106 1
1/0 121 145 163 94 113 127 1/0
2/0 138 166 186 108 129 146 2/0
3/0 158 189 214 124 147 167 3/0
4/0 187 223 253 147 176 197 4/0
250 205 245 276 160 192 217 250
300 234 281 317 185 221 250 300
350 255 305 345 202 242 273 350
400 274 328 371 218 261 295 400
500 315 378 427 254 303 342 500
600 343 413 468 279 335 378 600
700 376 452 514 310 371 420 700
750 387 466 529 321 384 435 750
800 397 497 543 331 397 450 800
900 415 500 570 350 421 477 900
1000 448 542 617 382 460 521 1000
Correction Factor
Ambient For ambient temperatures other than 20°C (68°F), Ambient
Temp. (C°) multiply the ampacities shown above by the appropriate factor shown below Temp. (C°)
21-25 1.08 1.05 1.04 1.08 1.05 1.04 70-77
26-30 1.00 1.00 1.00 1.00 1.00 1.00 78-86
31-35 0.91 0.94 0.96 0.91 0.94 0.96 87-95
36-40 0.82 0.88 0.91 0.82 0.88 0.91 96-104
41-45 0.71 0.82 0.87 0.71 0.82 0.87 105-113
46-50 0.58 0.75 0.82 0.58 0.75 0.82 114-122
51-55 0.41 0.67 0.76 0.41 0.67 0.76 123-131
56-60 - 0.58 0.71 - 0.58 0.71 132-140
61-70 - 0.33 0.58 - 0.33 0.58 141-158
71-80 - - 0.41 - - 0.41 159-176

*Unless specifically permitted elsewhere in the NEC, the overcurrent protection for conductor types shall not exceed
15 amperes for 14 AWG, 20 amperes for 12 AWG, and 30 amperes for 10 AWG copper; or 15 amperes for 12 AWG
and 25 amperes for 10 AWG aluminum and copper-clad aluminum after any correction factors for ambient tempera-
ture and number of conductors have been applied.

SOUTHWIRE 6-41
CHAPTER 6

TABLE 6-19 (NEC TABLE 310.81)

AMPACITIES OF SINGLE INSULATED COPPER CONDUCTORS

DIRECTLY BURIED IN EARTH BASED ON AMBIENT EARTH
TEMPERATURE OF 20°C (68°F), 100 PERCENT LOAD FACTOR
THERMAL RESISTANCE (RHO) OF 90,
CONDUCTOR TEMPERATURES OF 90°C (194°F) AND 105°C (221°F)
Conductor Size 2001-5000 Volts Ampacity 5000-35,000 Volts Ampacity
(AWG or
kcmil) 90°C (194°F) 105°C (221°F) 90°C (194°F) 105°C (221°F)
Type MV-90 Type MV-105 Type MV-90 Type MV-105
One Circuit-3 Conductors
8 110 115 - -
6 140 150 130 140
4 180 195 170 180
2 230 250 210 225
1 260 280 240 260
1/0 295 320 275 295
2/0 335 365 310 335
3/0 385 415 355 380
4/0 435 465 405 435
250 470 510 440 475
350 570 615 535 575
500 690 745 650 700
750 845 910 805 865
1000 980 1055 930 1005
Two Circuit-6 Conductors
8 100 110 - -
6 130 140 120 130
4 165 180 160 170
2 215 230 195 210
1 240 260 225 240
1/0 275 295 255 275
2/0 310 335 290 315
3/0 355 380 330 355
4/0 400 430 375 405
250 435 470 410 440
350 520 560 495 530
500 630 680 600 645
750 775 835 740 795
1000 890 960 855 920

For SI units: 1 in. = 25.4 mm.

SOUTHWIRE 6-42
 ELECTRICAL CHARACTERISTICS

TABLE 6-20 (NEC TABLE 310.69)

AMPACITIES OF INSULATED SINGLE COPPER CONDUCTOR ISOLATED
IN AIR BASED ON CONDUCTOR TEMPERATURE OF 90°C (194°F) AND
105°C (221°F) AND AMBIENT AIR TEMPERATURE OF 40°C (104°F)
2001-5000 Volts 5001-15,000 Volts 15,001-35,000 Volts
Conductor Ampacity Ampacity Ampacity
Size 90°C 105°C 90°C 105°C 90°C 105°C
(AWG or
(194°F) (221°F) (194°F) (221°F) (194°F) (221°F)
kcmil)
Type MV-90 Type MV-105 Type MV-90 Type MV-105 Type MV-90 Type MV-105
8 83 93 - - - -
6 110 120 110 125 - -
4 145 160 150 165 - -
2 190 215 195 215 - -
1 225 250 225 250 225 250
1/0 260 290 260 290 260 290
2/0 300 330 300 335 300 330
3/0 345 385 345 385 345 380
4/0 400 445 400 445 395 445
250 445 495 445 495 440 490
350 550 615 550 610 545 605
500 695 775 685 765 680 755
750 900 1000 885 990 870 970
1000 1075 1200 1060 1185 1040 1160
1250 1230 1370 1210 1350 1185 1320
1500 1365 1525 1345 1500 1315 1465
1750 1495 1665 1470 1640 1430 1595
2000 1605 1790 1575 1755 1535 1710

SOUTHWIRE 6-43
CHAPTER 6

TABLE 6-21 (NEC TABLE 310.85)

AMPACITIES OF THREE TRIPLEXED SINGLE INSULATED COPPER

CONDUCTORS DIRECTLY BURIED IN EARTH, BASED ON AMBIENT
EARTH TEMPERATURE OF 20°C (68°F) 100% LOAD FACTOR,
THERMAL RESISTANCE (RHO) OF 90 CONDUCTOR TEMPERATURES
OF 90°C (194°F) AND 105°C (221°F)
2001-5000 Volts 5001-35,000 Volts
Ampacity Ampacity
Conductor Size 90°C 105°C 90°C 105°C
(194°F) (221°F) (194°F) (221°F)
(AWG or kcmil)
Type MV-90 Type MV-105 Type MV-90 Type MV-105
One Circuit -
Three Conductors
8 90 95 - -
6 120 130 115 120
4 150 165 150 160
2 195 205 190 205
1 225 240 215 230
1/0 255 270 245 260
2/0 290 310 275 295
3/0 330 360 315 340
4/0 375 405 360 385
250 410 445 390 410
350 490 580 470 505
500 590 635 565 605
750 725 780 685 740
1000 825 885 770 830
Two Circuits -
Six Conductors
8 85 90 - -
6 110 115 105 115
4 140 150 140 150
2 180 195 175 190
1 205 220 200 215
1/0 235 250 225 240
2/0 265 285 255 275
3/0 300 320 290 315
4/0 340 365 325 350
250 370 395 355 380
350 445 480 425 455
500 535 575 510 545
750 650 700 615 660
1000 740 795 690 745

SOUTHWIRE 6-44
 ELECTRICAL CHARACTERISTICS

TABLE 6-22 (NEC TABLE 310.77)

AMPACITIES OF THREE SINGLE INSULATED COPPER CONDUCTORS

CABLED IN UNDERGROUND ELECTRICAL DUCTS
(THREE CONDUCTORS PER ELECTRICAL DUCT) BASED ON AMBIENT
EARTH TEMPERATURE OF 20°C (68°F), 100% LOAD FACTOR,
THERMAL RESISTANCE (RHO) OF 90, CONDUCTOR TEMPERATURE OF
90°C (194°F) AND 105°C (221°F)
2001-5000 Volts 5001-35,000 Volts
Ampacity Ampacity
Conductor Size
(AWG or 90°C 105°C 90°C 105°C
kcmil) (194°F) (221°F) (194°F) (221°F)
Type MV-90 Type MV-105 Type MV-90 Type MV-105
One Circuit
(Detail 1)
8 59 64 - -
6 78 84 88 95
4 100 110 115 125
2 135 145 150 160
1 155 165 170 185
1/0 175 190 195 210
2/0 200 220 220 235
3/0 230 250 250 270
4/0 265 285 285 305
250 290 315 310 335
350 355 380 375 400
500 430 460 450 485
750 530 570 545 585
1000 600 645 615 660
Three Circuits
(Detail 2)
8 53 57 - -
6 69 74 75 81
4 89 96 97 105
2 115 125 125 135
1 135 145 140 155
1/0 150 165 160 175
2/0 170 185 185 195
3/0 195 210 205 220
4/0 225 240 230 250
250 245 265 255 270
350 295 315 305 325
500 355 380 360 385
750 430 465 430 465
1000 485 520 485 515
Six Circuits
(Detail 3)
8 46 50 - -
6 60 65 63 68
4 77 83 81 87
2 98 105 105 110
1 110 120 115 125
1/0 125 135 130 145
2/0 145 155 150 160
3/0 165 175 170 180
4/0 185 200 190 200
250 200 220 205 220
350 240 270 245 275
500 290 310 290 305
750 350 375 340 365
1000 390 420 380 405
For SI units: 1 in.= 25.4 mm.
SOUTHWIRE 6-45
CHAPTER 6

TABLE 6-23 (NEC TABLE 310.67)

AMPACITIES OF INSULATED SINGLE COPPER CONDUCTOR CABLES
TRIPLEXED IN AIR BASED ON CONDUCTOR TEMPERATURE OF
90°C (194°F) AND 105°C (221°F) AND
AMBIENT AIR TEMPERATURE OF 40°C (104°F)
2001-5000 Volts 5001-35,000 Volts
Ampacity Ampacity
Conductor Size
(AWG or 90°C 105°C 90°C 105°C
kcmil) (194°F) (221°F) (194°F) (221°F)
Type MV-90 Type MV-105 Type MV-90 Type MV-105
8 65 74 - -
6 90 99 100 110
4 120 130 130 140
2 160 175 170 195
1 185 205 195 225
1/0 215 240 225 255
2/0 250 275 260 295
3/0 290 320 300 340
4/0 335 375 345 390
250 375 415 380 430
350 465 515 470 525
500 580 645 580 650
750 750 835 730 820
1000 880 980 850 950

TABLE 6-24 (NEC TABLE 310.73)

AMPACITIES OF AN INSULATED TRIPLEXED OR THREE SINGLE-
CONDUCTOR COPPER CABLES IN ISOLATED CONDUIT IN AIR BASED
ON CONDUCTOR TEMPERATURE OF 90°C (194°F) AND 105°C (221°F)
AND AMBIENT AIR TEMPERATURE OF 40°C (104°F)
2001-5000 Volts 5001-35,000 Volts
Conductor Size Ampacity Ampacity
(AWG or 90°C 105°C 90°C 105°C
kcmil) (194°F) (221°F) (194°F) (221°F)
Type MV-90 Type MV-105 Type MV-90 Type MV-105
8 55 61 - -
6 75 84 83 93
4 97 110 110 120
2 130 145 150 165
1 155 175 170 190
1/0 180 200 195 215
2/0 205 225 225 255
3/0 240 270 260 290
4/0 280 305 295 330
250 315 355 330 365
350 385 430 395 440
500 475 530 480 535
750 600 665 585 655
1000 690 770 675 755

SOUTHWIRE 6-46
 ELECTRICAL CHARACTERISTICS

TABLE 6-25 (NEC TABLE 310.83)

AMPACITIES OF THREE INSULATED COPPER CONDUCTORS CABLED

WITHIN AN OVERALL COVERING (THREE-CONDUCTOR CABLE)
DIRECTLY BURIED IN EARTH BASED ON AMBIENT EARTH
TEMPERATURE OF 20°C (68°F), 100% LOAD FACTOR,
THERMAL RESISTANCE (RHO) OF 90, CONDUCTOR
TEMPERATURE OF 90°C (194°) AND 105°C (221°F)
2001-5000 Volts 5001-35,000 Volts
Ampacity Ampacity
Conductor Size 90°C 105°C 90°C 105°C
(AWG or kcmil)
(194°F) (221°F) (194°F) (221°F)
Type MV-90 Type MV-105 Type MV-90 Type MV-105
One Circuit -
(Detail 5)
8 85 89 - -
6 105 115 115 120
4 135 150 145 155
2 180 190 185 200
1 200 215 210 225
1/0 230 245 240 255
2/0 260 280 270 290
3/0 295 320 305 330
4/0 335 360 350 375
250 365 395 380 410
350 440 475 460 495
500 530 570 550 590
750 650 700 665 720
1000 730 785 750 810
Two Circuits
(Detail 6)
8 80 84 - -
6 100 105 105 115
4 130 140 135 145
2 165 180 170 185
1 185 200 195 210
1/0 215 230 220 235
2/0 240 260 250 270
3/0 275 295 280 305
4/0 310 335 320 345
250 340 365 350 375
350 410 440 420 450
500 490 525 500 535
750 595 640 605 650
1000 665 715 675 730

For SI units: 1 in.= 25.4 mm.

SOUTHWIRE 6-47
CHAPTER 6

TABLE 6-26 (NEC TABLE 310.79)

AMPACITIES OF THREE INSULATED COPPER CONDUCTORS CABLED

WITHIN AN OVERALL COVERING (THREE-CONDUCTOR CABLE) IN
UNDERGROUND ELECTRICAL DUCTS (ONE CABLE PER ELECTRICAL DUCT)
BASED ON AMBIENT EARTH TEMPERATURE OF 20°C (68°F),100% LOAD
FACTOR, THERMAL RESISTANCE (RHO) OF 90, CONDUCTOR
TEMPERATURE OF 90°C (194°F) AND 105°C (221°F)
2001-5000 Volts 5001-35,000 Volts
Conductor Ampacity Ampacity
(Size 90°C 105°C 90°C 105°C
AWG or (194°F) (221°F) (194°F) (221°F)
kcmil)
Type MV-90 Type MV-105 Type MV-90 Type MV-105
One Circuit
(Detail 1)
8 64 69 - -
6 85 92 90 97
4 110 120 115 125
2 145 155 155 165
1 170 180 175 185
1/0 195 210 200 215
2/0 220 235 230 245
3/0 250 270 260 275
4/0 290 310 295 315
250 320 345 325 245
350 385 415 390 415
500 470 505 465 500
750 585 630 565 610
1000 670 720 640 690
Three Circuits
(Detail 2)
8 56 60 - -
6 73 79 77 83
4 95 100 99 105
2 125 130 130 135
1 140 150 145 155
1/0 160 175 165 175
2/0 185 195 185 200
3/0 210 225 210 225
4/0 235 255 240 255
250 260 280 260 280
350 315 335 310 330
500 375 405 370 395
750 460 495 440 475
1000 525 565 495 535
Six Circuits
(Detail 3)
8 48 52 - -
6 62 67 64 68
4 80 86 82 88
2 105 110 105 115
1 115 125 120 125
1/0 135 145 135 145
2/0 150 160 150 165
3/0 170 185 170 185
4/0 195 210 190 205
250 210 225 210 225
350 250 270 245 265
500 300 325 290 310
750 365 395 350 375
1000 410 445 390 415
For SI units: 1 in.= 25.4 mm.
SOUTHWIRE 6-48
 ELECTRICAL CHARACTERISTICS

TABLE 6-27 (NEC TABLE 310.71)

AMPACITIES OF AN INSULATED THREE-CONDUCTOR COPPER
CABLE ISOLATED IN AIR BASED ON CONDUCTOR TEMPERATURE
OF 90°C (194°F) AND 105°C (221°F) AND
AMBIENT AIR TEMPERATURE OF 40°C (104°F)
2001-5000 Volts 5001-35,000 Volts
Ampacity Ampacity
Conductor Size
90°C 105°C 90°C 105°C
(AWG or kcmil) (194°F) (221°F) (194°F) (221°F)
Type MV-90 Type MV-105 Type MV-90 Type MV-105
8 59 66 - -
6 79 88 93 105
4 105 115 120 135
2 140 154 165 185
1 160 180 185 210
1/0 185 205 215 240
2/0 215 240 245 275
3/0 250 280 285 315
4/0 285 320 325 360
250 320 355 360 400
350 395 440 435 490
500 485 545 535 600
750 615 685 670 745
1000 705 790 770 860

TABLE 6-28 (NEC TABLE 310.75)

AMPACITIES OF AN INSULATED THREE-CONDUCTOR COPPER
CABLE ISOLATED IN AIR BASED ON CONDUCTOR TEMPERATURE
OF 90°C (194°F) AND 105°C (221°F) AND
AMBIENT AIR TEMPERATURE OF 40°C (104°F)
2001-5000 Volts 5001-35,000 Volts
Ampacity Ampacity
Conductor Size
90°C 105°C 90°C 105°C
(AWG or kcmil) (194°F) (221°F) (194°F) (221°F)
Type MV-90 Type MV-105 Type MV-90 Type MV-105
8 52 58 - -
6 69 77 83 92
4 91 100 105 120
2 125 135 145 165
1 140 155 165 185
1/0 165 185 195 215
2/0 190 210 220 245
3/0 220 245 250 280
4/0 255 285 290 320
250 280 315 315 350
350 350 390 385 430
500 425 475 470 525
750 525 585 570 635
1000 590 660 650 725

SOUTHWIRE 6-49
CHAPTER 6

SEQUENCE IMPEDANCE

When a low resistance path occurs between any energized phase and ground or between
energized phases and ground or between energized phases, a “short circuit” or “fault”
occurs. The cause of the fault may be insulation failure, an arc discharge, or contact
between a low resistance object and one or more phases, creating a conducting path to
ground and/or between phases. A fault study on a power system can determine the values
of system voltages and currents during faulted conditions so that protective devices may
be set to detect and minimize the harmful effects of the resulting short circuit current. To
determine the fault current, sequence impedance data for cables is used in combination
with the sequence impedances for all components, including generators, motors, and
transformers. The result of the fault study are used to size, set, and coordinate system
protection equipment such as circuit breakers, fuses, instrument transformers, and relays.
This section introduces the use of symmetrical components to determine fault currents and
provides equations to calculate the sequence impedance of shielded medium voltage cables.

Symmetrical Components
Impedance is commonly taken to be the opposition to the flow of “normal” system
currents; sequence impedance is the opposition to the flow of abnormal fault currents.
The method of symmetrical components is generally used to quantify fault currents. This
method is a powerful tool in the evaluation of unbalanced polyphase circuits. Introduced
by C.L. Fortescue8 in 1918, this approach shows that an unbalanced system of phasors can
be resolved into a system of balanced phasors called symmetrical components. The
response of each circuit element depends upon its connections and the component of the
current being considered. Equivalent circuits, called “sequence circuits,” reflect the sepa-
rate responses of the elements to that component of the current. Three such equivalent
circuits exist for each element of a three-phase system. These circuits can be organized
into three sequence networks. Solving the sequence networks for the fault conditions
gives symmetrical current and voltage components. These components can be combined
to show the effects of the original unbalanced fault currents on the overall system.
According to Fortescue, three unbalanced phasors of a three-phase system can be
resolved into three balanced systems of phasors. The balanced set of components are:

1. Positive-sequence components consisting of three phasors equal in magnitude, each

with a phase difference of 120 degrees and having the same phase sequence as the
original phasors.
2. Negative-sequence components consisting of three phasors equal in magnitude,
each with a phase difference of 120 degrees and having a phase sequence opposite
to the original phasors.
3. Zero-sequence components consisting of three phasors equal in magnitude with no
difference in phase between them.

Positive Sequence Current Phasors Negative Sequence Current Phasors Zero Sequence Current Phasors

Figure 6-20

8
“Method of Symmetrical Coordinates Applied to the Solution of Polyphase Networks,” C.L. Fortescue, 1918, Transactions AIEE, vol. 37, pp. 1027-1140.
SOUTHWIRE 6-50
 ELECTRICAL CHARACTERISTICS

The parameters defining the contribution of power cables to the sequence network under
analysis are the positive-sequence (Z1) and negative-sequence (Z2) impedance, which are
equal in value and typically designated as Z1, and the zero-sequence impedance (Z0). The
sequence impedance is the sum of the path resistances and the effective impedance resulting
from the self-inductance and mutual inductance between phase conductors and between
phase conductors and any neutral and/or ground returns. Cable shields and concentric
neutrals must be considered because these elements also have path resistance and effective
self-inductance and mutual inductance between themselves and the metallic elements
of each phase.

The fault currents (If), when V equals the phase-to-phase or phase-to-ground voltage,
as appropriate, are given by:

(6-51)

(6-52)

Effect of Variables
System and equipment complexity and the lack of accurate parameters for many system
components make precise calculations of fault currents difficult, but extreme precision
is unnecessary. Fault current calculations do not require precise sequence impedance
values to provide reasonable accuracy. Many times the same data can be used for several
types of cable constructions and installations without having an appreciable effect on
overall system sequence impedance values and resulting short circuit currents.
However, the effects of different variables on the final values of sequence impedance
are of interest. These effects give an indication of which parameters are more or less
important for a given set of conditions. Figures 6-21 through 6-24 are plots of the
percentage change in sequence impedance versus selected key variables with other
variables held constant. These plots are intended to show trends and are not for
quantitative determinations. (Remember that phase-to-phase fault currents are inversely
proportional to Z1, and phase-to-ground faults are inversely proportional to the sum
of two times Z1 plus Z0.)
The typical case used in this analysis is three single 500 kcmil copper conductors, 15kV,
133% insulation level, tape shielded and jacketed cables. In the first three plots, the
cables are arranged in a triplexed configuration. In the cable spacing example,
triplexed cables are compared to parallel-laid cables with spacing as indicated.

Examination of these plots leads to several general conclusions.

1. In Figure 6-21, the steep slope of the curve suggests that shield resistance is critical
when determining Z0. Because shield resistance can vary considerably with the type,
configuration, and age of the cable, systems designers should pay close attention to
these values.

2. On the other hand, Figure 6-22 demonstrates that soil resistivity—which can some-
times be difficult to measure—has little impact on impedance calculations, even with
significant divergence from a nominal value.

