MODULE 2 – Conductors, insulators and cables

1. Introduction, Learning Objectives (Rationale)

Upon completion of this module, learners should be able to demonstrate

understanding of conductors and their properties, insulators and their
properties, cables and their properties, conductor and cable joints, methods of
installing cables and the factors to be considered when selecting a cable for a
particular application.

Content Learning Outcome

2.1 Conductors 2.1.1 State the purpose of a conductor

2.1.2 State the properties and uses of the following

conductors:

 Gold
 Silver
 Copper
 Aluminium
 Carbon

2.1.3 State the methods used to join conductors

2.1.4 State the requirements of a good conductor joint

2.2 Insulators 2.2.2 State the properties and uses of the following
insulators:

PVC
XLPE
Glass
Ceramic
Asbestos
Porcelain
Mica
Bakelite
Silicone
Magnesium oxide
2.3 Cables 2.3.1 Define the following:

Cable
Flexible cable
Flexible cord

2.3.2 Draw and label the following:

A PVC-insulated, wire-armoured cable.

 PILCSWA cable
PILCSTA cable
XLPE-insulated cable

2.3.3 State the functions of each part of a PVC-insulated,

wire-armoured cable.

2.3.4 State the advantages and disadvantages of the

following cables:

2.3.5 State the requirements of a good cable joint.

2.3.6 State the basic steps that must be followed when

making a cable joint.

2.3.7 Identify low voltage and high voltage cable joints.

2.3.8 Explain how a simple low-voltage resin joint is

made.

2.3.9 State the factors to be considered when selecting

a cable for a particular application.

2.3.10 State the methods used to install cables and state

also the advantages and disadvantages of each
method.

2. Subject Content (Activities to Engage Students, Provide Information)

2.1.1 State the purpose of a conductor.

A conductor is used to transmit electricity from one point to another. A

good conductor will have lots of free electrons in the outer-most energy
level around the atoms.

2.1.2 State the properties and uses of the following conductors:

 Gold

Gold has a very high conductivity and is very malleable and is also
very ductile. However, gold is very expensive. It is used in many
electronic devices such as cell phones, televisions etc.
  Silver

Silver is the best known conductor of electricity but its use is limited
as it is very expensive. It is used in batteries, and LED chips.

 Copper

Copper is the most commonly used conductor in the electrical

industry. It has high conductivity, is malleable, is ductile, solders
easily and has a high melting point. It is used in the electrical
industry, home and transport industry and ornaments and jewellery.

 Aluminium

Aluminium is the second most popular conductor, it’s very light and
fairly resistant to corrosion but it cannot be soldered or welded easily.
It is used mostly in the manufacture of cables and in overhead lines.

 Carbon

Carbon does not have a high conductivity but is hard wearing and
capable of withstanding extremely high temperatures.
Carbon is used to manufacture brushes for motors and generators.

2.1.3 State the methods used to join conductors

 Ferrules
 Terminal blocks
 Resin joints
 soldering

2.1.4 State the requirements of a good conductor joint

 The joint does not have a higher resistance than the rest of the
conductor.
 The joint is mechanically sound.
 The conductors are not damaged in any way.
 The manufacturer’s instructions are followed carefully.
 If the conductor is insulated, the insulation used to insulate the joint
is compatible and is applied to thickness that will afford the same
voltage rating as the rest of the conductor.
 The joint is neat.
 The joint is accessible.
2.2.2 State the properties and uses of the following insulators:

PVC

PVC is a plastic polymer extensively used in the electric industry. It is

waterproof but not heat resistant. It is also tough, easy to colour,
relatively cheap and tough. It is used in the manufacture of pipes. It is
also used as insulation in electrical cables.

XLPE

XPLE is waterproof and can also withstand high temperatures. It is

used in high-voltage and high-current cables.

Glass

Ordinary glass is a hard transparent substance with good insulating

properties. It is used in overhead line insulators, cable supports, fuse
olders, switchboard mountings and bushings.

Ceramic

The difference between ceramic and porcelain is the type of clay used
and the temperatures it is baked at. Porcelain is baked at a higher
temperature. Ceramic is made out of red, brown clay where porcelain
is made out of refined white clay. Ceramic is cheaper that porcelain
and is used in gas turbine engines etc.

