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Austra lia n/New Zealand Sta nda rd"

Conductors in insulated electric cablesand flexible cords

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AS/NZS l l25:2001This Joint Australian/Ncw Zealand standard was prcparcd by Joint Technicalcommittee_ EL-003, Electric wires and cables. It wds dpproved on beharf of thccouncil of Standards Australia on 2l May 2001 and on'tehalf of the council ofStandards New Zealand on 8 May 2001. lt was published on 29 June 2001.

The fol lowing interests ere reprcsented on Committee EL-003;Australasian Railway Associat ionAustralian Elcctrical and Elcctronic Manufacturcrs AssociationAustral ian Industry GroupDepartment of Deience, Austral iaDepartmcnt of Mincral Rcsources, N.S.W.Electrical Contractors Association of New ZealandElectr ici ty Supply Associat ion of Austral iaInst i tut ion of Engineers, Austral iaMinistry of Economic Dcvclopment, Ncw ZealandNational Elcctrical and Communications AssociationNew Zealand Menufacturers FederationRegulatory Authorities (Electrical)Testing interests (Australia)

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Keeping Stendrrds up-to-drteStandards are living documents which rcflcct progrcss in sciencc, technology andsystems. To maintain their currency, ail stand'ardi are periodicaliy reviewe?', andnew

_

editions are published. Between editions, amendments mav be isiued.Standards may also be withdrawn. lt is important that rcaders assuie themselvesthey -are usrng a current standard, which should include any amendmcnts which

may have been publishcd sincc the Standard was purchascd.Detailed information about joint Australian/New zealand Srandards can be found byvisiting the standards Ausiralia web site at www.standards.com.au or standard'sNew Zealand web site at www.standards.co.nz and looking up the iJlcrant Standardin the on-line catalogue.Alternatively, both organizations p_ublish an annual printed cataloguc with fulldetarls of all currcnt Standards. For morc frcqucnt- listings or n6tification ofrevisions, ?mendmcnts and withdrawals, Standarfs Australii-ani iianiaras 1.,"Zcaland offer a number of updale options. For information "Uout iirisc scrvices,users should contact their respective national standards organization.!!9^1!1 werco;1e suggestions for. improvemenr in our standards, and especiailycnco.urage readers to notify us immcdiately of any apparent

'inaccuraties o'r

ambiguities. Please addresi your commentj to thc-chiif Exccutive of eitherStandards Australia International or standards New Zcaland at thc addrcss shownon the back cover.

This Standard was issued in draft

AS/NZS 1125:2001

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COPYRIGHTg Standlrds Austr.lis/St!ndards lrlew ZealandAll rrghts rre resc'ed. No psrt ofthrs work may ba reproduced or copred In lny fonn or by 8nym.!r|!, ercrronrc or mcchankar, rrErudrng photocopyhg. withod the wrtnen pirmtsiton of rnepuUlsher.Joln0y publlshed.by Standards Austraila Intemarronar trd. Gpo Bor 5420. sydney, Nsw 2ool.nd Strnd.rd! Ner Z.hnd, prtvrro Blg 2439, Weillngton 60A0lsSt't 0 ?337 3957 1

Australian/New Zealand Sta ndard"

Gonductors in insulated electric cabtesand flexible cords

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Orlglnated as part of AS C32f-1960 and AS C4O7-1969.Prevlous edltlcn AS 1125-1993.Jolntly ravlsed rnd dElgnrted Agl,lZS 1 I 25:2fi)1.

IAS/NZS t l23:2001

PREFACE b{{i lA * l/" AThis Standard was prcparcd by the Joint Standards AustrafialStanaartd i.lew' Zealandcommittee EL-003, Electric wires and cables, to supersede As lr25-1993 andNZS/AS I125-1993, Conductors in insulated electric cables andflexible cords.The conductors specified herein have nominal cross-sectional areas idcntical with those ofcorresponding conductors specified in IEC 60228 (see below). This Standard includesconductors for which IEC makes no provision, namely Milliken conductors and solidsectoral circular conductors.This Standard differs from the previous edition in the following ways:(a) It is publishcd as a Joint AustralianA.{cw Zcaland Standard.(b) There has bccn considcrable reformatting including the consolidation of a number of