SOUTHWIRE 6-51
CHAPTER 6

3. The flat slope and low magnitude of the curves in Figure 6-23 suggests that insula-
tion thickness is also not a significant factor when determining either Z1 or Z0. A
practical result of this conclusion would be that engineers can use published
sequence impedance values for 100% or 133% insulation levels interchangeably.

4. Figure 6-24 shows a nonlinear relationship between Z1, and separation distance of
parallel-laid cables. The first increase of a couple of inches in separation causes
significant increase in Z1, whereas a similar increase from 14 to 16 inches has
considerably less impact.

Figure 6-21
Effect of Shield Resistance on Sequence Impedance

Figure 6-22
Effect of Earth Resistivity on Sequence Impedance

SOUTHWIRE 6-52
 ELECTRICAL CHARACTERISTICS

Figure 6-23
Effect of Insulation Thickness on Sequence Impedance

Figure 6-24
Effect of Cable Spacing on Sequence Impedance

SOUTHWIRE 6-53
CHAPTER 6

SEQUENCE IMPEDANCE EQUATIONS

The following formulas are based on three-phase power systems having a frequency of
60 Hz. The typical case of solidly grounded shields plus an earth return is assumed. For
power cables, Z1 is equal to Z2; therefore only Z1 needs to be calculated.
Traditionally, the effect of the cable’s grounding conductor(s) is not considered in the
calculation of sequence impedances. The quantification of the net effect of these factors is
beyond the scope of this work.

Tape Shielded Medium Voltage Cables

Three-Phase Positive- and Negative-Sequence (Z1)

And Zero-Sequence (Z0) Impedances.9

(6-53)

(6-54)

where: Zaa = self-impedance of each phase conductor with earth return

in ohms per 1000 feet
Zab = mutual impedance between phase conductors with earth
return in ohms per 1000 feet
Zas = mutual impedance between each phase conductor and its
tape shield in ohms per 1000 feet
Zss = self-impedance of each tape shield with earth return in
ohms per 1000 feet.

Self-Impedances
(6-55)

(6-56)

Mutual Impedances:

(6-57)

(6-58)

9
Underground Transmission Systems Reference Book, 1992 edition, Electrical Power Research Institute.

SOUTHWIRE 6-54
 ELECTRICAL CHARACTERISTICS

where: RØ = ac resistance of a phase conductor at the operating

temperature in ohms per 1000 feet
RS = effective shield resistance in ohms per 1000 feet
De = mean depth of earth return current in inches
GMRØ = geometric mean radius of the phase conductor R in inches
GMRS = radius from center of phase conductor to center of shield in inches.
GMDØ = distance between the centers of two phase conductors in inches

Wire Shielded and Concentric Neutral Medium Voltage Cables

Three-Phase Positive- and Negative-Sequence (Z13Ø) and

Zero-Sequence (Z03Ø ) Impedances10

(6-59)

(6-60)

where: Z13Ø = positive sequence impedance of three-phase

concentric neutral circuit in ohms per 1000 feet
Z03Ø = zero sequence impedance of three-phase concentric
neutral circuit in ohms per 1000 feet
Zaa = self-impedance of each phase conductor with earth
return in ohms per 1000 feet
Zab = mutual impedance between phase conductors with
earth return in ohms per 1000 feet
Zan/p = positive mutual impedance between phases and concentric
neutrals in ohms per 1000 feet
Znn/p = positive self-impedance of the concentric neutrals of
the three-phase circuit in ohms per 1000 feet
Zan/g3ø = mutual impedance between each phase and all concentric
neutrals in ohms per 1000 feet
Znn/g3ø = self-impedance of all concentric neutrals with earth
return in ohms per 1000 feet

Self-Impedances:

(6-61)

(6-62)

10
Electrical Transmission and Distribution System Analysis and Design Programs, Version 3.50, August 1992,
EDSA Micro Corporation, Bloomfield Hills, MI.
SOUTHWIRE 6-55
CHAPTER 6

(6-63)

Mutual Impedances:
(6-64)

(6-65)

(6-66)

where: RØ = ac resistance of a phase conductor at the operating

temperature in ohms per 1000 feet
Rn = effective resistance of the concentric neutral (or wire shield)
in ohms per 1000 feet
= earth resistivity in ohms-meter
GMRØ = geometric mean radius of the phase conductor in inches
GMRs = radius from center of phase conductor to center of shield in inches
GMRn = geometric mean radius of a single neutral strand in inches
GMDØ = distance between the centers of two phase conductors in inches
N = the number of shield or neutral wires
Kn = spacing factor of concentric neutral wires

Single-Phase Laterals
Single-phase lateral circuits require modifications of the three-phase formulas because
only phase-to-ground faults are applicable.11 As shown in Formula 6-52, If is dependent
upon Z1 and Z0. Z1 and Z0 are dependent upon Zab, which is in turn dependant upon the
geometric mean distance (GMDØ) between nonexistent phases. This contraction does
not present a practical problem because the Zab terms cancel in the calculation of single-
phase fault currents and can therefore be removed from the formula for Z11Ø and Z01Ø.

(6-67)

11
Distribution-System Protection Manual, McGraw-Edison.

SOUTHWIRE 6-56
 ELECTRICAL CHARACTERISTICS

(6-68)

where: Z11Ø = positive sequence impedance of single-phase lateral

concentric neutral circuit in ohms per 1000 feet
Z01Ø = zero sequence impedance of single-phase lateral
concentric neutral circuit in ohms per 1000 feet
Zaa1Ø = self-impedance of phase conductor with earth return
in ohms per 1000 feet
Zan/g1Ø = mutual impedance of a lateral phase conductor in ohms per
1000 feet
Znn/g1Ø = self-impedance of a concentric neutral lateral with
earth return in ohms per 1000 feet

Self-Impedances:
(6-69)

(6-70)

Mutual Impedance:

(6-71)

where: RØ = ac resistance of a phase conductor at the operating

temperature in ohms per 1000 feet
Rn = effective resistance of the concentric neutral (or wire
shield) in ohms per 1000 feet
= earth resistivity in ohms-meter
GMRØ = geometric mean radius of the phase conductor in inches
GMRn = geometric mean radius of a single neutral strand in inches
GMRs = radius from center of phase conductor to center
of shield in inches
N = the number of shield or neutral wires
Kn = spacing factor of concentric neutral wires

SOUTHWIRE 6-57
CHAPTER 6

Variables for Sequence Impedance Equations

Conductor Resistance (RØ)

The conductor’s ac resistance (RØ) is calculated by determining the dc resistance,
multiplying by the ac/dc ratio, and then adjusting for temperature. The conductor dc
resistance and ac/dc ratio are available in Chapter 2 of this manual.

(6-72)

For Copper:
(6-73)

For Aluminum:

(6-74)

where: RdcT = dc resistance of the phase conductor adjusted

for temperature in ohms per 1000 feet
Rac/dc = ac/dc resistance ratio of the phase conductor
(Chapter 2, Table 2-7)
Rdc = dc resistance of a phase conductor at 25°C in ohms
Per 1000 feet (Chapter 2, Table 2-6)
Tc = operating temperature of the conductor in degrees C
Ti = initial or reference temperature of the dc resistance in degrees C

Shield Resistance
The shield resistance is calculated by determining the effective shield resistance in
accordance with ICEA P-45-432 and then adjusting for temperature. As a practical matter,
it is not necessary to adjust the dc shield resistance for ac effects. The shield tape thickness
and wire diameters are small, resulting in negligible 60 cycle skin effect.
Helically Applied Copper Tape (RS)
(6-75)

(6-76)

(6-77)

(6-78)

where: Rs = effective shield resistance in ohms per 1000 feet

RtdcT = dc resistance of tape shield, corrected for temperature,
in ohms per 1000 feet
Ts = operating temperature of the shield in degrees C
Ti = initial or reference temperature dc resistance in degrees C
Rtdc = dc resistance of tape shield at 25∞C in ohms per 1000 feet
c = resistivity of copper tape shield in ohms-cmil per foot
(10.575 for uncoated copper at 25°C)
SOUTHWIRE 6-58
 ELECTRICAL CHARACTERISTICS

As = effective area of shield in circular mils

B = thickness of shield tape in mils
dm = mean diameter of shield in mils (dm equals diameter
under the metallic shield plus two times tape thickness)
L = lap of tape shield in percent

Helically Applied Copper Wire Shield or Concentric Neutral (Rn )

(6-79)

(6-80)

(6-81)

(6-82)

where: Rn = effective resistance of the concentric neutral (or wire

shield) in ohms per 1000 feet
RndcT = dc resistance of the concentric neutral, adjusted for
temperature, in ohms per 1000 feet
Tn = operating temperature of the concentric neutral wires in degrees C
Ti = initial or reference temperature for dc resistance in degrees C
RndcL = dc resistance of the concentric neutral, adjusted for lay
length, in ohms per 1000 feet
Rndc = dc resistance of the concentric neutral in ohms per 1000 feet
LF = the lay factor of the helically applied shield tape or shield wires,
as applicable
c = resistivity of copper tape shield in ohms-cmil per foot
(10.575 for uncoated copper at 25°C)
N = the number of shield or neutral wires
Dn = diameter of an individual shield or neutral wire in inches

Longitudinally Corrugated Copper Tape Shield (RS)

(6-83)

(6-84)

(6-85)

(6-86)

SOUTHWIRE 6-59
CHAPTER 6

where: Rs = effective shield resistance in ohms per 1000 feet

RtdcT = dc resistance of a tape shield, corrected for temperature,
in ohms per 1000 feet
Ts = operating temperature of the shield in degrees C
Ti = initial or reference temperature for dc resistance in degrees C
Rtdc = dc resistance of a tape shield at 25°C in ohms per 1000 feet
c = resistivity of copper tape shield in ohms-cmil per foot
(10.575 for uncoated copper at 25°C)
F = the increase in length factor for longitudinally corrugated tapes (LCT)
As = effective area of shield in circular mils
Di = diameter under the metallic shield in inches
B = longitudinal tape overlap in inches
b = thickness of shield tape in mils

A typical value for longitudinal tape overlap (B) is 0.5 inches. The increase in length
factor (F) takes into account the tape corrugations and is typically 1.2.

Mean Depth of Earth Return (De)

(6-87)

where: = earth resistivity in ohms-meter

An average earth resistivity of 100 ohms-meter is often used in these calculations. Soil
resistivity can vary with temperature and moisture content. The typical range is from 0.1
ohms-meter for sea water to 1,000 ohms-meter for dry soil.

Concentric Neutral or Wire Shield Spacing Factor (Kn)

(6-88)

where: N = the number of shield or neutral wires

Geometric Mean Distance (GMDØ)

Three Conductor Cables
(6-89)

Triplexed Single Cables

(6-90)

Parallel-Laid Cables
(6-91)

where: D0 = diameter over the metallic shield in inches

OD = overall single cable diameter in inches
dab,dbc,dac = center-to-center distance between respective phases
a, b, and c in inches

SOUTHWIRE 6-60
 ELECTRICAL CHARACTERISTICS

Figure 6-25
Conductor Spacing

Geometric Mean Radius (GMRØ)

Phase Conductor (GMRØ)

TABLE 6-29
GMR OF CLASS B STRANDED COPPER AND ALUMINUM CONDUCTORS
Conductor Size No. of Strands Round Compressed Compact
(AWG or kcmil) (inches) (inches) (inches)

8 7 0.053 - -
6 7 0.067 - -
4 7 0.084 - -
2 7 0.106 0.105 -
1 19 0.126 0.124 0.117
1/0 19 0.141 0.139 0.131
2/0 19 0.159 0.156 0.146
3/0 19 0.178 0.175 0.165
4/0 19 0.200 0.197 0.185
250 37 0.221 0.216 0.203
350 37 0.261 0.256 0.240
500 37 0.312 0.305 0.287
750 61 0.383 0.377 0.353
1000 61 0.442 0.435 0.413

Metallic Shield (GMRs )

(6-92)

where: Di = diameter under the metallic shield in inches

T = thickness of shield tape in inches

Single Neutral Strand (GMRn )

(6-93)

where: Dn = diameter of an individual shield or neutral wire in inches

SOUTHWIRE 6-61
CHAPTER 6

Figure 26
Shield Diameters

Typical Calculation
The following calculations illustrate how to determine the positive-, negative-, and zero-
sequence impedances for three 15kV (133%) rated medium voltage cables arranged in a
horizontal spaced configuration with center-to-center distances of 8, 8, and 16 inches
respectively. The individual single conductor cables have a 500 kcmil stranded bare com-
pressed copper conductor, a 0.220 inch wall of EPR insulation, a shield of 0.005 inch thick
helically applied copper tape with a lap of 12.5%, and an overall jacket. The typical case of
bonded and grounded shield(s) plus earth return shall apply.

1. Determine the effective conductor resistance (RØ):

a. Determine the operating temperature of the conductor (Tc) and the reference
temperature (Ti):

Ti given as 25ºC, and Tc as 90ºC

b. Next, determine the dc conductor resistance (Rdc) by first determining the dc

resistance per the published conductor tables in Chapter 2:

Rdc = 0.0216 ohms per 1000 ft. at 25°C

c. Adjust the conductor resistance for the operating temperature (R90) using
equation 6-73:

d. Adjust the dc conductor resistance (R90) for ac skin and proximity effects (Rac/dc)
using equation 6-72. Rac/dc is found in Table 2-7 of Chapter 2. In this
calculation, Rac/dc is equal to 1.06.

SOUTHWIRE 6-62
 ELECTRICAL CHARACTERISTICS

2. Determine the shield resistance of the helically applied copper tape shield (RS):
a. Determine the “effective area” of the helically applied copper tape shield (AS):
Convert the shield tape thickness (b) to mils:

Determine the mean diameter of the shield (dm):

Determine the effective area of the shield (AS) using equation 6-78:

b. Determine the dc resistance of the tape shield (Rtdc) using equation 6-77:

c. Determine the operating temperature of the shield (TS), and the reference
temperature (Ti):

Ti is given as 25°C, and Ts as the typical value of 45°C

d. Adjust the shield resistance for an operating temperature of 45°C (Rt45) using
equation 6-76:

SOUTHWIRE 6-63
CHAPTER 6

e. As a practical matter, it is not necessary to adjust the dc shield resistance for ac

effects (RS) because tape shields are very thin when compared to the 60 cycle
skin depth, therefore:

3. Determine the mean depth of the earth return (De), where the earth resistivity ( ) is
100 ohm-meters, using equation 6-87:

4. Determine the geometric mean distance (GMø) between phase conductors using
equation 6-91:
dab = 8 inches, dbc = 8 inches, dac = 16 inches

5. Determine the geometric mean radius of the conductor (GMRø) and the shield (GMRs).
a. Determine the geometric mean radius (GMRø) of the compressed conductor
from Table 6-29:

GMRø of 500 kcmil, 37 strand conductor = 0.305 inches

b. Determine the geometric mean radius (GMRs) of the shield. GMRs is measured
from the center of the phase conductor to the middle of the tape shield. Given
an innermetallic shield diameter (Di) of 1.4 inches, calculate the GMRs using
equation 6-92:

SOUTHWIRE 6-64
 ELECTRICAL CHARACTERISTICS

6. Calculate individual impedances of Zaa, Zab, Zas, and Zss, in ohms per 1000 feet, using
the equations for tape shielded medium voltage cables (6-55, 6-56, 6-57, and 6-58):

7. Finally calculate the positive- and negative-sequence (Z1) and zero-sequence (Zo)
impedances, in ohms per 1000 feet, using the equations for tape shielded medium
voltage cables (6-53 and 6-54):

SOUTHWIRE 6-65
CHAPTER 6

5kV TABLE 6-30

CABLE SEQUENCE IMPEDANCE DATA IN OHMS/1000 FEET
Three Single Conductor Cables Three Conductor Cable
Size
(AWG or kcmil) Positive/Negative Zero Positive/Negative Zero
2 0.210+j0.103 0.487+j0.506 0.205+j0.044 0.057+j0.555
1 0.168+j0.099 0.452+j0.488 0.163+j0.042 0.521+j0.531
1/0 0.134+j0.097 0.428+j0.462 0.129+j0.042 0.493+j0.495
2/0 0.108+j0.094 0.406+j0.444 0.103+j0.040 0.469+j0.473
3/0 0.087+j0.091 0.389+j0.426 0.082+j0.039 0.449+j0.449
4/0 0.070+j0.089 0.376+j0.407 0.065+j0.038 0.433+j0.425
250 0.060+j0.087 0.369+j0.387 0.055+j0.038 0.422+j0.401
350 0.046+j0.083 0.357+j0.355 0.040+j0.036 0.404+j0.363
500 0.035+j0.079 0.344+j0.314 0.029+j0.034 0.384+j0.316
750 0.027+j0.074 0.329+j0.268 0.021+j0.032 0.361+j0.265
1000 0.023+j0.070 0.317+j0.237 0.017+j0.031 0.343+j0.233

15kV
Three Single Conductor Cables Three Conductor Cable
Size
(AWG or kcmil) Positive/Negative Zero Positive/Negative Zero
2 0.210+j0.103 0.518+j0.412 0.205+j0.052 0.574+j0.428
1 0.168+j0.099 0.478+j0.396 0.164+j0.049 0.531+j0.410
1/0 0.134+j0.097 0.445+j0.383 0.129+j0.048 0.496+j0.394
2/0 0.108+j0.094 0.419+j0.368 0.103+j0.046 0.468+j0.376
3/0 0.087+j0.091 0.398+j0.352 0.082+j0.044 0.444+j0.358
4/0 0.070+j0.089 0.381+j0.334 0.065+j0.043 0.424+j0.338
250 0.060+j0.087 0.370+j0.316 0.055+j0.039 0.412+j0.317
350 0.046+j0.083 0.351+j0.291 0.040+j0.040 0.386+j0.289
500 0.035+j0.079 0.334+j0.261 0.029+j0.038 0.364+j0.258
750 0.027+j0.074 0.315+j0.227 0.021+j0.036 0.339+j0.222
1000 0.023+j0.070 0.301+j0.201 0.017+j0.034 0.320+j0.195

25kV
Three Single Conductor Cables Three Conductor Cable
Size
(AWG or kcmil) Positive/Negative Zero Positive/Negative Zero
1 0.168+j0.099 0.480+j0.374 0.164+j0.051 0.529+j0.383
1/0 0.134+j0.097 0.446+j0.361 0.129+j0.050 0.493+j0.368
2/0 0.108+j0.094 0.419+j0.347 0.013+j0.048 0.463+j0.352
3/0 0.087+j0.091 0.397+j0.328 0.082+j0.046 0.438+j0.330
4/0 0.070+j0.089 0.379+j0.311 0.065+j0.045 0.416+j0.312
250 0.060+j0.087 0.366+j0.296 0.055+j0.044 0.402+j0.295
350 0.046+j0.083 0.347+j0.273 0.040+j0.041 0.378+j0.270
500 0.035+j0.079 0.329+j0.246 0.029+j0.039 0.356+j0.241
750 0.027+j0.074 0.308+j0.211 0.021+j0.038 0.329+j0.206
1000 0.023+j0.070 0.296+j0.190 0.018+j0.035 0.313+j0.184

35kV
Three Single Conductor Cables Three Conductor Cable
Size
(AWG or kcmil) Positive/Negative Zero Positive/Negative Zero
1/0 0.134+j0.097 0.442+j0.316 0.130+j0.053 0.480+j0.316
2/0 0.108+j0.094 0.414+j0.304 0.103+j0.051 0.449+j0.303
3/0 0.087+j0.091 0.391+j0.291 0.082+j0.049 0.424+j0.289
4/0 0.070+j0.089 0.371+j0.277 0.065+j0.048 0.402+j0.274
250 0.060+j0.087 0.358+j0.263 0.055+j0.046 0.386+j0.259
350 0.046+j0.083 0.338+j0.243 0.040+j0.044 0.363+j0.238
500 0.035+j0.079 0.317+j0.217 0.029+j0.043 0.338+j0.212
750 0.027+j0.074 0.297+j0.190 0.021+j0.040 0.314+j0.184
1000 0.023+j0.070 0.283+j0.172 0.017+j0.037 0.298+j0.166
Tables are based on the following:
• Three single conductor cables spaced horizontally 7.5 inches center to center.
• Three conductor cables triplexed, paralleled or cradled.
• Conductor temperature of 90°C with a shield temperature of 45°C.
• Copper tape shield resistivity of 10.575 ohms/cmil-ft at 25°C.
• Earth resistivity of 100 ohms-meter.
• Tape Shield thickness of 0.005 inches helically applied with 12.5% lap.
SOUTHWIRE 6-66
 CABLE
INSTALLATION
Cables installed into conduits or trays have installation parameters such as maximum
pulling tensions, sidewall pressure, clearance, and jamming, which must be considered.
Other installations, such as buried and aerial, have different installation parameters.
Most installations involve some general considerations, such as field handling, storage,
training of ends, and junction box sizes. These and other considerations can make the
difference between a good installation and one resulting in damaged cable.
Cable damaged during installation can cause service failures. Mechanical stresses during
installation are generally more severe than those encountered while in service.
The following information provides guidance in recognizing these conditions and
provides a methodology to aid in keeping them within acceptable limits.

GENERAL FIELD PRACTICES

Introduction
The small details can make the difference between successful installations and having to
remove damaged cable. In preparing for a cable pull, it is just as important to cover the
small details as it is to assure that the cable does not exceed maximum sidewall pressure;
minimum bending radii and maximum pulling tensions. General field practices are provided
to aid in preparing for large and small cable installations.
Preplanning
Preplanning for a pull is very important and should include the following steps:

1. Review all applicable local, state, and federal codes.

2. Consult local inspector.
3. Consult applicable information provided by national standards, cable manufacturers,
and accessory and other suppliers.
4. Check cable for:
a. Correct size and type
b. Shipping damage
c. End seals
d. Special instructions
5. Check reels for:
a. Damage
b. Protruding nails that might damage cable
c. Staples

10
SOUTHWIRE 7–1
CHAPTER 7

6. Consult equipment and cable manufacturer for approval of proper pulling equipment:
a. When using wood reels, use reel jack stands to support an axle through the arbor
hole during payoff.
b. Steel reels or special reinforced wood reels are acceptable for use with
electric roller payoff methods. Caution: Electric rollers can severely damage or
completely collapse non-reinforced wood reels during installation.

