Chapter 3

MATERIALS FOR ELECTRICAL SERVICES

The materials used for electrical construction are mainly cable, switch, socket, plug,
regulator, rose, conduit, pipes, box, and so on.

3.1 Cables
Cables are classified in different ways, the mostly used one is based on voltage. They are
LT cable: voltage level up to 1 kV
HT cable: voltage more than 1 kV

For internal electrification, LT copper cables are used. The cables are normally single
core, PVC insulated and sometimes PVC sheathed. Mostly used one are
BYA: Single core PVC insulated non-sheathed copper cable
used for surface wiring
BYM: Single core PVC insulated white PVC sheathed copper cable
used for concealed wiring
NYY: Single core PVC insulated black PVC sheathed copper cable
used for underground service line

For 1-phase, 1 wire system:

The line is red and the neutral is black
For 3-phase, 4 wire system:
3 lines are red, yellow, blue and the neutral is black
The earth continuity conductor (ECC) is green

The comparison between copper and aluminum cables together with different codes of
cables are given below.

Properties of Copper and Aluminum

Copper Aluminum
Parameter Unit Hard-
Hard-drawn Annealed Annealed
drawn
Melting point ºC 1083 658
Specific gravity 8.892 2.703
Resistivity µΩ-cm 1.777 1.724 2.873 2.820
Tensile strength kgf/mm 34.47 20.28 15.20 7.14
Temp. co-efficient of
0.00381 0.00393 0.0040 0.0042
Resistance at 20 ºC
Co-efficient of linear
×10-6/ºC 17 23
expansion

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 Commonly used Abbreviations / Codes

BDS Bangladesh Standard

IEC International Electrotechnical Commission
VDE Union of German Electrical Engineer
BS British Standard
ASTM American Society for Testing of Materials
AAC All aluminum conductor
AAAC All aluminum ally conductor
ACSR Aluminum conductor steel reinforced

N According to VDE standard

B According to British standard
Y Insulation or sheath of thermoplastic based on PVC
A Insulated single core wire
I International color code (British)
M Sheathed wire
F Flat cable
E Earth continuity conductor (ECC)
R Galvanized steel round wire armoring
Gb Helical GS tape
re Conductor of single solid wire having circular cross-section
rm Conductor of multiple stranded wires having circular cross-section
sm Conductor of multiple stranded wires having sector-shaped cross-section
2X XLPE (Cross-linked polyethylene) insulation
S Shield of copper
SE Multi-core cable with individual screen
Ra Round aluminum wire armored
H Non-metallic semi-conducting screen over conductor and/or insulation
C Concentric conductor of copper

BYA PVC insulated non-sheathed copper cable

BYM PVC insulated PVC sheathed copper cable
NYA PVC insulated single core copper cable
NYY PVC insulated PVC sheathed copper cable
NYSEYFGbY Multicore copper cable with PVC insulation, field limiting
semiconducting layer over each insulation, copper shield over each core, 3
cores laid up, PVC inner sheath, flat galvanized steel wire armoring,
helical steel taping over common covering of cores and PVC sheath
N2XFGbY XLPE multicore copper cable, flat or round galvanized steel wire
armoring, helical steel taping over common covering of cores and PVC sheath

N2XSEYFGbY Multicore Aluminum conductor cable with XLPE insulation, field

limiting semiconducting layer over each insulation, metallic screen of
copper, colored strip for core identification, 3 cores laid up with fillers,
binder tape, PVC inner sheath, flat galvanized steel wire armor with or
without helix, overall PVC sheath

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3.2 Switches
Switches are used to ON / OFF an appliance. The commonly used switches are tumbler
or piano type.

Tumbler switch Piano switch Switch socket

The symbols used in the circuit to show different types of switch are shown below.

3.2.1 Special Types of Switches

• Mercury switch: Uses mercury for a contact so the switch must be installed right
side up and vertical for smooth operation.
• Dimmer switch: They are used to control the intensity of light and conserve
energy.

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 • Time delay switch: To make a light automatically turned off after someone left
that place.
• Pilot light switch: Useful for controlling outdoor or remote lights.
• Lighted handle switch: Helps to find a switch in the dark.
• Manual timer switch: Has a spring wound timer that can be used up to 12 hours.
• Clock switch: Has a digital read out of the time built into switch.
• Locking switch: Can be wired into circuits supplying outlets.