tables ofconductors.(c) conductor classes l, 2, 5 and 6 from lBc 60228 have becn introduced.(d) A definition of'metal-coated copper conductor'has been included.(e) The specification for tin coatings has been deleted.(f) The section on silver-plated and nickel-coated annealed coppr conductors has been

consolidated into a gcneral section on copper conductors.(g) The constructional specification for multiplc-stranded circular annealcd copper

conductors (ropc lay) has been.deleted.Attention is drawn to the fact that the conductors specified represent (with thc exception ofconductors for special purposes) the overall range in the types ofmetals currently sfecified.It does not necessarily follow that each of the types and sizes of conductor is to bc used fora particular cable. Thc individual Standard for such cable will spccify the size and type ofconductors that are applicable, from thc range given in this standard.In the preparation of this Standard, consideration was given to the following Standards:IEC60228 Conductors of insulated cablesBS3988 Specification for wrought aluminium for clectrical purposes. Solid conductors for

insulated cablesAcknowledgment is madc of thc assistance receivcd from thcse documents.The term 'informative' has been used in this Standard to define the application of theappendix to which it applies. An 'informativc' appcndix is only for

-information andguidance.

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AS/NZS l l25:2001

STANDARDS AUSTRALIA/STANDARDS NEW ZEALAND

Austral lan/New Zealand StandardConductors In Insulated electr lc cables and f lexlble cords

S E C T I O N I S C O P E A N D G E N E R A L| , : A(cr.r scopE l,lWUi,fu t;UThis Standard speiifieirequirenients-for conductors in insulated electric cables and flexiblecords used for general wiring cablcs for tand installations and, in the case of copperconductors only, for ships' wiringThis Standard applies particularly to conductors for those types ofcable and flcxible cord towhich the relevant Australian or AustralianA.{ew Zealand Standard makcs cross-reference.This Standard is not necessarily limited to conductors of such cables and cords and shouldbe applied, wherever practicable, to cables designed for general and special purposes.The conductors specified here do not apply to the following:(a) Magnet winding wire including litz wire (see AS/NZS I 194.1).(b) Mineral-insulated metal-sheathed (MIMS) cables (see ASA{ZS 3lg?).(c) Cables intended for use at audio or higher frequencies, e.g. telecommunication cables.(d) Welding cables (see ASA.{ZS 1995).

NOTE: The method of calculation uscd to cstablish the conductor maximum d.c. resistance valucsis givcn in Appcndix A.

1.2 REFERENCED DOCUMENTSThe following documents are rcferred to in this Standard:AS2848 Aluminium and aluminium alloys- compositions and designations2848.1 Part l: WroughtproductsAS/NZSn94 Winding wiresll94.l Part l: Enamelledroundcopperwindingwires1574 Copper and copper alloys-Wire for elccrical purposes1660 Test methods for elecnical cables, cords and conductors1995 Welding cables3000 Elcctical installations (known as the AustralianAlew TnalandWiring Rules)3187 Approval and lest specification-Mineral-insulated metal-sheathed cablesBS3988 Specification for wrought atuminium for electrical purposes. Solid conductors for

insulated cablcs

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AS/NZS l l25:2001

r.3 DEFrNrirroNS ail.'l.g'a?*

-.. .For the puipose of this Standard, the definitions below apply.1.3.1 /,iocfreO circulsr conductor ttA conductor consisting of a number of individual circular wires helically laid up together inrandom manner all in the same direction.t.3.2 Clrculer conductorA solid conductor, the cross-section of which is circular, or a group of wires assembledsuch that their combincd cross-section is approximately circular.1.3.3 CompactedconductorA circular or shaped stranded conductor in which, to reduce overall dimensions, pre-shapedwires have been assembled or circular wires have been assembled and pressed together.1.3.4 Compressed conductorA circular stranded conductor in which the wires have been pressed together after assemblywhich results in a smoother surface and an overall diametcr bctween those of the equivalentstranded and compacted conductors.f .3.5 ConductorThat portion of a cable which has the specific function of conveying current.1.3.6 Metel-coeted copper conductorA copper conductor, the individual strands of which are coated with a metal such as silver,tin or nickel.1.3.7 Mllllken conductorA circular conductor comprising shaped, stranded conductors ofequal size helically laid uptogether and lightly insulated from each other to reduce skin and proximity effects whencarryin g alternating currents.1.3.8 Multlple stranded circular conductor (rope lay)A helical arrangement of groups of wires in one or more layers, the wircs in each groupbcing assemblcd either by bunching or stranding.1.3.9 Routinc testrTests made by the manufacturer on conductors in each manufactured length of cable tocheck that each conductor meets the specified requirements.1.3.10 Sample testsTests made by thc manufacturer on conductors taken from samplcs of completed cable,adequate to verify that thc finished product mects the design spccifications.1.3.11 Shaped conductorA conductor, the cross-section of which is other than circular by design. It may be a singlewire of other than circular cross-seclion, or a group of wires assembled such that theircombined cross-section is other than circular1.3.12 Solld conductorA conductor consisting of a single wire.1.3.13 Solld sectorel clrcular conductorA conductor comprising four solid sectors of equal size helically laid up together.

