DEE 1

TOPIC 6: WIRING SYSTEMS

Def.
This is an assembly of parts used in the formation of one or more electrical circuits. It consists of the
conductor, its insulation, its mechanical protection and various accessories such as joint boxes, etc. for
fixing the system and joining and terminating the conductors
Factors to be considered in selecting the type of wiring systems
✓ Durability of the installation
Whether the installation is to last for the lifetime of the building or it’s a temporal installation
with a short life
✓ Appearance of the finished installation
Whether the installation should be run on surface or concealed. For example, surface wiring
can be done in an office set up but the same cannot be used in a residential building
✓ Flexibility
Whether the system should be one that will allow extension and or extensions in the future or
not.
✓ Type of the building
Whether the installation work is for the permanent, temporary or an extension to an existing
building
✓ Installation conditions to be withstood such as dampness, fumes, etc.
Whether the installation is likely to be subjected to mechanical damage, dampness/moisture,
fumes, extreme weather conditions, inflammables or explosives
✓ Cost of the installation
The amount of money available for electrical installation in the budget. The system chosen
should be of reasonable cost while maintaining the safety and adherence to wiring regulations
✓ Safety
This is the most sensitive factor to be considered above all. The type of system selected
should provide safety to the user.

TYPES OF WIRING SYSTEMS

PVC SHEATHED WIRING SYSTEM
Conductors are insulated with PVC and an overall sheath of PVC for protection against mechanical
damage.
Fixing is usually by tinned brass buckle clips fixed to surfaces with brassed-steel pins or hardened
PVC cable clips which can accommodate various sizes of cables.
They are clipped at intervals of 250mm for horizontal runs and 400mm for vertical runs.
PVC is affected by oil and high temperatures.
It’s mostly used in domestic and office wiring and for lighting and small heating loads
Advantages of PVC sheathed wiring system
✓ Relatively cheap
✓ Easy to install
Disadvantages
 ✓ Do not offer adequate protection against mechanical damage
PVC system is available as:
✓ Circular/flat twin with earth
✓ Three-core with earth
✓ Single core

STEEL CONDUIT SYSTEM

Annealed mild steel tubing is widely used for enclosing VIR or PVC insulated cables. The conduit is
annealed so that it may be readily bent or set to any angle without breaking, splitting or kinking
Classified according as light gauge conduit (plain) and heavy gauge conduit(screwed)

a) Light gauge conduit

i. Close joint: the tube is formed from a strip of metal bent into shape with the edges
butted together without a mechanical joint

ii. Brazed or welded joint: similar to close joint but the seam is mechanically joined by
brazing or welding

iii. Seamless or solid-drawn: this is produced by cold-drawing from the bar

b) Heavy gauge conduit(screwed)

In each case both ends of each length of conduit are screwed electric thread
i. Welded joint
ii. Solid-drawn

Requirements of steel conduit/properties of steel conduits

✓ Enamel finish – this is a flexible stove enamel/light enamel finish which should not chip or
flake in use.

✓ Galvanizing – this is done to prevent rusting when conduits are installed in conditions that
subject them to dampness or condensation. Galvanizing is done by use of an effective
covering of zinc spelter

✓ Sherardizing – is a special process by which zinc alloy is embedded in the surface of the
metal, making it rust-proof

Conduit fittings
These are used for electrical and mechanical continuity of conduits during installation. All conduit
fittings must be of the inspection type except at the terminations.

They include: Grip fittings, screwed elbows, circular/square boxes, split types, junction boxes
✓ lug-grip inspection bend (fig 39 pg 57) of electrical installation work by TG Francis
✓ lug-grip inspection tee box (fig 40 pg 57) of electrical installation work by TG Francis
✓ conduit boxes and fittings pg 62 of electrical installation work by TG Francis
Fixing of the conduits on the surface is done by saddle clips and crumpets.
Advantages of steel conduits
✓ They are long lasting
✓ They provide an earth return path
✓ Provide mechanical protection
✓ Can be easily extended
✓ Provide low fire risk

Disadvantages of steel conduit

✓ Expensive
✓ Take long time to install
✓ Require a lot of skill to cut, thread, bend and fix
✓ They are liable to corrosion

PVC CONDUIT SYSTEM

Available as heavy and light gauge.
The fittings used on these are of PVC
They can be bend into different shapes by use of internal bending spring
They are used where ambient temperatures are equal or less than 65℃
An earth continuity conductor is required in this system.
When mounted on surface they are fixed by saddles

Advantages of PVC conduit

✓ Non corrosive
✓ Easy to bend
✓ Easy to install

Disadvantages of PVC conduit

✓ Cannot act as an earth return path
✓ High fire risk
✓ Not durable as compared to steel conduit
✓ No mechanical protection as compared to steel conduit

COPPER CONDUITS

The advantage of copper conduit is that it is resistant to corrosion and is an excellent circuit
protective conductor (c.p.c.)
The system is expensive but has an extremely long life

