PVC INSULATED

HEAVY DUTY CABLES

1100 V.

Wiring the World

9001:2008

Polycab Wires PVt. Ltd.

14001:2004
Polycab House, 771, Mogul Lane,
Mahim (W), Mumbai 400 016, India.
OHSAS
Tel.: +91 22 2432 7070-74 18001:2007
Fax: +91 22 2432 7075
E-Mail : [email protected]
www.polycab.com
Apr 2013

Details make the Difference IS 1554 (Part I)

P r o d u c t R a n g e
■ L.V. PVC & XLPE POWER CABLES WITH
COPPER AND ALUMINIUM CONDUCTOR
■ L.V. PVC & XLPE CONTROL CABLES WITH COPPER CONDUCTOR
■ M.V. POWER CABLES UPTO 33 kV
■ EHV CABLES FROM 66kV TO 220kV
■ M.V. / L.V. AERIAL BUNCHED CABLES (ABC)
■ zero halogen cables
■ FIRE SURVIVAL cables (fs)
■ INSTRUMENTATION CABLES SCREENED / UNSCREENED
■ industrial braided cables
■ THERMO COUPLE / COMPENSATING CABLES
■ lead sheathed cables
■ rubber cables
■ RAILWAY SIGNALLING CABLES
■ TELEPHONE CABLES – DRY & JELLY FILLED
■ BUILDING WIRES – fr / frls / frzh / frlf / frfs
■ Single core industrial Flexibles – pvc / fr / frls /
frzh / hrfr / hr / hr-frls / frlf / frfs
■ multi core industrial flexible cables
■ SUBMERSIBLE flat and round CABLES
■ SUBMERSIBLE Wrapped winding wires
■ COAXIAL CABLES
■ LAN CAT-5E / cat 6 CABLES
■ welding cables
■ solar AC / dc cables
■ steel braided cables
■ speciality cables – suited for marine / oil & gas /
extreme fire conditions / highly corrosive
environment / traffic / aircraft / space station /
automobiles

Production Facilities at Daman Factory

POLYCAB REGIONAL OFFICES
CHENNAI : Old No. 5/2, New No.9/2 Gopalkrishna Road, T-Nagar, CHENNAI - 600 017. SECUNDERABAD : 401, A, 4th floor, Suryakiran Complex, S. D. Road,
Tel: 044 42022775 / 32969257 • Fax: 044 42022774 • Email : [email protected] SECUNDERABAD - 500 003.
Tel: 040 66326228 / 30962600 • Fax: 040 66326229 / 3072355
BARODA : 9, Khushbu Corner, 56, Vishwas Colony, Alkapuri, BARODA - 390 007.
Email : [email protected]
Tel: 0265 3252825 • Fax: 0265 3083366 • Email : [email protected]
DELHI : O-13, 3rd Floor, Lajpat Nagar II, NEW DELHI - 110 024.
PUNE : 36, Sangam Project, Off. Indian Air Lines, Near RTO (PUNE), Ambedkar Road,
Tel: 011 29841721-24 • Fax: 011 29841697 • Email : [email protected]
PUNE - 411 001. • Tel: 020 26058277 / 30209678 • Email : [email protected]
KOLKATA : 1-3, A, South End Park, KOLKATA - 700 029.
BENGALURU : #104/6, 5th Cross, 5th Block, SSI Area, Rajajinagar, BENGALURU - 560 010.
Tel: 033 32929602-3 • Fax: 033 24197706 • Email : [email protected]
Tel: 080 23102172 • Fax: 080 23102071 • Email : [email protected]
Contents

Details make the difference 2

Introduction 3-5

Tables 6-21

Rating Factors 22-24

Selection of Cables & FRLS 25

Short Circuit Rating 26

Handling 27-28

1
Details make the difference

THE CO MPA NY and hence customers’ satisfaction is its

POLYCAB, an ISO 9001:2008, ISO prime objective. Over the years sincere
14001:2004, OHSAS 18001:2007 company service and dedication to its Customers
is the largest Wire & Cable manufacturer has earned the Company distinguished
in India with a proven track record of Customers which includes demanding
over three decades. The fastest growing leaders in Sectors like Utilities, Power
company in the Indian Cable Industry Generation, Transmission & Distribution,
with consistent growth. Polycab group has Petroleum & Oil Refineries, Oem’s, EPC
crossed Rs. 3600 crore turnover in the year contractors, Steel & Metal, Cement,
2010-11 and is set to achieve Rs. 4000 Chemical, Atomic Energy, Nuclear Power,
crore turnover in the year 2011–12. Consultants & Specifiers etc.
From a modest beginning with Wires and POLYCAB has highly experienced qualified
Cables, over three decades ago Polycab set and dedicated professionals with strong
up State of Art manufacturing facilities at adherence to the quality management
Daman in 1996.The last 3 decades have system. Polycab has offices all over the
seen the core business develop along country and also has a wide network of
different product lines: - Low Voltage authorized distributors and dealers to
Cables, Medium Voltage Cables, Extra cater to all the customer segments in India
High Voltage Cables, Fire Survival & Fire and abroad.
Resistant Cables, Telecommunication
Cables, Instrumentation Cables and Aerial POLYCAB has earned the trust and
Bunched Cables. In the manufacture of reputation in India and abroad by winning
cables, a competitive edge lies not so the customers’ confidence. Several
much in product innovation as in providing thousands kilometers of LT PVC Cables
consistent quality, guaranteeing reliability in the voltage range of 1.1KV have been
and ready availability. Polycab’s Daman manufactured and are in operation in India
factory was created to address these key and abroad.
market determinants. The manufacturing
set up is sourced out from the world Polycab LT PVC Cables are preferred choice
renowned Machinery and Technology in Power Plants, Distribution Systems,
suppliers with constant upgradation and Heavy Industries, Various Utilities, The
expansions. Titans of Indian Industry & Consultants /
Specifiers.
CUS TO ME R SATISFACT ION
In an on going process to improve Customer DETAILS M AK E T HE DIF FEREN C E
Satisfaction Polycab offers a variety of More than 3 decades of experience have
services: enabled POLYCAB to develop a specific
• Commercially competitive prices. know how for each individual productline.
• Reliable & consistent quality. Attention to details allows the company
• Reliable & just in time delivery. to apply optimum technical solutions
• Product development for a changing and material selections to each and every
market. different project or application.
• A targeted stocking policy.
• Technical Support for Applications/ Other available Catalogues:
Projects Flexible Cables
CUS TO ME R FO CUSED LT XLPE Power & Control.
HT Cables upto 45KV
POLYCAB derives its strength from its
customers. The growth of the latter is a EHV Cables upto 132Kv
prerequisite to the growth of the company Fire Survival Cables.

