A Guide to Wire and Cable Construction - …

1 A Guide to wire andCable ConstructionA Guide to wire & Cable Construction3 AMERICAN INSULATED wire CORPORATION - Pawtucket, Rhode IslandBACK | NEXT | Policy ..4 Mission Statement .. Making Bodies ..5 Aluminum ..5 Copperweld ..5 Alumoweld ..5 Tinsel ..5 Thermocouple ..5 Copper Materials for Electrical Conductors ..5 Conductor ..6 MCM .. (Circular Mil) ..6 IACS (International Annealed Copper Standard) ..6 wire Coating ..6 Tinning Copper ..6 Tinned Copper ..6 Heavy Tin ..6 Bare Copper Overtinned ..6 Bare Copper Fused ..6 Tin Copper Overtinned ..6 Prebond ..6 Topcoat ..6 Overcoat .. Making Bars ..6 Rod ..6 Stranding ..6 Bunch Strand ..6 Concentric Strand ..7 Rope Lay - Bunch Stranded Members ..7 Rope Lay - Concentric Stranded Members ..7 Compact Round Conductor ..7 Compressed Round Conductor.

2 7 Sector Conductor ..7 Segmental Conductor ..7 Annular Conductor ..7 Filled Strand ..7 wire Breakdown Machines ..7 Intermediate Machines ..7 Fine wire Machines ..7 Dies ..7 Drawing Solution ..8 wire ..8 Tubular or Barrel Stranders ..8 Strander ..8 ASTM Standards for Copper Conductors ..8 Lay ..8 Direction of Lay ..8 Bird Caging ..8-Insulation and needs that determine the material selectionfor Insulation and Jackets ..8 Classes (Thermosetting and Thermoplastics) ..8 Special Definitions ..8 Types of Insulations and Jackets ..9-10 Assembly and of Shielding ..10 Types of Shielding and Armoring ..11 Color Coding (ICEA Methods)..11-12 Technical Coding Tables ..13-16 Nominal Temperature Operating Ranges forInsulation Materials ..17 Properties of Rubber Used for Insulation ..18 Properties of Plastic Used for Insulation.

3 18 Check Lists for Specifying wire and Cable ..19 Glossary of of ContentsA Guide to wire & Cable ConstructionAMERICAN INSULATED wire CORPORATION - Pawtucket, Rhode Island4 BACK | NEXT | INDEXCORPORATE PROFILEA merican Insulated wire is a leading manufacturer andsupplier of electrical and electronic wire , including powercable, building wire , control Cable , portable Cable andflexible cord, power supply and cord set products, servinga variety of markets through electrical distributors anddirect to OEMs. American s breadth of products allows it tobe classified as a total source supplier of custom andstandard wire and Cable products to meet diverse indus-trial was founded in 1924 and became a subsidiaryof Leviton Manufacturing Company (Little Neck, NY), aninternationally known manufacturer of wiring devices, in1937.

4 The company has three manufacturing sites,located in South Attleboro, Massachusetts, Pawtucket,Rhode Island, and Coffeyville, is backed by technical service, quality assurance,engineering and manufacturing, R&D and testing facilitiesthat have earned a reputation for quality, precision Business Development Representatives are respon-sible for specification development with engineeringarchitects and industrial MRO/OEM communities for allAmerican products. Their primary goal is develop end-user specifications for the company s range of American ServesAmerican Insulated wire s products are used to helpprovide electricity for: 1) appliances ( coffee makersINTRODUCTIONW elcome to American Insulated wire Corporation s Guide to wire & Cable Construction . It is designed to help yougain a more complete understanding of the basics of wire and Cable , and if you are already at that point, it will enhanceyour existing knowledge.