ALUMINIUM CONDUITS

Its light in weight, ease on working on it and is suited to tropical conditions. Precautions must be
taken to prevent occurrence of corrosion where a dissimilar metal is in the vicinity.
It offers excellent c.p.c facilities
It`s not strong mechanically and may require further protection where the risk of mechanical damage
is great
FLEXIBLE CONDUITS

is made of interlinked metal spirals often covered with a PVC sleeving. The tubing must not be relied
upon to provide a continuous earth path and, consequently, a separate CPC must be run
either inside or outside the flexible tube.
They are used for final connection of machinery and equipment e.g. electric motor where vibration
and the possible need to adjust the position of an equipment makes it rigid conduit connection
unsatisfactorily.
Flexible conduits can also deal with complicated bends and sets.
It is used for short runs where mechanical damage is unlikely to occur
It consists of a spirally wound partially interlocked light gauge galvanized steel strip and maybe water
light or non-water light.
Can be obtained with a PVC sheath.
During installation, a c.p.c must be run between the special brass adapter used to join the flexible to
ordinary screwed conduit.
Available sizes are from 16mm to 50mm internal diameter

Installation procedure of conduit wiring system

✓ Conduits are fixed on bare brick walls by means of crumpets but on finished surfaces such as
plastered walls, enamelled saddles or clips are preferred
✓ Marking out installation routes and points
✓ Installation of conduit deep pattresses (conduit boxes)
✓ Cutting, threading and bending conduits to required sizes and shapes
✓ Installation of saddles or crumpets on mounted conduits for surface installation. For conduits
concealed in the wall, fasten the them with binding wire instead of saddles before plastering
the wall
✓ Test the routes using steel tape
✓ Draw in cables
✓ Terminate the cables
✓ Install the necessary electrical fittings

IEE Regulation on Conduits

✓ Space factor of 40% should be allowed for circulation of air
✓ A maximum of two right angle bends per draw in length
✓ Radius of bends should be equally equal or more than a half times the diameter
✓ conduits of each circuit shall be erected complete before the cables are drawn in.
✓ Do not run cables supplying different circuits at different voltages in the same conduit
✓ All metal conduits must be effectively earthed and electrically continuous
✓ Conduit must not be in contact with water pipes, gas pipes, etc
✓ Conduit ends not terminating in metal outlet boxes must be brought to surface of walls or
ceilings. This means that the conduit must be brought well inside the back of wooden ceiling,
roses blocks or switch blocks
✓ Cables carrying a.c. must be bunched so that cables of all phases and neutral if any are drawn
into the same conduit.
Standard sizes (external diameters) of conduits include:
5
✓ 16 mm / 8 inch
3
✓ 20 mm / 4 inch
✓ 25 mm / 1 inch
 1
✓ 32 mm /14 inches
Preparation of the conduit fitting before joining

1. Conduit bending
Bending is done using bending machine for steel conduits and internal bending spring for PVC
conduits. It is necessary to set or bend the conduit to enable it to pass over an obstruction or to turn a
corner. The sets are made cold except in the larger sizes of conduit when the tubing needs to be
heated. To bend a piece of conduit satisfactorily requires practice to prevent kinking.

2. Cutting and screwing

Cutting is done using a hacksaw with a small toothed blade.
Screwing is done by means of stocks with appropriate sizes of dies
Remove the enamel from the conduit before screwing, and the length of screwing should be sufficient
enough to fit into the lugs/couplers
Remove the enamel from the inside of the lug by filing before fitting together to reduce the electrical
contact resistance on the surface.
Properly ream the ends after screwing to clean off sharp edges which can damage cable insulation.
The oil used to lubricate the dies must be cleaned.
While cutting and screwing ensure that the ceiling rose outlets and the switch fit in their exact
positions.
Fixing the conduit
Conduit is fixed to bare brick walls by means of crampets but to finished surfaces such as plastered
walls, enamelled saddles or clips are used. The saddles and clips are screwed to plugs fitted into
drilled holes in wall surfaces.
Spacing saddles are often used to hold the conduit away from the wall and to facilitate wall
decoration. Where running along or across steel girders, girder clips used
For hidden works, walls are chased to allow the tubes to be sunk into the surface and later plastered
over. In all cases of hidden works, sufficient freely accessible inspection type junction boxes must be
provided to allow for insertion of the cables later and to allow for withdrawal and renewal of the
cables in case of a fault.
Running coupler is used to connect together two pieces of screwed conduits. A conduit run should
terminate in a screwed bush if a terminal box is not used
check fig 43 page 60 and fig 44, 45 pg 61 of TG francis book
Conduit Termination
Drawing in the wires
IEE regulation requires that the conduits of each circuit shall be erected complete before the cables
are drawn in. Conduits should not be pulled round more than two 900 bends.
If inspection joint boxes are used freely it may not be necessary to employ iron draw wires. Use of
draw wires/steel tape is employed to aid in drawing in cables. The draw wire should be inserted
during erection of the conduit. The ends of the wires to be drawn are barred and twisted together to
form a firm loop. The draw wire is firmly attached to the loop. See fig 51 pg 65 of TG Francis
The cables can only be drawn in one short section of conduit at a time, generally from one connection
box to another.
TOUGH RUBBER SHEATHED (TRS)
The insulation is vulcanized rubber, the sheath is a tough rubber. Fixing is by tinned brass pins.
Rubber can`t withstand some mechanical damage and is affected by oil, however its cheap, flexible
and easy to work with.
The cable is available in:
✓ Single core (circular section)
✓ Flat twin
✓ Three-core
✓ Twin with earth
POLYCHLOROPRENE SHEATHED (PCP)
Is a form of plastic material which was developed because neither TRS nor PVC was quite suitable
for wiring where there was presence of steam ammonia fumes, lactic acids and milk fats, sulphur
fumes, direct sunlight and heat.
The cable consists of conductors insulated with vulcanized rubber and sheathed with PCP which is a
tough rubber like substance
Consists of TRS cable with additional protective covering of a partiality embedded braid and
compounded overly