3.2.2 The pull chain switches

This is one of the least expensive ways to build a switch.

Pull Chain switch 3-way switch 4-way switch

3.2.3 Single pole switch loop

When these types of switches are used two wires are necessary. Black wire connects with
the power line and white wire with the shell of the lighting fixture. A switch must be
installed in a hot wire and not in a neutral wire. It makes the device connected to the
switch to be in ground potential. This prevents any shock from the device.

3.2.4 Three way switch

This type of switch is used for a hall light that can be controlled from the bottom and top
of a staircase or an outside light be controlled from inside and outside of a house. A three
way switch is a single pole double throw switch. Three way switch means it has three
terminals and not three switches.

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3.2.5 Four way switch
It is used to control a light from three different points. Here a three way switch is
installed near the load and another distant from the load. The four way switches can be
installed between the three way switches.

3.3 Socket
Sockets are used as power provider to which we can connect an appliance. Socket may be
of 2-pin / 3-pin, flat / round, single / multiple / combined. Presently sockets with switches
are available.

3.4 Plug
Plugs are connected by cables with the appliance. Plugs may be of 2-pin / 3-pin, flat /
round, single / multiple / combined.

3.5 Regulator
Regulators (fan) are also known as dimmers (light). It is used to control the voltage to the
appliance to control the energy to the appliance.

3.6 Rose
Ceiling or wall roses are used to have connection of appliances.

3.7 Conduits
Types of conduits used:
• Rigid steel: This type of metal conduit is supplied in 10 foot lengths of steel or
aluminum. It can be of 6 inches of diameter. Its inner surface is smooth. If this
conduit has any chance to come in contact with the earth then a protective coating
is necessary. For cinder filled environment plastic coating can be given.
• Inter mediate metallic (IMC): Diameter of IMC can be up to 4 inches and it has
thinner wall than rigid type.
• Electrical metallic tubing (EMT): Electrical metallic tubing is similar to Rigid
type but it is thinner and its diameter can be up to 4 inches. It is not threaded and
has its own type of connectors.
• Flexible steel conduit: It is flexible in nature and can be given any shape. When
used a separate grounding wire must be provided as it has much higher resistance.

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  Rigid non-metallic conduit and Electrical non-metallic tubing (ENT): Non
metallic conduits are made of Polyvinyl Chloride (PVC), fiberglass, polyethylene,
transite and others. There are two basic types: rigid metal type and electrical non-
metallic tubing. It can be bent and given any shape via hot air, hot liquid or hot
box. No flames should be used. When two parts are needed to be joined a solvent-
type cement.

In addition to conduits, plastic (PVC) or steel pipes and plastic channels are used for
surface wiring.

3.7 Box
Electrical boxes can best described as the termination enclosures that accommodate
the entrance of the various types of conduits, armored cables or non-metallic sheathed
cables for the purposes of splicing the wires and providing circuit outlets for switches,
receptacles, fixtures and other electrical accessories.

Selection of boxes is dependent on the following things:

• The number of wires entering
• The kind and number of devices attached to it
• The wiring method used

3.7.1 General purpose metal boxes

General purpose boxes are of following types:
• Switch boxes: Switch boxes are gangable. This means two or three boxes can be
connected together.
• Octagon Boxes: These types of boxes are used for special purposes.
• Square boxes: Steel square boxes are versatile in nature as they can be used for
both concealed wiring work or exposed wiring installations.
• Ceiling pan boxes: These are used in roof tops.

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3.7.2 Installing boxes and cables
Consideration before wiring, Design factors
• An electric service with adequate capacity
• Wires of sufficient capacity throughout
• A sufficient number of circuits
• A sufficient number of plug in receptacles
• An adequate number of lights
• Wall switches in sufficient number
• Provision for security for both inside and outside

3.7.3 Requirement for installing boxes and cables

In walls: Base receptacle boxes are normally placed 12 or 16 inches high above the
ground. Wall switch boxes are normally located 44-48 inches above the floor on the latch
side of each door.
In ceiling: Proper placement must be made so that no harm is done on the roof.
Under floors: Similar remedies are taken.