Low Ambient Temperature

Low temperatures are a cause for concern when installing cables. Cable should be
handled more carefully and pulled more slowly during cold weather. When cables are
to be installed in cold weather, they should be kept in heated storage for at least 24
hours before installation. Cables should not be installed at ambient temperatures lower
than the following:

Type of Insulation or Jacket Minimum Temperature for Installation

PVC -10°C 14°F
EPR -40°C -40°F
PE -40°C -40°F
XLPE -40°C -40°F
SOLONON -40°C -40°F
PVC (Arctic) -40°C -40°F
CSPE (Hypalon®) or CPE -20°C -4°F

In climates where there are large temperature swings either intermittently or from
summer to winter, jacket movement and shrinkback can occur at splices and terminations.
This is probably due to a ratcheting effect associated with the expansion and contraction
cycles of the environment and cable. Under certain conditions, terminations may allow
entry of moisture and contaminants into the cable, thus precipitating insulation failure.
Mechanical restraints, such as hose clamps and shrinkable sleeves that extend over part of
the jacket and termination, that apply pressure at those points, have proven to be
effective at restraining the jacket movement.1

Equipment
Some of the equipment and arrangements used to install cable are illustrated in the
following figures:
a) At the feed-in, the curvature of the cable feed is in the same continuous
arc with no reverse bends. At the pull-out, the pulling rope exits the duct
directly to a pulling sheave.

Figure 7-1
Pulling Cable in Duct

1
IEEE 532-1993 “Guide for Selecting and Testing Jackets for Underground Cables.”

SOUTHWIRE 7–2
 CABLE INSTALLATION

b) The cable is fed from the cable reel directly into the conduit at floor level.
The cable is fed from the bottom of the reel so that its curvature is continuous
with no reversed bends.

Figure 7-2
Cable Feed into Conduit at Floor Level

c) From cable reel to cable tray, the cable is fed from the top of the reel to
maintain required curvature. Sheaves, or a shoe, may be used to guide the
cable into the tray.

Figure 7-3
Cable Feed into Cable Tray

d) Cable sheaves or a shoe may be used to guide cable into the desired direction,
maintain minimum bend radius, and reduce friction. Examples of proper and
improper sheave arrangements are illustrated in the following figures.

Figure 7-4
Single Sheave for 90° Change of Direction
(R is radius used to calculate sidewall pressure, SP)

SOUTHWIRE 7–3
CHAPTER 7

Figure 7-5
Multiple Sheaves

Figure 7-6
Sheave Arrangements for Feeding into Cable Tray

Training Radius
The training radius is the final positioning of cable ends after the cable has been
placed in the raceway. These limits should not be used for cables subjected to pulling
tensions during installation.
Larger bend radii shall be considered for conduit bends, sheaves, or other curved
surfaces around which the cable may be pulled under tension while being installed,
due to sidewall bearing pressure limits (Table 7-1) of the cable.

TABLE 7-1
600 VOLT CABLE CONSTRUCTIONS
RECOMMENDED MINIMUM BENDING RADII
Cable Construction Multiple of Cable O.D.
Type MC (Metal Clad) Cables (NEC 330.24)
a) Interlocked or Corrugated Sheath 7
b) Smooth Sheath
- Max diameter 0.750 inches 10
- Max diameter 1.500 inches 12
- Diameter larger than 1.500 inches 15
c) Shielded Conductors 12/7*

Type TC (Tray Cable) (NEC 336.24)

Single or Multiconductor Assembly (ICEA S-95-658)
a) Diameter 1.0 inch or less 4
b) Diameter between 1.0 inch to 2.0 inches 5
c) Diameter larger than 2.0 inches 6
d) Metallic Shielding 12

*12 times individual shielded conductor diameter or 7 times overall cable diameter, whichever is greater.

SOUTHWIRE 7–4
 CABLE INSTALLATION

TABLE 7-2
OVER 600 VOLT CABLE CONSTRUCTIONS
RECOMMENDED MINIMUM BENDING RADII
Single and Multiple Conductors (NEC 300.34) Multiple of Cable O.D.

Shielded and Lead Covered 12

Nonshielded and Nonarmored 8
Multiconductor or Multiplexed Cable 12/7*
*12 times individual shielded conductor diameter or 7 times overall cable diameter, whichever is greater.

A nonshielded cable can tolerate a sharper bend than a shielded cable. When bent too
sharply, helical metal tapes can separate, buckle, and cut into the insulation. This problem
is compounded by jackets concealing such damage. Corona problems related to metal
shield damage may be initially masked by the semiconductive shielding bedding tapes
or extruded polymers.

Handling and Storage Guidelines

a. Unloading equipment should not come in contact with the cable or its
protective covering.
b. If a crane is used to unload cable, a shaft through the arbor hole or a cradle
supporting both reel flanges should be used.
c. Forklifts must lift the reel by contacting both flanges.
d. Ramps must be wide enough to support both reel flanges.
e. Store reels on hard surface so that the flanges will not sink and allow reel
weight to rest on cable.

Figure 7-7
Proper Reel Handling

SOUTHWIRE 7–5
CHAPTER 7

Figure 7-8
Improper Reel Handling

f. Reels should be stored out of harm’s way. Consider both physical and
environmental hazards.
g. Cable ends must always be sealed to prevent the entrance of moisture, etc.
h. Remove temporary cable lashing.
i. While pulling, in order to eliminate sharp bend and crossovers, always have a
person feed the cable(s) straight into the conduit by hand or, for larger
cables, over a large diameter sheave.

Figure 7-9
Feed Into Conduit

j. Do not pull cable directly across short, sharp angles. After pulling completely
out of one side of the enclosure, feed cable into the other side of the enclosure
and pull that segment.

*Caution: Minimum bending radii must be maintained.

Figure 7-10
Pull-Through Enclosure

SOUTHWIRE 7–6
 CABLE INSTALLATION

Dynamometer Corrections
The dynamometer reading (R) is dependent upon the angle of pulling line ( ) from the
cable to the dynamometer idler and then to the pulling mechanism; therefore, a
correction to the dynamometer reading may be required to obtain the actual pulling
tension (T).

Figure 7-11
Variables for Dynamometer Correction Equation

(7-1)

where: R = dynamometer reading, in pounds

= angle between pulling line, in degrees
W = tare weight of idler pulley assembly, in pounds

Example:
What is the actual pulling tension of a cable pull where the dynamometer reading is
5000 pounds, the angle of the pulling line is 45,° and the tare weight of the idler
assembly is 15 pounds? Using (7-1):

SOUTHWIRE 7–7
CHAPTER 7

Diameters of Nonjacketed Cable Assemblies

The overall diameters of the cables in a multiple conductor assembly are used in
determining the circumscribed diameter of that assembly
DA = d • Factor (7-2)
where: DA = circumscribed diameter of assembly
d = diameter of one cable of assembly
Factor = for the following list

Number of Cables Factor

1 1.000
2 2.000
3 2.155
4 2.414
5 2.700
6 3.000
7 3.000
8 3.310
9 3.610

Pull Boxes
To estimate the size of a pull box, take the greater of:

For Straight Pulls

For Angle or “U” Pulls

Figure 7-12
Pull Box Dimensions

SOUTHWIRE 7–8
 CABLE INSTALLATION

where: L = minimum box length, in inches

L o = minimum distance between cable entry and exit on the the opposite
side of the box, in inches
L A = minimum distance between the cable entry and the exit of the
adjacent walls of the box, in inches
Ds = diameter of the largest shielded cable, in inches
DN = diameter of the largest nonshielded cables, in inches
D1, D2 ... = diameters of the remaining cable entering through the
same wall of the box, in inches

For more information on sizing of pull and junction boxes, refer to the NEC Article 314.
Information on spacing of conductors at pull and junction boxes is presented in Table 7-3.

TABLE 7-3
CONDUIT SPACING (INCHES)
CENTER-TO-CENTER SPACING
Size 1/2 3/4 1 1 1/4 1 1/2 2 2 1/2 3 3 1/2 4 5 6
1/2 1.38
3/4 1.50 1.62
1 1.75 1.88 2.00
1 1/4 2.00 2.12 2.25 2.50

1 1/2 2.12 2.25 2.38 2.62 2.75

2 2.38 2.50 2.75 3.00 3.12 3.38
2 1/2 2.62 2.75 3.00 3.25 3.38 3.00 4.00
3 3.00 3.12 3.38 3.62 3.75 4.00 4.38 4.75

3 1/2 3.38 3.50 3.62 3.88 4.00 4.38 4.62 5.00 5.38
4 3.69 3.88 4.00 4.25 4.38 4.75 5.00 5.38 5.62 6.00
5 4.38 4.50 4.62 4.88 5.00 5.38 5.62 6.00 6.25 6.62 7.25
5 5.00 5.12 5.25 5.50 5.62 6.00 6.25 6.62 7.00 7.25 8.00 8.62

Cable Lubrication Selection

1. Reducing the coefficient of friction is the primary factor in the selection
of a lubricant.
2. Compatibility of the lubricant with cable and conduit is extremely important.
The lubricant should not have any deleterious effects on the conduit or on
the physical or electrical properties of the cable insulation, semiconducting,
or jacket materials.
3. The lubricant and its residue should not propagate flame.
4. The lubricant should be UL or CSA listed.
5. The lubricant should contain no waxes or greases.

SOUTHWIRE 7–9
CHAPTER 7

Use
The cable jacket and/or conduit walls should be completely lubricated. The lubricant
should be applied immediately before, and/or, during the pull. This quantity should be
increased as needed for difficult pulling situations.

An estimate of the quantity of required lubricant can be determined from.2

(7-3)
where: Q = quantity, in gallons
L = conduit length, in feet
D = outside diameter of cable or inside diameter of conduit, in inches

INSTALLATION IN CONDUIT

Calculations should be made to indicate whether the pull looks “easy” or “impossible,”
making the decision to pull an obvious choice. When a “marginal” situation is
encountered, the entire pull should be reviewed. This review may include more rigorous
calculations or trial pulls. A final decision should be made based on installation factors
known to the end user and installer.
The sizes of the conduit are determined based on the calculations of the clearances,
jamming, and fill. Pulling tensions may then be evaluated by determining the maximum
tension based on the pulling device used and the maximum tension that can be applied
to the conductors. The lesser of these two values is the maximum allowable tension (Tm).
The pulling tension (T) required to pull the cable through the conduit is then calculated
and compared to the maximum allowable tension. If the pulling tension exceeds the
allowable tension, then conditions should be changed to ensure a successful pull.
After calculating pulling tensions, sidewall pressures (SP) may be calculated.
For further study on this subject, AEIC Publication G5-90 and IEEE Standard 1185
present additional details.3

Allowable Tension on Pulling Device

Do not exceed the allowable tension stated by the manufacturer of the pulling eye or
10,000 pounds, whichever is less. Traditional conservative practices limit the allowable
tension of a basket grip to 1,000 pounds. Under specific conditions, this limit can be
safely exceeded.

Maximum Tension on Cable Conductors

The conductors of the cable are generally the only members that can bear the pulling
forces without damage. Do not use metallic shielding wires, tapes, braids or armor not
designed for the purpose in pulling tension calculations.

2
Polywater, “Technical Talk,” volume 4.
3
AEIC Publication no G5-90, “Underground Extruded Power Cable Pulling, AEIC Task Group 28,” 2nd edition, May
2001; and IEEE Standard 1185-1994, “Guide for Installation Methods for Generating Station Cables.”

SOUTHWIRE 7–10
 CABLE INSTALLATION

Definitions for the following equations and examples:

Tc = tension on each conductor, in pounds
S = allowable stress from Table 7-4, in pounds/cmil
A = area of each conductor, in cmil
N = number of conductors
Tcable = maximum allowable tension in the cable in pounds
Tdevice = maximum allowable tension on device in pounds
Tm = maximum allowable tension is the lesser of Tdevice or Tcable in pounds

TABLE 7-4
MAXIMUM ALLOWABLE CONDUCTOR STRESS (S)
Cable Type Material Temper lb/cmil
All Copper Soft 0.008
Power Aluminum Hard 0.008
Power Aluminum 3/4 Hard 0.006
Power Aluminum AA-8000* 0.006
URD Aluminum 1/2 Hard 0.003
Solid Aluminum Soft 0.002

*3/4 hard aluminum is allowed for power cable. The 2005 NEC defines use of AA-8000 for solid (8, 10, and 12 AWG)
and stranded (8 AWG through 1000 kcmil) conductors.

TABLE 7-5
CONDUCTOR AREA
Size Cross-Sectional Area
AWG or kcmil cmil inches2 mm2
14 4110 0.00323 2.082
12 6530 0.00513 3.308
10 10,380 0.00816 5.261
8 16,510 0.01297 8.368
7 20,820 0.01635 10.55
6 26,240 0.02061 13.30
5 33,090 0.02599 16.77
4 41,740 0.03278 21.15
3 52,620 0.04133 26.66
2 66,360 0.05212 33.63
1 83,690 0.06573 42.41
1/0 105,600 0.08291 53.49
2/0 133,100 0.1045 67.42
3/0 167,800 0.1318 85.03
4/0 211,600 0.1662 107.2
250 250,000 0.1963 126.6
300 300,000 0.2356 152.0
350 350,000 0.2749 177.4
400 400,000 0.3142 202.7
450 450,000 0.3534 228.0
500 500,000 0.3927 253.4
550 550,000 0.4320 278.7
600 600,000 0.4712 304.0
650 650,000 0.5105 329.4
700 700,000 0.5498 354.7
750 750,000 0.5890 380.0
800 800,000 0.6283 405.4
900 900,000 0.7069 456.1
1000 1,000,000 0.7854 506.7

SOUTHWIRE 7–11
CHAPTER 7

Single Conductors
(7-4)

Example:
Power Cable, single conductor, 4/0 AWG aluminum, hard

Multiple Conductors
Multiple conductors in parallel, or multiplexed, and multiple conductor cables.
Three or fewer conductors
(7-5)
Example 1: Power cable, two single conductor, 4/0 AWG aluminum, hard

Example 2: Power Cable, three-conductor, 4/0 AWG aluminum, hard

More than three conductors

(7-6)
Example 3: Control Cable, four conductor, 6 AWG copper
Using equation (E-4):

Using equation (E-6)

CAUTION:
Pulling different conductor sizes at the same time is not recommended if the conductor
size or other cable characteristics are significantly different.
If you must pull different size conductors, it must be done with care. For example, if a
run requires three 350 kcmil and three 8 AWG single conductor cables, it would be
preferable, though not necessarily ideal, to pull the three 350 kcmil single conduct
cables and one three conductor 8 AWG multiple conductor cable at the same time.
Pulling additional cables into an existing conduit system is generally not recommended.
If this must be done, extreme caution must be taken. Of special concern is the cutting
action of the tensioned pulling rope.

SOUTHWIRE 7–12
 CABLE INSTALLATION

Equations for Pulling Tension

The following equations are used to calculate pulling tension. They include the
following variables:

Tin = tension into a section in pounds

Tout = tension out of a section in pounds
w = weight correction factor, dimensionless
␮ = coefficient of dynamic friction, dimensionless
W = total cable assembly weight on pounds/foot
L = straight section length in feet
⍜ = straight section angle from horizontal in radians
␾ = bend section angle in radians
R = bend section radius in feet
e = 2.71 natural logarithm base

Horizontal Straight Section

(7-7)

Inclined and Vertical Straight Section

Pulling Up a Straight Section
(7-8)

Pulling Down a Straight Section

(7-9)

Horizontal Bend Section

(7-10)

Vertical Concave Up Bend

Pulling Up Through a Bend

(7-11)

Pulling Down Through a Bend

(7-12)

SOUTHWIRE 7–13
CHAPTER 7

Vertical Concave Down Bend

Pulling Up Through a Bend

(7-13)

Pulling Down Through a Bend

(7-14)

Commonly Used Approximation for Bends

It is common practice to use the following approximation in lieu of bend equations
7-10, 7-11, 7-13, 7-14, and 7-15
(7-15)

Coefficient of Friction
The coefficient of dynamic friction (␮) is a measure of the friction between a moving
cable and the conduit. The coefficient of friction can have a large impact on the tension
calculation. It can vary from 0.1 to 1.0 with lubrication and can exceed 1.0 for unlubricated
pulls. Typical values for the coefficient of friction are presented in Table 7-2. Pulls should
never be stopped and restarted because the coefficient of static friction will always be
higher than the coefficient of dynamic friction.

TABLE 7-6
TYPICAL COEFFICIENTS OF DYNAMIC FRICTION (␮)
ADEQUATE CABLE LUBRICATION DURING PULL (A)
Type of Conduit (B)
Cable Exterior M PVC FIB ASB
PVC – Polyvinyl Chloride 0.4 0.35 0.5 0.5
PE – Low Density HMW 0.35 0.35 0.5 0.5
Polyethylene
PO – SOLONON™ 0.35 0.35 0.5 0.5
(Polyolefin)
CSPE – Hypalon® 0.5 0.5 0.7 0.6
(Chlorosulfonated Polyethylene)
XLPE – Cross-Linked PE 0.35 0.35 0.5 0.5
Nylon 0.4 0.35 0.5 0.5
CPE – Chlorinated PE 0.5 0.5 0.7 0.6

(A) These represent conservative values for use in lieu of more exact information. 4

(B) Conduit Codes:

M = metallic, steel or aluminum
PVC = polyvinyl chloride, thin wall or heavy schedule 40
FIB = fiber conduit—Orangeburg or Nocrete
ASB = asbestos cement—Transite or Korduct

The coefficient of friction between a cable exterior (jacket/sheath) and conduit varies
with the type of jacket or sheath, type and condition of conduit, type and amount of
pulling lubricant used, cable temperature, and ambient temperature. High ambient
temperatures (80°F and above) can increase the coefficient of dynamic friction for cable
having a nonmetallic jacket.
Pulling lubricants must be compatible with cable components and be applied while the
cable is being pulled. Pre-lubrication of the conduit is recommended by some lubricant
manufacturers.
4
Gene C. Neetz, “Coefficient of Friction Measurement Between Cable and Conduit Surfaces Under Varying Loads,” in
1985 IEEE Transactions on Power Apparatus and Systems, vol. PAS-104, no. 1, pp. 16-21.

SOUTHWIRE 7–14
 CABLE INSTALLATION

Configuration
The configuration of three single-conductor cables in a conduit is determined by the
ratio of the conduit inner diameter (D) to the outer diameter (d) of one of the single
cables (D/d ratio).

Figure 7-13
Configuration of Three Single Conductors

A cradled configuration develops when three single-conductor cables are pulled into a
conduit where the D/d ratio is 2.5 or greater. A triangular configuration develops when
three single conductor cables are pulled into a conduit where the D/d ratio is less than
2.5. These cables may be pulled from individual reels, tandem reels, or a single reel with
parallel wound cables.

Weight Correction Factor

The configuration of cables can affect cable tension. A weight correction factor (w) is
used in the tension equations to account for this effect. The value for the weight
correction factor is determined from the equations that follow:
1 cable (single)
(7-16)
3 cables (triangular)

(7-17)
3 cables (cradles)
(7-18)

4 cables or more (complex)

(7-19)
where: w = weight correction factor
D = inner diameter of conduit
d = outside diameter of the cable

Note: When pulling dual cables, use the conservative three-cable (triangular) factor.

Figure 7-14
Cable Configurations
SOUTHWIRE 7–15
CHAPTER 7

Sidewall Pressure
Sidewall Pressure (SP) is exerted on a cable as it is pulled around a bend. Excessive side-
wall pressure can cause cable damage and is the most restrictive factor in many installations.

Figure 7-15
Sidewall Pressure Factors

Sidewall pressure is calculated as follows:

For one single-conductor cable or multiple-conductor cable under a common jacket
T
SP = (7-20)
R
For three single-conductor cables, cradled

(7-21)
For three single-conductor cables, triangular

(7-22)

where: T = tension coming out of the bend in pounds

(See Table 7-9 for sweep elbows only)
R = bend radius, in feet
w = weight correction factor, dimensionless
SP = sidewall pressure in pounds/foot

Recommended maximum sidewall pressures are provided in Table 7-7 in the range of
300 to 500 pounds per foot, depending on type of cable. The AEIC publication
“Underground Extruded Power Cable Pulling Guide” provides maximum sidewall pressures
ranging from 1,000 to 2,000 pounds per foot depending on construction. Consult the
cable manufacturer prior to using these higher values.

TABLE 7-7
RECOMMENDED MAXIMUM SIDEWALL PRESSURES
Cable Type SP lbs/ft
600V 1 kV nonshielded power 500
5-15 kV power 500
25-35 kV power 300
Interlocked armored cable (All Voltage Classes) 300

SOUTHWIRE 7–16
 CABLE INSTALLATION

Clearance
Clearance is the distance between the top of the uppermost cable in the conduit and
the inner top surface of the conduit. It should be at least 10% of the conduit inner
diameter or one inch for large cables or installations involving numerous bends.
Equations for calculating clearance (CL) are presented as follows:

For single cable

(7-23)
For three cables, triplexed, triangular

(7-24)
For three cables, cradles

(7-25)

where: D = conduit inner diameter, in inches

d = cable outer diameter, in inches

When calculating clearance, ensure all cable diameters are equal. If in doubt, use the
triplexed configuration equation. The cables may be single or multiple-conductor
construction.