TRUNKING SYSTEM
Available in section squares and rectangular lengths are joined by couplers secured by screws. It is
available in both light gauge and heavy gauge.
A trunking system is an enclosure provided for the protection of cables which is square or rectangular
in cross section having one removable side
The system is used where many cables are required or cables of different voltages 250V or medium
voltages 650V are used
Cables are laid in the trunks hence installation is easier and faster as compared to conduit systems.
Cables can be added or removed after installation.

Types of trunking
i. Skirting trunking - Designed to take the place of the normal room skirting. It carries
lighting, telephone, power cables in various compartments. Sockets can be easily fitted as
an integral part of the trunking system
ii. Multi-compartment trunking - It’s the normal type square or rectangular and it is
provided with segregated compartments so that cables carrying different voltages can be
accommodated in the same trunking unit
iii. Lighting trunking - Designed for use where long rows of continuous lighting are
required. The steel enclosure not only carries the fluorescent and tungsten fittings but also
the control gear and supply cables
iv. Flush trunking - Trunking which fits flush with walls and it entails a lot of builder works
to install it
v. Cable tap trunking – doesn’t carry copper bars but insulted supports which can
accommodate VRI or PVC cables from supplies to machines and lighting circuits are
tapped through fused tap off boxes
Advantages of trunking system
✓ Much lighter than conduit of the same capacity
✓ Fewer fittings are required for one trunking length than a run of multiple conduits.
✓ Wiring is easier and fast as cables are laid in instead of being drawn in
✓ Installation time is reduced
✓ Its an easily adaptable wiring system
✓ Multiple compartment trunking is available where segregation of services is required
NOTE:
Rising mains are used to provide power to the various floors of multi storey buildings. They are sheet
metal steel trunking containing copper bars on insulated supports. Provision is made for tapping off at
each floor where required distribution boards are fixed direct to the trunking

CATENARY WIRING SYSTEM

This wiring system is used for taking supplies from one building to another by overhead means. Steel
wire is tightened between the two points i.e from one building to another) and then an insulated cable
is fastened or bound on it. For short runs the steel wire carries cables which are taped to it. If the
distance is long, a pole may be introduced to act as an intermediate support between the two ends.
For outdoor usage, it is advisable to fill the connectivity boxes with a plastic compound against the
entry of moisture.
Where the cable leaves the catenary, it should pass through a suitable glazed porcelain lead-in tube.
The catenary wire must be securely fixed at each end with adequate clearance between the cables and
the ground.
Drip loops should be provided at entry points so that rainwater is not let into the building by running
along the cable.

WIRING ACCESSORIES
Some of the wiring accessories used in installation include the following:
Lampholders – Are designed for quick removal and replacement of the lamp and yet they must hold
the lamp in firm metallic contact to prevent overheating. Some of the sizes of Lampholders include:
bayonet-cap (BC), Edison screw (ES),
Batten lamp holder

bayonet cap lamp holder

Ceiling roses

Major ceiling roses already contain either two or three connection plates, each
plate containing a pillar terminal for the circuit wires and a screw terminal with
washer for the flexible wire connection.
IEE regulation regarding ceiling roses
✓ ceiling rose shall not be installed in any circuit operating at a voltage normally
exceeding low voltage
✓ regulation requires shrouding of a live terminal of the ceiling rose
✓ a ceiling rose shall be provided with an earthing terminal for compliance
Lighting circuit switches : one way switch, two way switch, intermediate switch
Plugs and socket outlets - These are required to enable portable apparatus to be connected to the final
subcircuits. The socket-outlet is the fixed portion connected to the fixed wiring and comprises two or
three contact tubes and terminals. The plug is the movable part connected to the apparatus by flexible
wire and comprises two or three contact pins to fit into the contact tubes. Plugs and socket outlets are
made to BS standard specifications and the standard sizes are: 2A, 5A, 15A and 30A.
Fuses – a fuse element consists of a piece of copper or tin-lead alloy wire which will melt when
carrying excess current.
Distribution boards - This is an assembly of the parts including one or more fuses or circuit breakers
arranged for the distribution of electrical energy to final sub-circuits or to other distribution boards.
The regulation requires that the neutral conductors for the different subcircuits shall be connected in
the same order as the live conductors.
Main switch and fuses – consumer`s main switch and fuses may be combined in one case.
Conduit fittings accessories