These documents include information on the type of the cable, cable length and detail alongside gable name, drawing name, Source and destination (from-to) and electrical drawing number. In some documents, the cable gland is required to be specified in this document.
Equipment list (Step2) IO List (Step3) Network List (Step4) provide all the required component 

CABLE NAME CABLE FROM CABLE TO DESCRIPTION Drawing Page Ref for Connection.Page/Grid Length (m) / Quantity 2.5mm² 3 Core + E + N (Power Bus) 2.5mm² 3 Core + E (Motor Cable) 2.5mm² 2 Core + E (24VDC supply) 1.5mm² 4 Core (E/Stop + Control) Grey control, Numbered cores 1.5mm² 16 Core + E Grey control, Numbered cores 3C & E (2.5mm) with Plug Fitted Unscreened, 3m (DMS Power) 3C+SC & E (2.5mm) with Plug Fitted Screened, 3m (DMS to Motor) V1-G-5M-PUR 5m 4 Core M12 to free end for PEs V31-GM-5M-PUR 5m 4 Core M8 to free end for PEs VAZ-2T1-FK-5M-PUR-V1-W ASi network splitter cable Profibus Cable (Purple) ASi Cable (Yellow) ASi Cable AUX (Black)
-W_BTM003/BLG.BDT.23 BTM003 BLG.BDT.23 MCP TO Collector Belt -550/13 43 X
-W_BTM003/BlG.BDT.23n BTM003 BlG.BDT.23n MCP TO Collector Belt -551/13 33 X
-W_BTM003/BUS_3 BTM003 BUS_3 MCP bus to BTG.BDT.24 -053/32 28 X
-W_BTM003/BUS_2 BTM003 BUS_2 MCP bus to BTG.BDT.302B -053/22 35 X
-W_BTM003/BT1.29A.RMCP – P BTM003 BT1.29A.RMCP – P MCP TO RMCP -053/07 35 X
-W_BTM003/BT1.29B.RMCP – P BTM003 BT1.29B.RMCP – P MCP TO RMCP -053/07 35 X
-W_BTM003/ICM ABD 1&2 – P BTM003 ICM ABD 1&2 – P MCP TO ABD (Power) -053/42 35 X

Cable selection guide:

To calculate the Cable Sizing one needs to know the load parameter. The load parameters are:

Voltage (V): Specify the voltage 

Phase arrangement: 1 Phase AC, 3 Phase AC or DC.

Load (kW, kVA, A, hp): Specify the load in kW, kVA, A, or hp. At the end of the day we use Amps as the main parameter but quite easy to convert from power to Amps as long as we know the voltage and Power factor.

PF: Specify the load power factor (cos&Phi) when the load is specified in kW or hp.

Max. volt drop (%): The maximum allowable voltage drop at the load. mentioned in the equipment documents.

Distance (m): The cable length in meters from the source to the load. The return length is automatically included by the calculator.

Cable type: The number of cores in the cable. Ignore the earth conductor in three-phase cables.

Insulation type: The type of insulation. Typically “Thermoplastic (PVC), 75°C” or “Thermoset (XLPE), 90°C”. In special cases “Thermoset (XLPE), 110°C” is used. Note that there is no option for “Thermoplastic (PVC), 90°C” (V-90) cables in AS/NZS 3008. In this case, you can use “Thermoset (XLPE), 90°C” in the calculator. However, bear in mind that V-90 cables cannot be exposed to high mechanical stress at 90°C. Refer to AS 3008 for more details.

Live core type: Copper, Flexible copper or Aluminium.

Live core size: Mostly we are seeking for smallest cable that meets the three criteria for current rating, voltage drop, and fault current rating.

Earth core type: Only copper is currently supported. 

Earth core size: selecting Minimum Copper Earthing Conductor Size is preferable, although mostly the standard cable cover this part automatically.

The number of parallel cables (multi-core) or Active cables per phase (single-core): parallel cables is a series of cable that carries the shared load.

Typically only one cable per phase, for single- or multi-core cables. More than one cable may be selected for high load scenarios. 

