Unit 6

CONDUCTORS AND WIRING ACCESSORIES

INTENDED LEARNING
OUTCOMES:

After completing this unit,

you are expected to:

differentiate wire to a cable.

identify the different wires and cables used in various
electrical system.
to convert sizes of wires to different units.
to find the size of wire in a given amount of current.
to discuss the importance of raceways in wiring
installation.
identify different wiring accessories.
 Resistance wire
ohm cable
resistor stranded wire
Conductance solid wire
mil resistivity
circular mil

6.1 Classification of Materials According to Conductivity

Conductors – are substances or materials used to convey or allow the flow of electric
current.

Materials Considered as Good Electric Conductors are:

1. Silver 7. Zinc
2. Copper 8. Platinum
3. Gold 9. Iron
4. Aluminum 10. Lead
5. Nickel 11. Tin
6. Brass

Insulators – are substances or materials that resist the flow of electric current.

Various Kinds of Insulators:

1. Rubber 7. Latex
2. Porcelain 8. Asbestos
3. Varnish 9. Paper
4. Slate 10. Oil
5. Glass 11. Wax
6. Mica 12. Thermoplastic

Resistance as already discusses, is due to the friction between the flow of current,
and the conductor as well as the insulator. There is no such thing as perfect conductor, or
perfect insulator, because conductors, insulators, and resistors, are resistive materials.
Good conductors are those substances with extremely low resistance to current flow.
On the other hand, good insulators are those with extermeney high resistance to
current and moderate resistance to load resistor.

Conductor Insulators
 Electrical conductors are made in numerous designated by letters according to the
kind of insulation used. The conductor insulator serves as physical shield of the wire
against heat, water and other elements of nature. Insulation is rated by voltage from 300 to
15,000 volts. If the insulation used is above its specified rating, the risk of breakdown is
high which might cause short circuit and arcing that may result to fire. Ordinary conducot
wires for building is rated at 300 or 600 volts.

Conductor

Conductor Insulator

6.2 Wire and Cables

Wires are those electrical conductors 8 mm2 (AWG No. 8) and smaller sizes. Cables on the
other hand, are those which are larger than wires.

A cable is usually an assembly of one or more wires running side by side or bundled.

Wires and cables are either:

A. Stranded
A. Solid
Starndded Wire – consists of a group of wires twisted to form a metallic string. The
circular mil area of a stranded wire is found by multiplying the circular mil area of aech
strand by the total number of strand.

Cord – is the term given to an insulated sranded wire.

Mil – prior to the adoption of the Metric System (SI), all electrical wires and cable sizes
were expressed in terms of AWG (American Wire Gage) . The word mil thhta is equal to
1/1000 of unch was used to describe or measure a round wire diameter. If a wire has a
diameter of one mil, it has a cross sectional area of one circular mil.

Table 6-1 Different Types of Electric Wires and Cables

Product Description Operating Size Range Usage

Temperature

TW oil resistance 60°C 1.60 mm- Ordinary

thermoplastic 500 mm2 building wire
solid and
stranded
THW oil, heat and 75°C 1.60 mm- Building wire
moisture resistant 500 mm2 Wet and dry
thermoplastic solid and location
stranded
TF thermoplastic 60°C 0.60 mm- Fixture wire
Fixture wire 0.3 mm2 Single conductor
solid and 2-conductor
stranded twisted or
parallel
3-conductir
twisted
Copper line wire #12 – 1000 Polyethylene
MCM insulated
solid and weather
stranded resistant wire

Aluminum line wire 75°C 12 – 400 Polyethylene

AAC insulated
weather
resistant wire

Bare Copper Copper Bare overhead

Wire (solid) and 1.60 mm- Transmission
stranded 500 mm2 line
and for ground
wire
High-Temperature 105° #18 - # 8 Appliance
wire C machine
Tool, motor
load, and
Switchboard
wires
Armored (BX) cable 60°C 1.50 mm- General purpose
0.30 mm2
solid and
stranded
2-3 and 4
conductors

