Lecture Notes: Conductors and Cables
1. Introduction to Conductors and Cables
Conductors and cables are essential components in electrical installations. They serve as
pathways for electric current to flow from the power source to various electrical devices.
Learning Objectives
By the end of this lecture, learners should be able to:
Define conductors and cables.
Identify types of electrical conductors and cables.
Explain cable construction and insulation materials.
Understand cable ratings and selection criteria.
Apply safety measures in handling conductors and cables.
2. Conductors
2.1 Definition
A conductor is a material that allows the flow of electrical current with minimal resistance.
Conductors are primarily made of metals with high electrical conductivity.
2.2 Types of Conductors
1. Solid Conductors – A single piece of metal wire used in fixed installations.
2. Stranded Conductors – Multiple thin wires twisted together to improve flexibility.
3. Flexible Conductors – Made up of many fine strands to allow bending without breaking.
2.3 Common Conductor Materials
Material Properties Applications
Copper High conductivity, corrosion resistance, Domestic wiring, transformers,
flexible motor windings
Aluminum Lightweight, cheaper than copper, good Overhead transmission lines, busbars
conductivity
Silver Highest conductivity, expensive Specialized circuits, aerospace
applications
Gold Corrosion-resistant, good conductor High-end electronics, circuit boards
3. Electrical Cables
A cable consists of one or more conductors covered with insulation and sometimes additional
protective layers (sheath).
3.2 Cable Construction
A standard cable has the following components:
Conductor – Carries the current.
Insulation – Prevents short circuits and leakage of current.
Sheath – An outer protective covering against moisture, heat, and mechanical
damage.
3.3 Types of Electrical Cables
Electrical cables are categorized based on their application, insulation type, conductor material,
and voltage rating. Below are the main types:
a) Based on Application
Power Cables – Used for power transmission and distribution.
Control Cables – Used in automation and control circuits.
Instrumentation Cables – Used for transmitting low-voltage signals in monitoring and
control systems.
Communication Cables – Used for data transmission, including fiber optic and coaxial
cables.
Overhead Cables – Used in overhead power lines, such as ACSR (Aluminum Conductor
Steel Reinforced).
b) 2. Based on Conductor Material
Copper Cables – Excellent conductivity and durability.
Aluminum Cables – Lightweight and cost-effective but lower conductivity than copper.
c) Based on Voltage Rating
Low Voltage (LV) Cables – Up to 1kV, used in household wiring and small industries.
Medium Voltage (MV) Cables – 1kV to 33kV, used in industrial and urban power
distribution.
High Voltage (HV) Cables – 33kV to 220kV, used for power transmission over long
distances.
Extra High Voltage (EHV) Cables – Above 220kV, used in large power networks.
d) Based on Insulation Type
PVC (Polyvinyl Chloride) Cables – Common, cost-effective, and used for general wiring.
XLPE (Cross-Linked Polyethylene) Cables – Higher heat resistance and mechanical
strength.
Rubber-Insulated Cables – Used in flexible applications, including mining and welding.
e) Based on Structure
Single-Core Cables – A single conductor, used in simple installations.
Multi-Core Cables – Multiple conductors, used for control circuits and power
distribution.
Armored Cables – Have metallic armor for mechanical protection, used in underground
and industrial settings.
Unarmored Cables – No armor, used in low-risk environments.
3.4 Cable Insulation Materials
Insulation Type Properties Common Usage
PVC (Polyvinyl Chloride) Flame-retardant, durable, Domestic wiring
affordable
XLPE (Cross-linked High-temperature resistance, Underground and high-voltage
Polyethylene) chemical resistant applications
Rubber Flexible, water-resistant Industrial and outdoor settings
Teflon (PTFE) Heat-resistant, non-stick Specialized high-temperature
applications
4. Cable Color codes, Ratings and Selection
4.1 Factors Affecting Cable Selection
Current carrying capacity
Voltage rating
Environmental conditions
Flexibility requirements
Installation method (underground, surface, concealed)
4.2 Cable color coding
Uganda follows international standards for cable color coding, transitioning from the old British
standard to the new harmonized IEC (International Electrotechnical Commission) standard.
Single-phase Wiring
Function Old (British) Code New (Harmonized IEC) Code
Live (Phase) Red Brown
Neutral Black Blue
Earth (Protective) Green/Yellow Green/Yellow (unchanged)
Three-phase Wiring
Function Old (British) Code New (Harmonized IEC) Code
Phase 1 (L1) Red Brown
Phase 2 (L2) Yellow Black
Phase 3 (L3) Blue Grey
Neutral (N) Black Blue
Earth (PE) Green/Yellow Green/Yellow (unchanged)
4.3 IEC Standard Cable Sizes for Domestic Installations
Cable Size Calculation Guide
Step 1: Determine the Current (I)
To calculate the required cable size, first determine the current using the formula:
Step 2: Refer to the Cable Size Chart
Once the current (I) is determined, use a standard wire size chart to select the appropriate cable
size based on:
Current-carrying capacity – Ensure the cable can safely handle the calculated current.
Voltage drop – The voltage drop should remain within the acceptable range (typically 3-
5% for long distances).
Ambient temperature and installation method – Adjust for temperature and cable
grouping to avoid overheating.
Cable Type Conductor Size Current Carrying Example Application
(mm²) Capacity (A)
PVC Insulated 1.5 mm² 14 A Lighting circuits
(single-phase) 2.5 mm² 20 A Power outlets
4 mm² 25 A General power circuits
6 mm² 32 A Cooker or larger appliances
10 mm² 40 A High-power appliances (e.g.,
air conditioning)
PVC Insulated 2.5 mm² 20 A Small three-phase circuits
(three-phase) 4 mm² 25 A Three-phase outlets
6 mm² 32 A Three-phase power circuits
10 mm² 40 A High-power three-phase
appliances
XLPE Insulated 1.5 mm² 16 A Lighting circuits
(single-phase) 2.5 mm² 24 A Power outlets
4 mm² 32 A General power circuits
6 mm² 40 A Cooker or larger appliances
XLPE Insulated 2.5 mm² 24 A Small three-phase circuits
(three-phase) 4 mm² 32 A Three-phase outlets
6 mm² 40 A Three-phase power circuits
Step 3: Consider Additional Factors
Cable Material: Copper vs. Aluminum – Copper has higher conductivity, allowing for
smaller cable sizes compared to aluminum.
Installation Type: Whether the cable is buried, installed in conduit, or placed in open air
affects heat dissipation and cable sizing.
Short-Circuit Rating: Ensure the cable can withstand short-circuit conditions for the
required duration.
5. Safety Measures in Handling Conductors and Cables
Ensure Proper Insulation – Always use cables with intact insulation to prevent short
circuits.
Follow Load Ratings – Overloading cables may cause overheating and fire hazards.
Use Correct Cable Size – Undersized cables can lead to voltage drop and energy loss.
Proper Installation – Avoid bending cables excessively to prevent conductor breakage.
Earthing and Bonding – Ensure all exposed conductive parts are properly earthed.
Regular Inspections – Check for signs of wear, damage, or overheating in cables.
Personal Protective Equipment (PPE) – Use gloves and insulated tools while handling
live wires.