Polycab Wires Pvt. Ltd. takes every precaution to ensure the information given in this publication is correct.
E & O.E. all information is subject to change without notice.

2
PVC insulated LT Heavy Duty cables
are as per IS-1554 (Part I) 1988 and are suitable for fixed installations.

The cables are suitable for use on AC I.S. 1554 permits two types of PVC
single phase or three phase (earthed or insulation as follows :
unearthed) systems for rated voltage up to 1) Insulation with TYPE A PVC compound
and including 1100 volts. These cables can
as per I.S. 5831 which is suitable for
be used on DC systems for rated voltage up
to and including 1500 volts to earth. 70 deg.C continuous operation.
2) Insulation with TYPE C PVC compound
CO ND UCTO R as per I.S. 5831 which is suitable for
The most acceptable metals for conductors 85 deg.C continuous operation.
are copper and aluminium due to their The following colour code is used for
higher conductivity and ductility.
identification :
As copper has got higher affinity for sulphur, Single Core : Red, Black, Yellow or Blue.
it corrodes in the atmosphere where sulphur
fumes are present. In these conditions Two Cores : Red and Black
tinned copper should be used. Aluminium Three Cores : Red, Yellow and Blue.
oxide film which is always present on
Three & Half : Red, Yellow, Blue and
Aluminium conductor surface acts as barrier
and it protects the Aluminium conductor Reduced neutral Black.
from corrosion in fumes laden atmosphere. Four Core : Red, Yellow, Blue and Black.
Five Core : Red, Yellow, Blue, Black, & Grey
CONDUCTOR CONSTRUCTION
Six Cores : Two adjacent cores.
The most economical construction for
conductor is solid conductor i.e. conductor Blue and Yellow
is made of one single wire. As the area of (Counting and direction core)
conductor increase, solid conductor becomes And remaining Grey in each
more stiff and hence difficult to handle. In layer. OR By printing
this case stranded construction is adopted. numbers on each core.
Here the conductor is made of number of
strands. The strands are arranged in spiral LAYING UP
layers in 1+6+12+18+…….. formations. This The cores are laid up with suitable lay. The
construction provides more flexibility. Where final layer always has a right hand lay i.e.
crimping of lugs are required, the conductor
if you look along the cable, the cores move
has to be of stranded construction only.
to your right hand.
To economise in insulating material, weight
and overall diameter, shaped conductors INNERSHEAT H
are employed in bigger sized cables. Here
the stranded conductor is shaped in to a Innersheath is provided over the laid up
segment of a circle so that when all the cores. It is provided to give circular shape
cores are laid, they form a complete circle. to the cable and it provides bedding for
These segments are identified as 2 Core the armouring.
– 180 degree, 3 Core – 120 degree, 4 Core I.S. 1554 permits following two
– 90 degree and 3.5 Core – 100/60 degree. methods of applying the innersheath
I.S. 1554 permits solid conductor of any thermoplastic material i.e. PVC,
construction upto 10 sq.mm in Aluminium Polyethylene, etc.
and upto 6 sq.mm in copper. It permits the
use of shaped conductors for sizes from 16 a) EXTRUDED INNERSHEATH: Here
sq.mm onwards. the innersheath is provided by extrusion
of Thermoplastic over the laid up cores.
INS ULATIO N This type of the innersheath is generally
The PVC covering over conductor is called provided in cables having round cores i.e in
insulation and is provided by extrusion control cables and in power cables upto 10
process only. The insulated conductor is sq.mm size. This type of the innersheath
called core. also acts as a water barrier between cores

3
PVC insulated LT Heavy Duty cables
are as per IS-1554 (Part I) 1988 and are suitable for fixed installations.

and outersheath. In case of a puncture in used along with galvanized steel wires.
the outersheath the water can not reach Sometimes two layers of Round Steel
to the cores and hence we recommend Wire or Steel Strip are applied in opposite
that cables for outdoor underground uses direction with barrier tape in between are
should have extruded innersheath. provided to give extra protection.
b) TAPPED INNERSHEATH: Here the In case of single core armoured cables
innersheath is provided by wrapping for use in AC circuits, the material for
a thermoplastic tape over the laid up armouring has to be non magnetic, as in
cores. It is generally employed in cables this case the return current is not passing
having sector shaped cored i.e. multicore through the same cable and hence it will
cables of 16 sq.mm and above. not cancel the magnetic lines produced by
the current. These magnetic lines which are
This method saves a process and oscillating in case of AC current will give
hence manufacturers always provide rise to eddy current in magnetic armouring
this type of innersheath unless the and hence armouring will become hot, and
purchase specifications ask for extruded this may lead to the failure of the cable.
innersheath. Generally hard drawn aluminium wires /
strip are used for armouring in this case.
A RMO UR ING
In case of armoured cables, generally OUT ERSHEAT H
galvanized steel wire / strip armouring is The PVC covering over the armouring
provided over the innersheath in multi- in case of armoured cables and over the
core cables and Aluminium Round Wire innersheath in case of unarmoured cables
or Aluminium Strip over the insulation in is called outersheath.
single core cables. It provides mechanical I.S. 1554 specifies nominal and minimum
protection to inside cores and it carries thicknesses of outer sheath for unarmoured
earth return current in case of a short cables and only minimum thickess of outer
circuit of a core with armour. sheath for armoured cables.
As per I.S. 1554 (Part I) 1988, round wire It permits the following types of outer
armouring is provided in cable, where sheath PVC compounds.
calculated diameter under armour is upto 1) Outer sheath with type ST1 PVC
13 mm. Above this the armouring is either compound as per IS-5831, which
with round wire or strip of size 4 mm x 0.80 is suitable for 70°C continuous
mm. As strip construction is economical, operation.
the manufacturers always provide steel 2) Outer sheath with Type ST2 PVC
strip armouring unless wire armouring is compound as per IS-5831, which
specially specified. is suitable for 85°C continuous
In long run of cables and in case of mines, operation.
round wire armouring is must, as strip PVC has got fire retardant properties due to
construction provides higher resistance its halogen content. The fire in the cable
to earth fault current and sometimes this gets extinguished immediately on removal
current may not be sufficient to operate of the fire source.
the circuit breaker in case of earth fault.
In the modern Power, Chemical, Fertilizer
In mines, the resistance of the armour in and Cement Plants many PVC cables are
no case should exceed the resistance of bunched in the cable shaft or on cable
the main core by more than 33% for safety trays. In case of fire in these cables, the
reasons. To achieve this, sometimes tinned fire becomes self sustaining. Moreover due
hard drawn copper wires are required to be to the burning of PVC a dense corrosive