Coaxial cable  Home video

equipment
 Cable televison
 Measurement
electroncis
 Ham radio
setups

Automotive wire 105° #18 - # 2 Primary wire

C spark
plug and battery
cable

Power cable 60°C #14 - #10 Power cable for

#8 – 1000 aerial AND
MCM DUCT 600
VOLTS
Power cable for
aerial duct and
direct burial 600
volts
Non-metallic 60°C 1.60 mm- For exposed or
sheathed Cable 2.60 mm2 concealed works
Type NM 2-3 and 4 in air voids in
conductors masonry blocks
Round or or tile walls not
flat exposed to
excessive
moisture or
dampness, 600
volts

Appliance or electric No 22 – No. Heating

stove heater cord 12 equipment
Dry location

Jacketed wire 22/3 Extension cord

Conductors Telephone
equipment

Telephone drop 75°C No. 17/2 Service drop

Wire flat or twisted 19/2 from pole
or ESW

Self-supporting 6 pairs thru Arial insulation

Telephone cable 300 pairs
Intercom cable 1 pair thru Interior
Shielded or 100 pairs communications
unshielded and sound
system

ADT telephone cable 6 pairs thru For aerial and

(REA specs.) 909 pairs duct installation

DBT telephone cable 6 pairs thru For aerial and

(REA specs.) 909 pairs duct installation
GTO - 15 #14 Gas tube-oil
burner ignition
cable

Welding cable 60°C #6 - #8 For control

multi- circuits, aerial
conductors ducts and direct
burial

Royal cord 60°C No. 22 – No. Portable cords

4 2, 3 and 4
conductors
 Submersible pump 60°C #14 - # 1 For submersible
cable 2 and 3 pumps of deep
conductors water wells
Round
connection

Magnet wire 200° #14 -#30 For sealed

MW 200 C Single and hermetic motors
heavy class 14
insulation
MW 130 130° #7 - #13 Class A
C and insulation
#31 - #44
Single and
heavy
MWC 105 105° #7 - #13 Cotton covered
C Class A and
Class H
insulation
MWC 200 200° #14 - #30 Cotton covered
C Class A and H
insulation

Source: Marton Wires and Cables

Table 6-2 Characteristics of Selected insulated Conductors for General Wiring

Trade name Type Operating Application Provision

Letter Temperature
Moisture and heat resistant rubber KHW 75°C Dry and wet location
Thermoplastic T 60°C Dry location
Moisture resistant thermoplastic TW 60°C Dry and wet location
Thermoplastic heat resistant THHN 90°C Dry location
Moisture and heat resistant thermoplastic THW 75°C Dry and wet location
Moisture and heat resistant thermoplastic THWN 75°C Dry and wet location
Moisture and heat resistant cross-linked XHHW 90°C Dry location
thermosetting
Polyethylene P 75°C Wet location
Silicon asbestos SA 90°C Dry location
Asbestos and varnish cambric AVA 110 Dry location
SOURCE: The National Electrical Code
 21-Strand Conductor

Figure 5.1 Cross Section of a Cord

Diameter of each strand = 2 mils

Circular mil area = d2 = 22 = 4 circular mils
Total circular mil area of conductor is:
4 x 21 = 84 circular mils

6.3 The Cross sectional Area in Circular Mils

CM = circular mils

Area = d2 circular mils where d is the diameter expressed in mils

Area = r2 square mils where r is the radius in mils

1 mil = 1/1000 in
Conversion Factor

Square mil = Square inch x 0.000001

Square inch = Square mil x 1,000,000
Square mil = Circular mil x 0.7854
Circular mil = Square mil x 1.273
Square millimeter = Circular mil x 0.0005067

Example. What is the equivalent size in square millimeter of a cable 250 MCM?