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AS/NZS tt25:200t

S E C T I O N 2 C O P P E R C O N D U C T O R S

2.1 GENERALThe material, form and construction of plain or metal-coated anneated copper conductorsand plain or metal-coated hard-drawn copper conductors shall comply with thercquirements specified in clauses 2.2, 2.3, 2.4, 2.s, 2.6, 2.7, 2.g, 2.g, 2.lb and 2.ll asappropriate, and the tests specified in Table 2.1. The tests, criteria for tests, categories oftests and references for test methods shall be as specified in Table 2.1.

2.2 MATERIALConductors shall bc made from high conductivity copper wire complying with the chemicalcomposition designation Cl l000 in ASAIZS 1574.

2.3 FORM OF'CONDUCTORConductors shall be circular, shaped, solid, uniaxial, stranded, multiple-stranded circular,bunched circular, compressed, compacted, Milliken or tinsel as required for a particularcable.

2.4 JOINTS IN CONDUCTORS2.4.t Joints In enneeled conductorsJoints are permitted in a solid conductor by welding only.Joints are also permitted in the individual wires of a stranded, uniaxial or bunchedconductor and in the individual bunches or strands of a multiple-strandcd conductor, fromwhich it is formed. When joining conductors by silver-soldering, resistance butt welding orfusion welding, no joint in a wire shall be closer than 60 mm io that in any other wire orbunch in the same layer.This restriction shall not apply when welding by cold pressure welding.2.4.2 Jolnts ln herd-dralvn conductors2.4.2.1 Conductors containing seven wiresJoints in the individual wires shall be made only by cold-pressure butt welding and thcminimum distance between two such joints shall be l5 m.2,4,2.2 Conductors containing more than seven wiresJoints in the individual wires shall be made only by cold-pressure butt welding, resistancebutt welding or resistance brazing and the minimum distance between two sucijoints shallbe 15 m.2.s solrD CONDUCTORS (CLASS l)Thc solid conductors shall bc plain or metal-coated, anncaled or hard-drawn copper, asrequired by the appropriate cablc Standard.

, \,7^Iht maximum d-c' resistancc of conductors at 20oC shall be as specificd in Tablc 2.2 for

#f ^'l.ne:glgyail nominal cross-sectional area of conductor.

The use of solid conductors shall be restricted to a maximum of 2.5 mm2 unless otherwisespecified in the appropriate cable Standard.

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II

AS/NZS l l25:200t

2.6 STRANDED CONDUCTORS (CLASS 2)The wires in stranded conductors shall be plain or metal-coated, annealed or harddrawncopper, as required by the appropriate cable Standard.The minimum number of wircs and the maximum d.c. resistance at 2poC shall bc asspecified in Table 2.3 for the relevant nominal cross-sectional area of conductor.For stranded circular, uniaxial and circular compressed conductors the individual wiresshall be the same nominal diameter.For stranded shaped, circular compacted and Milliken conductors the ratio of the largestwire cross-sectional area to the smallest wire cross-sectional arca in the conductor shall notcxceed 4.The use of circular compactcd conductors shall be restrictcd to conductor sizes of 6 mm2 orgreater unless otherwise specified in the appropriate cable Standard.When a Milliken conductor is rcquired, thc conductor shall consist of sector-shapedstranded conductors lightly insulated from each other.