4
PVC insulated LT Heavy Duty cables
are as per IS-1554 (Part I) 1988 and are suitable for fixed installations.

smoke is emitted which makes fire fighting If required, we can provide Fire Retardant
very difficult, due to poor visibility and Low Smoke (FRLS) PVC Inner sheath and /
toxic nature of the smoke. HCL content or outer sheath. This PVC compound, apart
of the smoke, not only damages other
from meeting the requirements of Type ST2
costly equipment lying nearby, but also
penetrates the RCC and corrodes the steel as per IS-5831, has got better fire retardant
reinforcement. Due to this there is an properties and it emits lower smoke and
extensive damage to the property. acid fumes when it catches fire. (For more
To overcome these deficiencies FRLS i.e. Fire information please refer our catalogue on
Retardant Low Smoke PVC was developed. FRLS cables).

CA BLE CO D E
The following codes are used for designating the cables as per IS-1554.
CONSTITUENT CODE LETTER
COPPER CONDUCTOR —
ALUMINIUM CONDUCTOR A
PVC INSULATION Y
STEEL ROUND WIRE ARMOUR W
STEEL STRIP ARMOUR F
STEEL DOUBLE ROUND WIRE ARMOUR WW
STEEL DOUBLE STRIP ARMOUR FF
PVC OUTER SHEATH Y
YWY means Copper conductor, PVC insulated, round wire armoured and PVC sheathed cable.
AYFY means Aluminium conductor, PVC insulated, steel strip armoured and PVC sheathed cable.

E X A MPLE S in the following tables by 15%.

3 Core x 2.50 sq.mm YWY : Plain The weights of the cables mentioned in the
Copper conductor, PVC insulated, laid up, following tables are approximate and given
innersheathed, G.I. wire armoured and for guidance only. They should never be
PVC sheathed cable having 3 cores of 2.50 used as criteria to check the lengths of the
sq.mm conductor size. cables supplied. The best way to check
4 core x 4.0 sq.mm AYWY: Aluminium the length of the supplied cable is by
conductor, PVC insulated, laid up, resistance method. Take the resistance of
innersheathed, G.I. wire armoured and the full drum and divide the reading by the
PVC sheathed cable having 4 cores of 4.0 resistance of 1 mtr. length.
sq.mm conductor size. To decide the size of the conductor,
3 ½ core x 50 sq.mm AYFY: Aluminium particularly that of the sector shaped
conductor, PVC insulated, laid up, conductor, we recommend the following
innersheathed, Steel strip armoured and PVC method.
sheathed cable having 3 cores of 50 sq.mm Take weight of a small conductor piece and
and 1 core of 25 sq.mm conductor size. measure its weight in grams. Then find
The following tables give construction out the weight of the conductor in gms per
details of Polycab cables as per IS: 1554 meter length. Divide it by 2.7 in case of
({Part I) 1988. Aluminium and by 8.9 in case of copper.
For current rating of Polycab cables with It will give the area of the conductor in
H.R. insulation increase the rating given sq.mm.

5
Weight, Dimension data &
Current carrying capacity of cables

TABLE-1 “POLYCAB” 1.1 KV SINGLE CORE, ALUMINIUM CONDUCTOR, PVC INSULATED ALUMINIUM WIRE / STRIP
ARMOURED & PVC SHEATHED CABLES CONFORMING TO IS:1554 (PART I) AMENDED UPTO DATE

Nominal Nominal Armour Nominal Approx. Approx. Max. Dc Current Ratings

Cross Thickness Aluminium Aluminium Thickness Overall Weight of Conductor Direct In Ground In Duct In Air
Sectional of Wire Dia Strip of Outer Diameter Cable Resistance
2 Cables 3 Cables 2 Cables 3 Cables 2 Cables 3 Cables
Area Insulation Thickness Sheath at 20°C
Sq.mm mm mm mm mm mm kg/mm Ohm/Km Amps Amps Amps Amps Amps Amps
*4 1.3 1.4 - 1.24 11.0 155 7.410 36 31 33 30 32 27
*6 1.3 1.4 - 1.24 12.0 175 4.610 44 39 42 37 41 35
*10 1.3 1.4 - 1.24 13.0 205 3.080 50 51 56 51 56 47
16 1.3 1.4 - 1.24 14.0 230 1.910 75 66 71 65 72 64
25 1.5 1.4 - 1.24 15.0 300 1.200 97 86 93 84 99 84
35 1.5 1.4 - 1.24 16.0 350 0.868 97 100 110 100 120 105
50 1.7 1.4 - 1.24 18.0 430 0.641 120 120 130 115 150 130
70 1.7 1.4 - 1.40 20.0 530 0.443 145 140 155 135 185 155
95 1.9 - 4 x 0.80 1.40 21.0 610 0.320 170 175 180 155 215 190
120 1.9 - 4 x 0.80 1.40 22.0 710 0.253 205 195 200 170 240 220
150 2.1 - 4 x 0.80 1.40 24.0 840 0.206 230 220 220 190 270 250
185 2.3 - 4 x 0.80 1.40 26.0 1020 0.164 265 240 240 210 305 290
240 2.5 - 4 x 0.80 1.40 29.0 1250 0.125 300 270 270 225 350 335
300 2.7 - 4 x 0.80 1.56 32.0 1500 0.100 335 295 295 245 395 380
400 3.0 - 4 x 0.80 1.56 36.0 1910 0.078 370 325 335 275 455 435
500 3.4 - 4 x 0.80 1.56 40.0 2350 0.061 410 345 355 295 490 480
630 3.9 - 4 x 0.80 1.72 44.0 2920 0.047 435 390 395 320 560 550
800 3.9 - 4 x 0.80 1.88 48.0 3510 0.037 525 440 420 350 650 640
1000 3.9 - 4 x 0.80 2.04 53.0 4300 0.029 570 490 445 380 735 720
* If required, these sizes can be offered with stranded conductors also