Solution:
MCM stands for thousand circular mils
250 MCM = 250,000 circular mils

Square millimeter = Circular mil x 0.0005067

= 250,000 x 0.0005067
= 126.67 mm2

Example. What is the area in circular mils of a wire with a diameter of 0.125 in.?
Solution:
1 mil
0.125∈x mils
0.001∈¿=125 ¿

Area=d 2=( 125)2=15,625 circular mils

Table 6-3 Table of Circular Mil- Area Equivalent

Size Area Size Srea

AWG or MCM Circular mils AWG or MCM Circular mils
18 1,620 1 83,690
16 2,580 0 105,600
14 4,110 00 133,100
12 6,530 000 167,800
10 10,380 0000 211,800
8 16,510 250 250,000
6 26,240 300 300,000
4 41,700 350 350,000
3 42,620 400 400,000
2 66,360 500 500,000

Table 6-4 Physical Properties of Bare Conductors

Size Area Diameter (inch) DC resistance

AWG or MCM Circular Mils Solid Stranded Ohms/1000 ft
At 25°C
16 2,580 0.0508 4.10
14 4,110 0.0641 2.57
12 6,530 0.0808 1.62
10 10,380 0.1019 1.02
8 16,510 0.1285 0.64
6 26,240 0.1620 0.184 0.41
4 41,700 0.2040 0.232 0.26
2 66,360 0.2580 0.292 0.13
1 83,690 0.2890 0.332 0.13
0 105,600 0.3250 0.373 0.10
00 133,100 0.3650 0.418 0.081
000 167,800 0.4100 0.470 0.064
0000 211,800 0.4600 0.528 0.051
250 250,000 0.5000 0.575 0.043
300 300,000 0.5480 0.630 0.036
400 400,000 0.6320 0.728 0.027
500 500,000 0.7070 0.813 0.022
Source: Extracted from the National Electrical Code

6.4 Different Types of Cables

Armored Cable (AC) is a fabricated assembly of insulated conductors enclosed in
flexible metal sheath. Armored cable is used both on exposed and concealed work.

Metal Clad Cable (MC) is a factory assembled cable of one or more conductors each
individually insulated and enclosed in a metallic sheath of interlocking
tape of a smooth or corrugated tube. This type of cable is especially
used for service feeders, branch circuit, and for indoor or outdoor work

Mineral Insulated Cable (MI) is a factory assembly of one or more conductors

insulated with a highly compressed refractory mineral insulation
enclosed in a liquid and gas tight continuous copper sheath. This type of
cable is used in dry, wet, or continuously moist location as service
feeders or branch circuit.

Non-metallic Sheathed Cable (NM) is also a factory assembly of two or more

insulated conductors having a moisture resistant, flame retardant, and
non-metallic material outer sheath. This type is used specifically for one
or two family dwellings not exceeding 3-story buildings.
Shielded Non-Metallic Sheathed Cable (SNM) . This type of cable is a factory
assembly of two or more insulated condcutors in an extruded core of
moisture resistant and flame retardtand material covered within an
overlapping spiral metal tape. This type is used in hazardous locations
and in cable trays or in raceways.
Underground Feeder and Branch Circuit Cable (UF) is a moisture resistant cable
used for undergroung connections including direct burial in the ground
as feeder or branch circuit.

Service Entrance Cable is of the types SE and USE. A single or multiconductor

assembly provided with or without an over all covering primarily used
for service wire.

Power and Control Tray Cable (TC). This is a factory assembled two or more
insulated conductors with or without associated bare or covered
 grounding under a metallic sheath. This is used for installation in cable
trays, raceways, or where supported by messenger wire.

Flat Cable Assemblies (FC). Is an assembly of parallel conductors formed integrally

with an insulating material web designed especially for field installation
in metal surface or raceways.

Flat Conductor Cable (FCC) consists of three or more flat copper conductor placed
edge to edge separated and enclosed within an insulating assembly.
This type of cable is used for general purposes such as appliance branch
circuits, and for individual branch circuits, especially in hard smooth
continuous floor surfaces and the like.
Medium Voltage Cable (MV Cable) is a single or multi-conductor solid dielectric
insulated cable rated at 2,000 volts or higher. This type is used for
power system up to 35,000 volts.