Asbestos

Asbestos is a good insulator and can withstand very high

temperatures. Due to its robust nature, it is used to support heating
elements and is also used as insulation for the internal wiring of
stoves.

Porcelain

Porcelain has a moderate mechanical strength, excellent electric

insulation and high corrosive resistance. It is used in electrical
applications such as power transmission and distribution.

Mica

Mica is a silicate mineral found in granite and other rocks. It is an

extremely tough material that can withstand extremely high
temperatures up to 10000C. Mica is used to support heating elements
of bread toasters and also commutator segments of DC machines.
 Bakelite

Bakelite has excellent insulating properties. It is robust, heat and

chemical resistant, and can be easily moulded to form casings for
various electrical devices. It is used to manufacture circuit breaker
casings, telephone casings, automobile distributer caps etc.

Silicone

Silicone compounds have good electrical and mechanical properties.

As insulators they can withstand high temperatures of up to 100 0C to
3000C. they are used to insulate conductors exposed to relatively high
temperatures such as stoves and heaters.

Magnesium oxide

Magnesium oxide is a high-temperature insulating material in the form

of a compacted white powder. It is the ideal material for the production
of cartridge heaters, thermal cables, heating cables, fireproof cables
etc.

2.3.1 Define the following:

Cable

According to SANS 10142 regulation 3.9: length of one or more cores

that has solid or stranded conductors with strands of diameter
exceeding 0,51 mm that are assembled together during manufacture
and that may or may not have an overall mechanical covering.

Flexible cable

According to SANS 10142 regulation 3.9: cable of which the

conductors consist of strands of diameter not exceeding 0,51 mm and
of which the insulation and covering are such that they afford flexibility
and in which the nominal cross-sectional area of each conductor
exceeds 4 mm².

Flexible cord

According to SANS 10142 regulation 3.9.3: cable of which:

a) the nominal cross-sectional area of each conductor does not

exceed 4 mm², and

b) each conductor consists of strands of diameter less than 0,31 mm

2.3.2 Draw and label the following:

A PVC-insulated, wire-armoured cable

PILCSWA cable

PILCSTA cable

XLPE-insulated cable

2.3.3 State the functions of each part of a PVC-insulated, wire-armoured cable.

 Conductor – used to conduct electric current and normally made of

stranded copper or aluminium.

 PVC covering – surrounds each conductor. Its function is to

electrically separate the conductors.

 The galvanised steel – wire armouring protects the cable from

mechanical damage, serves as continuous earth and can carry
 heavy earth fault currents.

 The outer PVC sheath – also acts as a moisture barrier protecting

the wire armouring from corrosion.

2.3.4 State the advantages and disadvantages of the following cables:

PVC-insulated

Advantages:

 Relatively cheap
 Light and easy to handle
 Has a smaller bending radius
 Easier to end off and join
 Presents no drainage and sealing problems
 Self-extinguishing

Disadvantages:

 Has a low voltage rating

 Has a low temperature rating and therefore a lower current rating.

Paper-insulated

Advantages:

 Has a high voltage rating

 Has a high temperature rating and therefore a higher current rating.

Disadvantages:

 Expensive
 Heavy and more difficult to work with
 Difficult to end off and join

XLPE-insulated

Advantages:

 Has excellent mechanical and radiation resistance and is waterproof.

 Enhanced chemical stability and resistant to solvents.
 Can be used in high-voltage applications.
 Can be used in high-temperature applications
 Good flexibility at low temperatures (-100C)

Disadvantages:
  Poor heat resistance

2.3.5 State the requirements of a good cable joint.

 The joint must not have higher resistance than the rest of the
conductor.
 The joint must be mechanically sound.
 The conductor must not be damaged in any way.
 The manufacturer’s instructions, must be followed.
 The joint must be neat.
 The joint must be placed in suitable place.
 If the conductors are insulated, the insulation used to insulate the
joint must be compatible.
 Ensure that no strands of a stranded conductor are removed.

