Quality

Our achievement of a high quality performance is a continuous process affecting all aspects of operation Quality control testing guarantees that every product you install will perform in the application. We are an ISO 9001/2000 certified company , which reflects the degree of recognition and prestige we have secured in the industry.

TECHNICAL SPECIFICATION

Unilay HFFR Cables

Halogen Free Flame Retardant Cable - upto 1100V

- India's 1st Fire-safe Cable with HFFR insulation and UNILAY conductor.
- Zero Halogn.
- Does not catch flame, does not Propagate Fire.
- Non-Toxic, Non-Corrosive.

Applications: Suitable for use in conduit and for fixed, protected installation. Ideal for high density wiring. Wiring in all installations where fire safety is of utmost importance. Schools, theaters, commercial complexes, apartments, high rise buildings, laboratories, etc

Conductor: Thin strands of Electrolytic Copper are multi - drawn simultaneously for uniformity of Resistance, Dimension, and Flexibility. The drawn strands are uni-laid in high precision machines and compacted. A perfectly circular conductor is thus formed. This enables reduction in overall diameter for space saving in high density wiring. The strands do not get cut when stripping the insulation. The conductor offers perfect contact at pins, terminals and sockets. This eliminates spot heating and sparking. The cables are printed with generic marking.

Colours: Red, Yellow, Blue, Black, Green, Green/Yellow, Grey

Insulation: Specially formulated grade of Halogen Free Flame Retardant (HFFR) compound is used. The insulation does not burn readily. It does not melt and drip, smoke is negligible, transparent, non toxic. The victims trapped in fire do not suffocate and this facilitates fire fighting operations. Unlike PVC, the smoke emitted is non-corrosive. Suitable for low temp. areas stands from -55 deg. C to 300 deg. C.
Insulation conformity: IEC 60332-1 & 3, IEC 60754-1&2 

Packing: 90/80 mtrs. coils packed in protective cartons.

Physical and Electrical Properties of  flexible cables

Cross section

Area sq.mm

Overall Dia.,

mm., Max

Insulation Thickness,

mm., Nom

Conductor  Config.

No. of Wires/

Nom. Dia

Conductor Resist.

Ohm/km at

20° C Max

Max. current rating, Amp

.75

2.8

0.6

10/.3

26

9

1.0

3.0

0.6

14/.3

19.5

14

1.5

3.80

0.6

22/.3

13.3

18

2.5

4.0

0.7

36/.3

7.98

24

4.0

4.8

0.8

56/.3

4.95

32

6.0

6.4

0.8

84/.3

3.30

42

10.0

8.0

1.0

140/.3

1.91

55

16.0

9.6

1.0

226/.3

1.21

75

25.0

11.5

1.2

196/.4

0.780

100

35.0

13.0

1.2

276/.4

0.554

125

50.0

15.0

1.4

396/.4

0.386

165

 

FR + HR 105°C Single Core Unsheathed Copper Cables For voltages up to 1100 Volts AC.

Conductor :
Many thin strands of Electrolytic Copper are fine-drawn simultaneously for uniformity of characteristics such as Resistance, Dimension, Flexibility etc. The drawn strands are collected and closely twisted in high precision machines and further compacted. This not only imparts circularity to the bunched conductor but also prevents the tendency of the strands to separate and exert internal pressure on the insulation when the cable is bent during installation and usage.

Insulation :
Specially formulated grade of PVC compound is capable of withstanding higher conductor temperatures with flame retardant properties. A rating of 105° C with FR properties enables the cable to withstand overloads without compromising safety. The insulation is resistant to boiling water, steam and vapours to prevent aging and cracking in practical usages in kitchens, bathrooms, damp walls, chemical industries etc.

Marking : The cables are printed with generic marking.

Colours : Red, Yellow, Blue, Black, Green.

Packing : 90 mts. ( approx. 100 yards ) coils packed in protective cartons. Jumbo coils are also available to help reduce wastage at the time of installation.

Specifications generally conform to : BS 6004, BS 6500, IS 694, IEC 227, DIN VDE 0281-3

Sizes, Dimensions and Ratings :

 

Conductor
Area
Sq. mm.

Insulation
Thickness
mm.

Configuration

Max.
Overall
Diameter
mm,

Conductor
Resistance
Ohm/km
@ 20°C
(Max.)

Current Rating Amps.

Casing

Concealed

 

 

 

 

 

 

 

     0.75

0.6

10/0.3

2.8

24.5

9

8

1.00

0.6

14/0.3

3.2

18.1

14

13

1.50

0.6

22/0.3

3.4

12.1

18

16

2.50

0.7

36/0.3

4.2

7.41

24

20

4.00

0.8

56/0.3

4.8

4.95

32

26

6.00

0.8

84/0.3

5.6

3.30

42

35

Typical Applications : Power wiring to appliance sockets, industrial lighting, wiring susceptible to temporary overloads and all fixed installation indoor wiring, exposed to ambiance, in metal and plastic conduits or casing, in air or buried in walls, floors and ceilings.

F.R.Properties

Properties

Test Method

Value

Limited Oxygen Index

ASTM-D 2863

32%

Flame Propagation

SS 424- 1475

Unburnt portion 600/850 mm

Temperature Index

ASTM-D 2863

250°C

 

  WHY UNILAY?

ORDINARY BUNCH CONDUCTOR

UNILAY BUNCHED CONDUCTOR

Current carrying capacity reduces due to chances of strand breakage during usage.

Better current carrying capacity, due to uniform laying, no chances of strand breakage.

Because of the reduced current carrying capacity, the wire gets heated on load, which may result in melting of insulation and hence short circuit.

No chance of heating as complete capacity is imparted and wire takes full current at all times, so no chances of short circuit.

Usually due to loss of current capacity, the wireman usually for safety purpose opts for higher size wiring, thus increasing cost as well as more space is required for installation.

Downsizing of wiring is possible due to consistent current carrying capacity.

Chances of inductive losses.

No chances of inductive losses as the conductor behaves as good as solid conductor with superb flexibility.

WHY HR-FRPVC

COMPARISON OF HR AND FR

 HR MEANS HEAT RESISTANT :- Normally all the cables available in the market are with ordinary PVC which can withstand up to 70 degree Celsius of conductor temperature ( which takes place in case of overload) but HR can withstand up to 105 degree Celsius and for short time up to 125 degree Celsius.