6.5 Ampacity of Electrical Conductors

Ampacity is defined as the ability of the wire or conductor to carry current without
overheating. Conductor resistance to current flow, generate not only
heat but also contribute to the voltage drop expressed in the following
equations:

Voltage drop in wire = Circuit current x resistance in wire

Power loss in wire = Circuit current x voltage drop

p = I X (I x R)

P = I2 R

Power loss is equal to the components resistance time the current squared. The
power loss being converted into heat, must be dissipated. A small wire
diameter can safely carry more current in proportion to its weight. The
use of copper wire is most preferred. The National Electrical Code
provides that:

“Conductor size and rating shall have sufficient ampacity to carry load. They shall
have adequate mechanical strength and shall not be less than the rating
of the branch circuit and not less that the maximum load to be served.”

Conductor Ampacity is determined by the maximum operating temperature that its

insulation can withstand continuously without heating. Current flow
 and conductor’s resistance normally generates heat. Thus , the
operating temperature depends upon the amount of current flow, wire
resistance, and environment. Environment refers to either enclosed or
open condition which the wire is placed.

The ampacity or ability of the conductor to carry load , increases as the sizes of
conductor increases. If more than 3 conductors are inserted into a
conduit, the temperature also increases and it requires derating of the
conductors ampacity as prescribed in Table 6-5, 6-6, and 6-7.

Table 6-5 Allowable Ampacities of Insulated Copper Conductors not more than 3
Wires in Raceway.

Size Temperature Ratings of Conductor

60°C 75°C 90°C 110°C
Mm 2
AWG Type Types Types Type
MCM T RHW SA AVA
TW THW RHH
THWN THHN
XHHW XHHW
2.0 14 15 A 15 25 30
3.5 12 20 A 20 30 35
5.5 10 30 A 30 40 45
8.0 8 40 A 45 50 60
6 55 65 70 80
4 70 85 90 105
3 80 100 105 120
2 95 115 120 135
1 110 130 140 160
0 125 150 155 190
00 145 175 185 215
000 165 200 210 245
0000 195 230 235 275
250 215 255 270 315
300 240 285 300 345
350 260 310 325 390
400 280 335 360 420
500 320 380 405 470

600 355 420 455 525

700 385 460 490 560
750 400 475 500 580
800 410 490 515 600
 900 435 520 555

Table 6-6 Current Carrying Capacity Derating Factors

Number of Conductors in a Derating Factor

Raceway
4 to 6 0.80
7 to 24 0.70
25 to 42 0.60
43 and above 0.50

Table 6-7 Typical Ambient Temperature

Location Temperature Minimum rating required
conductor insulation
Well-ventilated normally
heated building 30°C See note below

Building with such major heat source

as power stations or industrial
processes 40°C 75°C

Poorly ventilated spaces such as attics 45°C

Furnaces and boiler room Min. 40°C 75°C

Max. 60°C 90°C

Outdoor in shade air 40°C 75°C

In thermal insulation 45°C 75°C
Direct solar exposure 45°C 75°C
Place above 60°C 110°C

Note: 60°C up to No. 8 AWG copper wire and 75°C for bigger that No. 8
Source: The National Electrical Code

Derating of Conductors Ampacity – means that, the full amount of allowable ampacity, is reduced
to a certain percentage due to the environmental condition it is exposed of and the
 number of wire placed inside the conduit. The current rating of wire in free air
environment is higher than those placed inside the conduit. Consonant with this, if
the ambient temperature is above 30°C, the allowable ampacity will be reduced by
the factors given in Table 6-6.

6.6 Raceway

Raceways are channels or wiring accessories so designed for holding wores, cable or busbars that
are either made of metal. plastic, or any insulating medium.

The Purpose of Electrical Raceways are to:

1. provide a means for the running wires from one point to another.
2. physically protect wire.
3. provide a grounded enclosure.
4. protect the surroundings against the effect of fault in the wiring.
5. protect the wiring system from damage by the building and the occupants.
6. protect the building and the occupants from damage by the electric system.