Jamming
Jamming is the wedging of three or more cables when pulled into a conduit. This usually
occurs because of crossovers when the cables twist or are pulled around bends. The
jam ratio is the ratio of the conduit inner diameter (D) and the cable outside diameter (d).

(7-26)

The probability for jamming is presented in Figure 7-16

Very Small Small Moderate Significant Moderate Small Very Small

2.4 2.5 2.6 2.9 3.0 3.2

Figure 7-16
Jamming Probabilities Using the Jam Ratio

In calculating jamming probabilities, a 5% factor was used to account for the oval
cross-section of conduit bends.
The cable diameters should be measured, since actual diameters may vary from the
published nominal values.

SOUTHWIRE 7–17
CHAPTER 7

Conduit Fill
Conduit fill is the percentage of the area inside the conduit taken up by the cable(s).
Consult applicable codes, industry standards, and manufacturers’ data for further
information on fill. Dimensions and percent area of conduit and tubing are provided in
Table 7-8. Dimensions for additional types of conduits can be found in Chapter 9 of the
2005 National Electrical Code.

(7-27)

where: d = outside diameter of the cable in inches

D = inside diameter of the conduit in inches
N = number of cables

TABLE 7-8
DIMENSIONS AND PERCENT AREA CONDUIT AND TUBING
ELECTRICAL METALLIC TUBING (EMT)
Trade Size Internal Diameter Total Area 2 Wires Over 2 Wires 1 Wire
Inches mm Inches mm 100% Sq. In. 31% Sq. In. 40% Sq. In. 53% Sq. In.
1/2 16 0.622 15.8 0.304 0.094 0.122 0.161
3/4 21 0.824 20.9 0.533 0.165 0.213 0.283
1 27 1.049 26.6 0.864 0.268 0.346 0.458
1 1/4 35 1.380 35.1 1.496 0.464 0.598 0.793
1 1/2 41 1.610 40.9 2.036 0.631 0.814 1.079
2 53 2.067 52.5 3.356 1.040 1.342 1.778
2 1/2 63 2.731 69.4 5.858 1.816 2.343 3.105
3 78 3.356 85.24 8.846 2.742 3.538 4.688
3 1/2 91 3.834 97.38 11.545 3.579 4.618 6.119
4 103 4.334 110.1 14.753 4.573 5.901 7.819

RIGID PVC CONDUIT SCHEDULE 40 AND HDPE CONDUIT

Trade Size Internal Diameter Total Area 2 Wires Over 2 Wires 1 Wire
Inches Inches mm 100% Sq. In. 31% Sq. In. 40% Sq. In. 53% Sq. In.
1/2 0.602 15.3 0.285 0.088 0.114 0.151
3/4 0.804 20.4 0.508 0.157 0.203 0.269
1 1.029 26.1 0.832 0.258 0.333 0.441
1 1/4 1.360 34.5 1.453 0.450 0.581 0.770
1 1/2 1.590 40.4 1.986 0.616 0794 1.052
2 2.047 51.99 3.291 1.020 1.316 1.744
2 1/2 2.445 62.10 4.695 1.455 1.878 2.488
3 3.042 11.27 7.268 2.253 2.907 3.852
3 1/2 3.521 89.43 9.737 3.018 3.895 5.161
4 3.998 101.5 12.554 3.892 5.022 6.654
5 5.016 127.4 19.761 6.126 7.904 10.473
6 6.031 153.2 28.567 8.856 11.427 15.141

SOUTHWIRE 7–18
 CABLE INSTALLATION

TABLE 7-8 (CONTINUED)

RIGID PVC CONDUIT, SCHEDULE 80
Trade Size Internal Diameter Total Area 2 Wires Over 2 Wires 1 Wire
Inches Inches mm 100% Sq. In. 31% Sq. In. 40% Sq. In. 53% Sq. In.
1/2 0.526 13.4 0.217 0.067 0.087 0.115
3/4 0.722 18.3 0.409 0.127 0.164 0.217
1 0.936 23.8 0.688 0.213 0.275 0.365
1 1/4 1.255 31.88 1.237 0.383 0.495 0.656
1 1/2 1.476 37.49 1.711 0.530 0.684 0.907
2 1.913 48.59 2.874 0.891 1.150 1.1523
2 1/2 2.290 58.71 4.119 1.277 1.647 2.183
3 2.864 72.75 6.442 1.997 2.577 3.414
3 1/2 3.326 84.48 8.688 2.693 3.475 4.605
4 3.786 96.16 11.258 3.490 4.503 5.967
5 4.768 121.1 17.855 5.535 7.142 9.463
6 5.709 145.0 25.598 7.935 10.239 13.567

FLEXIBLE METAL CONDUIT

Trade Size Internal Diameter Total Area 2 Wires Over 2 Wires 1 Wire
Inches Inches mm 100% Sq. In. 31% Sq. In. 40% Sq. In. 53% Sq. In.
3/8 0.384 9.75 0.116 0.036 0.046 0.061
1/2 0.635 16.1 0.317 0.098 0.127 0.168
3/4 0.824 20.9 0.533 0.165 0.213 0.282
1 1.020 25.91 0.817 0.256 0.327 0.433
1 1/4 1.275 32.39 1.277 0.396 0.511 0.677
1 1/2 1.538 39.07 1.857 0.576 0.743 0.984
2 2.040 51.82 3.269 10.13 1.307 1.732
2 1/2 2.500 63.50 4.909 1.522 1.964 2.602
3 3.000 76.20 7.069 2.191 2.827 3.746
3 1/2 3.500 88.90 9.621 2.983 3.848 5.099
4 4.000 101.6 12.566 3.896 5.027 6.660

Calculation Procedure
The following is a recommended procedure for calculating installation parameters for
cables in conduit:
a. Select conduit size based on required fill, clearance, jamming, and applicable codes and standards.
b. Select values for conduit type, bend radii, and coefficient of friction. Table 7-9 lists the inside
radius for manufactured rigid steel conduit sweep elbows.
c. Determine cable weight (W) from manufacturers’ data sheets.
d. Calculate weight correction factor (w).
e. Calculate maximum allowable tension.
f. Calculate pulling tension (T) and sidewall pressure (SP) for each segment.
g. Compare calculated results to established limits.
h. If limits are exceeded, consider one or more of the following:
1) Increase bend radii
2) Decrease fill
3) Reduce number of bends
4) Reverse pull
5) Pull in stages
6) Decrease length of pull

SOUTHWIRE 7–19
CHAPTER 7

TABLE 7-9
SWEEP ELBOW RADIUS
Elbow Centerline Radius (inches)
12 15 18 24 30 36 42 48
Conduit Size Elbow Centerline Radius (feet)
1 0.96 1.21 1.46 1.96 2.46 2.96 3.46 3.96
1 1/4 0.94 1.19 1.44 1.94 2.44 2.94 3.44 3.94
1 1/2 0.93 1.18 1.43 1.93 2.43 2.93 3.43 3.93
2 0.91 1.16 1.41 1.91 2.41 2.91 3.41 3.91
2 1/2 1.15 1.40 1.90 2.40 2.90 3.40 3.90
3 1.37 1.87 2.37 2.87 3.37 3.87
3 1/2 1.35 1.85 2.35 2.85 3.35 3.85
4 1.83 2.33 2.83 3.33 3.83
5 2.29 2.79 3.29 3.79
6 2.75 3.25 3.75

INSTALLATION IN CABLE TRAY

When pulling cable into cable trays the same approach should be used for cable
installed into conduit. Care must be given to the run lengths, number of cable turns,
and cable sheave size to ensure the cable’s maximum pulling tension, minimum bending
radius, and maximum allowable sidewall pressure are not exceeded, subjecting the
cable to possible damage.

Rollers and Sheaves

When pulling around bends in cable tray, excessive sidewall pressure can damage the
cable. Sidewall pressure can be reduced by using a large radius sheave. Many times, a
large radius sheave cannot be used and an assembly of multiple smaller sheaves is
used. Care should be given to prevent damage due to high sidewall pressure on the
individual sheaves. The individual sheaves should have a minimum inside radius of 1.25
inches with at least one sheave per 20° of the bend. A three-sheave assembly for a 90°
bend should never be used.
Rollers and sheaves must be well-maintained and lubricated to achieve the lowest
possible coefficient of friction.

Roller Mounting
• Rollers must be properly spaced to prevent the cable from touching the tray.
• Rollers must be free-turning.
• When the tray changes direction, vertically or horizontally, sheave radii must be large
enough to meet the minimum bending and maximum allowable sidewall pressure limits.

SOUTHWIRE 7–20
 CABLE INSTALLATION

Roller Spacing
Roller spacing will vary with:
• Cable weight
• Cable tension
• Cable construction
• Roller height above the tray

To estimate roller spacing, the following equation can be used:

(7-28)

where: s = distance between rollers, in feet

h = height of top roller above the tray bottom, in feet
T = tension, in pounds
w = weight of cable, per foot

The distance will be conservative for armored cable because the equation assumes a
perfectly flexible cable. When possible, a length of cable should be used to determine
maximum spacing under no tension, as a check for the calculated values.

Pulling Tensions
Calculations of pulling tensions for cable trays are similar to those for pulling cable in
conduit, adjusting the coefficient of friction to reflect using rollers and sheaves.

Horizontal Straight Sections

The tension for a horizontal straight section of cable tray can be estimated with the
following equation:

Tout = (7-29)

where: Tout = tension out of a section, in pounds

= coefficient of dynamic friction ( = 0.15)
W = total cable assembly weight, in pounds/foot
L = straight section length, in feet
Tin = tension into a section, in pounds

The coefficient of friction ( ) equal to 0.15 accounts for the low-rolling friction of
well-maintained rollers.

SOUTHWIRE 7–21
CHAPTER 7

Inclined Straight Sections

Use the following equation for pulling up an inclined straight section:
Tout = (7-30)
Use the following equation for pulling down an inclined straight section:
Tout = (7-31)

where: Tout = tension out of a section, in pounds

W = total cable assembly weight, in pounds/foot
= straight section angle from horizontal, in radians
L = straight section length, in feet
= coefficient of dynamic friction ( = 0.15)
Tin = tension into a section, in pounds

Vertical Sections
When pulling straight up or down, the equation for inclined pulls simplifies to the
following equations:

Pulling Straight Up
(7-32)

Pulling Straight Down

(7-33)
where: W = total cable assembly weight, in pounds/foot
L = straight vertical section length, in feet

Tension in Bends
If the sheaves in the bends in cable trays are well-maintained, they will not have the
multiplying effect on tension that bends in conduit have. The sheaves will turn with
the cable, allowing the coefficient of friction to be assumed zero. This results in the
commonly-used approximation for conduit bend equation , becoming one. Even
though cable tray bends produce no multiplying effect, it is essential for heavier cables
to include the force required to bend the cable around the sheave. A 200-pound adder
per bend should be used for a three-conductor 500 kcmil copper conductor armored
cable. If the sheaves are not well-maintained, the bend will have a multiplying effect.
The tension in the pull must then be calculated using the same equations used for
installations in conduit.

Tension Entering Cable Tray

Because the tension entering the cable tray is rarely zero, it is critical that the tension
required to remove the cable from the reel be used to calculate the total tension for
the installation.

SOUTHWIRE 7–22
 CABLE INSTALLATION

Many times it is difficult to know the location of the reel of cable until the cable is
being installed. The following equations are used to approximate the tension entering
the cable tray and can be used to determine how critical the reel position will be for
the cable pull.

Feeding Off Reel Horizontally

When the cable reel can be elevated so that the cable can be pulled directly into the
tray, the following equation should be used to approximate the tension required to
remove the cable from the reel:
Treel = 25W pound (7-34)
where: Treel = tension, in pounds
W = total cable assembly weight, in pounds/foot

Feeding Off Reel Vertically

When the cable reel must be positioned directly below the cable tray the following
equation should be used to approximate the tension required to pull the cable into the tray.
T = WL pounds (7-35)
where: W = total cable assembly weight, in pounds/foot
L = straight vertical section length, in feet

The tension can now be approximated for pulling the cable into the tray from a
horizontal position when the reel is placed directly under the tray. To estimate the tension
entering the cable tray when the reel must be placed away from and below the
entrance to the tray, use the equation for feeding off the reel vertically where the
height (L) is the vertical distance between the reel and cable tray. To allow for bending
forces as the cable comes off the reel, the minimum tension added should be 25W.

TYPICAL CALCULATION FOR CABLES IN CONDUIT

Example:
Three THHN single-conductor 4/0 AWG copper
Single-conductor diameter (d) = 0.626 inches
Cable weight (W) = 3x 0.711 lbs/ft = 2.13 lbs/ft
Pulling device (Tdevice) = 10,000 pound eye
EMT conduit, trade size 2 inch
Bends 1-2, 3-4, and 5-6 are 90° (1.57 radians)
Use 36-inch sweep elbows (inside radius 2.91 feet)
Elevation View
4
5.6.7 5
3 50’
6
100’
Pull

2
100’
S 400’ 1

Figure 7-17
Conduit Layout
SOUTHWIRE 7–23
CHAPTER 7

1. Select conduit size based on required fill, clearance, jamming, and applicable codes
and standards.
a) EMT trade size 2 inch: D = 2.067 inches from Table 7-4
b) Conduit fill, using equation (E-27):

Within limits, if we assume 40% fill as the maximum specification requirements.

c) Configuration, jamming, clearance

First determine configuration (See Figure 7-13)

Because:

Configuration will be cradled.

Jamming can now be evaluated using equation (7-25)

Jamming is acceptable because the probability for jamming is very small since:

Clearance can be determined using equation (7-22)

Clearance is acceptable because clearance is significantly greater than 10% of the

conduit inside diameter, and is also greater than 1 inch.

SOUTHWIRE 7–24
 CABLE INSTALLATION

2. Select values for conduit type, bend radii, and coefficient of friction.
EMT conduit, trade size 2 inch from Table 7-8
All bends are 90° (= 1.57 radians)
36-inch sweep elbow from Table 7-9
Bend radii = 2.91 feet
Coefficient of friction ( ) = 0.4 from Table 7-6

3. Calculate weight correction factor (w) using equation (7-18), three

cables, cradled.

4. Calculate maximum allowable tension (Tm) using equations (7-4) and (7-5):

Because Tcable is less than Tdevice

5. Calculate pulling tension for each segment of the cable run.

a) Tension at point S, assuming no reel drag.

b) Segment S to 1
For horizontal straight section using equation (7-7),
calculate tension Tout at point 1.

Within limits, below 5,079 lbs. (Tm)

SOUTHWIRE 7–25
CHAPTER 7

c) Segment 1 to 2
For horizontal bend section using approximate equation (7-18),
calculate tension Tout at point 2.

Within limits, below 5,079 lbs. (Tm)

d) Segment 2 to 3
For horizontal straight section using equation (7-7),
calculate tension Tout at point 3.

Within limits, below 5,079 lbs. (Tm)

e) Segment 3 to 4
For horizontal bend section using approximate equation (7-15),
calculate tension Tout at point 4.

Within limits, below 5,079 lbs. (Tm)

f) Segment 4 to 5
For horizontal straight section using equation (7-7),
calculate tension Tout at point 5.

Within limits, below 5,079 lbs. (Tm)

g) Segment 5 to 6
Vertical concave downbend using approximate equation (7-15),
calculate tension Tout at point 6.

CAUTION:
Probably acceptable even through slightly above 5,079 lbs. (Tm)

SOUTHWIRE 7–26
 CABLE INSTALLATION

h) Segment 6 to 7
Pulling down vertical straight section using equation (7-9),
calculate tension Tout at point 7.

Within limits, below 5,078 lbs. (Tm)—caution is advised.

6. Calculate sidewall pressures (SP) at each bend of the pull for cradled configuration
(E-18) and a maximum value of 500 pounds per foot from Table 7-7.

a) Segment 1 to 2

Within limits, less than 500 pounds per foot.

b) Segment 3 to 4

Within limits.

c) Segment 5 to 6

Exceeds limits. Not Acceptable: For possible solutions, refer

to page 7-19, Calculation Procedure section.

SOUTHWIRE 7–27
CHAPTER 7

CABLES BURIED DIRECTLY IN EARTH

The NEC, NESC, and IEEE provide basic information regarding direct burial of
electrical cables.5

Depth of Burial
1. The depth of burial shall be sufficient to protect the cable from damage imposed by
expected surface usage.
2. Burial depths as indicated in Table 7-6 are considered adequate for supply cables or
conductors, except as noted in a, b, or c.

Compacted Backfill
Optional Protective Cover

6“ to 8” Tamped Sand or
Stone-Free Earth
3“ to 4” Tamped Soft Bedding of Sand
or Stone-Free Earth
Figure 7-18
Typical Burial Cross-Section

TABLE 7-10
NESC TABLE 352-1
SUPPLY CABLE OR CONDUCTOR BURIAL DEPTH
Voltage Depth of Burial
Phase to Phase (in) (mm)
0 to 600 24 600
601 to 50,000 30 750
50,001 and above 42 1070

EXCEPTION: Street light cables operating at not more than 150 V to ground may be buried at a depth not less than
18 in. (450mm).
a. In area where frost conditions could damage cables, burial depths should be greater.
b.Lesser depths may be used where supplemental protection is provided. The supplemental protection
should be sufficient to protect the cable from damage imposed by expected surface usage.
c. Where the surface is not to final grade, the cable should be placed to meet or exceed the requirements
indicated above, both at the time of installation and when the surface is to final grade.

Trenching
The bottom of the trench should be smooth, undisturbed, well-tamped earth or sand.
When excavation is in rock or rocky soils, the cable should be laid on a protective layer
of well-tamped backfill. Backfill within 4 inches of the cable should be free of materials
that may damage the cable. Backfill should be adequately compacted. Machine
compaction should not be used within 6 inches of the cable.
A protective covering above the cable will warn excavators of the presence of an
underlying cable.

5
NEC, section 300.5; National Electrical Safety Code (NESC), 2002 edition, section 35; ANSI C2-2002, Secretariat IEEE.”

SOUTHWIRE 7–28
 CABLE INSTALLATION

Plowing
Plowing of cable should not result in damage to the cable from rocks or other solid
materials. The design of cable plowing equipment and the plowing of cable should not
damage the cable by exceeding bend, sidewall pressure, cable tension, or other
allowable limits.

Supplemental Information
A jacketed multiconductor is preferable to the installation of single-conductor cables to
ease installation and avoid crossovers.
Under vehicular and pedestrian traffic ways, it is good practice to pull cable through
a conduit.

AERIAL INSTALLATION

Sag and Tension

This information is intended for initial design information only. The cable manufacturer
can supply detailed data, which include thermal expansion and creep. These factors
increase the arc length after initial stringing, resulting in an increased sag.

The calculation for sag and tension is based on the equation for parabolas. This equation
closely approximates a catenary curve for small deflections, as given by:
(7-36)

where: TH = horizontal tension in conductor or messenger, in pounds

s = length of span between supports, in feet
w = weight of cable assembly, includes supporting conductor/
messenger, saddles, lashings, etc., in pounds per foot
d = sag, in feet
The total messenger tension, at its support, consists of a horizontal and a vertical
component. The vertical component has been neglected.

The tension shall not exceed:

a) 50% of rated breaking strength of the messenger under the assumed ice and
wind loading
b) 25% of rated breaking strength for final unloaded tension at 60°F (15°C)

SOUTHWIRE 7–29
CHAPTER 7

Ice and Wind Loading

Ice and wind loading on aboveground cables and conductors are determined by
location. The NESC divides the United States into three loading districts—Light,
Medium, and Heavy.
The weight of the ice, force of the wind, and resultant weight of the cable can be
calculated by the following equations.6
(7-37)

(7-38)

(7-39)

where: i = weight of ice, in pounds per foot

t = thickness of ice, in inches
D = outside diameter of cable, in inches
h = force of wind, in pounds per foot
P = horizontal wind pressure, in pounds per square foot
WL = resultant weight of loaded cable, in pounds per foot
W = weight of cable only (i.e. without ice), in pounds per foot
K = constant from NESC Table 251-1

Values of t, P, and K are presented in Table 7-11. This information is extracted from
Tables 250-1 and 251-1 of the NESC.

Figure 7-19
NESC Loading District Boundaries

6
Archer E. Knowlton, ed. Standard Handbook for Electrical Engineers, 8th edition (McGraw-Hill, 1949).

SOUTHWIRE 7–30
 CABLE INSTALLATION

TABLE 7-11
LOADING DISTRICT VARIABLES
Loading District*
Variables
Heavy Medium Light
t, radial thickness of ice (in) 0.50 0.25 0
**P, horizontal wind pressure (Pa) 4 4 9
K, a constant (lb/ft) 0.30 0.20 0.05
Temperature (°F) 0 15 30
*Figure 7-19 presents Loading District boundaries.
** For horizontal wind velocity of 70 mph and above, refer to NESC Table 250-2.

Additional Information
Additional information can be found in ICEA Publication P-79-561 “Guide for Selecting
Aerial Cable Messengers and Lashing Wires.”7
Typical breaking strengths of messengers are presented in the following table:

TABLE 7-12
MESSENGER CHARACTERISTICS
Nominal Number EHS Galvanized Steel
Messenger of
Size (inch) Strands Weight (lb/ft) Breaking Strength (lbs)
1/4 7 0.121 6,650
5/16 7 0.205 11,200
3/8 7 0.273 15,400
7/16 7 0.399 20,800
1/2 7 0.512 26,900
9/16 7 0.671 35,000
9/16 19 0.637 33,700

CABLES UNDER VERTICAL TENSION

ICEA Support Requirements

ICEA suggests that for supported vertical installations, such as vertical shafts or risers
and bore holes, the supporting member may be the conductor(s) or the armor wires in
wire armored cables.8 Strength requirements are expressed in terms of a minimum
safety factor (Fs), which is the ratio of rated cable strength to supported cable weight.
The equation is:

(7-40)

where: Fs = safety factor, per Table 7-9

N = number of conductors
A = cross-sectional area of one conductor or one armor wire,
in square inches
T = tensile stress allowed on supporting member from
Table 14, in psi
W = weight of cable, in pounds/foot
= length of cable, in feet
7
ICEA P-79-561-1985, “Guide for Selecting Aerial Cable Messengers and Lashing Wires.”
8
ICEA S-95-658 (NEMA WC70-1999) “Nonshielded Power Cables Rated 2000 Volts or Less For The Distribution of Electrical Energy” and ICEA
S-93-639 (NEMA WC 74-2000): “5 - 46 kV Shielded Power Cable for Use in the Transmission & Distribution of Electric Energy.”