Why HR PVC ?

  1.      The ambient temperature is increasing every year to year almost by 1 degree Celsius, hence

 2.      U nder these circumstances we are left with no other option to opt for higher temperature insulation. Now a days in domestic sector every now and then new appliances are added very frequently and this results in more drawing of current through same cable and this leads to more generation of heat(overloading) and hence you need HR PVC cable to overcome these over loadings and supply you electricity SAFELY and continuously.

For above reasons HR PVC CABLE are SAFE & RELIABLE.

FR  means FLAME RETARDANT

IT has got resistance to fire momentarily (by adding fillers in PVC compound) at the cost of decreasing in insulation properties(viz. Volume resistivity, ageing properties) by at least 10% comparing to normal PVC moreover its conductor temperature withstanding capability (during overload) remains only at 70 deg C same as ordinary PVC cables.

Also in PVC main culprit is SMOKE which is responsible for suffocation and ultimately making breathlessness to victim. If that smoke is as it is 100% than purpose for adopting FR remains UNSOLVED.

Hence FR alone is not the effective solution.

Therefore if the client really believes in SAFETY then the right solution is to put in either FRLS or best option is to use HFFR (smoke free, fire retardant) cables.

When we compare HRPVC and FRPVC, definitely HR has distinct advantages due to its over current carrying capacity.

 

 

 

WHY HALOGEN FREE(HFFR)?

 USP OF SA CABLES-HFFR CABLES:

Analysis of the various tests conducted comparing PVC and zero halogen CABLES reveals some distinct advantages in Halogen Free Cabling:

 

 

HFFR CABLES :

·          Have a characteristic of delayed ignition.

·          Virtually Smoke free, Emits Harmless Transparent Negligible Smoke.

·          FIRE DETERRANT Does not propagate fire.

·          Are 6 times less corrosive than standard PVC conductors based on cone calorimeter results.

·          Are 3 times less toxic than PVC conductors according to LC50 values from the University of Pittsburg toxicity test.

·          Have significant lower carbon monoxide emission levels.

·          Non Corrosive and Non Toxic

·          Environment friendly

·          Safe for Computers and PCB’s( Electronics circuitry)

.·          Ideal for high rise residential complexes.

Potential applications of SA CABLES-HFFR zero halogen insulated conductors include:

·          Commercial Buildings

·          Computer Rooms

·          Telecommunications

·          High Risk Buildings (Hospitals, Nursing Homes, Theaters, Hotels) – virtually all public places.

·          Industrial Application (Control Centers)

·          Subways

·          Shipboard

TECHNICAL BRIEFING ABOUT HALOGEN FREE:

The most common halogenated insulating material is polyvinyl chloride. Plasticized PVC compounds have been used for decades for insulation and jackets for building wires. Southwire Company and Union Carbide Chemicals and Plastics Company, Inc. have worked to develop several zero halogen polyolefin based insulating materials as an alternate to PVC. The fire retarding effect of polyolefin based reduced emission compounds is brought about by the use of hydrated mineral fillers. Up to 30% of these fillers is hydrated water that is released in a fire situation. When exposed to flame, available heat is used to volatilize the water of hydration, thus cooling the flame and slowing decomposition. The water vapors will block the oxygen supply from the fuel, and the fire may be extinguished or its progress may be retarded.

Conductor insulating materials containing halogens(LIKE PVC) have been used for many years. The halogens found in insulating materials are chlorine, bromine, and fluorine.

Halogens improve certain properties such as flame, chemical and oil resistance but also have some negative effects. Gases produced during combustion of halogenated insulating materials react with moisture to produce halogen acids; for example, hydrogen chloride forms (HCl) and hydrogen bromide forms (HBr). Major negative effects of these acids are, corrosion, smoke obscuration, and toxicity.

 

Toxic Cabling

Cabling: What You Don't Know Can Kill You

Halogen cabling can emit toxic fumes in a fire. Many international governments have moved to less lethal alternatives.

Most of the cable contains halogens--chemicals that give off toxic fumes when they burn. In a fire, halogen cable can release acid gases that sear the eyes, nose, mouth, and throat. The fumes can disorient victims, preventing them from escaping the blaze. They

can cause severe respiratory damage. And they can kill. Recognizing this potentially deadly problem, a number of international governments have already standardized on zero-halogen cabling.

Halogen insulation helps prevent cables from catching fire, but if the cable jackets do ignite the resultant fumes can drive up the death toll. And this dilemma has been at the heart of a decade-long debate about the continued use of halogen. "Fluorinated polymers are hundreds of times more toxic than zero-halogen cabling," comments Marcelo Hirschler, a consultant with BGH International Inc. (Mill Valley, Calif.), a firm that specializes in fire-safety issues. "They're also far less flammable."

McCormack believes the code should be changed to restrict the use of halogen cabling, which some tests show to be more than five times as toxic as its acid-free equivalent.

This time around, however, the anti-halogen forces are taking a different tack. They now argue that these chemicals should be outlawed because of the catastrophic effect acid fumes have on computer circuitry--causing millions of dollars worth of damage even in small fires. "Corrosivity is the Achilles' heel of halogen cables," comments Michael Keogh, corporate fellow at Union Carbide Corp. (Danbury, Conn). "It's a matter of machine toxicity, not human toxicity." Union Carbide makes the raw materials used in both halogen and halogen-free cable

Many countries--including Australia, France, Italy, Japan, Korea, New Zealand, and the U.K.--have also moved to halogen-free cabling. And even in countries where the choice of cable is still left to the installer, zero-halogen is becoming the technology of choice, according to IBM's Erba. "Halogen-free cables account for 40 percent of the total communications cable in Europe," he says. He believes that the remaining 60 percent is halogen-sheathed PVC (polyvinyl chloride).

It's a different story overseas. In order to meet rigorous international toxicity specs cable manufacturers avoid halogens altogether, instead adding metal hydrates to their polyethylene and polypropylene cable insulation. When heated, these chemicals release steam.

