Things to Consider Before Buying Wires & Cables - IAC Electricals

The base of every electrification work is associated with wires and cables, be it your home, office or any industrial area. To complete the electrical installation, you must have an idea about the quality of cables and wires that you are about to choose.

You will agree that electric elements have a high-risk factor if you are not careful enough. These can also lead to accidents due to electric currents and overloading. Other than these, you might also have to witness electrical fluctuations. You must take utmost care about the power cable accessories while planning and executing any project.

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So, your first concern should be safety whenever you upgrade the wires and cables or construct a new building. Budget is the next big concern but never go for low-cost wires and cables, which will compromise the system.

Difference Between Wires and Cables

The words “Wire” and “Cable” are used interchangeably, but significant differences are between them.

A Wire – It has a single electrical conductor and is made of either copper or aluminum that conducts electricity. It enables a smooth flow of electricity through the path.

A Cable – It has multiple conductors, and these are wrapped in a non-conductive material, which is commonly known as a ‘jacket’. Here the wires are sheathed together.

Tips for Selecting Supportive Power Cable Accessories

1. Quality of Conducting Material

To understand more about the conductivity – you must find out the size of the cable and the insulation material used. You also need to consider whether the voltage needs to be carried for a long distance. Usually, two types of wires are used – aluminum and copper. Aluminum is considered if you are looking for an inexpensive solution. And, copper is used if you want a higher resistance and low conductivity.

 2. Size of The Power Cable Accessories

Choose a large cable or wire, irrespective of the voltage systems. Check the acceptable volt drop-down of the cable whenever a certain amount of current passes through the wire/cable. Check the gauge sizes of the wire, and it will decide the current carrying capacity and short circuit rating.

3. Insulation

This element insulates the bare conductor and marks it safe for installation. Look if they are resistant to fire and water. You can go for Flame retardant grade PVC (polyvinyl chloride). For cable insulation, choose FR PVC, and for sheathing FR or non-FR grade, PVC would be suitable.

 4. Temperature

750V copper wire and PVC are used to manufacture cables, and it is commonly applied to electrical panels and sockets. Thus, the power cable accessories’ longevity depends on the cable’s temperature.

5. Can handle Overheat

Wires and cables tend to get overheated due to the flow of currents. So, you must choose the one that can handle currents safely, and neither the wire nor the insulation gets overheated. Calculate the passage of current through the cable and its resistance; this will help you detect the amount of heat generated.

Read More: Design And Development Of Conductor Fittings For HTLS Conductors

6. Flexibility

You can get both flexible and solid conductors in the market. If you want an easy-to-lay conduit and electrician friendly solution, then use flexible wires. They have more number of annealed conductors. Flexible cables can be found on the market in two insulation levels – 750V and V (thicker layers of insulation).

 7. Protection and shield

The wire is partly within the insulation system and partly exposed, without proper shielding. So, shielding is really needed to avoid short circuits in terms of power cable accessories safety.

8. Check the packaging

It is quite common for manufacturers to put a stamp or seal on the package. It will notify you about the national standardization and Industrial quality) and there are also guidelines. This ensures the safety and quality of its products. Do not add the products to your cart even if one of these seals is missing.

Lastly, Reliability is important

From bottles and plastic bags to toys, pipes, credit cards, and medical equipment, polyvinyl chloride (PVC) is one of the world’s most commonly used plastics. 

For electrical workers, PVC is one of several insulation options for protecting conductors. But how does it work as an insulation, and what applications make the most sense? 

What is PVC Insulation? 

Polyvinyl chloride, AKA vinyl, was one of the first plastics discovered. Today, it’s the third-most produced plastic polymer, behind only polyethylene (PE) and polypropylene. 

To make PVC, vinyl chloride monomers, reactive molecules that react with other reactive molecules, undergo a process called polymerization. During this process, chemical bonds turn the monomers into a polymer chain. Once complete, the result is light, strong, fire-resistant PVC. 

Sometimes manufacturers use additives to make PVC stronger, more rigid, or water resistant, or plasticizers to make it softer and flexible.  
 
Generally, PVC operates well in temperatures from –20°C to 60°C, though additives can improve its temperature rating to a range of –55°C to 105°C. 

Wide-Ranging Use 

Polyvinyl chloride is about 200 years old (FIRST discovered in , then again in ), but its real history begins in the s. 

B.F. Goodrich scientist Waldo Semon was the first to create plasticized PVC, a flexible, durable, and inert product. His discovery sparked a flurry of innovation, leading to the PVC material used for wire and cable products today. 

PVC works well across a wide range of wet and dry temperatures, from -25°C to 75°C. It also excels in many locations, as it’s fire, moisture, abrasion, gas, oil, acid, and chemical-resistant. 