SOUTHWIRE 7–31
CHAPTER 7

TABLE 7-13
SAFETY FACTOR FOR CABLES UNDER VERTICAL TENSION
Cable Type Safety Factor
Fs
Unarmored 7
Armored Riser & Shaft 7
Armored Borehole 5

TABLE 7-14
MAXIMUM STRESS ALLOWED ON SUPPORTING MEMBERS
Tensile Stress, (T)
Materials psi
Annealed Copper 24,000
Medium Hard Copper 40,000
Aluminum 1350 17,000
Armor Wire, Galvanized Steel 50,000

Support can be achieved by cable clamps that will not damage cable components.
The spacing (S) of clamps can be determined by using the following equation which
results in an approximate value.

(7-41)

where: D = outer diameter of cable in inches

L = length of clamp along cable axis in inches
W = weight of cable in pounds/foot

NEC Support Requirements

The NEC defines support in vertical raceways—one vertical support at the top, or as
close as practical, plus a support for each spacing interval as defined in Table 7-15.

TABLE 7-15
NEC TABLE 300.19 (A) SPACING FOR CONDUCTOR SUPPORTS*
Size of Wire Support of Aluminum or
AWG or Conductors in Copper-Clad Copper
kcmil Vertical Aluminum
18 AWG through 8 AWG Not Greater Than 100 feet 100 feet
6 AWG through 1/0 AWG Not Greater Than 200 feet 100 feet
2/0 AWG through 4/0 AWG Not Greater Than 180 feet 80 feet
Over 4/0 AWG through 350 kcmil Not Greater Than 135 feet 60 feet
Over 350 kcmil through 500 kcmil Not Greater Than 120 feet 50 feet
Over 500 kcmil through 750 kcmil Not Greater Than 95 feet 40 feet
Over 750 kcmil Not Greater Than 85 feet 35 feet
* Reprinted with permission from NFPA 70-2-5, the National Electric Code®, Copyright 2005, National Fire Protection
Association, Quincy, MA 02269. This reprinted material is not the complete and official position of the National
Fire Protection Association on the referenced subject which is represented only in the standard in its entirety.

SOUTHWIRE 7–32
 CABLE INSTALLATION

FIELD REMOVAL OF MOISTURE FROM POWER CABLES

Normally, cable ends are sealed until the cable is installed to prevent moisture from
entering the cable. When open cable ends are submerged or exposed, water can
migrate inside the cable. If water remains in a medium-voltage cable, it can accelerate
insulation deterioration and lead to premature failure.
You can remove water from wet cable by purging the cable with dry nitrogen gas
under pressure. Any wire or cable product that does not contain fillers and is suitable
for wet locations, can be purged under engineering supervision.
If you do have to purge a length of wire or cable, always test it before you energize it.
At a minimum, conduct an insulation resistance test with a megohm-meter.

NOTE: The purging procedures described here assume the water in the wire or cable
does not contain unusually high concentrations of oils or chemicals, such as may be
found in floodwaters. If you suspect that water inside a cable carries unusual contami-
nates, consult the manufacturer before deciding to continue using the wire or cable.
If you are not certain about the source of water in cable, water samples from the cable,
the work site, and the manufacturer can be analyzed for mineral content. Comparing
mineral contents can, many times, identify the source of the water.

Required Materials
The medium for purging moisture from cable is dry nitrogen gas, available at most
welding supply houses. You will need:
1. A cylinder of dry nitrogen gas with a dew point of –60°C.
2. A regulator to reduce the gas pressure to approximately 15 psi.
3. Some 1/4” gas hose—and some hose clamps—to run between the tank
and the cable end.
4. A hose nipple to connect the hose to the regulator.
5. A cable cap that fits the cable end and a radiator hose clamp that fits
the end cap.
6. An automobile tire valve stem assembly—with no valve core installed—
to connect the hose to the cable cap.
7. Plastic bags to enclose gas-exit end of the cable. One-gallon bags are a good size.
8. Color indicating desiccant: anhydrous cupric sulfate or Silica Gel desiccant.
Cupric sulfate is available from laboratory supply houses. These desiccants
absorb water and change color—to either off-white or pink—when exposed
to moisture.

General Purging Process

The purging setup is shown in Figure 7-20. To purge several cables at once, connect
them to the gas supply with a manifold, as shown in Figure 7-21. If only one end of the
cable contains water, apply purging gas to the dry end. If the whole cable is wet, apply
purging gas to the higher end.

SOUTHWIRE 7–33
CHAPTER 7

Always purge the cable shield separately from the insulated strands. If you try to do
them at the same time, the gas will flow only through the path offering the least
resistance.
Before purging installed cables, remove cable terminations and splices. Do not try to
purge across or through splices.

Figure 7-20 Figure 7-21

Cable Purging Setup Multiple Cable Purging
Setup

Purging Cable Conductors

1. Select an end cap that fits over the cable core.
2. Cut a hole in the end cap for the valve stem and install the valve stem.
3. At the dry (or higher) cable end, apply two layers of half-lapped high voltage
insulating tape as a sealing cushion for the end cap.
4. Install the end cap on the cable using the radiator hose clamp.
5. Connect the low pressure side of the nitrogen regulator to the end cap
with the gas hose.
6. Turn on the nitrogen and adjust the regulator to 15 psi.
7. If water is not running or dripping out of the open cable end, sprinkle a
tablespoon of color-indicating desiccant into a plastic bag and tape or
clamp the bag to the open cable end.
8. Check to make sure the bag is filling with nitrogen. If it is, make a small
vent hole by clipping off one corner of the bag.
9. After a few hours, check the desiccant to see if it has changed from the
blue to off-white or pink. This indicates moisture coming out of the cable. If
the desiccant has changed color, replace it with fresh desiccant and continue
purging. (You can also check for moisture by holding a piece of tissue or
blotter paper next to the vent hole for a few minutes. If the paper gets
damp, moisture is still coming out of the cable.)
10. Change the desiccant every few hours until it stops changing color. When
you have gone several hours with no sign of moisture, you can assume the
cable is dry. Depending on how much moisture is in the cable, purging may
take up to eight hours—occasionally even longer. One cylinder of nitrogen
should be enough for at least one cable run.

SOUTHWIRE 7–34
 CABLE INSTALLATION

You can also drive water vapor from conductor strands by lightly loading the cable
with low voltage and low current. This process does not dry out the shield assembly.
The cable terminations must have an open strand design or terminations must be
removed to let the water vapor escape.

Purging Cable Shield

You can purge cable shield systems by following the conductor purging process with
the following exceptions: (1) block the conductor strands so no gas can pass through
them, and (2) place end caps over the jacket rather than the cable core. Apply gas
pressure and check for moisture as before. Do not exceed 15 psi maximum.

Cable on Reels
You will have to unlash the cable ends to connect the purging set-up to cables on reels.
If you find water in only one end of a reel of cable, position the reel so the wet end is
in its lowest possible elevation. If you see moisture at both ends of the cable, position
the inside end of the cable as low as possible and purge from the outer end of the cable.

SOUTHWIRE 7–35
 DESIGN AND INSTALLATION
OF CABLE ACCESSORIES
NOTE: IEEE Standard 404 distinguishes a splice and a joint differently from the way
these terms appear in this text.1 The common phraseology in the industry today is to
refer to the connection of two pieces of cable in the field as a splice. We have
therefore chosen to use the term “splice” in this manual.

GENERAL

The foundation for understanding the principals of cable accessories is dependent

upon understanding the “Basics of Insulated Power Cable Construction” presented in
Chapter 1 of this manual.

CABLE ACCESSORIES

Cable accessories included in this section are limited to terminations and splices of
shielded and nonshielded cable systems for extruded dielectric cables through 35kV.

Design Concepts
The following items are basic to all methods of terminating or splicing power cables,
shielded or nonshielded.
The compatibility of the accessory is dependent on matching the cable’s electrical,
chemical, and physical characteristics as closely as possible. A terminal or splice connector
should maintain the resistive and thermal capability of the cable conductor. The
insulation materials employed should be chemically and physically compatible with
the cable materials.
Construction of an accessory is actually a systematic destruction of the cable cross-section
and a systematic reconstruction of a dielectric system to maintain cable circuit continuity
with an acceptable level of service reliability. A strict adherence to design, construction
principals, specified installation procedures, and cleanliness of the cable and accessory
materials is required during installation of the accessory.

1
IEEE Standard 404-2000, “IEEE Standard for Extruded and Laminated Dielectric Shielded Cable Joints Rated 2,500V
through 500,000V.”

10
SOUTHWIRE 8-1
CHAPTER 8

Basis of Electrical Design

Design must embody both theoretical and practical considerations. The theoretical
considerations are those primarily of dielectric stress control. The practical considerations
are those associated with environmental conditions such as mechanics of assembly,
ambient conditions, and economics.

Dielectric Stress Control

Dielectric stresses within a cable and its accessories must be held within tolerable limits.
Stresses are influences by the characteristics of the dielectrics employed and are generally
classified as follows:

Cable
Due to its generally uniform construction, radial stresses are the prime
consideration in the cable.

Accessory
Although equipotential and electrostatic lines within a cable and an accessory
are similar (except for magnitude), the stresses in an accessory are more complex
than in a cable. In addition to radial stresses, contour changes in the components
of an accessory produce stresses that are radial, longitudinal, and tangential.
These stresses are more critical in accessories associated with shielded cables.

Environmental Conditions
The environment and cable operating conditions have an effect on the design of a cable
accessory. Direct burial or duct installation, ambient temperature, and corrosive
environment are some of the factors that will have an effect. Also, because the accessory
is installed in the field under less than ideal conditions, it is very important that the
installers be proficient in their craft.

Characteristics of Components
Conductor connections should prevent the possibility of thermal and physical damage
of the accessory and cable insulation during its operating life.
The geometry of the accessory insulation and its interface with the cable insulation
must prevent partial discharge at operating voltages and safely withstands the stresses
to which it is subjected.
The resistivity of shield materials must be adequate to conduct the electrostatically
induced voltages, charging currents, and leakages currents to ground.
Electromagnetically induced currents and fault currents must be safely handled across
the splice area.
The outer protective cover of a splice must provide physical strength and rigidity,
protection against moisture entry into the splice dielectric, and resistance to attack by
other environmental contaminants.
The outer covering of a termination must resist electrical tracking, provide protection
to the cable insulation from ultraviolet attack, and prevent moisture entry into the
cable system.

SOUTHWIRE 8-2
 DESIGN AND INSTALLATION OF CABLE ACCESSORIES

Design Testing
An indication of service performance can be obtained by subjecting specific designs
to selected test levels. The materials used in these designs are also subjected to certain
tests to determine their suitability for design incorporation.
Engineering economics preclude testing of all designs for field installation. Reliable
results are attained by subjecting specific designs to selected tests to determine operating
criteria. The testing of accessory design is an area of study by itself.

Terminations of Nonshielded Cables

Terminations of nonshielded cable are not complex. Primary considerations are
compatibility of connectors with the conductor material and any added insulating
material with existing cable insulation.

Terminations of Shielded Cables

Terminating shielded cables is more complex than terminating nonshielded cables.
Shielded cable terminations require closer attention to details.

Design
In addition to the compatibility of the connector with the conductor and insulating
materials with the existing insulation, the electrical function of the various materials
used in making the termination must be considered.

Flashover
Flashover is an electrical arc that can occur between the exposed insulation
shield and the exposed cable conductor. To prevent flashover, the insulation
shield must be removed for a specified distance.

Dielectric Voltage Stresses

As discussed in Chapter 1, the dielectric field in a shielded power cable is
symmetrical. No abnormal voltage stresses in the insulation are present as long
as the cable components remain intact. When terminating a cable, it becomes
necessary to disrupt these components. As stated above, the insulation shield
must be removed for a specified distance to prevent flashover. Removal of this
shield results in severe distortion of the dielectric field. This distortion creates
abnormally high voltage stresses in the insulation at the edge of the insulation
shield (see Fig. 8-1). These stresses must be relieved in order to prevent cable
terminal failure.

SOUTHWIRE 8-3
CHAPTER 8

Fig. 8-1
Dielectric Field - No Stress Relief

Stress Relief
Stress relief is the common term applied to the control or relief of the high
voltage stresses in the insulation at the edge of the insulation shield. Stress
relief can be achieved by either of two methods:

a. The classical method is the use of a receding ground plane (see Fig. 8-2). The
receding ground plane is commonly supported by a cone of insulating material
that is compatible with the cable insulation. The conical shape of the receding
ground plane gives rise to the term “stress relief cone.”

Fig. 8-2
Dielectric Field - Receding Ground Plane - Stress Relief Cone

b. Another method with proven reliability is the use of a material that controls
the voltage gradient at the edge of the insulation shield (see Fig. 8-3). This
method does not require the use of a stress cone and results in a termination
with a slender profile.

SOUTHWIRE 8-4
 DESIGN AND INSTALLATION OF CABLE ACCESSORIES

Fig. 8-3
Dielectric Field-Voltage Gradient (Material)-Stress Relief

In the preceding figures, the representations of the dielectric fields neglect

the differences between the dielectric constants of the cable dielectric, the
stress relief materials, and the surrounding air.

Materials
Upon establishing the design requirements for terminations, it is necessary to determine
the materials to be used that will result in meeting the design requirements.

Terminal Connector
The connector to be installed on the conductor must be compatible with the
conductor. Connectors for use only with copper conductors should be marked
CU. SOL or STR markings indicate use with solid or stranded conductors,
respectively. Connectors for use only with aluminum should be marked AL and
either SOL or STR. Connectors for use with either copper or aluminum conductors
are marked AL-CU or CU-AL and either SOL or STR. All terminal connectors may
be either compression, solder-sweat, or mechanical types.

Conductor Shield
In a termination, the conductor shield cable component loses its functional
significance and requires no special treatment other than removal for installing
the connector.

Insulation
The important consideration for the cable insulation is a control of the voltage
stresses in the insulation at the edge of the insulation shield.
In the receding ground plane method of stress relief, an insulating base for the
receding ground plane is applied over the exposed cable insulation. This field-
applied insulation must be compatible with the cable insulation. It may be a
butyl rubber, polyethylene, or an ethylene-propylene rubber based compound.
Similarly, the materials used in the voltage gradient material method of stress
relief must be compatible with the cable insulation.

SOUTHWIRE 8-5
CHAPTER 8

Insulation Shield
The treatment of the edge of the cable insulation shield is critical to the
successful function of the termination.
In the receding ground plane method, the receding ground plane is an
extension of the cable insulation shield.
The resistivity of the material used must be adequate to function as an extension
of the cable insulation shield. It is usually a polymer having a butyl rubber or
ethylene propylene rubber base. Additionally, the applied conducting polymer
must be compatible with the cable insulation, the cable insulation shield, and
the insulating material applied over the cable insulation to support the receding
ground plane.

Jacket or Outer Covering

For outdoor or contaminated areas, it is absolutely necessary to seal the cable
conductor to prevent entry of water and to provide a track resistant covering
over the termination. This requirement is considered good practice for other areas.

Performance Requirements
After the termination design is determined and the proper selection of materials is
made, the termination must be tested to establish its functional reliability.
Design tests should be performed by the manufacturer. These tests must meet or
exceed the requirements of IEEE Standard No.482.

Splices of Nonshielded Cables

As with terminations, splices of nonshielded cables are not complex. Primary considerations
are compatibility of connectors with the conductor material and any added insulating
material with the existing cable insulation.

Splices of Shielded Cables

The basic concept to be remembered in splicing two cables is that the cable splice is in
fact a short piece of cable that is fabricated in the field. As such, the splice must have
the same components as the cables.

Design
For shielded cables, the splice design must take into consideration not only compatibility
of materials, but also the continuation of each cable component in order to keep
abnormal voltage stresses to a minimum.

2
IEEE Standard 48-2003. “Standard for Test Procedures and Requirements for Alternating Current Cable Terminations 2.5kV through 765kV.

SOUTHWIRE 8-6
 DESIGN AND INSTALLATION OF CABLE ACCESSORIES

Dielectric Voltage Stresses

The cable components must be disrupted to make a splice. The splice results in a
distortion of the dielectric field, producing nonsymmetrical voltage stresses in
the insulation. The design of the splice will control these voltage stresses and
should prevent splice failure. The dielectric voltage stresses in splices are radial,
tangential, and longitudinal (see Fig. 8-4 and 8-5).

Fig. 8-4
Dielectric Field-Equipotential Lines-Tape Type Splice

Fig. 8-5
Dielectric Field-Equipotential Lines-Premolded Splice

In the preceding figures, the representations of the dielectric fields neglect

the differences between the dielectric constants of the cable dielectric and the
splice materials.

Radial Voltage Stresses

Radial stresses were defined earlier and exist throughout the splice. Of primary
concern are the maximum radial stresses that occur at the areas of minimum
diameters at the cable conductor shield and the shield applied over the connector.

Tangential Voltage Stresses

Tangential stresses occur because of a change in the dielectric field due to a

change in the geometry of the components. The areas of critical tangential
stresses are at the base of the cable insulation where the insulation was penciled,
the shoulder of the connector shield for tape splices, and at the base of the
applied splice insulation belt taper for both tape and premolded splices.

Longitudinal Voltage Stresses

Longitudinal stresses exist along the interface of the cable insulation and the
applied splice insulation material.
A properly designed splice takes into consideration all the above voltage stresses.

SOUTHWIRE 8-7
CHAPTER 8

Materials
Upon establishing the design requirements for splices, it is necessary to determine the
materials to be used that will result in meeting the design requirements. Additionally,
the materials must be compatible with the cable components as they relate to the
function of the splice.

Conductor Connector
The splice connector must be compatible with the conductor as previously
outlined for terminations. Also, the contour of the splice connector must be
smooth and preferably with tapered ends for tape-type splices.

Connector Shield
The resistivity of the material applied over the connector and exposed cable
conductor must remain stable throughout the temperature range of the
conductor and connector. This material is usually a polymer having a butyl rubber
or ethylene-propylene rubber base. Additionally, the material must be compatible
with the cable conductor, connector, cable conductor shield, cable insulation,
and the insulation applied to insulate the splice.

Insulation
The insulation applied over the conductor shield must be highly compatible
with the cable insulation and capable of interfacing with the cable insulation
in a manner that will prevent failure along the interface.
The thickness of the applied insulation must be sufficient to prevent insulation
failure and still not impose a thermal limit on the cable being spliced. This
material may be a polymer with a butyl rubber, polyethylene, or ethylene-
propylene rubber base.

Insulation Shield
The resistivity of the material applied over the splice insulation, the cable
insulation, and the cable insulation shield must remain stable throughout the
temperature range of the splice. Additionally, the material must be compatible
with the splice insulation, cable insulation, and cable insulation shield. The
material is usually a polymer having a butyl rubber or ethylene-propylene rubber
base. In most applications, a metallic tape or braid is applied over the polymeric
material to provide adequate conductance to keep the shield at a safe potential.

Jacket or Outer Covering

A jacket or outer covering of appropriate material should be applied for
environmental protection.

Performance Requirements
After the splice design is determined and the proper selection of materials is made, the
splice must be tested to establish its functional reliability.
Design tests should be performed by the manufacturer. These tests must meet or
exceed the requirements of IEEE Standards 404 and 592.3

3
IEEE Standard 404-2000, “Standard for Extruded and Laminated Dielectric Shielded Cable Joints Rated 2,500V through 500,000V and
“IEEE 592-1996 “Standard for Exposed Semiconducting Shields on High voltage Cable Joints and Separate Insulated Conductors.”

SOUTHWIRE 8-8
 DESIGN AND INSTALLATION OF CABLE ACCESSORIES

FIELD INSTALLATION

Good installation practices include cleanliness, cable and preparation, conductor

connections, dielectric system application, and personnel qualification. It is of prime
importance that the installer explicitly adhere to the installation instructions and good
installation practices.

Cable Component Identification

To assist in the field reconstruction of a short length of cable, it is appropriate to identify
the components of typical cables.

Nonshielded Cable
Components identified in Fig. 8-6 can be related to Fig. 1-1 in Chapter 1.

Fig. 8-6
Nonshielded Cable

Some nonshielded cables may have a jacket that is not integral to the cable dielectric.

Shielded Cable
Components identified in Figs. 8-7 and 8-8 can be related to Chapter 1.

Fig. 8-7
Shielded Cable - Wire Primary Shield

SOUTHWIRE 8-9
CHAPTER 8

Observe the additional components in comparison to the nonshielded cable. The metallic
shielding may be tape instead of wire.

Fig. 8-8
Shielded Cable - Metal Tape Primary Shield

This cable has a metal tape as the primary shield, while the cable in Fig. 8-7 has wires
as the primary shield. Both cables have an extruded semiconducting layer as an
auxiliary shield.

Cleanliness
The manufacture of cable within the factory is in accordance with high standards of
cleanliness to meet electrical insulation requirements. The field reconstruction of the
cable for a termination or a splice installation must follow the same principles.
Cleanliness of materials, tools, and immediate work area will minimize contamination
possibilities of the termination and splice installation.

Cable End Preparation

The foundation of a good termination or splice is proper cable end preparation. Cable
ends should be straight and squarely cut. If insulation pencils are required, they should
be made to the proper length. All exposed cable insulation should be smooth and
free of nicks, gouges, and contaminates.
Construction drawings and instructions should be available for on-site reference by the
installer. These instructions are typified by the following procedural steps.