When the PVC cables used in building risers burn they emit both hydrogen chloride (an acid gas) and dioxin, which Greenpeace, the environmental advocacy group, calls "the most toxic synthetic chemical known to science". Long-term exposure to dioxin has been linked to a number of health problems, including cancer, reproductive disorders, birth defects, impaired neurological development, diabetes, and immune system suppression.

Learn Not To Burn

Champions of halogen-free cable are quick to point out that in a fire what can't be seen is far more lethal than what can. Invisible gases given off by burning material are the cause of more than 80 percent of fire deaths, according to research published in the British Medical Journal. In the U.S. that translates into as many as 6,000 deaths a year. And halogen's opponents are sure that the chemicals are killers.

The anti-halogen forces have answers ready on all counts. For one thing, they argue that while carbon monoxide poisoning may be the direct cause of death in a fire, acid gases can disorient victims and prevent them from escaping a burning building. What's more, they assert that where cable is located is just as important as the smoke it gives off. Since building plenum is typically used by the air-conditioning system, wiring ducts can distribute toxic fumes throughout the workplace--even if a fire hot enough to release the fumes is restricted to a small area. "If there's smoke in the plenum return it can be sucked back and redistributed," explains Mike Kerwin, principal at Cablenet System Inc. (Woburn, Mass.), which installs cabling systems for corporations and educational organizations

The Düsseldorf Disaster

That appears to be what happened during a fire at Düsseldorf Airport, Germany in April 1998 in which 16 people were killed and more than 60 hospitalized for smoke inhalation.

The fire appears to have been sparked off by welders working in a combined ventilation and cable shaft in the main arrival hall. According to the British newspaper The Independent, "PVC-covered cables began to smolder, emitting cyanide, chloride, carbon monoxide, and possibly dioxin fumes that spread through the building's ventilation shafts." The International Herald Tribune reported that the "fire carried a flood of lethal fumes into elevators, ventilation ducts, and passenger lounges."

That sort of disaster makes halogen opponents understandably nervous--especially since there's far more cable in building plenums than ever before.

The Uphar Cinema tragedy

Resultant of this Halogenated toxic cabling, most of the people died as they could not escape due to poor visibility and toxicity of fumes suffocated them to death.

FIRE SURVIVAL CABLES

In continuation to a series of premium products by SA CABLES since last three years, the company is proud to add another feather in its cap by introducing an exceptionally quality product with wonderful features for the Indian market.

Why FS Cables???

The presently available products and developments are at the stage when people started converting from Aluminium to solid copper cables to flexible wiring and latest to unilay conductor technology. In insulation VIR/CTS were replaced by deadly PVC which emits dense black smoke on fire. An improvement was sought with FRLS range and HFFR (ZERO HALOGEN) cables certainly relieved the users to some extent. Still the lights went off under fire conditions.

THE NEED OF THE HOUR!!!!!

The need was felt for cables which continue to conduct electricity even under severe fire conditions to enable victim evacuation, to run emergency systems, fire alarms and various stringent applications.

The RESULT:

The SA CABLES –FS (Fire Survival) cables have been specifically developed to meet the growing demand for cost effective fire resistant cables for use in installations where non halogen, low smoke cables are required to maintain “CIRCUIT INTEGRITY” during severe fire conditions.

A major consideration of SA CABLES when specifying the cable for development is the protection of people, the buildings and their contents. SA CABLES -FS is ideally suited for use in FIRE ALARM, LIFTS and EMERGENCY LIGHTING circuits.

With SA CABLES -FS we guarantee:-

1) Service during FIRE

2) Minimize the smoke emission.

3) Minimize emission of toxic fumes and corrosive gases

4) Allow people for rapid evacuation.

5) Assure the operation of emergency systems.

CABLE CONSTRUCTION:

 Electrolytic grade pure bright, annealed copper conductor.

Screen of specially formulated material to absorb excessive heat.

Insulation with special Halogen Free Flame retardant material.

The cables will be manufactured as per the requirement and specific orders only.

 

Specific application areas:

§          Mains power,

§          Emergency Lighting,

§          Control and emergency services for hotels, hospitals, theatres, and high rise buildings, in fact, wherever public safety is important.

§          In potentially hazardous constructions such as oil refineries, gas and chemical works,

§          Power stations, steel works and related industries.

§          Building management

§          Metro (underground) railways.

§          Mines.

§          Ships

The cables generally conform to following international specifications:

1.       Circuit integrity test as per IEC 331/ BS 6387- CAT. C: cables are subjected to fire at 750 deg C for 3 Hrs. with electricity flowing through it.

2.       Low smoke emission as per IEC 1034/ BS 7622/ASTMD 2843

3.       ZERO Halogen as per IEC 754 pt1/ BS 6425 pt 1

4.       Flame propagation as per IEC 332-1/ BS 4066-1

5.       Fire Propagation as per IEC 332-3/ BS 4066-3

6.       Use in Emergency lighting premises as per BS 5266-1

7.       Use in fire detection and alarm systems as per BS 5839-1

 

HOW TO SELECT AN ELECTRIC CABLE

To determine the size of cable to be used for particular application, the following variables need to be known:

Power - This can be in kVA, kW or in Amps.

  • Voltage
  • Permissible voltage drop - (Usually 5%)
  • Distance to load
  • Fault current:
    • Short circuit (Symmetrical Fault Current)
    • Earth fault (Asymmetrical Fault Current)

 

  • Mechanical Conditions:
    • Temperature, depth of burial, soil thermal resistivity, presence of other cables, or other heat sources.
    • Armouring requirements.
    • Sheath requirements.

 

1.       ELECTRICAL PROPERTIES OF CABLES:

Cross section area, sq.mm.

Approx. AWG

Overall. Dia., mm

Max..

Insul. Thickness,mm,

Nom.

Cond. Config.

No. of wires/ max.dia..