Cable installation: How the cable will be installed. Consider the worse case section of the cable installation. It applies a cofactor to the calculation.

An online calculator

https://www.jcalc.net/cable-sizing-calculator-as3008

Guideline of wire current carrying capacity

In careful engineering the voltage drop, insulation temperature limit, thickness, thermal conductivity, and air convection and temperature should all be taken into account.

AWG
gauge
Diameter
Inches
Diameter
mm
Ohms per
1000 ft
Ohms
per km
Max amps chassis wiringMax amps power transmission
OOOO0.4611.6840.0490.16072380302
OOO0.409610.403840.06180.202704328239
OO0.36489.265920.07790.255512283190
00.32498.252460.09830.322424245150
10.28937.348220.12390.406392211119
20.25766.543040.15630.51266418194
30.22945.826760.1970.6461615875
40.20435.189220.24850.8150813560
50.18194.620260.31331.02762411847
60.1624.11480.39511.29592810137
70.14433.665220.49821.6340968930
80.12853.26390.62822.0604967324
90.11442.905760.79212.5980886419
100.10192.588260.99893.2763925515
110.09072.303781.264.13284712
120.08082.052321.5885.20864419.3
130.0721.82882.0036.56984357.4
140.06411.628142.5258.282325.9
150.05711.450343.18410.44352284.7
160.05081.290324.01613.17248223.7
170.04531.150625.06416.60992192.9
180.04031.023626.38520.9428162.3
190.03590.911868.05126.40728141.8
200.0320.812810.1533.292111.5
210.02850.723912.841.98491.2
220.02540.6451616.1452.939270.92
230.02260.5740420.3666.78084.70.729
240.02010.5105425.6784.19763.50.577
250.01790.4546632.37106.17362.70.457
260.01590.4038640.81133.85682.20.361
270.01420.3606851.47168.82161.70.288
280.01260.3200464.9212.8721.40.226
290.01130.2870281.83268.40241.20.182
300.010.254103.2338.4960.860.142
310.00890.22606130.1426.7280.70.113
320.0080.2032164.1538.2480.530.091
Metric 2.00.007870.200169.39555.610.510.088
330.00710.18034206.9678.6320.430.072
Metric 1.80.007090.180207.5680.550.430.072
340.00630.16002260.9855.7520.330.056
Metric 1.60.00630.16002260.9855.7520.330.056
350.00560.142243291079.120.270.044
Metric 1.4.00551.14033911140.260.043
360.0050.127414.813600.210.035
Metric 1.25.004920.125428.214040.200.034
370.00450.1143523.117150.170.0289
Metric 1.12.004410.112533.817500.1630.0277
380.0040.1016659.621630.130.0228
Metric 1.003940.1000670.221980.1260.0225
390.00350.0889831.827280.110.0175
400.00310.07874104934400.090.0137

Wiring Color Codes

Wiring for AC and DC power distribution branch circuits are colour coded for the identification of individual wires. In some jurisdictions, all wire colours are specified in legal documents. In other jurisdictions, only a few conductor colours are so codified. In that case, local custom dictates the “optional” wire colours.

IEC, AC: Most of Europe abides by IEC (International Electrotechnical Commission) wiring colour codes for AC branch circuits. These are listed in the table below. The older colour codes in the table reflect the previous style which did not account for proper phase rotation. The protective ground wire (listed as green-yellow) is green with a yellow stripe.

Technical Cable Guide

Fiber Optic

Single-mode fibres are designed to carry one mode of light over long distances. They have a small core typically 9 microns that carries one ray of light at a time. This allows them to carry large amounts of data over very long distances up to 10 km.

Multi-mode (Cheaper Option) fibres are designed to carry multiple modes of light over short distances. They have a large core typically 50 or 62.5 microns that carries multiple rays of light at the same time. This allows them to carry large amounts of data over shorter distances up to 2 km.

Cable Parts

Cable or Wire?

What is the difference between a wire and cable? This is one of the most basic questions that still need to be answered. Wire is a single conductor and cable is a group of two or more insulated conductors. If there was not any insulation on the two conductors then it would not be a cable, it would still be a single conductor which would classify as a wire.