Removal of Protective Jacket

The protective jacket should be removed to expose the underlying primary metallic
shield. This shield may be either wires or tape. Observe the condition of the shield to
obtain indications of the presence of moisture in the cable. If moisture is discovered,
follow the procedures given in Chapter 7 for the field removal of moisture in the cable.

Removal of the Primary Shield

The wires or tape should be untwisted for the specified distance and secured.

SOUTHWIRE 8-10
 DESIGN AND INSTALLATION OF CABLE ACCESSORIES

Removal of the Auxiliary Semiconducting Shield

Great care and caution is required to avoid damage to underlying cable insulation
when removing the auxiliary shield. The auxiliary shield should be removed and
terminated at the specified distance and with the specified geometry.

Preparation of Cable Insulation Surface

The cable accessory manufacturer’s instruction usually specifies use of abrasive cloths
having a nonconducting grit and with a specific grit size. The cloth is to be used to buff
or polish the cable insulation surface, which must be smooth and free of nicks, gouges,
and contaminates. The surface is then wiped clean with a solvent-dampened, lint-free,
cloth. The solvent should be compatible with the cable insulation. The cable insulation
and conductor shield are then removed from the end of the cable to accommodate the
required connector or terminal lug.

Protection of Prepared Cable End

Some installation procedures may require temporary protection of prepared cable ends
until they are covered by permanent materials.

Conductor Connections
The conductor connector or terminal lug may be crimped, compressed, sweated with
solder, or heat-fused. In certain applications, mechanical connections provide satisfactory
performance.
Care should be used in the selection of connectors to verify that they are approved for
the type and size conductor being used.

Aluminum Conductor Connections

The Aluminum Association Guide No. 51 provides guidance for selection of connectors
for insulated aluminum conductors.4
Aluminum conductors oxidize rapidly. This oxide has an insulating value and it must
be penetrated to ensure an effective connection. Though not mandatory, it is good
practice to use oxide inhibitors when terminating aluminum conductors.

a. Crimped or Compressed - Connectors and terminal lugs have an inhibitor

compound within their bore. This compound generally contains particles,
which break down the oxide film of the conductor strand surfaces when the
connection is crimped. The compound prevents reforming of the oxide film.
Some instructions may require wire brush cleaning of the aluminum conductor
strands before their insertion into the connector. For shielded cable splices, the
indentations from the crimps may require filling with conducting material.
b. Solder Sweated - Special solders and techniques can be employed to achieve a
solder sweated connection.
c. Heat-Fusion - Heat-fusion connections use heat to achieve a fusion of metal
between conductor ends and within the conductor strands. Special techniques
of welding or thermite-type procedures, such as the Cadweld®, have been
successfully used.

4
Aluminum Association Guide no. 51, “Aluminum Building Wire Installation Manual and Design Guide.”

SOUTHWIRE 8-11
CHAPTER 8

d. Mechanical - This type of connection is not typically used for splicing because
of its inherent bulk. A mechanical connection lends itself more to termination
applications. An inhibitor compound, such as that used in the crimped or
compressed connection, must be used.
e. Large Sizes of Solid Aluminum - Large sizes of solid aluminum conductors
require special crimped or soldered connectors.

Copper Conductor Connections

Oxides also form on the surface of copper conductors. Typically, they do not have as
high of an insulating value as the oxides that form on the surface of aluminum conductors.
Also, copper oxides form at a much slower rate than aluminum oxides. This property
results in somewhat simpler preparation and completion of a copper conductor connection.

a. Crimped or Compressed - The gentle abrasion of the conductor strand surface

before insertion into the connector or terminal lug is the recommended
practice for copper connections. This type of connection should meet the
performance requirements of EEI-TD-161.5 The indentations caused by crimping
of the connector may require filling with conducting material for shielded
cable connections.
b. Solder-Sweated - EEI-TD-160 provides performance requirements of a split
tinned copper connector.6
c. Heat-Fusion - This type of connection uses heat to achieve fusion of metal
between conductor ends and within conductor strands. Welding, brazing,
silver-solder, and thermite techniques can be used.
d. Mechanical - This type of connection is not usually used for splicing because
of its inherent bulk. The mechanical connection lends itself more to
terminating applications.

Dielectric Systems Materials

The materials used for the dielectric system can be classified as: 1) self-amalgamating,
2) premolded slip-on, 3) field-molded, and 4) shrinkable.

Self-Amalgamating
Self-amalgamating materials require the field applications of tape-type laminates to
achieve a homogeneous dielectric profile. Tensioning during application is usually
required to achieve self-amalgamation.
Each component of the dielectric system must be refabricated as generally outlined below:

a. For shielded splices, the indentations or crimps of compression connectors

may require filling with a conducting material. The shoulder formed at the
connector and the conductor may also require filling with a conducting
material to prevent failures because of high dielectric stresses.
b. The insulating material must be applied within specified profile parameters
in order to obtain acceptable dielectric stresses, both radial and tangential.
c. The auxiliary semiconducting shield must be refabricated over
the insulation to obtain an acceptable dielectric stress control.

5
EEI-TD-161, “Specifications for Straight Compression Type Connectors for Insulated Copper Conductors.”
6
EEI-TD-160, “Specification for Solder-Sweated Split Tinned Copper Connectors.”

SOUTHWIRE 8-12
 DESIGN AND INSTALLATION OF CABLE ACCESSORIES

d. For continuity of the primary shield of the cable, a metallic component

should be applied over the auxiliary semiconducting shield.
e. The jacketing material used for environmental protection of the cable must
be refabricated over the completed splice. A track-resistant material is used
over the termination to replace the removed jacket.

The above material may consist of tapes of rubber or plastic compound, which may be
purchased as kits or bulk material.

Premolded Slip-On
A premolded splice or termination is a factory-produced device using heat-amalga-
mated materials, which are molded into unitized modular components for rapid field
assembly. The devices include in their cross section the design concept components
identified for self-amalgamating cable accessories. These devices are diameter sensitive
and must be correctly sized for specific construction dimensions. Because of their ease
of use, their major application is to meet large volume requirements in the marketplace.

Field Molded
A field molded splice or termination is the field application of heat-amalgamated
materials, usually in tape form as used in the self-amalgamating method. Heat is
required with special equipment and techniques to achieve field molded profiles.
Economics usually favor this method for transmission cable voltages.

Shrinkable
A shrinkable splice or termination is an assembly of materials, either heat or mechanically
expanded, to achieve shrink down to prepared cable ends. They are available for both
nonshielded and shielded cable systems. Repair sleeves to seal damaged cable jackets
are also available.

CABLE END PREPARATION TOOLS

For extruded dielectric cables, tools are specially designed for the preparation of the
cable ends during terminating and splicing. These are in addition to the normal
complement of hacksaw, pliers, knives, files, ruler, diameter tape, calipers, etc.
Templates, provided by some accessory manufacturers, facilitate verifying proper dimensions.
Special tools are available for removal of cable insulation and insulation shield. A partial
list of manufacturers follows:

Adalet/PLM Cleveland, OH
G&W Electric Blue Island, IL
Ripley/Utility Tool Cromwell, CT
Speedsystems Brookfield, WI

These should not to be interpreted as Southwire recommendations or as the only

manufacturers or suppliers of the tools.

SOUTHWIRE 8-13
CHAPTER 8

HARDWARE FOR INTERLOCKED ARMOR CABLES

Southwire does not make individual recommendations or approvals for this type of
hardware. A partial list of manufacturers follows:

Adalet/PLM Cleveland, OH
Appleton Elec. Co. Chicago, IL
O-Z/Gedney Terryville, CT
Hubbell/Kellems Stonington, CT
Preformed Line Products Cleveland, OH

CABLE ACCESSORIES MANUFACTURERS

Southwire does not make individual recommendations or approvals of products for

terminating or splicing. A partial list of manufacturers follows:

Adalet/PLM Cleveland, OH
Amerace/Elastimold Hackettstown, NJ
G&W Electric Blue Island, IL
ITT Blackburn St. Louis, MO
Joslyn Chicago, IL
MAC Products Kearney, NJ
3M Co. Austin, TX
O-Z/Gedney Terryville, CT
Plymouth/Bishop Canton, MA
Raychem/Sigmaform Menlo Park/Santa Clara, CA

SOUTHWIRE 8-14
 FIELD TESTING
The purpose of this chapter is to summarize procedural and technical information for
the performance of field testing of cable systems. The procedural aspects cover subjects
related to personnel and safety, but are not intended to be all-inclusive.
Manufacturers perform various electrical tests on finished wire and cable products to
ensure they can safely handle their maximum voltage and current ratings. Some
installation procedures- such as pulling through conduit, installation into cable trays, or
framing members- can damage conductors and cables enough to create an electrical
hazard. For example, incorrect calculations of pulling force, sidewall pressure, or
conduit fill may lead to tearing of a conductor’s insulation as it is pulled through
conduit. Because post-installation testing is a good general practice, some installation
contracts may require testing by the installer.

SAFETY

Electrical tests can be dangerous and should be conducted by personnel who are
qualified to perform the tests. Both low potential and high potential testing have
inherent hazards to personnel and equipment. Thus, a thorough understanding of the
safety rules, test equipment, wiring system, and connected equipment is essential in
preventing damage to the conductors and equipment, and in preventing electrical
shock to the persons performing the tests. IEEE Standard 510 typifies recommended
industry practices for safely conducting field testing.1

PREPARATION FOR TESTING

Before conducting tests on any cable system, verify that the cable system is properly de-
energized. If the cable system has been previously energized, you must follow the pre-
scribed rules for conducting the switching necessary to de-energize, lock-out, tag, and
ground the cable system.
High voltage conductors that are energized can induce voltage in ungrounded conductors
in close proximity. It is good practice to disconnect cables from non-cable system
equipment and to ground all conductors not under test for safety concerns and to prevent
erroneous test results. In the case of High Voltage testing, disconnecting the cable will
prevent damage to equipment and apparatus.
Check that adequate physical clearances exist between the cable ends and other
equipment, other energized conductors, and to electrical ground.
At all ends remote from where the test equipment is to be connected, position a
personnel guard or barricade the area to prevent unauthorized access to the cable
system under test.

Note: Verify the procedures are taken to clear all tap(s) or lateral(s) in the circuit.
Remove grounds from the cable phase to be tested. Phases not under test are to
remain grounded at all ends.

1
IEEE Standard 510-1992, “Recommended Practices for Safety in High Voltage and High Power Testing.”

10
SOUTHWIRE 9-1
Chapter 9

CONDUCTING TEST

Follow the instructions provided by the manufacturer of the test equipment for its
proper operation.
Conduct test in accordance with prescribed procedures and instructions.
Record test results and retain for future reference.

CONCLUSION OF TESTING

Maintain grounds on all conductors until the test equipment is disconnected and
packed for removal.

Caution: For HVDC tests, the accumulation of a potentially dangerous voltage can
remain on the cable system if the conductors have not been grounded for a sufficient
time period after the completion of the test. A rough guide is to maintain the grounds
for one to four times the test duration before they are removed and the cable are
reconnected into the circuit.2

Follow prescribed procedures to return or place the cable circuit into service.

FIELD ACCEPTANCE TESTS

Cable System Integrity

During the design of the power cable system, it is appropriate to evaluate the require-
ments of the field acceptance tests that can determine the integrity of the installed sys-
tem. The following types of tests may be readily conducted.

Conductor Continuity
Tests for conductor continuity can include a simple check with an ohmmeter, 500 Volt
megohm meter, or a device that measures conductor resistance. This test determines if
the conductors complete an electrical circuit by ensuring the conductor metal has not
been broken.

Dielectric Condition of the Cable

The electrical integrity of the system dielectric can be measured by the use of ohmme-
ters or megohm meters for insulation resistance. A more complex high voltage dc test,
commonly referred to as a dc high-pot test, can also be done to evaluate “leakage currents.”

2
IEEE Standard 400-1991. “Guide for Field Testing and Evaluation of the Insulation of Shielded Power Cable Systems.”

SOUTHWIRE 9-2
 FIELD TESTING

Metallic Shield Condition

For shielded cables, the metallic component of the insulation shield of jacketed cables
can be tested for its condition. A continuity test can be accomplished with an ohmmeter
or megohm meter tester. A more complex test arrangement is required to measure the
value of the shield resistance. A comparison of the shield resistance value can then be
made against specified values.

Jacket Integrity
Insulating jackets of directly buried or water-submerged cables can be tested for insulation
resistance (IR). It may be possible to test integrity of conductive, nonmetallic jackets or sheaths.

Low Potential Testing of Dielectric

Insulation Resistance (IR)
The IR of the insulation components of the cable system is commonly tested using an
unidirectional (dc) potential as opposed to using the ac operating frequency. Low
voltage, nonshielded cables can be tested using a battery-powered ohmmeter. The
reading from an ohmmeter for shielded higher voltage cables may be questionable as
it does not have the capability to promote an inherent defect into an electrical fault,
even though it can detect a low-resistance or bolted fault.
A megohm meter is commonly employed for the detection of questionable conditions
in shielded and nonshielded cables.

Equipment and Voltage Output

Hand-held ohmmeters generally have outputs from 6 to 24 volts. They are excellent for
detecting direct “shorts” such as bolted faults and low resistance measurements in the
kilohm range.
Manual- or motor-driven megohm meters are available for a range of fixed dc volt-
ages. Typical fixed dc voltages are 500, 1000, 2500, and 5000 volts. These instruments
are also available with multi-voltage selections within the same device.

Interpretation of Results
Industry practice recognizes tests with a dc potential of 500 or 1000 volts dc. The insu-
lation resistance reading should be taken after 1 minute to allow the reading to stabilize.

• For spot short time readings, IR readings should be evaluated with respect to
the test conditions to determine if the results should be considered acceptable.
IR readings can vary greatly depending on the environmental conditions.
Conditions such as humidity, moisture in the conduits, and leftover residue on
the conductor from pulling compounds are among some of the factors that
influence IR readings and make detection of problems more difficult. The
following “2 to 50 Megohm Rule” is a good indicator to use for evaluating
IR readings.

Acceptable: A megohm meter reading of 50 megohms or higher

should be considered acceptable.

SOUTHWIRE 9-3
Chapter 9

Investigate: A megohm meter reading of 2 to 50 megohms may be

used for deciding when to investigate the cable installation.
In most cases, a 2 to 50 megohm reading does not indicate
the insulation quality, therefore, 2 to 50 megohms
should not be specified as a pass/fail value. These readings
are usually associated with long circuit lengths, moisture, or
contamination. Ends of conductors that are dirty or damp
may need to be cleaned and dried.
Unacceptable: Readings less than 2 megohms will most likely indicate
damaged insulation or severe test conditions.

• A more technically oriented evaluation is to use the “time resistance” technique.

Good insulation shows an increasing IR with respect to time at a constant dc
voltage. This is commonly called an “absorption” test.
• Some credence is given to determining the “dielectric absorption ratio.” This
is the ratio of the 60-second megohm meter reading divided by the 30-second
reading. This method is common for coil insulation, but is not widely accepted
for cable system insulation.
• Some standards recognize a “polarization index.” This method typically is a
10-minute reading divided by the 1-minute reading.
• For tests requiring several seconds to minutes, it is important that the voltage
be constant. Typically, a motor-driven megohm meter is used.

If further sophistication is desired, use the previous techniques at varying volt-

age levels. A downward trend of results at a higher voltage(s) is an indication
of a questionable condition.

High Voltage Withstand Testing

High voltage withstand tests help determine whether a conductor can withstand a
prescribed test voltage without breakdown or failure. One way to ensure that a con-
ductor is free from major defects or installation damage is to test it at a higher ac or dc
voltage than the maximum operating voltage of the conductor. The cable either
withstands the voltage or it breaks down. The test does not indicate how close the
cable came to failure.

High Potential DC Testing of Dielectric

The normal high potential testing procedure is to employ direct current voltages.2 The
use of alternating current voltages requires that the test equipment be of sufficient kVA
capacity to supply the charging
current requirements of the circuit under test. Direct current voltage test equipment is
much smaller and lighter than ac test equipment of equivalent test voltage output. Thus,
for reasons of economics and handling, dc test equipment is predominantly used.
It is common practice when conducting high potential testing to use high voltage direct
current levels (HVDC). For these situations, personnel should be familiar with IEEE
Standard 400.2

2
IEEE Standard 400-1991. “Guide for Field Testing and Evaluation of the Insulation of Shielded Power Cable Systems.”

SOUTHWIRE 9-4
 FIELD TESTING

Withstand Test

During Installation
Tests should be conducted on the cable prior to installation for damage that may
have occurred during transit and subsequent handling. This minimizes labor and
productivity losses. Applicable cable specifications define limitations on voltage
and time of test. These limitations are generally within those presented in IEEE
Standard 400.

Field Acceptance
After installation of the cable and prior to installing terminations or splices, it is
recommended to test the cable for possible damage that may have occurred
during installation. This test can be performed at a reduced level as defined in
the applicable specification. The cable system may be subjected to a final
acceptance test after the system is assembled, terminated, and spliced, and
before connection to any non-cable equipment or devices. This test will reveal
any errors in final termination of the cable system. As for the previous test,
applicable specifications define voltage and time limits. These specifications also
are generally within those presented in IEEE Standard 400.

Periodic Maintenance
Although not a design criteria, this topic is presented here for completeness on
the types of HVDC tests that can be conducted. After the system has been in
service, some organizations conduct periodic tests as a maintenance procedure
to evaluate any possible deterioration of the system dielectric.

Interpretation of Results
With any HVDC testing, it is highly recommended that IEEE Standard 400 be
understood and that the manufacturers of the cables, terminals, and splices
concur prior to the performance of any proposed testing.
The test voltages and times for HVDC tests are defined in IEEE Standard 400. For
convenience, Table 9-1 is a reproduction of a part of Table 1 of IEEE Standard 400.

TABLE 9-1
FIELD TEST VOLTAGES FOR SHIELDED POWER CABLE SYSTEMS FROM
5 KV TO 35 KV SYSTEM VOLTAGE
System Voltage System BIL Acceptance Test Maintenance Test
(kV rms) (kV) Voltage* Voltage*
(phase-phase) (crest) (kV dc) (kV dc)
(cond-gnd) (cond-gnd)
5 75 28 23
8 95 36 29
15 110 56 46
25 150 75 61
28 170 85 68
35 200 100 75

*Acceptance test voltage duration is normally 15 minutes. Maintenance test voltage duration is normally not less
than 5 minutes or more than 15 minutes.

SOUTHWIRE 9-5
Chapter 9

IEEE Standard 400 tests are “go, no-go” tests. The system is required to withstand the
specified voltage for the specified time duration. These tests will normally reveal gross
imperfections resulting from improper field handling such as excessive bending or air
gaps between the insulation and shield interfaces.

TABLE 9-2
DC TEST VOLTAGES AFTER INSTALLATION PER ICEA3
Rated Circuit Voltage Conductor Size Maximum dc Field Test Voltage (kV)
(Phase-to-Phase Voltage in Volts) (AWG or kcmil) 100 Percent Insulation Level 133 Percent Insulation Level
2001-5000 8-1000 28 28
1001-3000 28 36
5001-8000 6-1000 36 44
1001-3000 36 44
8001-15000 2-1000 56 64
1001-3000 56 64
15001-25000 1-3000 80 96
25001-28000 1-3000 84 100
28001-35000 1/0-3000 100 124
35001-46000 4/0-3000 132 172

DC test voltages are applied to discover gross problems such as improperly installed accessories or mechanical
damage. DC testing is not expected to reveal deterioration due to aging in service. Evidence exists that dc testing of
aged cables can lead to early cable failure. For alternative testing methods to dc testing, consult IEEE P-400.
The dc voltage proof test shall be made immediately after installation not exceeding the maximum specified value.
The voltage shall be applied between the conductor and the metallic shield with the shield and all other metallic
components of the cable grounded. The rate of increase from the initially applied voltage to the specified test
voltage shall be approximately uniform and shall not be more than 100 percent in 10 seconds nor less than 100
percent in 60 seconds.
The duration of the dc voltage test shall be 15 minutes.

Time-Leakage Test
For more sophisticated evaluations, it is important to recognize the components of dc
“leakage” current. The output current of the test set into the cable is not the true
leakage current. The output current is the sum of three currents: geometric capacitance,
absorption, and true leakage current. The absolute value of output current is not of
primary importance. This value is virtually impossible to predict and is dependent upon
the previously mentioned factors, which can affect the resultant output current from a
few to hundreds of microamperes.

Figure 9-1
Components of DC Test Output Current

3
ICEA S-93-639 (NEMA WC 74-2000): “5 - 46 kV Shielded Power Cable for Use in the Transmission & Distribution of Electric Energy.”

SOUTHWIRE 9-6
 FIELD TESTING

where: it = ia + ig +ic
ig = geometric capacitance current
ia = absorption current
ic = leakage/conduction current
it = total current

The shape of the total current curve (it) with respect to time indicates the condition of
the dielectric. A drop-off of current with respect to time is an indication of sound
insulation. A distinct or fast rising current is an indication of questionable condition or
impending failure. A flat curve is generally a result of test conditions.
The output current variation with respect to time of voltage application is generally
considered more indicative than the absolute value. The characteristic shapes of the
time-leakage current curve and probable causes are outlined below.

1. A fast rising leakage curve at a steady voltage may be indicative of faulty

insulation. However, other leakage paths (over porcelain surfaces and
through insulating fluids) can contribute to such a result.

2. A falling leakage curve is indicative of good insulation characteristics

especially if it is at similar levels for all phases.

3. A flat leakage curve at low value is generally indicative of acceptable insulation.

Flatness may be influenced by circuit length, cable geometry, and possible
presence of moisture or contaminants over terminal surfaces.

