The British Standards Institution (BSi) has the distinction of being the oldest national standards body in the world, playing a crucial role in publishing indispensable standards.

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While BSi does not function as a regulatory body, its published standards are frequently referenced in various laws and regulations both within the UK and around the globe. Moreover, BSI serves as the UK's representative to CENELEC, the European Standards Organization, and is a signatory to the CELENEC Certification Agreement, which facilitates the acceptance of unified European standards by national standard organizations.

What Constitutes British Standard Cables?

British Standard cables, commonly referred to as BS cables, are electrical cables that are designed and manufactured in compliance with specific British Standards. Manufacturers of electrical cables convey their adherence to these standards by marking a BS symbol on the sheath of their cables.

While following these standards is generally optional unless dictated by customer or supplier specifications, compliance significantly reduces the risk of potential issues. For example, the current 18th Edition of BS offers vast technical and practical guidance for designing, constructing, and validating low-voltage fixed wiring electrical systems—a guideline that licensed electrical engineers would typically consider imperative.

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Types, Sizes, and Installation of Electrical Cables

Electrical cables are engineered to transmit electric energy from one location to another. Their final applications will determine various configurations, all structured in accordance with national and international standards.

Voltage Categories of Electrical Cables

Electric cables are classified based on their voltage ratings as follows:

• Low voltage cables (up to 750 V): These cables come in various applications, using thermoplastic and thermoset coatings and are designed according to harmonized standards.
• Low Voltage cables (up to 1,000 V): (also referred to as 0.6/1 kV) utilized for industrial installations across diverse fields including general industry, public applications, and infrastructure, designed per international standards (UNE, IEC, BS, UL).
• Medium Voltage cables: spanning from 1 kV to 36 kV, these cables play a role in the distribution of electricity from substations to transformers.
• High Voltage cables: exceeding 36 kV, these cables are essential for the transportation of electricity from generation sites to substations.

Classification of Electrical Cables by Use

Low Voltage Cables

Flexible cables for electrical cabinet wiring are ideal for domestic settings, public installations, and internal wiring of electrical cabinets or small devices.

Energy cables designed for industrial and public deployment are notable for their use in power transmission across all types of low voltage connections, as well as in variable frequency drive (VFD) applications.

Armoured cables, utilizing aluminum or steel reinforcement, are prevalent in environments susceptible to mechanical harm, such as rodents or in settings where fire and explosion risks exist (ATEX).

Versatile rubber cables can be employed both in fixed industrial installations and mobile applications. Welding cables are specifically designed with rubber sheaths, permitting the transmission of high current between the welding generator and electrode.

High Security Halogen Free (LSZH) Cables emit minimal smoke and corrosive gases in case of fire, suitable for wiring electrical panels and public spaces, emergency circuits, and public distribution networks.

Control cables intended for fixed or mobile setups must remain flexible for functionality in small domestic appliances and for linking machine components for manufacturing.

Furthermore, many electric cables for unique installations exist that accommodate scenarios such as temporary lights for expos, connections for cranes and lifts, and configurations in aquariums or pools.

Medium Voltage Cables

Medium Voltage Cable type RHZ1, featuring XLPE insulation, is characterized by being halogen free, non-flame propagating, making it fit for distributing energy in Medium Voltage networks.

MV-90

This variant also adheres to American standards, suited for energy transfer within medium voltage contexts.

Additionally, copper and aluminum cables for medium voltage, are preferentially utilized in applications where exposure to oil or other chemical agents is a possibility.

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Components of Electrical Cables

A standard electric cable comprises:

• Conductor: responsible for channeling the electric flow
• Insulation: encases and maintains the electrical flow within the conductor.
• Auxiliary elements: These safeguard the cable, enhancing its lifespan.
• Outer sheath: the protective layer encompassing all internal components.

Kinds of Electric Conductors

• Bare Conductor: Single solid wire, inflexible and uncoated.
• Aluminium Conductors: Although aluminum is a lesser conductor compared to copper, it's utilized in certain applications.
• Copper Conductors: The most prevalent material used in cables.
• Flexible Copper Wires: Formed from fine wires shielded with insulating material, these conductors are malleable.
• Single-Core Cable: A cable with a solitary conductor.
• Multi-Core Cable: A cable featuring multiple conductors.

Insulation Types for Electrical Cables

The insulation process entails applying a coating that prevents current leakage from the conductor. This insulation falls into two primary categories: thermoplastic and thermosetting.