Ingredients!

The picture above shows structure of a sample wire, although all cables or wire may don’t have all part of mentioned parts.

Insulation: two kind of insulation are common in industries

  1. PVC: Max. degree is 70 Celsius
  2. XLPE: Max. degree is 90 Celsius

If cable uses in outdoor circumstance the cable has Amour,
If cable uses in oily circumstance the cable has jacket
If cable uses for transferring DC or HV the cable has copper shield

The picture above shows a complete cable and most of cables don’t have all parts shown in the picture.

The conductor can be a single solid wire or made up of a number of thin strands. Solid or single-stranded wire is not very flexible and is used where rigid connections are acceptable or preferred – usually in high current applications in power switching contractors.

Stranded wire is flexible and most interconnections between components are made with it.

Wire specifications

There are several ways to describe the wire type. The most used method is to specify the number of strands in the conductor, the diameter of the strands, the cross sectional area of the conductor then the insulation type.

Example: 35/0.25 PVC 0.28 mm2 è the conductor comprises 35 strands. Each strand is 0.25mm and insulated with PVC the conductor has a cross-sectional area nominally of 0.28mm2.

Solid wire can also be specified using the Standard Wire Gauge or SWG system.

British Standard Wire Gauge is a set of wire sizes is generally abbreviated to SWG. It is also known as: Imperial Wire Gauge or British Standard Gauge.

D(AWG)=.005·92((36-AWG)/39) inch.

Note that in AWG the diameter goes up as the gauge goes down, but for metric gauges it is the opposite. Probably because of this confusion, most of the time metric sized wire is specified in millimeters rather than metric gauges.

The SWG number is equivalent to a specific diameter of conductor

SWGinmm
7/00.512.700
6/00.46411.786
5/00.43210.973
4/00.410.160
3/00.3729.449
2/00.3488.839
00.3248.230
10.37.620
20.2767.010
30.2526.401
60.1924.877
70.1764.470
80.164.064
90.1443.658
100.1283.251
110.1162.946
120.1042.642
130.0922.337
140.082.032
150.0721.829
160.0641.626
170.0561.422
180.0481.219
190.041.016
200.0360.914
210.0320.813
220.0280.711
230.0240.610
240.0220.559
250.020.5080
260.0180.4572
270.01640.4166
280.01480.3759
290.01360.3454
300.01240.3150
310.01160.2946
320.01080.2743
330.010.2540
340.00920.2337
350.00840.2134
360.00760.1930
370.00680.1727
380.0060.1524
390.00520.1321
400.00480.1219
410.00440.1118
420.0040.1016
430.00360.0914
440.00320.0813
450.00280.0711
460.00240.0610
470.0020.0508
480.00160.0406
490.00120.0305
500.0010.0254

Wires in the market

Standards wires produce in different companies. But all companies produce below sizes:

Diameter mm2: 0.5 – 0.75 – 1 – 1.5 – 2.5 – 4-6-10-16-25-35-50-70-95-120-150-185-240-300-400-500

Power Cable specifications

Low Voltage: Cables generally used for rated voltage less than 1 kV.

Medium Voltage: Cables generally used for rated voltage between1 kV and 36 kV.

High Voltage: Cables generally used for rated voltage bigger than 36 kV.

Common type for describing a cable is NxM+M0. M shows Number of main wire inside of cable, N shows diameter of main wires, M0 shows one more wire in the cable uses for Earth.

For example: 3*25+15 means the cable has 3 main wires, diameters of wires are 25mm2 and it has one 15mm2 wire for earth.

Examples:

NA2XS2Y 1×35 RM/16 6/10 KV

Single core XPLPE insulated cable with PE sheath, circular, stranded aluminum conductor with nominal cross section 35mm2 cover with cooper screen 16 mm2 and rating voltage (U0/U) 6/10 KV

U0 is cable nominal voltage between contactor and metal covering or earth

U is cable nominal voltage between phase contactors for 3 phase u=√3 u0


Leave a comment