Cond. Resist.,

W/km

At 20°C

Max

Max. current rating,

A

Approx. voltage drop per amp per meter, mV

0.5

22

2.6

0.6

16/0.20

36.0

6

46.0

0.75

20

2.8

0.6

24/0.20

24.5

9

31.0

1.0

18

3.0

0.6

32/0.20

19.5

14

22.0

1.5

16

3.4

0.6

30/0.25

13.3

18

15.0

2.5

14

4.2

0.7

50/0.25

7.98

24

9.1

4.0

12

4.8

0.8

56/0.30

4.95

32

5.7

6.0

10

5.6

0.8

84/0.30

3.30

42

3.8

10.0

8

7.0

1.0

140/0.30

1.91

55

2.2

16.0

6

8.2

1.0

126/0.40 or 226/0.30

1.21

75

1.4

25.0

4

10.0

1.2

196/0.40

0.780

100

0.89

35.0

2

11.5

1.2

276/0.40

0.554

125

0.64

50.0

1

13.0

1.4

396/0.40

0.386

165

0.45

70.0

2/0

15.0

1.4

360/0.50

0.272

240

0.32

95.0

3/0

17.5

1.6

475/0.50

0.206

300

0.24

120

4/0

19.0

1.6

608/0.50

0.161

325

0.19

150

-

21.5

1.8

750/0.5

0.129

352

0.15

185

-

24.0

2.0

926/0.5

0.106

400

0.12

240

-

27.0

2.2

1200/0.5

0.0801

475

0.10

300

 

29.5

2.4

1500/0.5

0.0641

500

0.08

Note: The voltage drop tabulated above are for single cables only. For circuits of single 50 Hz a.c. or two wire d.c. the figures shown above should be multiplied by 2 and for three phase 50 Hz. a.c. multiplied by 1.732.

2.       PERMISSIBLE VOLT DROP

Q. What is voltage drop?

A. A term expressing the amount of voltage loss from original input in a conductor of given size and length.

                                    Vd
               Vr = 100  -----     percent
                            El

Where: Vr = Voltage regulation in percent, Vd = Voltage drop, El = voltage at load

Look up the mV/A/m figure - The relevant table has been reproduced later from our Facts and Figures booklet.

Volt drop = mV/A/m x Current (Amps) x Distance (metres).

= mVolts (Convert to volts by dividing by 1000).

Usually 5% volt drop is allowed. For a 400 Volt 3 phase system, 5% is equal to 20 Volts.

 3.       CURRENT RATING (AND DERATING) OF CABLES
The allowable current, or the current rating of an electric cable is that current which will result in the conductor temperature rising to the maximum operating temperature.

For PVC this is 70°C, 85°C & 105°C

When a cable is installed in a hot environment, for example against a boiler, it stands to reason that the cable will have a lower current rating than the same cable installed in cooler conditions.

Brochure quoted current ratings are based on the following standard conditions:

Ground Temperature: 25°C

Ambient Temperature: 40°C

Ground Thermal resistivity (g): 1.2K.m/W

Depth of laying to top surface of cable or duct 0.8m

The derating factors, which are to be multiplied for different ambient temperatures is listed below.

Kindly multiply these factors with the current rating of the cable at 40 deg C ambient temperature.

 i)                     Ambient temperature derating factors:

 Ambient temperature Deg C

25

30

35

40

45

50

55

60

65

Rating factor for cables

1.22

1.15

1.08

1.00

0.91

0.82

0.70

0.57

0.40

 BASIC ASSUMPTIONS:

a)             Ambient air temperature                                                                         400C

b)             Maximum continuous operating conductor temp.  1050C

c)             Thermal resistivity of PVC                                                    6500C cm/W

 

 

 

 ii) PVC RATED TEMPERATURE DERATING FACTOR

PVC RATED TEMPERATURE

70

85

95

105

RATING FACTORS

0.707

0.845

0.926

1.0

 

SUSTAINED CURRENT RATING FACTORS FOR NON-STANDARD CONDITIONS
iii) Derating factors for depth of laying -

  Depth of laying (mm)

  Direct in ground

  In single way ducts

  500

  1,00

  1,00

  800

  0,97

  0,97

  1000

  0,95

  0,96

  1250

  0,94

  0,95

  1500

  0,93

  0,94

  2000

  0,92

  0,93

iv) Derating factors for ground thermal resistivity

  Thermal Resistivity (Km/W)

  Direct in ground

  In single way ducts

  1,00

  1,08

  1,04

  1,5

  0,93

  0,96

  2,0

  0,83

  0,88

  2,5

  0,78

  0,87

 

 

 

v) Derating Factor For Groups:

For groups of circuits unenclosed, the single-circuit ratings apply provided that:

1)       the horizontal clearance between the circuit is:

a.       Not less than 6 times overall diameter of an individual cable; and

b.       Not less than overall width of an individual circuit, except that the horizontal clearance need not in any case exceed 150mm;

2)       the vertical clearance between circuits is not less than 150 mm; and

3)       if the number of circuits exceed 4, they are installed in horizontal plane. In all the other cases, unless a more precise evaluation of current rating has been made on experimental work or calculated data, the following factors are applicable:

 Number of circuits(pairs of cables, single-phase ac or dc 3 cables per circuit, or 4 where one is the neutral. 3 phase ac

2

3

4

5

6

8

10

12

14

16

18

20

 

Rating factor

Single core

0.80

0.69

0.62

0.59

0.55

0.51

0.48

0.43

0.41

0.39

0.38

0.36

Twin & multicore

0.80

0.70

0.65

0.60

0.57

0.52

0.48

0.45

0.43

0.41

0.39

0.38

 

FAULT CURRENT
This topic is mainly concerned with higher voltages than LV.

Two types of fault current need to be considered:

1.       Short circuit current (sometimes called symmetrical fault current).

2.       Earth fault current (sometimes called asymmetrical fault current).

A)    SHORT CIRCUIT CURRENT
When we experience a fault on an electrical system, the protection equipment will detect the fault and trip out the faulty circuit. It cannot however trip instantaneously, and a delay, (of up to a few seconds) will occur.

 The formula for the short circuit current withstand capability of an electric cable is:

Isc = K * A/sqrt(t)

 Where:
Isc = Short circuit rating of cable (kA)
A = Area of conductor (mm²)
t = Time to trip (in seconds)
K = 96 for PVC, Copper conductor

 

Area of conductor

Short circuit current

sq.mm

for 1 sec in A

0.5

48

0.75

72

1

115

1.5

170

2.5

280

4

460

6

690

10

1150

16

1840

25

2875

35

4000

50

5750

70

8000

95

10925

120

13800

150

22500

185

24275

240

27600

 

 

 

 

B) EARTH FAULT CURRENT
If the phase conductor comes into contact with the earth conductor (lead sheath, copper tape or armour) then we must ensure that this earth conductor can survive the resulting fault current.