2.3.6 State the basic steps that must be followed when making a cable joint.

 Ensure that the cables are isolated

 Prepare the ends
 Join the conductors
 Insulate
 Re-shield
 Re-jacket

2.3.7 Identify low voltage and high voltage cable joints.

Low voltage cable joints

 Resin joint.
 Taped joint in a metal box.
 Screw connectors in a joint box.
 Strip connectors in a joint box.
 Metal joint boxes filled with sealing compound.
 Acceptable cable couplers.
 Cold shrink joints.

High voltage cable joints

 Resin joints with taped conductors

 Metal joint box
 Hot shrink joint
 Cold shrink joint

2.3.8 Explain how a simple low-voltage resin joint is made.

1. Ensure that the cables to be joined are isolated and disconnected

from any power source.
 2. Choose the correct joining kit and carefully read the manufacturer’s
instructions.

3. Using the plastic joint box, measure the length of the cable end that
must be prepared for joining. Allow for approximately 10 mm of the
outer sheath (jacket) to extend into the joint box.

4. Using a cable knife, remove the correct length of outer sheath and
then carefully bend the wire armouring backwards. Remove some of
the strands of the wire armouring if necessary.

5. Using the cable knife again, very carefully remove the PVC bedding
(inner sheath). Leave approximately 10 mm of the inner sheath
uncut.

6. Remove the correct length of insulation from around each conductor.

7. Join the conductors using the correct size and type of ferrules as well
as the correct crimping tool.

8. Carefully insulate each conductor joint.

9. Join the armouring using crimped ferrules.

10. Place the two-part plastic joint box over the cable joint, clip together
and then tape the ends.

11. Remove the resin from the foil packet and mix.

12. Pour the resin into the joint box and allow to dry.

13. Test the cable using a suitable Megger.

2.3.9 State the factors to be considered when selecting a cable for a particular
application.

 The load to be supplied.

 The permissible voltage drop.
 The prospective fault current.
 The circuit protection that is available.
 Environmental conditions.

2.3.10 State the methods used to install cables and state also the advantages
and disadvantages of each method.
Lecturer Tips:

3. Exercises (Students need to Practice, Apply, Synthesise)

1. A domestic installation has a declared phase-to-neutral voltage of 240V.

Calculate:

𝐺𝐼𝑉𝐸𝑁: 𝑉 = 240𝑉

1.1. The maximum permissible voltage drop in any circuit of the

installation.

𝑉𝑑𝑟𝑜𝑝 = 5% × 𝑉𝑠𝑢𝑝𝑝𝑙𝑦

5 240
= ×
100 1

= 12 𝑉
 1.2. The maximum allowable voltage at any point of consumption in
the building.

𝑉𝑑𝑟𝑜𝑝 = 𝑉𝑠𝑢𝑝𝑝𝑙𝑦 − 𝑉𝑑𝑟𝑜𝑝

= 240 − 12

= 228 𝑉

2. An industrial consumer is supplied is supplied with a 400V, three-phase

supply. Determine:

𝐺𝐼𝑉𝐸𝑁: 𝑉 = 400 𝑉

2.1. The consumers line voltage.

𝑉𝐿 = 400 𝑉

2.2. The phase-to-neutral voltage.

𝑉𝐿
𝑉𝑃 =
√3

= 230,940 𝑉

2.3. The maximum permissible voltage drop in any sub circuit of the
factory.

𝑉𝑑𝑟𝑜𝑝 = 5% × 𝑉𝑠𝑢𝑝𝑝𝑙𝑦

5 230,940
= ×
100 1

= 11,547 𝑉

2.4. A minimum allowable voltage at any point of consumption in the

factory.

𝑉𝑑𝑟𝑜𝑝 = 𝑉𝑠𝑢𝑝𝑝𝑙𝑦 − 𝑉𝑑𝑟𝑜𝑝

= 230,94 − 11,547
= 219,393 𝑉

3. A 35mm2, two core PVC-insulated cable with aluminium conductors is

used to connect a certain load to a supply. Determine the maximum fault
current this cable will carry for a period of 2 seconds. Take CIF to be 62.