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2.7 UNTAXTAL CONDUCTORS w Jd. /7F1 Wc_i_d4___ wr " (/. (The afy'licatlbn of uniaxial conductors shall be restricte4 to conductors up to and includinglo mm2. bl ^I oL['The minimum number of wires and the maximum d.c. resistance at 20oC shall be asspecified in Table 2.3 for the releyantnominal cross-sectional area of conductor for circularor compressed conductors. d(lrrtr ".1

2.8 FLEXTBLE CONDUCTORS (CLASS s)The wires in Class 5 flexible conductors shall be plain or metal-coated annealed copper, asrequired by the appropriate cable Standard.The individual wires shall be the same nominal diameter. The maximum wire diameter andthe maximum d.c. resistance at 20oC shall be as specified in Table 2.4 for the relevantnominal cross-sectional area of conductor.

2.9 FLEXTBLE CONDUCTORS (CLASS 6)The wires in Class 6 flexible conductors shall be plain or metal-coated annealed copper, asrequired by the appropriate cable Stindard. Class 6 conductors are more flexible thanClass 5.The individual wires shall have the same nominal diamcter. The maximum wire diameterand the maximum d.c. resistance at 20"C shall be as specified in Table 2.5 for the rclevantnominal cross-sectional area of conductor.

The wires in multiple-stranded circular flexible conductors (ropc lay) shall be plain ortinne(^ann-galed copper, as required by the appropriate cable Standlard.Th. iffJfr"d wires shalt be the same nominal diamcter. The maximum wire diameter andthe maximum d.c. rcsistancc at 20"C shall be as specified in Table 2.6 for the relevantnominal cross-sectional area of conductor.

2.10 MULTTPLE-STRANDED CTRCULAR FLEXTBLE CONDUCTORS (ROPE h - I ;t 1,"L A U 4 t l - , , ' dl,a'

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AS/NZS l l25:2001

2.II TINSEL CONDUCTORSTinsel conductors shall consist of an assembly of strands, either rope-laid in groups, orrope-laid individually around a centre core ofcotton or suitable textile thread. Each strandshall consist of one or more fine, flattened, plain copper wires wrapped around around acentre core ofcotton or suitable textile thread.The rope lay shall be such that the strands are laid up helically and symmetrically so thatwithin any one layer, the pitch of the strands is uniform.The d.c. resistance of the conductor shall not exceed 270 O/km at 20oC.

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AS/f lZS l l25:2001

TABLE 2.1TESTS FOR PLAIN OR METAL.COATED COPPIR CONDUCTORS

' Provided that thc minimum avcragc elongation of all wircs testcd is maintaincd, any individual wire or group ofwircs removcd from a multipte wirc conductor may have an elongation of not less than 50 perccnt of thcrppropristc valuc in thc sccond column.1 Grcyish appcarance ofthi coating shall not conslitute failure.NorE: For samplc tests the minimum numbcr of individual wires to bc tesred for thc clongarion, tensilc strength,sorting continuiry and wrapping tests shall bc thc square root of thc total numbcr of wircs in thc conductor (to thcncrctt wholc numbcr), subject to a maximum of 20 wires.

Tert Crlterle Crtcgory of tert Refcrcncc fortcrt mcthod

Elongrl ion of sol idcircular annealed

Thc clongation shall bc not lcas than rhc followingvllue, as appropriste

Samplc AS/NZS r660

conductors ano wlrcs tatcnfrom uniaxial, strandedcircular and bunchcdcircular annealcdconductors onlYr

Wire diametcr

mm

Minimumaverage clongation

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Tcnsilc strcngth ofhard-drrwn solidconductors and wircs takcnfrom strandcd circularhard-drawn conductorsonly

For metal-coated wires, thc tensile strcngth shallbc not lcss than 370 MpaFor plain wircs, thc tcnsile strcngth shall bc notlcss than thc following value as appropriatc

Semple AS/NZS 1660

Wire diamctcr

mm

Minimumtensile strength

MPa

s1 .50> I .50 2.50 3.00

425405395380

Wntpping test ofhard-drawn solidconductors and wires takcnfrorn strandcd circularhard.drawn conductorsonly