Ief = K x A/ sqrt(t)

Where K depends on earth path material (steel wire armour or copper tape)

A= CSA of earth path

T=Fault duration in sec.

What is dielectric constant?

A specific property of insulating material. Dielectric constant is defined as the ratio of the electrical capacitance of a given capacitor having a specific electrode/dielectric geometry to the capacitance of the same capacitor with air as a dielectric. The preferred symbol for dielectric constant is (epsilon).

                    Typical dielectric values
                    =================
                    PVC            3.4 - 8.0
                    EPR            2.5 - 3.5
                    PE               2.5 - 2.6
                    XLPE          2.3 - 6.0

 

 What is insulation resistance (ir)?

It is a ratio of an applied dc voltage to the small dc current which flows through the insulation to ground. This dc current is commonly called a leakage current.

                             E
                   IR  = ---------         ohms
                            Il

Where: E= applied dc 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 20C.

 

Bending Radius calculation:

 

MINIMUM BENDING RADII FOR NON-SHIELDED/NON-ARMOURED POWER CABLES

THICKNESS of CONDUCTOR INSULATION (MM)

CABLE O.D. (MM)

0 TO 25 MM

25.1 MM TO 50 MM

50 MM AND ABOVE

MINIMUM BENDING RATIOS AS A MULTIPLE OF CABLE O.D.

0 TO 4 MM

4

5

6

4 MM AND ABOVE

5

6

7

Values taken from ICEA S-95-658

 

 

                    

 

 

 

 

NOMINAL THICKNESS OF INSULATION & SHEATH AS PER IS ; 694

 

Nominal cross Sectional Area of Conductor

Nominal Thickness of Insulation

Nominal Thickness of Sheath

MM2

MM

Single Core

(MM)

Twin Core

(MM)

Three Core

(MM)

Four Core

(MM)

1.0

0.6

0.8

0.9

0.9

0.9

1.5

0.6

0.8

0.9

0.9

0.9

2.5

0.7

0.8

1.0

1.0

1.0

4.0

0.8

0.9

1.0

1.1

1.1

6.0

0.8

0.9

1.1

1.1

1.2

10.0

1.0

0.9

1.2

1.2

1.3

16.0

1.0

1.0

1.3

1.3

1.4

25.0

1.2

1.1

1.4

1.5

1.6

35.0

1.2

1.1

1.5

1.6

1.7

50.0

1.4

1.2

1.6

1.7

1.8

*FOR COPPER CONDUCTOR ONLY.

 

NOMINAL THICKNESS OF INSULATION & SHEATH FOR ARMOURED,UNARMOURED,SINGLE & MULTICORE CABLES AS PER IS : 1554(PART-1)

 

Nominal cross Sectional Area of Conductor

 Thickness of Insulation

MM

Thickness of Outer Sheath(MINIMUM)

MM

Thickness of Inner Sheath.(MINIMUM)

MM2

Armoured

Unarmoured

Armoured

Unarmoured

MM

1.5

1.1

0.8

1.24

1.24

0.3

2.5

1.2

0.9

1.24

1.24

0.3

4.0

1.3

1.0

1.24

1.24

0.3

6.0

1.3

1.0

1.24

1.24

0.3

10.0

1.3

1.0

1.24

1.24

0.3

16.0

1.3

1.0

1.40

1.40

0.3

25.0

1.5

1.2

1.56

1.56

0.4

35.0

1.5

1.2

1.72

1.72

0.5

50.0

1.7

1.4

2.20

2.20

0.6

70.0

1.7

1.4

2.84

2.84

0.7

95.0

1.9

1.6

3.00

3.00

0.7

120.0

1.9

1.6

3.00

3.00

0.7

150.0

2.1

1.8

3.00

3.00

0.7

185.0

2.3

2.0

3.00

3.00

0.7

240.0

2.5

2.2

3.00

3.00

0.7

300.0

2.7

2.4

3.00

3.00

0.7

400.0

3.0

2.6

3.00

3.00

0.7

500.0

3.4

3.0

3.00

3.00

0.7

630.0

3.9

3.4

3.00

3.00

0.7

800.0

3.9

3.4

3.00

3.00

0.7

1000.0

3.9

3.4

3.00

3.00

0.7

 

SA CABLES ARMOURED / UNARMOURED CABLES

PVC INSULATED HEAVY DUTY POWER & CONTROL CABLES

Typical Examples of Design & Construction As per IS 1554

Power Cable

 

Control Cable

Steel strip, armoured

 

Steel strip, armoured

 

IS Specification

 

Conductor:

8130

Conductor:

EC Grade

 

High Conductivity

Aluminium

 

Grade Copper

Insulation:

5831

Insulation:

PVC Type

 

PVC Type

A or C

 

A or C

Inner Sheath:

5831

Inner Sheath:

PVC Type

 

PVC Type

ST1 or ST2

 

ST1 or ST2

Armour:

3975

Armour:

Galvanized

 

Galvanized

Steel Strip

 

Steel Strip

Outer Sheath:

5831

Outer Sheath:

PVC Type

 

PVC Type

ST1 or ST2

 

ST1 or ST2

CORE IDENTIFICATON

For power cables and control cables upto 4 cores,
The cores are identified by different colours as per IS 1554:

Single Core:

Red, Yellow, Blue, Black etc.

2 Core:

Red and Black

3 Core:

Red, Yellow, and Blue

3 1/2 Core:

Red, Yellow, Blue, and reduced neutral core in Black

4 core:

Red, Yellow, Blue and Black

5 Core:

Red, Yellow, Blue, Black and Grey

When the number of cores exceeds 5, two adjacent cores are Blue for reference and Yellow for direction in each layer. The remaining cores in each layer are Grey.

On specific request we can also provide core numbering for control cables.

Classification Of PVC Compound

 

Type

Application

Max. Conductor Temperature

A

Insulation

700C

C

Insulation

850C & 1050C

ST1

Sheath

700C

ST2

Sheath

900C

 

PRODUCT CODE

As per IS 1554 / Part-l /1998, the product is coded by alphabets:

Aluminum conductor
(No abbreviations are used for copper.)