3.7.4 Installing type NM cable in metal boxes

Wires must be placed so that proper connection is possible.

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3.7.5 Making wire connection
Striping NM cable sheaths: For this a stripper is used. NM cable is penetrated to the
stripper, and it is squeezed and moved to cut adequate amount of insulation. A knife is
used to remove the sheath. Stripping armored cable sheaths: A fine tool hacksaw is the
best for this job.
Stripping wire insulation: To strip wire insulation one must not cut the sheath at right
angles, he should use 60 degree angle. This prevents unnecessary wire cutting.

3.7.6 Splicing wire

Proper splicing is necessary to avoid accidents in case of heavy loads.
Wirenut Connectors: This is the most basic type of connection between two wires.
Electrical tape can be wrapped around the base of the wirenut and the wires.

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Crimp Connectors: Crimp connectors are used when cables entering metal boxes
require the splicing individual bare grounding wires together. Here wires are twisted
together first and then a ring is used to make the contact. Ring is squeezed to make
connection. Connectors for Larger wire sizes: For this clamp or split bolt type connectors
are used.

3.7.7 Rain tight boxes and covers

They are usually made of painted sheet metal and have a guard to protect against the
entry of rain falling on top of the box. Some feature like self-closing is also available.

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3.7.8 Watertight boxes and box extensions
These are built to protect switches from temporary immersion or sprinkling. Box
extensions are available for this sort of fittings. They eliminate costly and time
consuming breaking and repairing of walls.

3.8 BBT (Bus Bar Trunking)

Bus bar trunking is used to increase the current carrying capability of a system. Here
multiple buses are used in parallel.

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This Unified Recommendation is for the test and installation of busbar trunking systems
arranged outside of switchboards for supplying section or distribution boards or
consumers, instead of cables. They are not recommended to be installed in hazardous
areas or on the exposed weather deck.

3.8.1 Protection of BBT

• General Systems should comply with the specific requirements of local electrical
codes.
• Temperatures should be in the range from 0 to 45oC.
• Nearby foreign bodies or water pipes must be placed away from bus bars to
protect them.
• The system should be designed to withstand a vibration level of 1mm amplitude
in the frequency range of 2 Hz to 13.2 Hz and of 0.7g acceleration in the
frequency range of 13.2 Hz to 100 Hz.
• It should be suitable for automatic draining where condensation is possible.
• Fire test arrangements should be compatible with the local codes.

3.9 Consumer unit

A consumer unit is a combination of single row fuses and breakers. If only fuses exist,
then it is called fuse box.

3.10 Distribution Board

Distribution board is a collection of fuses and breakers. They are placed in a double
array. Distribution board is responsible for all the power supply at home.

3.11 Service Entrance Panel

Most service entrance panels are provided with main disconnect circuit breaker. It
prevents the home from accidents and ensures over-current protection. Normally main
circuit breaker is connected to two parallel bus bars. Branch circuit breakers are then
connected to each of them to feed each of the branch circuits. Branch circuits can also be
connected remotely from the service entrance.

Branch circuits are responsible to loads to energy sources. They provide wiring between
final protecting device and the outlet of a circuit. Each branch circuit has three wires. One
is main energy carrier, second one is neutral wire and final one is ground wire. If we need
more than rated voltage two branch circuits are to be considered simultaneously.

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3.12 Types of Branch Circuits
There are mainly two types of branch circuits available.
Single outlet branch circuit:
Following outlets are connected to a single outlet branch circuit.
• Dishwasher
• Range
• Clothes dryer
• Garbage disposal
• Water heater
• Each appliances rated more than 1000W
• Each permanently connected motor rated half horse power or more.

Two or more outlet branch circuits:

Different wires are used for different branch circuits, such as,
Circuit Rating in Copper Wire Size
AMPs

15 14
20 12
30 10
40 8
50 6

15 amps branch circuit is normally used for ordinary lighting instruments. 20 amps
circuits are used for refrigeration purpose, pantry, breakfast room, dining room etc. When
20 amps circuits are provided both 15 and 20 amps receptacles are to be provided. A 15
amps circuit can be fed into a 20 amps receptacle but reverse cannot be done. 30 or 40
amps branch circuits are used for clothes dryer and other high current equipments in
dwelling places.

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3.13 Symbols of Materials (BNBC)

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