The common types of raceways for household wiring installations are:

1. Conduit pipe
2. Wire or Cable raceway
3. Cable trays, cable bus

6.6.1 Conduit

Conduit pipe is the most common electrical raceways used for all types of construction. With
respect to the type of materials used, conduit maybe classified into:
 6.6.2 Wire or Cable Raceway

6.6.3 Cable Tray

In the electrical wiring of buildings, a cable tray system is used to support insulated electrical
cables used for power distribution, control, and communication. Wikipedia
6.7 Outlet

An outlet is a point in the wiring system at which current is taken to supply utilization equipment.

In a simple term, an outlet is any point that supplies an electric load.

Different Kinds of Outlet

1. Convenience outlet

2. Lighting outlet

6.7.1 Convenience outlet

Convenience outlet is a device that acts as a convenient source of electrical energy for
current consuming appliances. It is where the male plug of an appliance is inserted
and is usually fastened on the wall or connected in an extension cord.

Types of Electrical Outlets

 1. Standard Outlets

Chances are, standard outlets are the ones you see scattered about your home and office. You can plug in just about any
small appliance to them (TV, computer, hair dryer, toaster) because they supply a basic 120 volts of electricity.

GFCI Outlets
In rooms that sometimes get wet (kitchens, bathrooms, garages), you will usually find GFCI
(ground fault circuit interrupter) outlets. GFCI outlets can be identified by two special buttons in the center—one black
and one red. They contain a circuit breaker so that if water tampers with the outlet, the receptacle will turn itself off
without shutting off electricity in the rest of the house. You can use the black button to test the outlet and the red button
to reset it.
Range Outlets and Dryer Outlets
Some appliances in your house require too much power to work with standard outlets. A range outlet (top photo)
provides electricity specifically to your cooking range and is attached to its own circuit breaker. A dryer receptacle
(bottom photo) comes with four pins so that it can supply 240 volts of electricity. Some homes have dryer receptacles
with three pins, but these are fading out because new homes are required to be built with four-pin dryer receptacles.

USB Outlets
Finally, you may soon start to see standard outlets fitted with two extra holes—USB charging ports. These USB outlets
allow homeowners to plug in items that are charged using a USB connector, like cell phones and MP3 players. They’re
very convenient if you’re not near a computer, but they’re still quite rare.

6.7.2 Lighting Outlet

Lighting outlet is an outlet intended for direct connection to a lamp holder, lighting fixture, or a
pendant cord, terminating in a lamp holder.
6.8 Other wiring accessories

1. Junction box
2. Utility box
3. Receptacles
4. Pull box
5. Switches

6.8.1 Junction box

Junction boxes are metal or plastic enclosures used as housings for wiring connections. The

connections within are called branch circuits and usually represent the end of a conduit run.
Junction boxes make wire access easy, since all one must do is remove the covering to make
alterations, repairs, or additions to a conduit. Junction boxes also protect wiring from the
elements or environment, which can sometimes be corrosive or otherwise harmful to wiring
material. Finally, junction boxes protect wiring from unwanted tampering, whether malicious or
unintentional.

Type of Junction Box

6.8.2 Utility Boxes

Utility boxes are used for convenience outlets and switches.

Metal PVC Surface-Mounted Utility Box

6.8.3 Receptacle

Receptacle is defined by the National Electrical Code as:

“A contact device intsllaed at the outlet for the connection of a single attachment plug.”

It includes all receptacles and their matching cap (plug), wall switches, small dimmers, and
outlet box mounted lights.

6.8.4 Pull box

The Pull Box is a box with a blank cover that is inserted in one or more runs or raceways to
facilitate pullig in the conductors. It may also serve to distribute the conductors.
6.8.5 Switch

Switch is a device that opens or closes the circuitry in an electric circuit.

Three-gang switch Two-gang switch one-gang switch

6.9 Other Wiring Accessories:

(Can be made of metal or non-metal)