A

PVC insulation

Y

Steel round wire armour

W

Steel strip armour

F

Steel double round wire armour

WW

Steel double strip armour

FF

PVC outer sheath

Y

Al wire armour

AW

This product code is stenciled on the surface of the drum flange.Note: Conductor construction classified as
re: single strand
rm: multi-stranded circular
sm: sector shaped

Current Ratings

 

 The current ratings given in tables are based on normal conditions of installation described below:

 

1. Maximum Conductor                            70°C for PVC Insulation & 85°C for HRPVC Insulation

Temperature

2. Thermal Resistivity of soil                 150°C cm/w

3. Thermal Resistivity of PVC                   650°C cm/w

4. Ground temperature                             30°C

5.. Ambient air temperature                      40°C

6. Depth of laying                                      75 cms

(to the highest point of cable laid direct in the ground)

 

Cables shall only be operated at their full rating if the minimum current at which circuit protection is designed to operate does not exceed 1.5 times (in the case of cables in air or in ducts) or 1.3 times (in the case of cables laid direct in the ground) the values tabulated, in tables VI to VIII.

 

Duration of short ckt. in sec.

1 cycle =0.02 s

2 cycles

5 cycles

10 cycles

25 cycles

50 cycles

2 sec.

3 sec.

4 sec.

5 sec.

Short ckt. Constant per unit area

536

378

239

169

107

75.5

53

43.6

37.8

 

34.0

 

Note: For cables in air, no reduction in current rating is necessary provided that      

1.The horizontal clearance between circuits is: (a) not less than six times the overall diameter of an individual cable, and (b) not less than the overall width of an .individual circuit, except that the horizontal clearance need not in any case exceed 150 mm.

2. The vertical clearance between circuits is not less than 150mm.

 

3. If the number of circuits exceeds 4, they are installed in a horizontal plane.

 

However, for installation conditions other than above, current rating factors incorporated in IS 3961 Part II may please be applied.

The following points should be taken into consideration before selecting any particular size and type of cable:

 1 . The system of power & voltage source where the cables are being used.

 2. Conditions ofinstallation at site.

 3. Current carrying-capacity of cable.

 4. Voltage drop of the cable.

 5. Short circuit capacity of cable.

 6. Availability ofthe selected size of cable.

 

 

 

 

 

Current Rating of SA CABLES Copper Armoured / Unarmoured Cables 650 /1100 V Grade in Air

 

Area, Sq. mm.

Twin Core, Amp.

3, 3.5, 4 Core, Amp.

25

105

90

35

125

110

50

155

135

 

Note: The entire range of Power and Control cables can be supplied with Flame Retardant Low Smoke (FRLS) or Halogen Free Flame Retardant (HFFR) sheathing on request.

 

Tables I to III: Copper Conductor. PVC Insulated. PVC Sheathed Cables

 

Table I: 2 Core, 3 Core & 4 Core Copper Conductor, PVC Insulated, PVC Sheathed,

Unarmoured (YV) / Armoured (YWY & YFY) Cables  650 /1100 Volts

 

 

 

Unarmoured

 

 

Armoured

 

 

 

A.C. Current Rating

 

 

 

 

 

 

 

 

 

 

Max. D.C.

InAir

In Ground

No. of

Nom.

Nom.

Approx.

Approx.

Nom.

Approx.

Approx.

Conductor

PVC

HRPVC

PVC

HRPVC

Cores

Cross

Thickness

Overall

Overall

Steel

Overall

Weight

Resistance

Insulation

Insulation

Insulation

Insulation

 

Sectional

of PVC

Dia.mm.

Weight

Armour

Dia.mm.

kg./km.

at 20'C

Amps.

Amps.

Amps.

Amps.

 

Area

Insulation

 

kg./km.

Size mm.

 

 

Ohm / km

 

 

 

 

 

Sq.mm.

mm.

 

W

F

 

 

 

 

 

 

 

2

4

1.0

14.5

290

1.4

 

17.5

640

4.61

35

43

41

48

2

6

1.0

15.8

390

1.4

 

18.6

780

3.08

45

55

50

58

2

10

1.0

18.1

520

1.4

 

20.9

960

1.83

60

73

70

81

2

16

1.0

20.6

705

 

4x0.8

22.6

1045

1.15

78

95

90

105

3

4

1.0

15.4

380

1.4

 

18.2

760

4.61

30

37

36

42

3

6

1.0

16.6

460

1.4

 

19.4

880

3.08

39

48

45

53

3

10

1.0

19.6

640

1.4

 

22.8

1120

1.83

52

63

60

69

3

16

1.0

21.3

875

 

4x0.8

23.3

1245

1.15

66

81

77

90

4

4

1.0

16.6

410

1.4

 

19.4

810

4.61

30

37

36

42

4

6

1.0

18.0

570

1.4

 

20.8

1030

3.08

39

48

45

53

4

10

1.0

20.1

795

 

4x0.8

22.1

1160

1.83

52

63

60

69

4

16

1.0

23.1

1100

        4x0.8

24.7

1490

1.15

66

81

77

90

 

 

Table II: 1.5 Sq. mm.,.Solid Copper Conductor, PVC Insulated, PVC Sheathed,

 Unarmoured (YV) / Armoured (YWY & YFY) Multi Core Control Cables  650 /1100 Volts

 

 

 

Unarmoured

 

         Armoured

 

 

 

A.C, Current Rating

 

 

 

 

 

 

 

 

 

Max. D.C.

In Air

In Ground

No. of

Nom.

Approx.

Approx.

Nom.

 

Approx.

Approx.

Conductor

PVC

HRPVC

PVC

HRPVC

Cores

Thickness

Overall

Overall

Steel

 

Overall

Weight

Resistance

Insulation

Insulation

Insulation

Insulatiqn

 

of PVC

Dia.mm.

Weight

  Armour

Dia.mm.

kg. / km.

at 20'C

Amps.

Amps.

Amps.

Amps.

 

Insulation

 

kg. / km.

  Size mm.

 

 

Ohm / km

 

 

 

 

 

mm.