Electrical wire and cables can have standard PVC, semi-rigid (SR-PVC), or plenum PVC insulation. Plenum cables must meet stricter fire tests and may call for low-smoke PVC insulation. 

Benefits of PVC Wire Insulation 

Why do some installers choose PVC over other wire insulation types? The insulation has some welcome benefits. 

Low-Cost Option 

When cost is a concern, PVC cable jackets are less expensive than other options and more readily available. 

If you want to learn more, please visit our website Polyvinyl Chloride Insulated Cables.

PVC is common for low- and medium-voltage wiring projects used in open-air environments. Often, this is used as a jacket, lowering costs and keeping projects on budget. 

Additionally, unlike other insulations, PVC is 100% recyclable. Other plastic insulations may need polymers for strength and elasticity, making them harder, if not impossible, to recycle. PVC offers great protection without additives, so it’s easier to strip from conductors and recycle into other things. 

Flame Resistance 

PVC products are flame-retardant, also known as FR-PVC. Unfortunately, because of their high chlorine makeup, PVC insulation could be lethal when burned. 

To soften the plastic and make it usable for other applications, including wire insulation, we need other additives. These include materials like plasticizers, fillers, heat stabilizers, and UV absorbers that enhance the insulation’s properties.  

Of course, the additives needed for flexibility and protection reduce PVC’s natural flame-retardant abilities. Manufactures then add agents for other protection. 

In the s and s, technology caught up with PVC development. Scientists produced new plasticizers and additives, which improved its fire and smoke retardance beyond its natural capabilities. These new additives allowed PVC materials to work in new applications, including plenum spaces. 

Today, PVC provides excellent flame resistance compared to other insulations, including HDPE, polypropylene, and nylon. 

Durability and Flexibility 

Pure PVC is rigid, but additives can be incorporated to improve flexibility without losing strength and durability. 

PVC wire insulating material performs well across a wide temperature range, but also carries oil, chemical, and abrasion resistances. When the wire or cable needs more protection, other additives can improve sunlight, water, and heat resistance. 

What Are the Drawbacks of PVC Wire? 

Although PVC gets plenty of high marks for its protective capabilities, it isn’t perfect.  

Depending on the application and environment, it might be best to look at other options beyond standard PVC insulation. 

High Attenuation 

Attenuation occurs when there’s a loss of signal strength or amplitude as the signal moves along a wire. 

Although attenuation is natural and some signal is always absorbed, rising resistance, long runs, and high frequencies could also cause problems. 

To reduce signal loss, projects may use larger gauge conductors or shorter runs. Larger wires and cables have more surface area, allowing more current to pass through. Shorter runs result in less drop-off as current flows through the conductor, leading to better signals. 

Restrictive Temperature Range for Some Applications 

Most PVC compounds do not have extremely high and low temperatures, ranging from -20°C to 60°C. In some special cases, formulations may allow PVC to operate in conditions as low as –55°C and as high as 105°C. 

For common PVC formula, conditions deteriorate once temperatures surpass 70°C. At this point, the insulation will soften or melt, exposing conductors and reducing performance. 

This is because manufacturers apply PVC insulation using a thermoplastic process. Other insulations like XLPE use a thermoset process, creating stronger molecular bonds. As a result, polyethylene insulations offer excellent heat resistance while PVC provides good protection but can reach an excellent rating through unique formulations. 

Less Flexible Compared to Other Insulations 

PVC is generally more flexible than other insulations because of its thermoplastic process but becomes brittle in extremely low temperatures. 

When temperatures drop below 10°C (14°F), PVC insulation becomes harder to bend. At that point, it will stiffen and become brittle. Unlike XLPE insulation, which doesn’t lose bendability in colder temperatures, PVC’s weaker molecule chains struggle. 

Cold temperatures combined with pressure can cause PVC to snap or crack, exposing conductors and putting people at risk. 

Where Is PVC Insulation Used? 

When jobs require a flexible, durable, low-cost cable, PVC gets the job done safely and reliably. 

PVC insulated wire has a wide range of applications across several industries, including: 

• Solar Inverter Cable Jacketing

• UF Cable

• Horizontal Directional Drilling Cable

• TW/THW + THW-2  

• MTW/TEW/AWM  

• Ground Wire  

• VNTC and XPTC Tray Cable Jacketing 

When cost is considered, PVC punches above its weight. Its chemical makeup and durability are useful across many applications, from underground installations and grounding to industrial and commercial options. 

Know Your Project 

No matter what, understand every aspect of the application before buying wire. 

Every project is different. Sometimes, PVC seems like a great way to reduce upfront costs but may cause problems later. 

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