Thc wirc shall not brcak Sample AS/NZS t660

Tcnri lc test of t insclconductors onlv

At lcast threc of thc fivc samples shall cachwithstand a forcc of90N without fracturc

Samplc AS/NZS r660

Coating continuity tcst fortinncd rnd silver platedconductors

The colour of thc rcst solution aftcr immcrsion oftbe tcst specimcn shall not be darkcr than that ofthc rcfcrcnce colour standard solution

Sample AS/NZS 1660

Corting continuity test fornickcl-coated conductors

Thcre shell bc no bhckcning of the conductor f Sample ASTNZS t660

Conductor rcsistance Rcsistance valucs shall be in accordance withTables 2.2, 2.3,2.4,2.5 or 2.6 as appropriatc

If not specifiedthc tcst shell be asamplc tcst

AS/NZS 1660

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t l

TABLE 2.2CLASS r

SOLID COPPER CONDUCTORS FOR SINGLE-COREAND MULTICORE CABLES

ASNZS l125:2001

* To obtain thc maximum resirtancc for hard-drawn copper conductors, the rabulatedvalucs should bc divided by 0.97.

Nomlnrl crorr-sectlonrl rrcr

mtn2

Mulrnum d.c, rerlttrncc of conductor rt 20oC

fUkn

Phln ordlvcr-plrtcd

rnncrlcd coppcr.

Tlnncd rnncrlcdcoppcrr

Nlckcl-coetcdrnncrlcd coppcr

0.50.751 . 0t {2.546

l 0t 625

36.024.5r 8 . lt2.l7 .414.613.0Er .83t . t 5o.727

36.724.8tE.2

t2.27 .564.70

3. i l1 . 8 4l . t 6

39.6

19.7

t3.2

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AS/NZS l l25:2001

TABLE 2.3CLASS 2

STRANDED COPPER CONDUCTORS FOR SINGLE.COREAND MULTICORE CABLES

i To obtain thc maximum rcsistancc for hard-drawn copper conductors, thc tabulatcd valucs should bc dividcdby 0.9?.t Rcsistence values arc applicable only to singlc-core cablcs, For multi-corc cables, thcsc resistancc valucsrbould bc mult ipl ied by 1.02.