 

W

Y

 

 

 

 

 

 

 

2

0.8

12.6

180

1.4

 

14.4

420

12.1

20

24

23

27

3

0.8

13.0

210

1.4

 

15.0

480

12.1

17

21

21

24

4

0.8

13.5

250

1.4

 

15.5

530

12.1

17

21

21

24

5

0.8

14.5

290

1.4

 

16.0

600

12.1

14

17

17

19

6

0.8

14.6

330

1.4

 

17.0

670

12.1

13

16

15

18

7

0.8

14.6

340

1.4

 

17.0

680

12.1

12

15

14

17

9

0.8

18.0

430

1.4

 

19.0

800

12.1

12

14

14

16

10

0.8

18.6

470

1.4

 

20.5

900

12.1

11

13

13

15

12

0.8

18.6

500

 

4x0.8

19.7

820

12.1

10

12

12

14

14

0.8

20.0

580

 

4x0.8

20.5

930

12.1

10

12

11

13

16

0.8

22.0

640

 

4x0.8

21.5

1020

12.1

9

11

11

12

19

0.8

23.0

720

 

4x0.8

22.6

1105

12.1

9

10

10

12

24

0.8

26.0

910

 

4x0.8

25.6

1350

12.1

8

10

9

11

27

0.8

27.0

970

 

4x0.8

26.0

1420

12.1

8

9

9

10

30

0.8

27.0

1050

 

4x0.8

26.9

1520

12.1

7

9

9

10

37

0.8

28.0

1260

 

4x0.8

28.6

1730

12.1

7

8

8

9

44

0.8

32.0

1460

 

4x0.8

32.0

2000

12.1

6

7

7

8

52

0.8

33.0

1680

 

4x0.8

33.0

2250

12.1

6

7

7

8

61

0.8

35.0

1930

 

4x0.8

34.5

2520

12.1

6

7

6

7

 

 

 

 

Table III: 2.5 Sq. mm., Solid Copper Conductor, PVC Insulated, PVC Stteathed,

 Unarmoured {YV} / Armoured {YWY & YFY} Multi Core Control Cables - 650 /1100 Volts

 

 

 

Unarmoured

 

Armoured

 

 

 

A.C. Current Rating

 

 

 

 

 

 

 

 

 

Max. D.C.

In Air

.In Ground

 

 

 

 

 

 

 

 

 

 

 

 

 

No. of

Nom.

Approx.

Approx.

Nom.

 

Approx.

Approx.

Conductor

PVC

HRPVC

PVC

HRPVC

Cores

Thickness

Overall

Overall

Steel

 

Overall

Weight

Resistance

Insulation

Insulation

Insulation

Insulation

 

of PVC

Dia.mm.

Weight

Armour

Dia.mm.

kg./ km.

at 20'C

Amps.

Amps.

Amps.

Amps.

 

Insulation

 

kg. / km.

Size mm.

 

 

Ohm / km

 

 

 

 

 

mm.

 

W

Y

 

 

 

 

 

 

 

2

0.9

14.0

240

1.4

 

16.0

570

7.41

27

3:C

32

37

3

0.9

14.0

290

1.4

 

16.8

620

7.41

24

29

27

31

4

0.9

15.0

350

1.4

 

18.0

690

7.41

24

29

27

31

5

0.9

17.0

400

1.4

 

19.0

770

7.41

19

23

23

27

6

0.9

18.0

450

1.4

 

20.1

880

7.41

18

21

21

25

7

0.9

18.0

490

1.4

 

20.1

900

7.41

17

20

20

23

9

0.9

20.0

630

 

4x0.8

21.0

951

7.41

16

19

19

22

10

0.9

21.0

680

 

4x0.8

23.0

1000

7.41

15

18

18

20

12

0.9

22.0

790

 

4x0.8

23.0

1100

7.41

14

17

17

19

14

0.9

24.0

870

 

4x0.8

24.0

1250

7.41

13

16

16

18

16

0,9

24.7

970

 

4x0.8

25.6

1390

7.41

12

15

15

17

19

0.9

25.5

1100

 

4x0.8

27.5

1500

7.41

12

14

14

16

24

0.9

30.6

1390

 

4x0.8

32.0

1900

7.41

11

13

13

15

27

0.9

31.0

1440

 

4x0.8

32.0

2000

7.41

10

12

12

14

30

.0.9

32.5

1600

 

4x0.8

33.0

2190

7.41

10

12

12

13

37

0.9

33.1

1950

 

4x0.8

34.5

2500

7.41

9

11

11

12

44

0.9

37.6

2300

 

4x0.8

38.5

2900

7.41

9

10

10

11

52

0.9

39.5

2600

 

4x0.8

4'0.0

3300

7.41

8

9

10

11

61

0.9

41.5

2950

 

4x0.8

42.5

3750

7.41

8

9

9

10

Note: The sizes up to 50 Sq. mm. X 4 Core available on request

 

 

 

 

 

Recommendations for Storage & Insulation of Cables

For easy and'convenient installation conditions, and desired performance following recommendations are made:

1) No drums should be stored one above the other.

2) Drums should be stored preferably on a plain ground without having any projected hard stones above the ground surface. The drums should be       stored   preferably in the shed.

3) Drums should be stored and kept in such a way that bottom cable end does not get damaged.

4) Drums should be rotated only in the direction mark on the drum.

5) While laying of the cable.in a trench the cable end should be pulled with pulling eye only after mounting the drum on the jacks.

6) 100% drums shall be checked for continuity and cross continuity tests to ensure that there is no internal damage to cable during transportation.

7) Insulation resistance shall be measured with 500V megger between the cores and all the cores to earth (Armour).

8) After the cable is installed, before commissioning it shall be tested for high DC voltage test. Recommended volts and duration of test between each   core and metallic armour (earth) at 3KVDC is for 5 minutes. During High Voltage test all the electrical equipments related to the cable installation must be earthed and adequate clearance should be maintained from the,other equipments and from work to prevent flash over.

     9) Where the cable is to be joined with an existing cable, the sequence of cores at the two ends to be joined should be in the opposite direction i. e. if at one end it is the clockwise direction, at the other end it should be in the anti-clockwise direction. This is neccessary to avoid the crossing of cores while jointing. This will also decide the direction in which the cable is to be pulled.