𝐺𝐼𝑉𝐸𝑁: 𝐴 = 𝑚𝑚2 , 𝑡 = 2 𝑠 , 𝐶𝐼𝐹 = 62

𝐶𝐼𝐹 × 𝐴
𝐼𝑓𝑐 =
√𝑡
 (62)(35)
=
√2
= 1534,422 𝐴

4. Determine the maximum time that a 50mm2, four core cable can carry a
fault current of 3kA. Take CIF to be 78.

𝐺𝐼𝑉𝐸𝑁: 𝐴 = 50𝑚𝑚2 , 𝐼𝑓𝑐 = 3000 𝐴 , 𝐶𝐼𝐹 = 78

𝐶𝐼𝐹 × 𝐴
I𝑓𝑐 =
√𝑡

𝐼𝑓𝑐 × √𝑡 = 𝐶𝐼𝐹 × 𝐴

𝐶𝐼𝐹 × 𝐴
√𝑡 =
𝐼𝑓𝑐
2
𝐶𝐼𝐹 × 𝐴
∴𝑡= ( )
𝐼𝑓𝑐
2
= [(78)(50)
3000
]

= 1,69 𝑠

Lecturer Tips:

4. Assessment (Student Reflection/Review/Inner-perspectve)

You should be able to answer / do the following:

1. State the purpose of a conductor

2. State the properties and uses of the following conductors:

 Gold
 Silver
 Copper
 Aluminium
 Carbon

3. State the methods used to join conductors

4. State the requirements of a good conductor joint

5. State the properties and uses of the following insulators:

PVC
XLPE
Glass
Ceramic
Asbestos
Porcelain
Mica
Bakelite
Silicone
Magnesium oxide

6. Define the following:

Cable
Flexible cable
Flexible cord

7. Draw and label the following:

A PVC-insulated, wire-armoured cable.

PILCSWA cable
PILCSTA cable
XLPE-insulated cable

8. State the functions of each part of a PVC-insulated, wire-armoured

cable.

9. State the advantages and disadvantages of the following cables:

10. State the requirements of a good cable joint.

11. State the basic steps that must be followed when making a cable joint.

12. Identify low voltage and high voltage cable joints.

13. Explain how a simple low-voltage resin joint is made.

14. State the factors to be considered when selecting a cable for a

particular application.

15. State the methods used to install cables and state also the advantages
and disadvantages of each method.

Additional summative questions you should be able to answer.

 1. A domestic installation has a declared phase-to-neutral voltage of 220V.
Calculate:

1.1. The maximum permissible voltage drop in any circuit of the

installation.

1.2. The maximum allowable voltage at any point of consumption in

the building.

2. An industrial consumer is supplied is supplied with a 380V, three-phase

supply. Determine:

2.1. The consumers line voltage.

2.2. The phase-to-neutral voltage.
2.3. The maximum permissible voltage drop in any sub circuit of the
factory.
2.4. A minimum allowable voltage at any point of consumption in the
factory.

3. A 50 mm2, two core PVC-insulated cable with aluminium conductors is

used to connect a certain load to a supply. Determine the maximum fault
current this cable will carry for a period of 5 seconds. Take CIF to be 78.

4. Determine the maximum time that a 35mm2, four core cable can carry a
fault current of 2kA. Take CIF to be 62.

Lecturer Tips:

5. Summary
 A conductor can be defined as a substance or material that can freely
conduct the flow charge carries in the form of electrons from one atom to
another in a specific material.
 Good conductors are gold, silver, copper and aluminium.
 Silver is the best known conductor of electricity.
 Copper is the most commonly used.
 An insulator can be defined as a substance that prevents the flow of electric
current through it.
 Insulators are used to electrically separate conductors, and sometimes to
support them.
 Examples of good insulators are PVC, glass, ceramic and Bakelite.
 An electrical cable is a single assembly of conductors each with its own
insulation, screening, assembly protection and protective coverings.
 The maximum permissible voltage drop allowed on a cable is 5%.
 The amount of current flowing through a circuit depends on whether the
circuit is inductive or resistive.
 Cable can be installed in open air, in ducts or buried underground.

6. Additional Lecturer Resources

For a lesson on cables click on the link below.

https://youtu.be/9xO1S0ajpWw

Past exam paper videos click on the link below.

https://youtu.be/P9v01NUe93w (August 2019)
https://youtu.be/iajr-Sb9aUI (November 2019)
https://youtu.be/IJZr2aGjaLI (August 2020)
https://youtu.be/Hpn7mp_ScCw (November 2020)