TABLE 2 “POLYCAB” 1.1 KV SINGLE CORE, ALUMINIUM CONDUCTOR, PVC INSULATED

UNARMOURED PVC SHEATHED CABLES CONFORMING TO IS:1554 (PART I) AMENDED UPTO DATE
Nominal Nominal Nominal Approx. Approx. Max. Dc Current Ratings
Cross Sec- Thickness of Thickness Overall Weight of Conductor Direct In Ground In Duct In Air
tional Area Insulation of Outer Diameter Cable Resistance
Sheath at 20°C 2 Cables 3 Cables 2 Cables 3 Cables 2 Cables 3 Cables
Sq. mm mm mm mm Kgs./Km Ohm/Km Amps. Amps. Amps. Amps. Amps. Amps.
*1.5 0.8 1.8 7.0 55 18.100 21 17 19 17 18 15
*2.5 0.9 1.8 7.5 65 12.100 28 24 25 24 25 21
*4.0 1.0 1.8 8.0 75 7.410 36 31 33 30 32 27
*6.0 1.0 1.8 9.0 90 4.610 44 39 42 37 41 35
*10 1.0 1.8 10.0 105 3.080 54 51 56 51 56 47
16 1.0 1.8 11.0 140 1.910 75 66 71 65 72 64
25 1.2 1.8 12.5 195 1.200 97 86 93 84 99 84
35 1.2 1.8 13.5 235 0.868 120 100 110 100 120 105
50 1.4 1.8 15.0 305 0.641 145 120 130 115 150 130
70 1.4 1.8 17.0 385 0.443 170 140 155 135 185 155
95 1.6 1.8 19.0 515 0.320 205 175 180 155 215 190
120 1.6 2.0 21.0 610 0.253 230 195 200 170 240 220
150 1.8 2.0 22.5 735 0.206 265 220 220 190 270 250
185 2.0 2.0 25.0 885 0.164 300 240 240 210 305 290
240 2.2 2.0 28.0 1100 0.125 335 270 270 225 350 335
300 2.4 2.0 30.0 1335 0.100 370 295 295 245 395 380
400 2.6 2.2 34.0 1665 0.078 410 325 335 275 455 435
500 3.0 2.2 38.0 2130 0.061 435 345 355 295 490 480
630 3.4 2.4 43.0 2685 0.047 485 390 395 320 560 550
800 3.4 2.4 47.0 3255 0.037 525 440 420 350 650 640
1000 3.4 2.6 51.5 3960 0.029 570 490 445 380 735 720
* If required, these sizes can be offered with stranded conductors also

6
Weight, Dimension data &
Current carrying capacity of cables

TABLE-3 “POLYCAB” 1.1 KV SINGLE CORE, COPPER CONDUCTOR, PVC INSULATED ALUMINIUM WIRE / STRIP
ARMOURED & PVC SHEATHED CABLES CONFORMING TO IS:1554 (PART I) AMENDED UPTO DATE

Nominal Nominal Armour Nominal Approx. Approx. Max. Dc Current Ratings

Cross Thickness Aluminium Aluminium Thickness Overall Weight of Conductor Direct In Ground In Duct In Air
Sectional of Wire Dia Strip of Outer Diameter Cable Resistance
Area Insulation Thickness Sheath at 20°C 2 Cables 3 Cables 2 Cables 3 Cables 2 Cables 3 Cables

Sq. mm mm mm mm mm mm Kgs/Km Ohm/Km Amps. Amps. Amps. Amps. Amps. Amps.

*4 1.3 1.4 - 1.24 11.0 180 4.610 46 39 42 38 43 35
*6 1.3 1.4 - 1.24 12.0 215 3.080 57 49 54 48 54 44
*10 1.3 1.4 - 1.24 13.0 270 1.830 75 65 72 64 72 60
16 1.3 1.4 - 1.24 14.0 330 1.150 94 85 92 83 92 82
25 1.5 1.4 - 1.24 15.0 460 0.727 125 110 120 110 125 110
35 1.5 1.4 - 1.24 16.0 575 0.524 150 130 140 125 155 130
50 1.7 1.4 - 1.24 18.0 740 0.387 180 155 165 150 190 165
70 1.7 1.4 - 1.40 20.0 970 0.268 220 190 200 175 235 205
95 1.9 - 4 x 0.80 1.40 21.0 1200 0.193 265 220 230 200 275 245
120 1.9 - 4 x 0.80 1.40 22.0 1460 0.153 300 250 255 220 310 280
150 2.1 - 4 x 0.80 1.40 24.0 1770 0.124 340 280 280 245 345 320
185 2.3 - 4 x 0.80 1.40 26.0 2170 0.099 380 305 305 260 390 370
240 2.5 - 4 x 0.80 1.40 29.0 2740 0.075 420 345 340 285 445 425
300 2.7 - 4 x 0.80 1.56 32.0 3360 0.060 465 375 370 310 500 475
400 3.0 - 4 x 0.80 1.56 36.0 4400 0.047 500 400 405 335 570 550
500 3.4 - 4 x 0.80 1.56 40.0 5450 0.037 540 425 430 355 610 590
630 3.9 - 4 x 0.80 1.72 44.0 6820 0.028 590 470 465 375 680 660
* If required, these sizes can be offered with stranded conductors also

TABLE-4 “POLYCAB” 1.1 KV SINGLE CORE, COPPER CONDUCTOR, PVC INSULATED

UNARMOURED PVC SHEATHED CABLES CONFORMING TO IS:1554 (PART I) AMENDED UPTO DATE

Nominal Nominal Nominal Approx. Approx. Max. Dc Current Ratings

Cross Sec- Thickness of Thickness Overall Weight of Conductor Direct In Ground In Duct In Air
tional Area Insulation of Outer Diameter Cable Resistance
Sheath at 20°C 2 Cables 3 Cables 2 Cables 3 Cables 2 Cables 3 Cables
Sq. mm mm mm mm Kgs./Km Ohm/Km Amps. Amps. Amps. Amps. Amps. Amps.
*1.5 0.8 1.8 7.0 65 12.100 25 22 23 21 24 20
*2.5 0.9 1.8 7.5 82 7.410 35 30 31 29 32 27
*4.0 1.0 1.8 8.0 100 4.610 46 39 42 38 43 35
*6.0 1.0 1.8 9.0 130 3.080 57 49 54 48 54 44
*10 1.0 1.8 10.0 170 1.830 75 65 72 64 72 60
16 1.0 1.8 11.0 240 1.150 94 85 92 83 92 82
25 1.2 1.8 12.5 350 0.727 125 110 120 110 125 110
35 1.2 1.8 13.5 455 0.524 150 130 140 125 155 130
50 1.4 1.8 15.0 620 0.387 180 155 165 150 190 165
70 1.4 1.8 17.0 820 0.268 220 190 200 175 235 205
95 1.6 1.8 19.0 1105 0.193 265 220 230 200 275 245
120 1.6 2.0 21.0 1355 0.153 300 250 255 220 310 280
150 1.8 2.0 22.5 1665 0.124 340 280 280 245 345 320
185 2.0 2.0 25.0 2040 0.099 380 305 305 260 390 370
240 2.2 2.0 28.0 2590 0.075 420 345 340 285 445 425
300 2.4 2.0 30.0 3200 0.060 465 375 370 310 500 475
400 2.6 2.2 34.0 4150 0.047 500 400 405 335 570 550
500 3.0 2.2 38.0 5230 0.370 540 425 430 355 610 590
630 3.4 2.4 43.0 6600 0.280 590 470 465 375 680 660
* If required, these sizes can be offered with stranded conductors also