1. Thermoplastic Insulation

The most commonly used materials for electrical cable manufacturing include:

• PVC: Polyvinyl Chloride
• Z1: Polyolefins
• PE: Linear Polyethylene
• PU: Polyurethane

2. Thermosetting Insulation

Common thermosetting materials include:

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• EPR: Ethylene Propylene
• XLPE: Crosslinked Polyethylene
• EVA: Ethyl Vinyl Acetate
• SI: Silicone
• PCP: Neoprene
• SBR: Natural Rubber

Metal Protection Variants for Electrical Cables

Cables may feature metallic shields in certain applications:

• Screens: Electrical metal shields that isolate internal signals from external interference.
• Armours: Provide mechanical protections against external stresses, including pests and impact damage.

Nomenclature of Electrical Cables as per Standards

Each cable is assigned a standard designation that consists of specific letters and numbers indicating a range of product characteristics (materials, voltage ratings, etc.), facilitating the selection of the right cable for distinct requirements and minimizing potential supply errors.

Any cable lacking clear indicative data could be considered defective, non-compliant with safety regulations, and might jeopardize reliability and longevity.

Designation per Insulation Type

Designation Coding:

Cable Type RCrosslinked polyethylene (XLPE), XCross-linked polyethylene (XLPE), Z1Halogen-free thermoplastic polyolefin, ZHalogen-free thermosetting elastomer, VPolyvinyl chloride (PVC), SHalogen-free thermosetting silicone compound, DEthylene-propylene elastomer (EPR)

Screen, Interior Lining, and Armature Designations

Designation Coding:

Cable Type C3: Copper wire screen, helically arranged, C4: Copper shield in braid on insulated conductors, V: Polyvinyl Chloride (PVC), Z1: Halogen-free thermoplastic polyolefin.

If no screen, inner lining, or armature seat is present, no letter is assigned.

Designation of Various Armor Types

Designation Coding:

Cable Type F: Steel strapping arranged in a helical pattern, FA: Aluminum strapping arranged in a helical manner, FA3: Longitudinally corrugated aluminum strip, MS: Steel wire crown, MA: Aluminum wire crown.

Outer Sheath Designation

Designation Coding:

Cable Type V: Polyvinyl Chloride (PVC), Z1: Halogen-free thermoplastic polyolefin, Z: Halogen-free thermosetting elastomer, N: Vulcanized chlorinated polymer.

Conductor Designations

Designation Coding:

Cable Type K: Flexible copper (class 5) for fixed installations, F: Flexible copper (class 5) for mobile services, D: Flexible for welding machine cables, AL: Indication for aluminum conductors.

Rated Voltage

Rated Voltage Designation: 0.6/1 kV.

Explanation of Conductor Count

Designation Coding:

Cable Type nGS: Number and cross-section of wires, in mm2, with Yellow/Green conductor, nxS: Number and cross-section of conductors, in mm2, without Yellow/Green conductor.

Cable Design Regulations

Cable design rules are cited in each cable marking, including UNE and IEC standards.

Supplementary Information

Cable Type CECE: represents the CE marking required for marketing within the European Community. This marking may be present on the product or packaging. The manufacture date (YYMMDD) is usually indicated for traceability purposes.

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Electrical Conductors Dimensioning Criteria

There are two criteria for sizing copper conductors:

• American Wire Gauge (AWG): Conductors are defined by a specified number of wires and each wire's diameter.
• European Sizing (mm²): Conductors are defined through the maximum resistance of the conductor (Ω/km). The actual geometrical sections are typically smaller than the nominal sizes indicated.

Electrical Cable Measurements

CROSS-SECTION in mm²(AWG)CURRENT CONSUMPTIONUSED

25 mm²

4

Very highCentral air conditioning and industrial equipment..

16 mm²

6

High airConditioners, electric stoves and electric power connections.

10 mm²

8

Medium high

Refrigerators and dryers.

6 mm²

10

Medium

Microwave and blenders

4 mm²

12

Medium

Lighting

2.5 mm²

14

UnderLamps

1.5 mm²

16

Very low

Thermostats, bells or security systems.

Color Variations in Electrical Cables and Their Significations

The coloration of electrical cables abides by the International Electrotechnical Commission (IEC) Standard, allowing for the following conductor colors: black, brown, red, orange, yellow, green, blue, violet, gray, white, pink, and turquoise.

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• Neutral conductor: identified by the blue color. To avoid confusion, it is advisable to limit the use of blue conductors.
• Phase conductor: can come in black, grey, or brown.
• Earthing conductor: features two colors, yellow, and green, while using a single yellow or green colored cable is permissible only in instances where there's no risk of confusion with the grounding system.