4. A flat leakage curve at high value may indicate any of the following conditions:
a. presence of moisture
b. contaminants over terminal surfaces or other creepage surfaces
c. surface leakage greater than volume leakage
d. moist laminated insulation
e. condition of insulating fluids
f. air ionization losses (corona) from projections

5. Dissimilar leakage curves are indicative of non-uniformity of circuit insulation.

The characteristic curve of each phase should be analyzed to determine the
cause of dissimilarity. Air ionization losses from projections may affect one
phase more than the others, dependent upon corona shielding (such as at
terminals),temperature and humidity transients, air movement, and the like.

Generally speaking, the increase of current with test voltage is approximately linear for
sound insulation. Care should be exercised to prevent terminal corona and minimize
terminal surface leakage as these can mask test results.

SOUTHWIRE 9-7
 APPENDIX RELATED
INFORMATION
The appendix provides related information for power cable selection and purchasing.
Included are sample calculations and many of the conversion factors or equivalents that
may be encountered when working within this field.

CAPACITY AND DRUM DIAMETER OF REELS

Reel Capacity Equation

The rigorous formula for calculating footage capacities of reels for a round cable is
shown as follows. A 5% nesting factor and a 95% traverse utilization have been built
into the equation. Therefore, cables must be wound evenly to obtain uniformity,
compactness, and the nesting of successive turns and layers.

(A-1)

where: F = feet of cable on reel

A = flange diameter, inches
B = drum diameter, inches
C = inside traverse, inches
D = cable outside diameter, inches
X = defined as the distance between cable and the outer edge
of the reel flange. Clearance is equal to 1 inch or one cable
diameter, whichever is larger. On “T” suffix reels, the
clearance is based on diameter less tire consideration.

ROUND CORE CABLE

Consisting of Multiplier for D

Single Conductor 1.0

Duplex Conductor 2.0
Triplex Conductor 2.16
Quadruplex Conductor 2.414

10
SOUTHWIRE A-1
APPENDIX

Typical Reel Capacity Calculation

How many feet of cable, with a diameter of 1 inch, will properly fit on a reel with
the following dimensions?

A = 36 inches
B = 18 inches
C = 22 inches

(Calculations to 2 decimal places)

(Truncate decimal places)

Approximate Reel Capacity Equation

(A-2)

where: A = flange diameter

X = clearance
Clearance is two inches or twice the cable diameter,
whichever is greater. Clearance is to be taken from both
sides of flange.
B = drum diameter
C = traverse
D = cable diameter

Minimum Drum Diameter

Reels used for shipment or storage should have a drum diameter (B) of not
less than:
(A-3)

where: B = minimum drum diameter in inches

D = diameter of cable in inches
F = the factor for specific cable constructions taken
from NEMA WC 261 and included in Table A-1
B and D are in the same units.

SOUTHWIRE A-2
 RELATED INFORMATION

TABLE A-1
FACTORS FOR DETERMINING MINIMUM DRUM DISTANCES
Type of Cable Factor
1. Single and multiple conductor nonmetallic covered cable
a. Nonshielded and wire shielded, including cables with concentric wires:
1) 0-2000 volts 10
2) Over 2000 volts
(1) Nonjacketed with concentric wires 14
(2) All Others 14
b. Tape shielded 14

2. Single and multiple conductor metallic covered cable:

a. Tubular metallic sheathed:
1) Lead 14
2) Aluminum:
(1) Outside diameter - 1.750” and less 25
(2) Outside diameter - 1.751” or larger 30
b. Wire armored 16
c. Flat tape armored 16
d. Corrugated metallic sheathed 14
e. Interlocked armor 14

When metallic sheathed cables are covered only by a thermosetting or thermoplastic jacket, the “outside diameter”
is the diameter over the metallic sheath itself. In all other cases, the outside diameter is the diameter outside of all
the material on the cable in the state in which it is to be wound upon the reel.
For “flat twin” cables (where the cable is placed upon the reel with its flat side against the drum), the minor outside
diameter should be multiplied by the appropriate factor to determine the minimum drum diameter.

TABULATIONS OF EQUIVALENTS

Nominal Conductor Area

TABLE A-2
CONDUCTOR AREA EQUIVALENTS
Conductor Size Area
AWG or kcmil Circular mils Sq. mm Sq. inches
14 4,110 2.08 0.00323
12 6,530 3.30 0.00513
10 10,380 5.25 0.00815
8 16,510 8.35 0.0130
6 26,240 13.3 0.0206
4 41,740 21.1 0.0328
2 66,360 33.6 0.0521
1 83,690 42.3 0.0657
1/0 105,600 53.4 0.0829
2/0 133,100 67.3 0.104
3/0 167,800 84.9 0.132
4/0 211,600 107 0.166
250 250,000 127 0.196
350 350,000 177 0.275
500 500,000 253 0.393
750 750,000 380 0.589
1000 1,000,000 507 0.785
Above values calculated based upon:
Sq. mm = circular mil area x 506 x 10-6
Sq. inches = circular mil area x 0.785 x 10-6

SOUTHWIRE A-3
APPENDIX

Conversion Factors

TABLE A-3
CONVERSION FACTORS
Column Column A to B B to A
A B Multiply By Multiply By
in mil 1,000 0.001
in micron 1,000,000 1 x 10-6
in mm 25.4 0.0394
mil mm 0.0254 39.37
ft m 0.3048 3.2808
mile km 1.6093 0.6214
in2 mm2 645.16 1.55 x 10-3
circular mil mm2 5.067 x 10-4 1973.5
circular mil square mil 0.786 1.273
gal liter 3.785 0.2642
fahrenheit centigrade (°F-32) x 5/9 (°C x 9/5) + 32
V/mil kV/mm .0394 25.4
horsepower watts 745.7 1.341 x 10-3
megohms microhms 1012 10-12
megohms ohms 106 10-6
micron meter 10-6 106
loge (x) log10 (x) 2.303 0.434
ohms/1000ft ohms/km 3.28 0.3048

SOUTHWIRE A-4
 RELATED INFORMATION

Temperature Equivalents

TABLE A-4
TEMPERATURE EQUIVALENTS
Centigrade (°C) Fahrenheit (°F) Absolute (K)
°C = (°F - 32) x 5/9 °F = (°C x 9/5) + 32 °K = °C + 273
-100 -148 173
-80 -112 193
-60 -76 213
-40 -40 233
-20 -4 253
-18 0 255
0 32 273
5 41 278
10 50 283
15 59 288
20 68 293
25 77 298
30 86 303
35 95 308
40 104 313
45 113 318
50 122 323
55 131 328
60 140 333
65 149 338
70 158 343
75 167 348
80 176 353
85 185 358
90 194 363
95 203 368
100 212 373
105 221 378
110 230 383
115 239 388
120 248 393
140 284 413
160 320 433
180 356 453
200 392 473
250 482 523
All values rounded to nearest degree

Metric Unit Multiples

TABLE A-5
METRIC UNIT MULTIPLES
Multiple Prefix Symbol Multiple Prefix Symbol
10-12 pico p 10 deca da
10-9 nano n 102 hecto h
10-6 micro
103 kilo k
10-3 milli m 106 mega M
10-2 centi c 109 giga G
10-1 deci d 1012 tera T

SOUTHWIRE A-5
APPENDIX

SYMBOLS

Greek Alphabet

TABLE A-6
GREEK ALPHABET
Name Large Small
Alpha A 
Beta B 
Gamma  
Delta  
Epsilon E 
Zeta Z
Eta H

Theta  
Iota I l
Kappa K k
Lambda 
Mu M

Nu N 
Xi  
Omicron O o
Pi  
Rho P 
Sigma  
Tau T 
Upsilon Y 
Phi  
Chi X 
Psi  
Omega Ω 

SOUTHWIRE A-6
 RELATED INFORMATION

Typical Symbol Usage

TABLE A-7
TYPICAL SYMBOL USAGE
Symbol Meaning – Units
V or E Voltage – Volts
A Amperes – Amps
R or Ω Resistance – Ohms
A Areas – Circular Mils – kcmil
L Inductance – Henries
X Reactance – Ohms
C Capacitance – Picofarads
 Volume Resistivity – Ohms – Circular Mil/Ft.
Thermal – °C-cm/watt
Z Impedance – Ohms (typically total impedance)
XL Inductive Reactance – Ohms
XC Capacitive Reactance – Ohms
 Temperature Coefficient of Resistance
AWG American Wire Gauge
F Frequency – Hertz
PSI Pounds per Square Inch
 Dielectric Constant – Permittivity
 Dielectric Constant
SIC Specific Inductive Capacitance
K (IR) Insulation Resistance Constant
pf Power Factor
 Angle between Voltage and Current
 Imperfection Angle Between Voltage and Current tan
tan  Indication of insulation losses
kVA Apparent Power – 1000 Volt Amperes
kW Actual Power – Kilowatts – 1000 Watts
W Power – Watts
log10 Logarithm Base 10
loge or IN Logarithm Basee (e=2.718 natural log)
 Phase

Micro 10-6
S Stress – Pounds/Circular Mil or Volts/Mil

Coefficient of Dynamic Friction
 Straight Section Angle from Horizontal-Radian
 Bend Section Angle – Radians
R Bend Section Radius – Feet
 Angle of the Pulling Line to the Direction of Pull – Degrees
Circular mil Area of Circle Having a Diameter of 1 mil (0.001) in.
kcmil Thousands Circular mils

SOUTHWIRE A-7
APPENDIX

REFERENCE PUBLICATIONS

Chapter 1. Basics of Insulated Power Cable Construction

1957 Edison Electric Institute (EEI) Underground Systems Reference Book (UGSRB)

T.A. Balaska, “Jointing of High Voltage Extruded Dielectric Cables: Basis of Electrical
Design and Installation,” 1974 IEEE Underground Transmissioˆn and Distribution
Conference, Dallas, TX.

Chapter 2. Conductors
1. ASTM Standards, volume 02.03 Electrical Conductors, B 231-99, B 496-01, and B 787-01.

2. ASTM Standards, volume 02.03 Electrical Conductors, B 1-01, B 2-00, and B 3-01.

3. ASTM Standards, volume 02.03 Electrical Conductors, B 233-03 and B 800-00.

4. National Electrical Code (NEC), 2005, NFPA 70.

5. ASTM Standards, volume 02.03, B 233-03.

6. ICEA T-31-610-1994, “Water Penetration Reference Test, Sealed Conductor.”

7. “Committee Report on AC/DC Resistance Ratios at 60 Cycles,” ICEA Project 359,

June 1958, reprinted 1973.

8. 1957 EEI UGSRB.

Chapter 3. Insulations
ICEA S-93-639 (NEMA WC 74-2000): “5 - 46 kV Shielded Power Cable for Use in the
Transmission & Distribution of Electric Energy.”

UL 1072, “Medium-Voltage Power Cables.”

CSA C22.2, No.38-M1986, “Thermoset Insulated Wires and Cables”; CSA C68.3-97,
“Shielded and Concentric Neutral Power Cables Rated 5-46kV – Third Edition.”

SOUTHWIRE A-8
 RELATED INFORMATION

Chapter 4. Shielding or Screening

1957 EEI UGSRB

1. ICEA S-93-639 (NEMA WC 74-2000): “5 - 46 kV Shielded Power Cable for Use in the
Transmission & Distribution of Electric Energy.” AEIC CS8-00 (1st edition),
“Specification for Extruded Dielectric, Shielded Power Cables Rated 5 through 46kV.”

2. ICEA S-93-639 (NEMA WC 74-2000): “5 - 46 kV Shielded Power Cable for Use in

the Transmission & Distribution of Electric Energy.”

3. ANSI/IEEE Standard 525-1992, “IEEE Guide for the Design and Installation of
Cable Systems in Substations. 1992”

Chapter 5. Jacketing, Sheathing, and Armoring

ICEA S-93-639 (NEMA WC 74-2000): “5 - 46 kV Shielded Power Cable for Use in the
Transmission & Distribution of Electric Energy.” AEIC CS8-00 (1st edition), “Specification
for Extruded Dielectric, Shielded Power Cables Rated 5 through 46kV.” IEEE Standard
532-1993, “IEEE Guide for Selecting and Testing Jackets for Underground Cables.” CSA
C68.3-97, “Shielded and Concentric Neutral Power Cables Rated 5-46kV – Third Edition and
CSA C22.2, No. 131-M89, “Type Teck 90 Cable-Third Edition; General Instruction No 1-5.”

1. ICEA T-33-655-1994, “Low-Smoke, Halogen-Free (LSHF) Polymeric Cable Jackets.”

2. ICEA S-93-639 (NEMA WC 74-2000): “5 - 46 kV Shielded Power Cable for Use in

the Transmission & Distribution of Electric Energy”, and IEEE Standard 635-2003,
“IEEE Guide for Selection and Design of Aluminum Sheaths for Power Cables.”

3. ICEA S-93-639 (NEMA WC 74-2000): “5 - 46 kV Shielded Power Cable for Use in

the Transmission & Distribution of Electric Energy.” Other standards also apply.

Chapter 6. Electrical Characteristics of Cable Systems

1. National Electrical Code (NEC), 2005, NFPA 70.

2. ICEA P-32-382, “Short Circuit Characteristics of Insulated Cable” – Fourth Edition,

1999.”

3. ICEA P-45-482, “Short Circuit Characteristics of Metallic Shields and Sheaths on

Insulated Cable” – Fourth Edition, 1999.

4. 1957 EEI UGSRB. ANSI/IEEE Standard 525-1992, “IEEE Guide for the Design and
Installation of Cable Systems in Substations.”

5. ANSI/IEEE Standard 525-1992, “IEEE Guide for the Design and Installation of
Cable Systems in Substations.”

6. ICEA P-53-426/NEMA WC 50-1976. “Ampacities, Including Effect of Shield Losses

for Single-Conductor Solid- Dielectric Power Cable 15kV through 69kV (Copper
and Aluminum Conductors). Second Edition, Revised 1999.”

SOUTHWIRE A-9
APPENDIX

7. IEEE 835/ICEA P-46-426, “IEEE-ICEA Power Cable Ampacities, Copper Conductors,

Aluminum Conductors. Revised 2000.”

8. “Method of Symmetrical Coordinates Applied to the Solution of Polyphase

Networks,” C.L. Fortescue, 1918, Transactions AIEE, vol. 37, pp. 1027-1140.

9. Underground Transmission Systems Reference Book, 1992 edition, Electrical

Power Research Institute.

10. Electrical Transmission and Distribution System Analysis and Design Programs,
Version 3.50, August 1992, EDSA Micro Corporation, Bloomfield Hills, MI.

11. Distribution-System Protection Manual, McGraw-Edison.

Chapter 7. Cable Installation

R.C. Rifenberg, “Pipe Line Design for Pipe Type Feeders,” in “AIEE Transactions on
Power Apparatus and Systems” (December 1953), volume 8, paper no. 53-389.

ANSI/IEEE Standard 525-1992, “IEEE Guide for the Design and Installation of Cable
Systems in Substations.” ANSI/IEEE Standard 690, “IEEE Standard for the Design and
Installation of Cable Systems for Class 1E Circuits in Nuclear Power Generating Stations.
2002.”

1. AEIC Publication no G5-90, “Underground Extruded Power Cable Pulling, AEIC

Task Group 28,” 2nd edition, May 2001; and IEEE Standard 1185-1994, “Guide for
Installation Methods for Generating Station Cables.”

2. Gene C. Neetz, “Coefficient of Friction Measurement Between Cable and Conduit

Surfaces Under Varying Loads,” in 1985 IEEE Transactions on Power Apparatus
and Systems, vol. PAS-104, no. 1, pp. 16-21.

3. NEC, section 300.5; National Electrical Safety Code (NESC), 2002 edition, section
35; ANSI C2-2002, Secretariat IEEE.”

4. Archer E. Knowlton, ed. Standard Handbook for Electrical Engineers, 8th edition
(McGraw-Hill, 1949).

5. ICEA P-79-561-1985, “Guide for Selecting Aerial Cable Messengers and Lashing
Wires.”

6. ICEA S-95-658 (NEMA WC70-1999) “Nonshielded Power Cables Rated 2000 Volts or
Less For The Distribution of Electrical Energy.” and ICEA S-93-639 (NEMA WC 74-
2000): “5 - 46 kV Shielded Power Cable for Use in the Transmission & Distribution
of Electric Energy.”

7. IEEE 532-1993 “Guide for Selecting and Testing Jackets for Underground Cables.”

8. Polywater, “Technical Talk,” volume 4.

SOUTHWIRE A-10
 RELATED INFORMATION

Chapter 8. Cable Accessories

T.A. Balaska, “Jointing of High Voltage Extruded Dielectric Cables: Basics of Electrical
Design and Installation,” 1974 IEEE Underground Transmission and Distribution
Conference, Dallas, TX.

1. IEEE Standard 404-2000, “IEEE Standard for Extruded and Laminated Dielectric
Shielded Cable Joints Rated 2,500V through 500,000V.”

2. IEEE Standard 48-2003, “Standard for Test Procedures and Requirements for
Alternating Current Cable Terminations 2.5kV through 765kV.

3. IEEE Standard 404-2000, “Standard for Extruded and Laminated Dielectric

Shielded Cable Joints Rated 2,500V through 500,000V and “IEEE 592-1996
“Standard for Exposed Semiconducting Shields on High voltage Cable Joints and
Separate Insulated Conductors.”

4. Aluminum Association Guide no. 51, “Aluminum Building Wire Installation

Manual and Design Guide.”

5. EEI-TD-161, “Specifications for Straight Compression Type Connectors for

Insulated Copper Conductors,”

6. EEI-TD-160, “Specification for Solder-Sweated Split Tinned Copper Connectors.”

Chapter 9. Field Testing

T.A. Balaska and A.L. McKean, “Fault Location Experience and Practice on Industrial
Systems,” 1966 IEEE Special Technical Conference on Underground, Chicago, IL.

1. IEEE Standard 510-1992, “Recommended Practices for Safety in High Voltage and
High Power Testing.”

2. IEEE Standard 400-1991, “Guide for Field Testing and Evaluation of the Insulation
of Shielded Power Cable Systems.”

3. ICEA S-93-639 (NEMA WC 74-2000): “5 - 46 kV Shielded Power Cable for Use in

the Transmission & Distribution of Electric Energy.”

APPENDIX

Funk and Beaty, Standard Handbook for Electrical Engineers, 12th edition.

1. NEMA WC 26-2000, “Binational Wire and Cable Packaging Standard-EEMAC

201-2000.”

SOUTHWIRE A-11
 INDEX
A B
AA-1350 (aluminum alloy), 2-12, 2-13 backfill, 7-28
AA-8000 series aluminum alloy, 2-12 balanced load, 6-2
abrasive cloths, 8-11 basket grip, 7-10
absorption current, 9-6–7 bend, 7-5, 7-6, 7-13–14, 7-16, 7-20, 7-22, 7-27, 7-29
acceptance tests. See testing radius, 7-3, 7-4–6, 7-16, 7-19, 7-20, 7-25
accessories. See cable accessories bending forces, 7-20, 7-22, 7-23
ac/dc ratios, 2-17–18 binder tape, 8-9
acid resistance, 3-3, 3-4 blocking compound, 2-13
AEIC. See Association of Edison bore holes, 5-4, 7-31
Illuminating Companies braided shield, 6-21, 8-8
aerial installations, 5-3, 7-29–31 brazing, 8-12
alcohols: resistance to, 3-4 breakdown strength, insulation, 6-10
alkalies: resistance to, 3-4 breaking strengths, 2-11
alternating current (ac) Brown & Sharpe gage. See American Wire Gage
circuits, 1-5, 6-1–2, 6-12 burial, 6-26, 7-28
resistance, 2-17, 2-18, 2-19 butyl rubber, 8-5, 8-6, 8-8
aluminum
and ampacity tables, 6-30–41 C
and connections, 8-5, 8-11–12 cable accessories
and installation, 7-11–12, 7-14, 7-31–32 design of, 8-1–8
and short circuit current, 6-14, 6-18, 6-19, 6-20 installation of, 8-9–13
properties of, 2-3–15, 2-18, 6-58, 6-61 manufacturers of, 8-14
sheathing, 5-3, 6-24, A-2, A-3 cable construction, 1-1–3
Aluminum Association Guide, 8-11 cable spacing, 4-3, 6-51, 6-60, 6-61, 6-24, 6-53
ambient temperature, 6-26, 6-28, 7-2, 7-14, 8-2 cable system integrity test, 9-2, 9-3
American Society of Testing and Materials (ASTM), cable tray
2-3, 2-4, 2-6, 2-8, 2-9, 2-10, 2-11, 2-12, 2-13, and cable ampacity, 6-30
3-3, 5-1 and cable installation, 7-3–4, 7-20–23
American Wire Gage (AWG), 2-1, 2-4–12, 2-14–18 Cadweld, 8-11
ampacity, 4-3, 6-23, 6-26–29 Canadian Standards Association (CSA), 5-1, 5-4, 7-9
tables, 6-30–49 capacitance, 6-6, 6-7, 9-6–7
uprating factors, 6-28 capacitive reactance, 6-6–7
ampere determination: from power ratings, 6-10 capacity, of reels, A-1–2
animals: and potential damage to cable, 5-1 carbon black, 3-1, 3-2, 3-4
annealing, 2-11, 2-12 charging current, 6-7, 8-2
arcing, 1-4 chemical resistance
armored cable, 1-4, 5-1–4, 6-26, 7-16, 7-21, 7-22, of insulations, 3-1
8-4, 8-5, 8-14, A-2, A-3 of jackets, 5-1–2
Association of Edison Illuminating Companies (AEIC) chloride, 3-3
4-2, 5-1, 7-10, 7-16 chlorinated polyethylene (CPE), 5-1, 5-2, 7-2, 7-14
ASTM. See American Society for Testing chlorine, 3-3
and Materials chlorosulfonated polyethylene (CSP; Hypalon),
auxiliary shield, 1-4, 4-1, 8-9–10, 8-11, 8-13 3-3, 3-4, 5-1, 5-2, 6-28, 7-2, 7-14
AWG. See American Wire Gage circuit diagrams, 6-1–3
clamps, cable, 7-24
Class B stranded conductors, 2-8, 2-9, 2-10, 2-11,
2-14, 2-15
Class C stranded conductors, 2-4, 2-5, 2-8, 2-9,
2-14, 2-15
SOUTHWIRE I-1
INDEX