      10) The minimum bending radius for cable should not be less than the values shown below, wherever possible 25% higher value should be adopted.

8 x overall diameter: Single core (As per table I).

The 12 x overall diameter: Multi core (As per table VI, VII & VIII).

11) Avoid excessively high temperature when sealing joints of cable. Cool the sealant to about 100'C before pouring.  

 

Introducing  India’s  only  &  first  ever  range  of  multi-solid  flexible  cables.

 Applications: Suitable for use in conduit and for fixed, protected installation. Ideal for high density wiring. Wiring in all installations where fire safety is of utmost importance. Schools, theaters, commercial complexes, apartments, high rise buildings, laboratories, etc

Conductor: Thin strands of Electrolytic Copper are multi - drawn simultaneously for uniformity of Resistance, Dimension, and Flexibility. The drawn strands are uni-laid in high precision machines and compacted. A perfectly circular conductor is thus formed. This enables reduction in overall diameter for space saving in high density wiring. The strands do not get cut when stripping the insulation. The conductor offers perfect contact at pins, terminals and sockets. This eliminates spot heating and sparking. The cables are printed with generic marking.

Colours: Red, Yellow, Blue, Black, Green, Green/Yellow, Grey

Insulation: Specially formulated grade of Halogen Free Flame Retardant (HFFR) compound is used. The insulation does not burn readily. It does not melt and drip, smoke is negligible, transparent, non toxic. The victims trapped in fire do not suffocate and this facilitates fire fighting operations. Unlike PVC, the smoke emitted is non-corrosive. Suitable for low temp. areas stands from -55 deg. C to 300 deg. C.
Insulation conformity: IEC 60332-1 & 3, IEC 60754-1&2 

Packing: 90 mtrs. coils packed in protective cartons.

                       Physical and Electrical Properties of multi-solid flexible cables

Cross section

Area sq.mm

Overall Dia.,

mm., Max

Insulation Thickness,

mm., Nom

Conductor  Config.

No. of Wires/

Nom. Dia

Conductor Resist.

Ohm/km at

20° C Max

Max. current rating, Amp

.75

2.8

0.6

5/.4

26

9

1.0

3.0

0.6

7/.4

19.5

14

1.5

3.80

0.6

11/.4

13.3

18

2.5

4.0

0.7

19/.4

7.98

24

4.0

4.8

0.8

30/.4

4.95

32

6.0

6.4

0.8

45/.4

3.30

42

10.0

8.0

1.0

75/.4

1.91

55

16.0

9.6

1.0

121/.4

1.21

75

 

Co-Axial Cables for CATV Networks

                                                          

- High quality Co-axial for Cable TV network
- Notch free attenuation values over wide range of frequencies
- The special jacketing offers increased life even in rugged conditions

Conductor: The central conductor is made of solid electrolytic grade copper conductor, which has distinct advantages
over traditional copper conductor.

Insulation: The insulation provided over the conductor is of foam PE which acts as a dielectric.

Screen: Aluminium Mylar tape is provided over the insulated conductor to shield the conductor and ensure disturbance free transmission of signals.

Braiding: The braiding is generally provided with 60% coverage of ATC (Annealed tinned copper) / AL (alloy).

Marking: The cables are marked .


PVC Electrical Conduit Pipes & Fittings

Ensure total protection to your wire & cables
Salient Features
-> Adaptable to standard concealed wiring system as per IS: & BS:
-> Virgin Suspension grade K-67 PVC.
-> Processed on twin screws extruders.
-> Minimum filler ensures high impact strength.
-> Unplasticised PVC Formulation to Improve the mechanical strength.
-> UV stabilized.
Range of Products:
Pipes :
PVC Electrical Conduit Pipes are available in sizes of 20mm, 25mm, 32mm, 40mm, 50mm, & 63mm with mechanical strength of light (LMS ), Medium(MMS), Heavy(HMS) series as per IS:9537 part-III - 1983 standards. These pipes are available in standard length of 3 mtrs.
Fittings:
Coupler, Reducer, Fabricated Bend .
Colors : Ivory, Grey & Black
Technical Data
Mechanical Properties
-> Percentage of Compression with specified load less than 25%
-> Percentage of Compression without load less than 10%
-> High Impact Strength
-> Tensile Strength - 390-420 Kg./cm2
Thermal Properties
-> Working Temp. = 70°C
-> Burning rate = Self Extinguishing
-> Flammability = UL94V-0
-> Flame Die out Time = Less than 30 seconds.

 

PVC Casing Capping / Trunking

SA-Presents a durable wiring system that matches the stringent electrical safety standards for your home, office & showroom. Made from unplasticised high impact strength Polyvinyl Chloride. SA Trucking enhances your interiors while allowing easy access for maintenance.
Salient Features:
-> High impact strength & robust configuration
-> Unplasticised formulation ensures no change in dimension/shape even after prolonged use / storage
-> Many sizes to suit different applications
-> Available in Ivory / white Colour
Thermal Properties
» Working temp.: 60° C - 65° C
» Flammability: UL 94V - O
» Burning rate: Self extinguishing (ASTM D635)
» Flame die out time: Less than 30 seconds
Sizes(in mm):
25x16,30x15,38x19
Chemical Properties
» Water absorption: 0-10 - 0 - 25% weight in 24 hrs.(ASTM D570)
» Effect of acids & alkalies : Highly resistant (ASTM D543)
Electricals Properties
» Dielectric constant: 1.7 -3.00 (ASTM D 150)
» Insulation resistance: more than 100 megaohms
» Electric Strength: No breakdown at 2kv x 50 Hz. for 15 minutes.

About Us

From modest beginning in 1995 when our first unit of the manufacturing of PVC Cables was set up SA has grown from strength to strength over the years.

We have been expanding and diversifying rapidly and today we have been recognized as one of the leading and fast expanding company in PVC Cables ,PVC Pipe manufacturing, PVC Casing Capping/ Trunking, PVC Compound, Copper/ Aluminium Wire Drawing
Read More

Testimonials

It has been a great pleasure doing business with you. Your Company should be forever grateful to have such polite and professional staff members working for them. You were able to handle my order with great ease and professionalism your experience and politeness will certainly make me recommend others to do business with your company in the future.

Alba Group
Managing Director