7
Weight, Dimension data &
Current carrying capacity of cables

TABLE-5 “POLYCAB” 1.1 KV TWIN CORE, ALUMINIUM CONDUCTOR, PVC INSULATED, INNER SHEATHED,
ARMOURED PVC SHEATHED CABLES CONFORMING TO IS : 1554 (PART I) AMENDED UPTO DATE

Nominal Nominal Nominal Armour Minimum Approx. Approx. Max. Dc Current Ratings
Cross Thickness of Thickness Galv. Round Galv. Flat Thickness Overall Weight of Conductor Direct In Ducts In Air
Sectional Insulation of Inner Steel Wire Steel Strip of Outer Diameter Cable Resistance In Ground
Area Sheath Nominal Dia. Nominal Sheath at 20°C
Thickness
Sq. mm mm mm mm mm mm mm Kgs./Km Ohm/Km Amps. Amps. Amps.
*1.5 0.8 0.3 1.4 - 1.24 12.5 320 18.100 18 16 16
*2.5 0.9 0.3 1.4 - 1.24 13.5 380 12.100 25 21 21
*4.0 1.0 0.3 1.4 - 1.24 15.0 450 7.410 32 27 27
*6.0 1.0 0.3 1.4 - 1.24 16.0 500 4.610 40 34 35
*10 1.0 0.3 1.4 - 1.24 18.0 600 3.080 55 45 47
16 1.0 0.3 - 0.8 1.40 18.0 500 1.910 70 58 59
25 1.2 0.3 - 0.8 1.40 20.0 650 1.200 90 76 78
35 1.2 0.3 - 0.8 1.40 21.5 750 0.868 110 92 99
50 1.4 0.3 - 0.8 1.40 24.5 950 0.641 135 115 125
70 1.4 0.3 - 0.8 1.56 28.0 1150 0.443 160 140 150
95 1.6 0.4 - 0.8 1.56 31.0 1460 0.320 190 170 185
120 1.6 0.4 - 0.8 1.56 33.0 1670 0.253 210 190 210
150 1.8 0.4 - 0.8 1.72 37.0 2010 0.206 240 210 240
185 2.0 0.5 - 0.8 1.88 40.5 2450 0.164 275 240 275
240 2.2 0.5 - 0.8 2.04 45.0 2950 0.125 320 275 325
300 2.4 0.6 - 0.8 2.20 50.0 3560 0.100 355 305 365
400 2.6 0.7 - 0.8 2.36 56.0 4500 0.078 385 345 420
500 3.0 0.7 - 0.8 2.68 62.5 5600 0.061 410 370 450
* If required, these sizes can be offered with standard conductors also

TABLE-6 POLYCAB 1.1 KV TWIN CORE, ALUMINIUM CONDUCTOR, PVC INSULATED, INNER SHEATHED,
UNARMOURED, PVC SHEATHED CABLES CONFORMING TO IS: 1554 (PART I) AMENDED UPTO DATE.

Nominal Nominal Nominal Nominal Approx. Approx. Max. Dc Current Ratings

Cross Thickness of Thickness of Thickness of Overall Weight of Conductor Direct In Ducts In Air
Sectional Insulation Inner Sheath Outer Sheath Diameter Cable Resistance at In Ground
Area 20°C
Sq. mm mm mm mm mm Kgs./Km Ohm/Km Amps. Amps. Amps.
*1.5 0.8 0.3 1.8 11.0 115 18.100 18 16 16
*2.5 0.9 0.3 1.8 12.0 150 12.100 25 21 21
*4.0 1.0 0.3 1.8 13.5 185 7.410 32 27 27
*6.0 1.0 0.3 1.8 14.5 220 4.610 40 34 35
*10 1.0 0.3 1.8 16.0 275 3.080 55 45 47
16 1.0 0.3 1.8 17.5 285 1.910 70 58 59
25 1.2 0.3 2.0 19.5 405 1.200 90 76 78
35 1.2 0.3 2.0 20.5 490 0.868 110 92 99
50 1.4 0.3 2.0 24.0 650 0.641 135 115 125
70 1.4 0.3 2.0 27.0 800 0.443 160 140 150
95 1.6 0.4 2.2 28.5 1065 0.320 190 170 185
120 1.6 0.4 2.2 33.0 1250 0.253 210 190 210
150 1.8 0.4 2.4 34.0 1550 0.206 240 210 240
185 2.0 0.5 2.4 37.0 1880 0.164 275 240 275
240 2.2 0.5 2.6 42.5 2400 0.125 320 275 325
300 2.4 0.6 2.8 45.5 2920 0.100 355 305 365
400 2.6 0.7 3.2 51.5 3815 0.078 385 345 420
500 3.0 0.7 3.4 57.0 4750 0.061 410 370 450
* If required, these sizes can be offered with stranded conductors also

8
Weight, Dimension data &
Current carrying capacity of cables

TABLE-7 “POLYCAB” KV TWIN CORE, COPPER CONDUCTOR, PVC INSULATED, INNER SHEATHED,
ARMOURED PVC SHEATHED CABLES CONFORMING TO IS : 1554 (PART I) AMENDED UPTO DATE