5 Whatever the case may be, this will be a valuable source of information for you, and it willallow you to more efficiently service the needs of those that you work manual focuses on many aspects of wire and Cable , such as basic electricity, manufacturing processes, selectionand types of materials and compounds, and different governing agencies. (American offers a separate booklet focusingon its full line of products.)There are a variety of end-user requirements or applications so our wires and cables are available in a broad range ofstandard types and optional characteristics include: Size (AWG or KCMIL) Strength (Physical) Cold Temp. Withstand Radiation Resistance Weight Electrical Properties Chemical/Oil Resistance Moisture Resistance Flexibility Heat/Operating Temp.

6 Mechanical Damage Sunlight & Flame ResistanceAvailability and reasonable costs are also important information found in this Guide will help you focus on the appropriate selection of materials to sell, recommendand manufacture wire and Cable products that meet application Policy: American Insulated wire Corp. is committed to a qualitysystem of continuous improvement for use in the manu-facturing of wire and Cable products. It is our policy todevelop, produce and deliver products and services whichconsistently meet our customers needs. Mission Statement: To provide unparalleled service whilemanufacturing the highest quality prod-uct to meet our customers needs at acompetitive price. and lamps); 2) electrical tools; and, 3) industrial, commer-cial and residential buildings.

7 American plays a vital role insupplying the world with electrical and electronic wire , Cable and cord products. Our products can be found inthe home, steel mills, at Construction sites, telephonecompanies, malls, sport complexes almost anywherethere s a need for electricity. To meet customer needs, weserve three markets - Electrical Distribution, OEM, DistributionAmerican Insulated wire goes to market by serving theelectrical distributor who, in turn, resells the product to theend-user. To assist this customer base, American employsan aggressive sales organization which includes specifica-tion specialists whose purpose is to help end-users inspecifying the correct products for their s sale force works with electrical distributors byproviding various types of product information includingnew product updates, training, end-user calls, inventoryand MarketAmerican is a leader in the manufacture of wire , Cable andcord products for the OEM marketplace.

8 The companyproduces a complete line of hook-up wire , portable Cable ,flexible cords and and power supply cords to meet OEMspecifications or requirements. Because American utilizesan OEM sales force that is technically oriented andA Guide to wire & Cable Construction5 AMERICAN INSULATED wire CORPORATION - Pawtucket, Rhode IslandBACK | NEXT | INDEX provides engineering support, the company offers assis-tance to customers during the development stage of theOEM product. In many instances, American assisted acustomer in the design of a product that has helpedreduce the manufactured cost of the final has also worked with OEMs to design wire , Cable and cord products that provide value added MarketAmerican is the recognized leader in providing theTelecommunication Industry central office power cableproducts, as well as products for inside and outside plantuse.

9 The company has continued to be in the forefront inthe development of products to meet the needs andrequirements of the telecommunications industry. Thisincludes non-halogenated and low smoke designed powercable products and is currently working on the nextgeneration. We manufacture standard types of wire andcable products for the telecommunications industry andcustom or engineered product to customer specificationsor standard is An agreement on a definition. By referenc-ing standards which may be either a test method, or aphysical or electrical description, the task of obtaining acable having the desired properties is Making BodiesICEA ..Insulated Cable Engineers AssociationNEMA ..National Electrical Manufacturers AssociationAEIC ..Association of Edison Illuminating CompaniesUL.

10 Underwriters Laboratories Incorporatedc(UL) ..Underwriters Laboratories Incorporated (Canada)CSA ..Canadian Standards AssociationCSA NRTL ..Canadian Standard AssociationCSA NRTL/C ..Canadian Standard AssociationNEC .. National Electrical CodeANSI ..American National Standards InstituteAAR ..American Association of RailroadsIMSA ..International Municipal Signal AssociationASTM ..American Society for Testing and MaterialsAAA ..Aluminum Association of AmericaISA ..Instrument Society of AmericaIEEE ..Institute of Electrical and ElectronicsEngineersIEC ..International Electrotechnical CommissionBASIC ELECTRICITYT ransmitting electricity is the basic function to be consid-ered when making wire and Cable perform properly. Metalconductors carry the electrons which is generated by anelectromotive There are three major components ofbasic electricity:1.