WIRE AND CABLE MAXIMUM TEMPERATURE AND RISE IN AIR DESIGN NOTE November 1996, Updated September 2009

by Douglas P. Arduini - Consultant AD&D (Arduini Design & Development) 2415 San Ramon Valley Blvd., #4-415 San Ramon, California 94583-1651 Phone/FAX 925/804-6063 E-Mail: darduini@yahoo.com URL: http://www.AD-andD.com Considerations for wire and cable analysis 1. The maximum wire temperature is calculated by adding the temperature rise to the ambient air temperature around the wire insulation, which includes outside ambient air temperature plus sun loading plus local temperature rise. A typical system sun loading can be 10-20 degrees C and a typical system internal temperature rise can be 10-20 degrees C. 2. Additional departing of maximum current ampacity for a given wire/insulation maximum temperature rating should include the altitude and thermal limitations from degraded free convection air, or be up-rating of maximum current ampacity with improved thermal resistance with conduction other than air, forced air, or pressurized air. 3. A wire or cable system life can be estimated to be halved for every 10 degrees C of wire/insulation temperature increase, using the hottest wire in a bundle or cable for the weakest point of failure for the calculation. A Mean-Time-To-Failure (MTBF) rule of thumb calculation may be used at 10,000 hours operating at the maximum temperature of the wire/insulation rating. Actual field life can be expected to be higher due to average stress is less than calculated worst case or MTBF analysis. (Note that the rating may be derated due to degraded free convection air and altitude.) A Simplified Wire Temperature Rise Calculation The following is a simplified temperature rise formula for copper wire:
t = I2 K
t = Temperature rise in oC Where: K = Constant for oC/Watt, representing a resistance times a constant versus temperature (derived from MIL-W-5088L, Figure 3, Amps/wire size at 50 o C rise)

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Simplified Calculation Assumptions 1. Wire thermal resistance of the wire remains constant at any current or power dissipation. 2. Wire temperature is proportional to I2R of the wire, where the wire resistance increases (positive temperature coefficient) with current. 3. Wire temperature rise is based on MIL-W-5088L, Figure 3, Single Copper Wire in Free Convection Air.
TABLE 1. WIRE "K" FACTOR

GAUGE 26 24 22 20 18 16
GAUGE 26 24 22 20 18 16 K 1.49 0.822 0.481 0.283 0.161 0.117

K 1.49 0.822 0.481 0.283 0.161 0.117

GAUGE 14 12 10 8 6 4

GAUGE 14 12 10 8 6 4
K 1.49 0.822 0.481 0.283 0.161 0.117 GAUGE 2 1 1/0 2/0 18 16

K 6.61E-02 3.65E-02 2.08E-02 9.13E-03 5.21E-03 2.83E-03

K 1.49 0.822 0.481 0.283 0.161 0.117

GAUGE 2 1 1/0 2/0 3/0 4/0

K 1.31E-03 1.03E-03 8.00E-04 5.95E-04 4.33E-04 3.13E-04

An additional departing multiplier must be multiplied times the constant (K) factor for temperature rise based on MIL-W-5088L, Figure 4, Bundle Departing Curves.
TABLE 2. CABLE BUNDLE LOAD DEPARTING FACTOR.

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TOTAL EST. BUNDLE LOADING (%) 20 40 60 80 100

NUMBER OF WIRES IN BUNDLE 2 1.042 1.087 1.117 1.156 1.212 3 1.070 1.163 1.227 1.307 1.389 4 1.105 1.242 1.333 1.429 1.515 5 1.143 1.316 1.429 1.550 1.667

The calculated temperature rise is then compared to the maximum wire current ampacity for the applicable maximum wire/insulation temperature from Table 3.

TABLE 3. MAXIMUM WIRE CURRENT FOR SINGLE COPPER WIRE IN FREE AIR (MS5088, FIG. 3.)

GAUGE 125 C 150 C 200 C GAUGE 125 C 150 C 200 C 26 8.8 9.6 11 8 115 125 145 24 11.7 13 14.7 6 157 170 197 22 15.5 17 19 4 210 233 270 20 20.5 22 25.5 2 290 320 365 18 27.5 30 34 1 340 370 420 16 31 35 40 1/0 390 430 495 14 43 47 54 2/0 455 500 590 12 58 63 72 3/0 540 590 690 10 76 82 95 4/0 640 700 810

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