Nominal Nominal Nominal Armour Minimum Approx. Approx. Max. Dc Current Ratings
Cross Thickness of Thickness Galv. Round Galv. Flat Thickness Overall Weight of Conductor Direct In Ducts In Air
Sectional Insulation of Inner Steel Wire Steel Strip of Outer Diameter Cable Resistance In Ground
Area Sheath Nominal Nominal Sheath at 20°C
Dia. Thickness
Sq. mm mm mm mm mm mm mm Kgs./Km Ohm/Km Amps. Amps. Amps.
*1.5 0.8 0.3 1.4 - 1.24 12.5 350 12.100 23 20 20
*2.5 0.9 0.3 1.4 - 1.24 13.5 415 7.410 32 27 27
*4.0 1.0 0.3 1.4 - 1.24 15.0 500 4.610 41 35 35
*6.0 1.0 0.3 1.4 - 1.24 16.0 580 3.080 50 44 45
*10 1.0 0.3 1.4 - 1.24 18.0 730 1.830 70 58 60
16 1.0 0.3 - 0.8 1.40 18.0 740 1.150 90 75 78
25 1.2 0.3 - 0.8 1.40 20.0 960 0.727 115 97 105
35 1.2 0.3 - 0.8 1.40 21.5 1200 0.524 140 120 125
50 1.4 0.3 - 0.8 1.40 24.5 1580 0.387 165 145 155
70 1.4 0.3 - 0.8 1.56 28.0 2020 0.268 205 180 195
95 1.6 0.4 - 0.8 1.56 31.0 2650 0.193 240 215 230
120 1.6 0.4 - 0.8 1.56 33.0 3160 0.153 275 235 265
150 1.8 0.4 - 0.8 1.72 37.0 3870 0.124 310 270 305
185 2.0 0.5 - 0.8 1.88 40.5 4750 0.099 350 300 350
240 2.2 0.5 - 0.8 2.04 45.0 5930 0.075 405 345 410
300 2.4 0.6 - 0.8 2.20 56.0 7300 0.060 450 385 465
400 2.6 0.7 - 0.8 2.36 55.9 9450 0.047 490 425 530
* If required, these sizes can be offered with standard conductors also

TABLE-8 POLYCAB 1.1 KV TWIN CORE, COPPER CONDUCTOR, PVC INSULATED, INNER SHEATHED
UNARMOURED, PVC SHEATHED CABLES CONFORMING TO IS: 1554 (PART I) AMENDED UPTO DATE.
Nominal Nominal Nominal Nominal Approx. Approx. Max. Dc Current Ratings
Cross Thickness of Thickness of Thickness of Overall Weight Of Conductor Direct In Ducts In Air
Sectional Insulation Inner Sheath Outer Sheath Diameter Cable Resistance at In Ground
Area 20°C
Sq. mm mm mm mm mm Kgs./Km Ohm/Km Amps. Amps. Amps.
*1.5 0.8 0.3 1.8 11.0 135 12.100 23 20 20
*2.5 0.9 0.3 1.8 12.0 185 7.410 32 27 27
*4.0 1.0 0.3 1.8 13.5 235 4.610 41 35 35
*6.0 1.0 0.3 1.8 14.5 295 3.080 50 44 45
*10 1.0 0.3 1.8 16.0 400 1.830 70 58 60
16 1.0 0.3 1.8 17.5 485 1.150 90 75 78
25 1.2 0.3 2.0 19.5 715 0.727 115 97 105
35 1.2 0.3 2.0 20.5 925 0.524 140 120 125
50 1.4 0.3 2.0 24.0 1270 0.387 165 145 155
70 1.4 0.3 2.0 27.0 1670 0.268 205 180 195
95 1.6 0.4 2.2 28.5 2250 0.193 240 215 230
120 1.6 0.4 2.2 33.0 2750 0.153 275 235 265
150 1.8 0.4 2.4 34.0 3410 0.124 310 270 305
185 2.0 0.5 2.4 37.0 4170 0.099 350 300 350
240 2.2 0.5 2.6 42.5 5370 0.075 405 345 410
300 2.4 0.6 2.8 45.5 6640 0.060 450 385 465
400 2.6 0.7 3.2 51.5 8770 0.047 490 425 530
* If required, these sizes can be offered with stranded conductors also

9
Weight, Dimension data &
Current carrying capacity of cables

TABLE-9 “POLYCAB” 1.1 KV THREE CORE, ALUMINIUM CONDUCTOR, PVC INSULATED, INNER SHEATHED,
ARMOURED PVC SHEATHED CABLES CONFORMING TO IS : 1554 (PART I) AMENDED UPTO DATE

Nominal Nominal Nominal Armour Minimum Approx. Approx. Max. Dc Current Ratings
Cross Thickness Thickness Galv. Round Galv. Flat Thickness Overall Weight of Conductor Direct In Ducts In Air
Sectional of of Inner Steel Wire Steel Strip of Outer Diameter Cable Resistance In Ground
Area Insulation Sheath Nominal Nominal Sheath at 20°C
Dia. Thickness
Sq. mm mm mm mm mm mm mm Kgs./Km Ohm/Km Amps. Amps. Amps.
*1.5 0.8 0.3 1.4 - 1.24 12.5 375 18.100 16 14 13
*2.5 0.9 0.3 1.4 - 1.24 14.0 425 12.100 21 18 18
*4.0 1.0 0.3 1.4 - 1.24 15.5 500 7.410 28 23 23
*6.0 1.0 0.3 1.4 - 1.24 17.0 575 4.610 35 30 30
*10 1.0 0.3 1.4 - 1.4 19.0 700 3.080 46 39 40
16 1.0 0.3 - 0.8 1.40 20.0 650 1.910 60 50 51
25 1.2 0.3 - 0.8 1.40 22.0 800 1.200 76 63 70
35 1.2 0.3 - 0.8 1.40 25.0 950 0.868 92 77 86
50 1.4 0.3 - 0.8 1.56 27.0 1200 0.641 110 95 105
70 1.4 0.4 - 0.8 1.56 31.0 1500 0.443 135 115 130
95 1.6 0.4 - 0.8 1.56 34.0 1900 0.320 165 140 155
120 1.6 0.4 - 0.8 1.72 38.0 2240 0.253 185 155 180
150 1.8 0.5 - 0.8 1.88 42.0 2700 0.206 210 175 205
185 2.0 0.5 - 0.8 1.88 46.0 3200 0.164 235 200 240
240 2.2 0.6 - 0.8 2.20 52.0 3990 0.125 275 235 280
300 2.4 0.6 - 0.8 2.36 56.5 4850 0.100 305 260 315
400 2.6 0.7 - 0.8 2.52 64.0 6100 0.078 335 290 375
500 3.0 0.7 - 0.8 2.84 72.0 7600 0.061 350 310 410
* If required, these sizes can be offered with standard conductors also

TABLE-10 “POLYCAB” 1.1 KV THREE CORE, ALUMINIUM CONDUCTOR, PVC INSULATED, INNER SHEATHED
UNARMOURED PVC SHEATHED CABLES CONFORMING TO IS : 1554 (PART I) AMENDED UPTO DATE