clearance: in conduit, 7-17 cross-linked polyethylene (XLPE), 3-1–2, 3-3–4,

coating: of copper wire, 2-11 6-6, 6-8
coefficient of friction, 7-9, 7-14, 7-20, 7-21, and installation considerations, 7-2, 7-14
7-22, 7-25 and short circuit factors, 6-14, 6-21
combination unilay, 2-3 cross-linking, 3-3, 5-1
compact round, 2-2 CSA. See Canadian Standards Association
compact sector, 2-2 curing process, 3-1, 3-2, 3-3, 5-1
compatibility: of cable accessories, 8-1, 8-6, current, 6-23–25, 6-26
8-8, 8-11 and grounding, 4-2, 4-3
components, symmetrical, 6-50 and sequence impedance, 6-50–51
compressed round, 2-2 and time-leakage test, 9-6–7
compressed terminal connectors, 8-5, 8-11, 8-12 and voltage drop, 6-11, 6-12, 6-13, 6-14
compressed unilay, 2-3
concentric neutral (CN) wires: as part of primary D
shield, 4-1, 6-25, 6-55, 6-59, 6-60 density, conductor, 2-3
concentric round, 2-2 depth of burial, 7-28
concentric stranding, 2-2 desiccants, 7-33, 7-34
concrete encased installations, 5-3 design considerations of cable accessories, 8-1,
conductivity, 2-3, 2-13 8-2–7
conductor, 1-1–3, 1-4, 1-5, 2-1–6, 2-8–19, 2-21, design tests, splice, 8-8
8-7–8, 9-2 diameter
aluminum as, 2-16 cable assembly factor, 7-8
characteristics of, 2-3–11 of conduit, 7-18–20
copper as, 2-16 of copper and aluminum conductors, 2-4,
resistance tabulations, 2-13–21 2-5, 2-6, 2-7, 2-8, 2-9
shield, 1-2, 1-3, 1-4, 1-5, 4-1, 8-5, 8-7, 8-8, 8-11 of reels, A-1–2
short circuit, 6-14–20 dielectric, 1-1–2, 1-3, 1-4, 1-5, 8-1, 8-9, 8-12
size of, 2-1–9, A-3 absorption ratio, 9-4
strand block, 2-13 constant, 3-1, 3-2, 3-3, 3-4, 6-6
conduit field, 1-2, 1-3, 1-4, 1-5, 4-1, 4-2, 6-11, 8-3, 8-7
and ampacity tables, 6-30 strength, 1-2, 3-1–2, 3-3, 3-4
and coefficient of friction, 7-14 direct burial
dimensions and percent area, 7-18–19 and ampacity tables, 6-30, 6-31, 6-32, 6-33,
installation of cable in, 7-1, 7-10–20 6-38, 6-42, 6-44, 6-47
sweep elbow inside radius, 7-20 installation, 7-28–29
cone, stress relief, 8-4–5 direct current (dc), 6-7
configuration of cables, 7-15 and high potential testing, 9-4
connectors, 1-1, 8-12 circuits, 1-5, 6-1, 6-10, 6-12–14
construction: of insulated power cable, 1-1–5 resistance, 2-11, 2-13–19
contaminants: effect on time-leakage current, 9-7 discharge-resistant jacket, 4-2
contaminated areas: terminations in, 8-6 dissipation factor, 3-1, 3-2, 3-3, 3-4
conversion factors, table, A-4 down-hole installations, 5-1
copper, 2-1, 2-3–16, 2-18, 2-21, 6-28, 6-61, 8-5, 8-12 drain wires, 4-1
and ampacity tables, 6-30–49 drum diameter, A-2, A-3
and short circuit current, 6-14, 6-15–17 ducts, 5-3, 5-4, 6-26, 6-30, 7-2, 8-8-3
installation of, 7-11, 7-31, 7-32 duration, electrical test, 9-5, 9-6
metallic shield, 5-3, 5-4, 6-21, 6-24, 6-25, 8-10 dynamometer corrections, 7-7
properties of, 2-3–12, 6-58, 6-59
corona, 3-1, 3-2, 7-5, 9-7 E
corrosive environment: and cable accessories, 8-2 earth: and direct burial, 7-28
corrugated sheathing, 5-3, 6-21, 7-4, A-3 earth resistivity, 6-52, 6-56, 6-57, 6-60, 6-64
cradled configuration, 2-18, 7-15, 7-27 elastomeric properties, 3-2
creep, 7-29 electrical characteristics of cables, 6-1–66
crimped conductor connector, 8-11, 8-12 and ampacity, 6-26–49

SOUTHWIRE I-2
 INDEX

and sequence impedance, 6-50–66 friction, coefficient of, 7-9, 7-14, 7-19–20,
and shield voltage, 6-23–25 7-21–23
and short circuit currents, 6-14–22 frost conditions, 7-28
and voltage drop, 6-11–14
basic power system, 6-1–4 G
formulas, 6-4–10 gas/vapor tight armoring, 5-3
insulation levels, 6-3, 6-4 geometric mean distance (GMD), 6-56, 6-60–61
electrical ground, 1-2, 1-4, 1-5 geometric mean radius (GMR), 6-61–62
electrical insulation Greek symbols, A-6
properties of, 3-1–4 ground plane, receding, 8-4–6
See also insulation ground potential, 1-4, 4-1
electrical tracking, 8-2 grounded shields, 6-24, 6-25
electromagnetic field, 4-3 grounded systems, 6-3–4
electrostatic discharges, 4-2 grounding, 1-5, 4-2–3, 9-1
electrostatic flux lines, 1-2, 1-4
emergency overload, 6-28 H
environmental conditions, 1-4, 5-1, 5-2, 8-2, 8-13 halogen, 3-2–3
EPR. See ethylene-propylene rubber hazardous locations, 5-3
equipment heat-fused conductor connector, 8-11
cable installation, 7-2–4 high density polyethylene (HDPE) conduit, 7-18
electrical test, 9-1, 9-3–4 high-direct-voltages (HVDC) testing, 9-1–5
purging moisture, 7-33 high potential testing, 9-4–7
equipotential lines, 1–2, 1-4, 2-14 Hypalon, 3-3, 6-21, 7-2
ethylene and vinyl acetate (EVA), 3-1, 3-2
ethylene gas, 3-1 I
ethylene-propylene rubber (EPR) ICEA. See Insulated Cable Engineers Association
and cable accessories, 8-5, 8-6, 8-8 identification of cable components, 8-9–10
and short circuit factors, 6-14, 6-21 IEEE. See Institute of Electrical and
as insulation, 3-2, 3-4, 3-6, 6-6, 6-8, 6-28, 9-6 Electronics Engineers
installation considerations for temperature, 7-2 impedance, 6-7, 6-9, 6-11, 6-12
expansion, 2-3, 7-2, 7-29 sequence, 6-66
extrusion, 3-1, 5-1, 5-3 impulse strength, 3-2
inductance, 6-4–5, 6-51
F mutual, 6-23, 6-51
factors installation of cable, 7-1–35
conductor short circuit, 6-14 aerial, 7-29–31
correction, mutual inductance, 6-23 and testing, 9-1–7
for determining ac resistance, 2-19 direct burial, 7-28–29
or determining cable diameter, 7-8, 7-9 field removal of moisture, 7-33–35
for emergency overload uprating, 6-28 general field practices, 7-1–10
shield short circuit, 6-21 handling and storage guidelines, 7-5–6
fault currents, 1-4, 6-50, 6-51 in cable tray, 7-3–4, 7-20–23
field installation, 7-1–10, 8-9–13 in conduit, 7-3, 7-6, 7-10–20, 7-23–27
field testing, 9-1–7 low temperature, 7-2
fill: conduit, 7-18–19 of cable accessories, 8-9–13
fire performance, 3-3–3-4 under vertical tension,7-31–32
flanges, reel, 7-5, A-1–2 Institute of Electrical and Electronics Engineers (IEEE)
flashover, 8-3 standards, 4-2, 5-1, 5-2, 6-24, 6-26
flat tape armored cable, 5-3, A-3 for accessory testing, 8-6, 8-8
flexibility, 1-1, 3-2, 3-4, 5-2, 5-3 for cable accessories, 8-1
fluid resistance, 3-3, 3-4, 5-1, 5-2 for field tests, 9-1–2, 9-4–6
frequencies for installation, 7-10, 7-28–29
correction factor for ampacity, 6-29
correction factor for resistance, 2-19–21

SOUTHWIRE I-3
INDEX

Insulated Cable Engineers Association (ICEA) mechanical terminal connectors, 8-5, 8-11, 8-12
guidelines, 2-17, 6-14, 6-28 megohm meter (Megger), 7-33, 9-2–4
for conductor resistance, 2-14, 2-15, 2-17 melting point: of copper and aluminum, 2-3
for installation, 7-31 messenger, 6-37, 7-29, 7-31
for insulation, 1-2, 3-4, 3-5 metal
for jacketing materials, 5-1, 5-2 armor, 4-2, 5-3, A-3
for shield resistance, 6-21, 6-25, 6-58–59 conduit, 7-14, 7-18–19
insulated power cable construction, 1-1–5, 8-9–10 metric unit multiples, A-5
insulation, 3-1–7 mid-section grounding, 4-3
and cable accessories, 8-3, 8-5–6, 8-8, 8-12, 8-13 moisture
and voltage, 6-3, 6-4 presence of, 9-7
breakdown strength, 6-10 protection against, 2-13, 5-2, 5-3, 5-4, 7-6, 8-2
properties of, 3-4 removal of, 7-33–35
resistance, 6-7–8; test, 7-33, 9-3, 9-4 multiconductor cable, 1-1, 3-5
shield, 1-4, 1-5, 4-1–2, 8-3–6, 8-8, 8-13 and ampacity tables, 6-30, 6-38–41, 6-47–49
thickness, 3-5, 3-7 and drum diameter, A-2–3
types of, 3-1–4 and installation, 7-12, 7-16, 7-17
interlocked armor, 5-3, 5-4, 7-4, A-3 and sequence impedance, 6-66
splice and termination hardware, 8-14 multiple-point grounded system: for insulation
International Annealed Copper Standards (IACS), shield, 4-2, 4-3
2-13
International Electrotechnical Commission, 2-13 N
interpretation of field test results, 9-3–4, 9-5 National Bureau of Standards, 2-19
ionization, air, 9-6–7 National Electrical Code (NEC)
and aluminum, 2-12, 7-11
J and ampacity, 6-26, 6-30–49
jacketing, 5-1–4, 9-3 and installation, 7-9, 7-18, 7-28, 7-32
and installation, 7-10, 7-14, 8-6, 8-9, 8-10 National Electrical Manufacturers Association
and nonshielded cable, 1-1, 8-9 (NEMA), 5-1
and shielded cable, 1-3–4, 8-9–10 National Electrical Safety Code (NESC), 7-28, 7-30
jamming, 7-17, 7-19 neutral conductor, 6-2
junction boxes, 7-9 non-halogen ethylene copolymers, 3-3–4, 5-1
non-halogen flame retardants, 3-2
K nonshielded cable, 1-1–2, 1-4, 1-5, 2-18, 3-5, 9-3, A-3
kcmil (thousand circular mils), 2-1, 2-4–12, and cable accessories, 8-1, 8-3, 8-6, 8-9
2-14–15, 2-18, 2-21 and minimum bending radii, 7-4, 7-5

L O
laminates, tape type, 8-12 ohmmeter, 9-2, 9-3
lead, 4-1, 5-2, 5-3, 7-5, A-3 oil resistance, 3-4
leakage current, 1-4, 6-7, 8-2, 9-2, 9-6–7 open circuit shield, 4-2
line voltage, 6-2 open trays, 5-3
load current density, 1-1 overhead applications: copper used for, 2-12, 2-13
loading district, NESC, 7-30, 7-31 overload, emergency, 6-28
longitudinal voltage stresses, 8-7 oxide film, 8-11, 8-12
low potential testing, 9-3–4 ozone resistance, 3-2, 3-3, 3-4
low-voltage cables, 1-2
lubricant, 4-2, 7-9–10, 7-14 P
path resistances, 6-51
M PE. See polyethylene
magnetic conduit: ac/dc ratio, 2-18 performance requirements, of splices, 8-8
maintenance tests, 9-5 permittivity, 6-6
mechanical protection, 5-1, 5-3 peroxide, 3-1, 3-2
mechanical stresses, 6-10, 7-1 phase conductors, 6-51, 6-54–58, 6-61

SOUTHWIRE I-4
 INDEX

phasors, 6-50 of shield, 6-21, 6-23–24, 6-25, 6-51–52, 6-55,

plasticizer, 3-3 6-58–59, 6-60, 6-63
plowing: and direct burial of cables, 7-29 resistivity, 2-3, 2-13, 3-1, 3-2, 3-4, 8-2, 8-6, 8-8
polarization index, 9-4 and impedance, 6-51–52, 6-58–59
polyethylene (PE), 3-1 shield, 4-3, 6-23–24, 8-2, 8-8
and electrical characteristics, 6-6, 6-8, 6-14, riser installations, 5-1, 7-31–32
6-21, 6-28 rollers, 7-20–21
and installation, 7-2, 7-14 rubber, 3-1, 8-5–6, 8-8
as jacketing, 5-1, 5-2
polymer, 3-2, 3-3, 8-6, 8-8 S
polyphase systems, 6-2–3, 6-50 sag: and aerial installation, 7-29
polypropylene, 3-3 screening, 4-1
polyvinyl chloride (PVC), 3-1, 3-3, 3-4 selection of connectors, 8-11
and conduit, 7-14, 7-18–19 self-amalgamating materials, 8-12–13
and electrical characteristic, 6-6, 6-8, 6-14, semiconducting material, 1-3, 4-1, 5-4
6-21, 6-28 sequence
and installation, 7-2, 7-14 circuits, 6-50
as jacketing material, 5-1, 5-2, 5-3, 5-4 impedance, 6-50–66
power series circuit, 1-5
factor, 6-8–9, 6-11–12, 6-13–14 service-entrance cable, 2-12
systems, 6-1–3 service performance, 1-5, 7-1
premolded slip-on material, 8-13 shafts, 5-4, 7-31, 7-32
premolded splice, 8-7–8, 8-13 sheathing, 1-4, 2-17, 5-1–3, 6-26, 7-5
pressure, sidewall, 7-1, 7-4, 7-16, 7-19–20, 7-29 sheaves, 7-3–4, 7-21, 7-23
primary shield, 1-4, 4-1, 4-3, 8-9, 8-10, 8-13 shield, 4-1–3, 5-1, 6-11, 7-35, 8-7–8, 8-12–13
propylene, 3-2 interrupters, 4-3
protection resistance, 6-21, 6-23, 6-25, 6-51–52, 6-58, 6-62
and direct burial of cables, 7-28–29 short circuit factors, 6-21, 6-22
of prepared cable end, 8-11 voltages, currents, and losses, 6-23–25
proximity effect, 2-17–18 shielded cable, 1-3–5, 3-5–7, 4-1–3, 7-35, A-3
pull boxes, 7-8–9 and cable accessories, 8-1–12
pulling and electrical characteristics, 6-6, 6-51–52
during installation, 4-2, 7-1–9, 7-10–23 testing of, 9-3, 9-4–5, 9-6
lubricants, 4-2, 7-5–6, 7-9–10 short circuit, 4-2, 5-1, 6-14–22, 6-50
purging process for removal of moisture, 7-33–35 sidewall pressure, 7-1, 7-4, 7-16, 7-19, 7-20, 7-29
PVC. See polyvinyl chloride silane, 3-1, 3-2
Silica Gel, 7-33
R silicate, 3-2
raceways, 5-3, 5-4, 6-30, 6-31, 6-41, 7-4 single-conductor cable, 1-1–5, 2-17, 3-5, 6-6, 6-23,
radial stresses, 8-2, 8-7 6-24, 6-27, 6-60, 6-66, A-3
radius, sheave, 7-20–21 and ampacity tables, 6-30, 6-32–38, 6-42–46
reactance and tension during installation, 7-11–12,
shield mutual, 6-23–24 7-15, 7-16, 7-17
total cable, 6-7, 6-9, 6-11–12, 6-13–14 single-phase ac systems, 6-1, 6-2, 6-10, 6-12
reels single-point grounded system, 4-2–3
and cable installation, 7-1–6, 7-15, 7-22–23, size
7-35 of conductors, 2-1–5, 6-14–20
capacity equation, A-1, A-2 of conduit, 7-10, 7-18–19
relief of stress, 8-4–5, 8-6 skin effect, 2-19–21, 6-58
resistance, 2-3, 2-13, 2-15–17, 2-18–21, 6-26, 6-27 soil, 6-26, 6-60
and impedance, 6-9, 6-58, 6-59, 6-60, 6-62–63 resistivity, 6-51–52, 6-60
and voltage drop, 6-11–12, 6-13–14 solder-sweat terminal connectors, 8-5, 8-11, 8-12
of concentric neutral, 6-56, 6-57, 6-59 solid conductors, 2-1, 2-4, 2-5, 2-6, 2-7, 2-12–15, 8-5

SOUTHWIRE I-5
INDEX

solvents, 3-3, 8-11 terminal

spacing, 6-4–5, 6-23, 6-24 connector, 8-5
conduits, 7-9 lug, 8-11, 8-12
rollers, 7-21 terminations, 8-6
vertical supports, 7-32 tools, 8-13
splicing, 4-3, 8-1, 8-2, 8-6–8 testing, 9-1–7
split tinned copper connector, 8-12 field acceptance, 9-2–7
steel for breakdown strength, 6-10
armoring, 5-3, 5-4, 6-24 of cable accessories, 8-3, 8-6, 8-8
conduit, 7-14, 7-19 thermal
messenger, 7-31 circuit, 6-26–27
storage guidelines, 7-5–6 expansion, 7-29
strand block, 2-13 protection, 5-1, 5-4
street lights, cable burial depth, 7-28–29 resistance, 6-26, 6-27
strength, breaking, 2-10, 2-11, 7-29, 7-31 thermoplastic
stress insulation, 3-1, 3-3, 6-14, 6-17, 6-20, 6-21
and cable accessories, 3-4–6, 8-2 jacket, 5-4
and voltage, 6-10–11, 8-4–7 thermoset insulation, 3-1, 3-2, 3-3, 6-14, 6-15,
control layers, 4-1 6-16, 6-18, 6-19, 6-21, 8-9–10
maximum allowable, on conductor, 7-11–12, time-leakage test, 9-6–7
7-32 track resistant material, 8-6, 8-13
submarine installations, 5-1 training radius, 7-4, 7-5
symbols, typical, A-7 treeing, 2-13, 3-1, 3-2, 5-4
symmetrical components, 6-50 trenching, 7-28
system categories, percent insulation level, 6-3–4 tubular shield, 6-21

T U
tangential voltage stresses, 8-7 UL. See Underwriters Laboratories
tape ultraviolet (UV) protection, 3-1–2, 8-2
armor, 5-1, 5-3, 5-4 underground
bedding, 7-28 cables, 2-12, 5-4
shield, 6-21, 7-10 duct: ampacaties in, 6-30, 6-33, 6-36, 6-39,
splicing, 8-7, 8-8 6-45, 6-48
Teck Cable, 5-4 Underwriters Laboratories, 2-12, 3-3, 3-5, 5-1, 7-9
television reception interference, 4-2 ungrounded systems, 6-3
temper, 2-11, 2-12, 2-13 unilay stranded conductors, 2-3
temperature
and ampacity, 6-26–29, 6-31–49 V
and impedance, 6-58–60 vector diagrams, power factor, 6-8–9
and installation, 7-2, 7-14, 7-31 vertical
and insulation, 3-2, 3-3, 6-7–8 riser cables, 5-4
and resistance, 2-16–17, 2-19 tension, 7-31–32
and short circuit current calculations, 6-14–21 voltage
equivalents, table, A-5 drop, 6-11–14
tensile strength, insulations, 3-2, 3-3, 3-4 field testing, 9-3–6
tension, pulling gradients, 4-1, 6-11, 8-4, 8-5
and cable configuration in conduit, 7-15 potentials, 6-4
and dynamometer corrections, 7-6–7, 7-10 stress, 6-10–11, 8-3, 8-4, 8-5, 8-6, 8-7
and installation, 7-10–11, 7-20–23, 7-25–27, system categories, 6-3
7-29, 7-31–32 vulcanize, 3-1, 5-1
and maximum allowable, 7-10–12
and plowing (direct burial), 7-29

SOUTHWIRE I-6
 INDEX

W
wall thickness, insulation, 3-5–7
water, 3-1, 3-4, 4-1, 5-1, 5-3, 8-6
blocked stranded conductors, 2-13
field removal from cables, 7-33–35
treeing, 2-13, 3-1, 3-2, 5-4
wax, 7-9
weight
correction, 7-15
of copper and aluminum conductors, 2-6, 2-7,
2-8, 2-9
of ice, 7-30
of steel messenger, 7-31
welding, copper conductor connectors, 8-11, 8-12
wind, 7-30–31
wire armored cable, 5-1, 5-3
withstand test, voltage, 9-5

X
XLPE. See cross-linked polyethylene

SOUTHWIRE I-7
Southwire Company
One Southwire Drive
Carrollton, Georgia 30119, USA
800.444.1700

W W W. S O U T H W I R E . C O M
10000/0306 ® 2006 Southwire Company