Types of cables

When purchasing electrical cable or wire, it’s important to consider several factors including wire gauge, flexibility, conductor material, insulation, outer sheath. Here you will find some tips that will help you to buy electrical cables adapted to your specific requiremets.

DC wires (direct current cables) used in rectified direct current transmission systems. Compared to AC cords, DC cables have less power loss during transmission and are easy to install and maintain. They are also less expensive.
AC cords (alternating current cables) are commonly used in power frequency power systems. AC cables have high safety requirements on insulation. They are more complex in construction and cost about three times as much as DC cables.

The most common insulation materials for the cables are PVC, PE, XLPE, goma, etc.
Among them, PVC material has the advantages of simple structure, easy fabrication and processing, light weight and lower cost. Therefore, It is widely used in insulation for medium and low voltage cables.
XLPE cables have higher overload capacity and longer lifespan compared to PVC. But they are also more expensive than PVC. PVC cables typically have a life expectancy of 20 years in good surroundings. While, XLPE cables typically have a life expectancy of 40 years.
Rubber cables are soft and flexible. They have a small radius of curvature. This type of cables is suitable for use in scenarios where frequent movement is required, like sea cables, mining cables, etc.
Allowable long-term operating temperature: 70°C (PVC), 90°C (XLPE/ERP).
Maximum allowable temperature in case of short circuit: 160°C (PVC), 250°C (XLPE/ERP).

The most common types of electrical cables by their use are:
Power cables
Armoured cables
Rubber or Neoprene cables
Halogen-free safety cables
Fire resistant cables
Control and screened cables
Instrumentation cables
Cables for electric panels
Solar cables
Special cables
Aluminium cables
Medium Voltage Cables, and Fiber optic cables
More info here.

Solid wire is a single conductor made of a single piece of metal, usually used for low-voltage applications, such as residential wiring. Stranded wire is made of multiple strands of metal woven together. It is often used for higher-voltage applications, such as industrial and commercial use.

• Copper and tinned copper: are defined in class 1, class 2, class 5 and class 6.
• Aluminium and aluminium alloys: are defined in class 1 and class 2. Classes 5 and 6 are not defined in IEC 60228.

Single-core cables are single insulated conductors. Multi-core cables are multiple insulated conductors bundled together and insulated with a protective outer sheath.

All cables manufactured and commercialized by Top Cable comply with RoHS requirements to keep our users safe from hazardous materials. The RoHS restricts the use of hazardous materials. While this directive comes from the European Union, its importance have impacted the worldwide production of wiring and electronics.

A cable labeled RoHS compliant follows the guidelines listed by the European Union under the Restriction of Hazardous Substances Directive (RoHS). A product that is RoHS compliant contains no lead, cadmium, mercury, hexavalent chromium, polybrominated biphenyls, or polybrominated diphenyl ethers. RoHS material substitutes these with more environmentally-friendly alternatives.

The EU RoHS Directive aims to protect the environment and reduce exposure-related health risks by restricting the use of hazardous materials in the manufacturing of electronic and electrical equipment.

Most power cables have a design life of between 20 to 30 years, considering a cable manufactured to international standards and wired indoors according to proper guidelines.

The skin effect means that in an AC circuit, more of the current will travel along the outside edge as compared to the current going through the center of the wire.

The skin effect influences cable design in several ways:
• Increased resistance: As AC frequency increases, skin depth decreases, leading to higher resistance and power losses.
• Heat generation: More resistance results in more heat, which can affect cable insulation and longevity.
• Cable sizing: Engineers may need to use larger or differently designed cables to mitigate these effects.

To reduce the impact of the skin effect, engineers can:
• Use stranded conductors, which have more surface area for current flow
.• Choose materials with higher conductivity and lower magnetic permeability.