Nominal Nominal Nominal Nominal Approx. Approx. Max. Dc Current Ratings

Cross Thickness of Thickness of Thickness of Overall Weight Of Conductor Direct In Ducts In Air
Sectional Insulation Inner Sheath Outer Sheath Diameter Cable Resistance at In Ground
Area 20°C
Sq. mm mm mm mm mm Kgs./Km Ohm/Km Amps. Amps. Amps.
*1.5 0.8 0.3 1.8 11.5 130 18.100 16 14 13
*2.5 0.9 0.3 1.8 12.5 170 12.100 21 18 18
*4.0 1.0 0.3 1.8 13.5 210 7.410 28 23 23
*6.0 1.0 0.3 1.8 15.0 255 4.610 35 30 30
*10 1.0 0.3 1.8 16.5 325 3.080 46 39 40
16 1.0 0.3 1.8 17.5 360 1.910 60 50 51
25 1.2 0.3 2.0 22.0 520 1.200 76 63 70
35 1.2 0.3 2.0 23.0 640 0.868 92 77 86
50 1.4 0.3 2.0 27.0 850 0.641 110 95 105
70 1.4 0.4 2.2 31.0 1110 0.443 135 115 130
95 1.6 0.4 2.2 33.0 1425 0.320 165 140 155
120 1.6 0.4 2.2 36.0 1690 0.253 185 155 180
150 1.8 0.5 2.4 41.0 2120 0.206 210 175 205
185 2.0 0.5 2.6 45.0 2600 0.164 235 200 240
240 2.2 0.6 2.8 50.0 3290 0.125 275 235 280
300 2.4 0.6 3.0 55.5 4050 0.100 305 260 315
400 2.6 0.7 3.4 63.5 5290 0.078 335 290 375
500 3.0 0.7 3.8 71.0 6570 0.061 350 310 410
* If required, these sizes can be offered with stranded conductors also

10
Weight, Dimension data &
Current carrying capacity of cables

TABLE-11 “POLYCAB” 1.1 KV THREE CORE, COPPER CONDUCTOR, PVC INSULATED, INNER SHEATHED,
ARMOURED PVC SHEATHED CABLES CONFORMING TO IS : 1554 (PART I) AMENDED UPTO DATE

Nominal Nominal Nominal Armour Minimum Approx. Approx. Max. Dc Current Ratings
Cross Thickness Thickness Galv. Round Galv. Flat Thickness Overall Weight of Conductor Direct In Ducts In Air
Sectional of Insula- of Inner Steel Wire Steel Strip Of Outer Diameter Cable Resistance In Ground
Area tion Sheath Nominal Nominal Sheath at 20°C
Dia. Thickness
Sq. mm mm mm mm mm mm mm Kgs./Km Ohm/Km Amps. Amps. Amps.
*1.5 0.8 0.3 1.4 - 1.24 12.5 405 12.100 21 17 17
*2.5 0.9 0.3 1.4 - 1.24 14.0 475 7.410 27 24 24
*4.0 1.0 0.3 1.4 - 1.24 15.5 580 4.610 36 30 30
*6.0 1.0 0.3 1.4 - 1.24 17.0 700 3.080 45 38 39
*10 1.0 0.3 1.4 - 1.40 19.0 890 1.830 60 50 52
16 1.0 0.3 - 0.8 1.40 20.0 950 1.150 77 64 66
25 1.2 0.3 - 0.8 1.40 22.0 1270 0.727 99 81 90
35 1.2 0.3 - 0.8 1.40 25.0 1600 0.524 120 99 110
50 1.4 0.3 - 0.8 1.56 27.0 2150 0.387 145 125 135
70 1.4 0.4 - 0.8 1.56 31.0 2800 0.268 175 150 165
95 1.6 0.4 - 0.8 1.56 34.0 3670 0.193 210 175 200
120 1.6 0.4 - 0.8 1.72 38.0 4470 0.153 240 195 230
150 1.8 0.5 - 0.8 1.88 42.0 5500 0.124 270 225 265
185 2.0 0.5 - 0.8 1.88 46.0 6650 0.099 300 255 305
240 2.2 0.6 - 0.8 2.2 52.0 8450 0.075 345 295 355
300 2.4 0.6 - 0.8 2.36 56.5 10450 0.060 385 335 400
400 2.6 0.7 - 0.8 2.52 64.0 13525 0.047 425 360 455
* If required, these sizes can be offered with standard conductors also

TABLE-12 “POLYCAB” 1.1 KV THREE CORE, COPPER CONDUCTOR, PVC INSULATED, INNER SHEATHED
UNARMOURED PVC SHEATHED CABLES CONFORMING TO IS : 1554 (PART I) AMENDED UPTO DATE

Nominal Nominal Nominal Nominal Approx. Approx. Max. Dc Current Ratings

Cross Thickness of Thickness of Thickness of Overall Weight of Conductor Direct In Ducts In Air
Sectional Insulation Inner Sheath Outer Sheath Diameter Cable Resistance at In Ground
Area 20°C
Sq. mm mm mm mm mm Kgs./Km Ohm/Km Amps. Amps. Amps.
*1.5 0.8 0.3 1.8 11.5 160 12.100 21 17 17
*2.5 0.9 0.3 1.8 12.5 220 7.410 27 24 24
*4.0 1.0 0.3 1.8 13.5 290 4.610 36 30 30
*6.0 1.0 0.3 1.8 15.0 370 3.080 45 38 39
*10 1.0 0.3 1.8 16.5 510 1.830 60 50 52
16 1.0 0.3 1.8 17.5 660 1.150 77 64 66
25 1.2 0.3 2.0 22.0 990 0.727 99 81 90
35 1.2 0.3 2.0 23.0 1290 0.524 120 99 110
50 1.4 0.3 2.0 27.0 1780 0.387 145 125 135
70 1.4 0.4 2.2 31.0 2410 0.268 175 150 165
95 1.6 0.4 2.2 33.0 3190 0.193 210 175 200
120 1.6 0.4 2.2 36.0 3920 0.153 240 195 230
150 1.8 0.5 2.4 41.0 4910 0.124 270 225 265
185 2.0 0.5 2.6 45.0 6040 0.099 300 255 305
240 2.2 0.6 2.8 50.0 7750 0.075 345 295 355
300 2.4 0.6 3.0 55.5 9620 0.060 385 335 400
400 2.6 0.7 3.4 63.5 12715 0.047 425 360 455
* If required, these sizes can be offered with stranded conductors also