I t

t 3 4 5 6 7Nominrl

crotl-rcct lonrl rret

mml

Mlnlmum numbcr of wlrcr In conductor Mrrlmnm d.c. rcsktrncc of conductor rt 20"C

O/km

Clrculrr orcomprercdconductor

Clrculrrcomprclcdconductor

Shrpcdconductor

Plr ln orrllvcr-plrtcd

rnncrlcdcoppcrr

Tlnnedrnncrlcdcoppcrr

Nlckcl-cortcdenncrlcdcopperr

0.50.75r . 0

1 .52.54

6l 0t 6

253 550

1095120

r 5 01 8 5240

300400500

630E00

960 (4 x 240)| 000| 200| 6002000

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1

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1

1

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11 |5 t I6r II6 r I6 r l

6 r IIe r I

e t INumber of wirc

Ie l l

Numbcr of wirtNumbcr of wirc

INumber of wirc

666

666

666

l 2l 5I E

l 83034

345353

5353

not spccificd

5 3not spccificdnot spccificd

not spccified

666

t 2l 5l 8

t 830t4

345353

1

3E.425.12t .2

r 3.67 .414.6 t

3.08r . E 3t . l 5

0.7270.5240.3 87

0.2680 . t930 .1 53

0.t240.099 r0.0154

0.060 l0.04700.03661

0.028310.02210 .0189

0 .01760 . 0 t 5 10 . 0 r | 30.0090

19.626.02t .6

I3 .E7.564.70

3 . 1 Ir .E4l . l 6

0.'t340.5290.39 r

0.2700 . t950 . r54

0.1260 .1000.0't62

0.060?0.04750.03691

0.02E6t0.02240.01 89

0.0t770 . 0 t 5 |0 .0 r r3

0.0090

i.tt4 .98 . t 45.06

3.342.00

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t 3 ASAIZS l l25:2001

TABLE 2.4CLASS 5

FLEXIBLE COPPER CONDUCTORS F'OR SINGLE.CORE ANDMULTICORE CABLES AND FLEXIBLE CORDS

Nomlnel crosc-cectlonel rrcr

mm1

Mrrlmum dhrnctcrof wlrtr lnconductor

Mrrlmum d.c. rcr lr trncc of conductor rt 20.C(Ukm

Phln orrllvcr-plttcd

rnnctlcdcoppcr

Tlnncdrnnctlcdcoppcr

NIckcl-cortedrnnctlcdcoppcr

0.50.751 . 01 . 52 .546

I Ol 62535507095

1201 5 01 8 5240300400500

0.2 r0.210 .210.260.260.3 r0.3 r0.4 l0.410.4 I0 .410 .410.5 I0.5 t0.5 r0 .510 .510.5 |0 .5 l0.5 r0.6 t0.6 t

39.026.01 9 . 5

r3 .37.984.953.30| .9Et . 2 l0.7800.5540.3860.2720.2060 . 1610.t290.r060.0E010.064 |0.M860.03840.0287

40. l26.720.0t3.78 .2 l5.093.392.021.240.7950.5650.3930.2770 .2 t00 .1640 . t320.1 080.08 t 70.06540.04950.03910.0292

43.128.721.5t4.78.825.473.65

r

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COPYRTGHT

AS/NZS ll25z2o0l

TABLE 2.5CLASS 6

FLEXIBLE COPPER CONDUCTORS FOR SINGLE-COREAND MULTICORE CABLES

TABLE 2.6FLEXIBLE MULTIPLE.STRANDED CIRCULAR COPPER CONDUCTORS(ROPE LAY) FOR SINGLE-CORE AND MULTICORE FLEXIBLE CABLES

l 4

Nomlnrl crols-rcctlonrl rrcr

mmr

Mulmum dlrmcter ofrvlrcr In conductor

mm

Mrrlmum d.c. rcr lr trncc of conductor rt 20oC

fUkrn

Phln or rllvcr-plrtcdrnncrlcd copp.r

Tlnncd rnncrlcd copper

0.50.75Ir . 5a (

46

t 0t 6253550'to95

t20150r E 5240

0 . l t0 . l t0 . l r0 . l r0 . l t0 . l t0,20.20.20.20.20.30.30.30.30.30.40.40.4

39.026.019 .51 3 . 37.984.953.30l . 9 tt . 2 l0.7800.5540,3E60.2720.2060 . 1 6 10 . t290.1060.080l0.064 |

40. I26.720.013.78 .215.093.39l.95t .240.7950.5650.3930.2770 .2100 . t640 . t320 . t0E0.0E r 70.0654

Nomlnr l crorc-rcct lonr l r rcr

mmr

Merlmum dhmctcr ofwlrcr In conductor

mm

Mrrlrnum d.c. rcrlrtrncc of conductor rt 20cC

fUkm

Phln rnnetlcd coppcr Tlnncd enncdcd coppcr6

t 0l 62535t01095

r 2 0t 5 0lE5240300400500

0.3 r0.410.4 l

0.4 r0.410.410.680.680.680.6t0.680.68

0.680.680.6E

3 .30l . 9Et . 2 l0.7310.5360.4020.2660.20&0 . t 6 r0.t260 .1040.08030.06320.04650.0384

3.392.021 .240.7460.5470 .4 t00.2710.2120.1640 . t290 . t060.0E | 80.06440.04750.0392

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AS/NZS t t25:200t

S E C T I O N 3 A L U M I N I U M C O N D U C T O R S

3.1 GENERALThe material, form and construction of aluminium conductors shall comply with therequirements specified in clauses 3.2,3.3,3.4, 3.5 and 3.6, as appropriate and thc testsspecified in Table 3.1. The tests, criteria for tests, category oftests and references for testmethods shall be as specified in Table 3.1.

NOTE: Rcstrictions arc placed on thc minimum size of aluminium conductors. For dctailcdrequirements see AS/NZS 3000.

3.2 MATERIAL3.2.1 Al loyConductors shall be made from alloy 1350 as specified in AS 2848.13.2.2 Stranded conductorsTensile strength shall comply with Table 3.1.Stranded aluminium conductors normally do not have a cross-sectional area less than

-

10 mm2, but 4 mm2 and 6 mm2 sizes may be used subject to special consideration of thefsuitaUility of the conductor for the type of cable and its apqication. Vl arrfr- r