11
Weight, Dimension data &
Current carrying capacity of cables

TABLE-13 “POLYCAB” 1.1 KV 3 1/2 CORE, ALUMINIUM CONDUCTOR, PVC INSULATED, INNER SHEATHED,
ARMOURED PVC SHEATHED CABLES CONFORMING TO IS : 1554 (PART I) AMENDED UPTO DATE

Nominal Cross Nominal Thickness Minimum Armour Minimum Approx. Approx. Max. Dc Conductor Current Ratings
Ssectional Area of Insulation Thick- Galv. Flat Thick- Overall Weight Resistance At 20° C Direct In In Ducts In Air
Main Neutral Main Neutral ness of Steel ness of Diameter of Cable Main Neutral Ground
Inner Strip Outer
Sheath Nominal Sheath
Thickness
Sq. mm Sq. mm mm mm mm mm mm mm Kgs./Km Ohm/Km Ohm/Km Amps. Amps. Amps.
25 16 1.2 1.0 0.3 0.8 1.40 23.5 900 1.200 1.910 76 63 70
35 16 1.2 1.0 0.3 0.8 1.40 26.0 1030 0.868 1.910 92 77 86
50 25 1.4 1.2 0.3 0.8 1.56 30.0 1350 0.641 1.200 100 95 105
70 35 1.4 1.2 0.4 0.8 1.56 32.5 1725 0.443 0.868 135 115 130
95 50 1.6 1.4 0.4 0.8 1.56 36.5 2130 0.320 0.641 165 140 155
120 70 1.6 1.4 0.5 0.8 1.72 40.5 2580 0.253 0.443 185 155 180
150 70 1.8 1.4 0.5 0.8 1.88 44.0 3050 0.206 0.443 210 175 205
185 95 2.0 1.6 0.5 0.8 2.04 50.0 3650 0.164 0.320 235 200 240
240 120 2.2 1.6 0.6 0.8 2.20 55.0 4580 0.125 0.253 275 235 280
300 150 2.4 1.8 0.6 0.8 2.36 61.0 5500 0.100 0.206 305 260 315
400 185 2.6 2.0 0.7 0.8 2.68 68.0 7000 0.078 0.164 335 290 375
500 240 3.0 2.2 0.7 0.8 2.84 75.0 8600 0.061 0.125 350 310 410

TABLE-14 “POLYCAB” 1.1 KV 3 1/2 CORE, ALUMINIUM CONDUCTOR, PVC INSULATED, INNER SHEATHED,
UNARMOURED PVC SHEATHED CABLES CONFORMING TO IS : 1554 (PART I) AMENDED UPTO DATE

Nominal Cross Nominal Thickness of Minimum Nominal Approx. Approx. Max. Dc Conductor Current Ratings
Sectional Area Insulation Thickness Thickness Overall Weight of Resistance at 20°C
Main Neutral Main Neutral of Inner of Outer Diameter Cable Main Neutral Direct In In Ducts In Air
Sheath Sheath Ground
Sq. mm Sq. mm Sq. mm Sq. mm mm mm mm Kgs./Km Ohm/Km Ohm/Km Amps. Amps. Amps.
25 16 1.2 1.0 0.3 2.0 22.5 615 1.200 1.910 76 63 70
35 16 1.2 1.0 0.3 2.0 25.0 715 0.868 1.910 92 77 86
50 25 1.4 1.2 0.3 2.2 29.0 955 0.641 1.200 110 95 105
70 35 1.4 1.2 0.4 2.2 33.0 1290 0.443 0.868 135 115 130
95 50 1.6 1.4 0.4 2.2 36.5 1640 0.320 0.641 165 140 155
120 70 1.6 1.4 0.5 2.4 39.0 2020 0.253 0.443 185 155 180
150 70 1.8 1.4 0.5 2.4 42.5 2380 0.206 0.443 210 175 205
185 95 2.0 1.6 0.5 2.6 47.0 2945 0.164 0.320 235 200 240
240 120 2.2 1.6 0.6 3.0 54.0 3800 0.125 0.253 275 235 280
300 150 2.4 1.8 0.6 3.2 58.0 4650 0.100 0.206 305 260 315
400 185 2.6 2.0 0.7 3.4 65.0 6000 0.078 0.164 335 290 375
500 240 3.0 2.2 0.7 3.8 74.0 7400 0.061 0.125 350 310 410

12
Weight, Dimension data &
Current carrying capacity of cables

TABLE-15 “POLYCAB” 1.1 KV 3 1/2 CORE, COPPER CONDUCTOR, PVC INSULATED, INNER SHEATHED,
ARMOURED PVC SHEATHED CABLES CONFORMING TO IS : 1554 (PART I) AMENDED UPTO DATE

Nominal Cross Nominal Thickness Minimum Armour Minimum Approx. Approx. Max. Dc Conductor Current Ratings
Ssectional Area of Insulation Thick- Galv. Flat Thick- Overall Weight Resistance At 20°C Direct In In Ducts In Air
Main Neutral Main Neutral ness of Steel ness of Diameter of Cable Main Neutral Ground
Inner Strip Outer
Sheath Nominal Sheath
Thickness
Sq. mm Sq. mm mm mm mm mm mm mm Kgs./Km Ohm/Km Ohm/Km Amps. Amps. Amps.
25 16 1.2 1.0 0.3 0.8 1.40 23.5 1465 0.727 1.150 99 81 90
35 16 1.2 1.0 0.3 0.8 1.40 26.0 1780 0.524 1.150 120 99 110
50 25 1.4 1.2 0.3 0.8 1.56 30.0 2435 0.387 0.727 145 125 135
70 35 1.4 1.2 0.4 0.8 1.56 32.5 3245 0.268 0.524 175 150 165
95 50 1.6 1.4 0.4 0.8 1.56 36.5 4210 0.193 0.387 210 175 200
120 70 1.6 1.4 0.5 0.8 1.72 40.5 5240 0.153 0.268 240 195 230
150 70 1.8 1.4 0.5 0.8 1.88 44.0 6270 0.124 0.268 270 225 265
185 95 2.0 1.6 0.5 0.8 2.04 50.0 7675 0.099 0.193 300 255 305
240 120 2.2 1.6 0.6 0.8 2.20 55.0 9780 0.075 0.153 345 295 355
300 150 2.4 1.8 0.6 0.8 2.36 61.0 12000 0.060 0.124 385 335 400
400 185 2.6 2.0 0.7 0.8 2.68 68.0 15570 0.047 0.099 425 360 455

TABLE-16 “POLYCAB” 1.1 KV 3 1/2 CORE, COPPER CONDUCTOR, PVC INSULATED, INNER SHEATHED,
UNARMOURED PVC SHEATHED CABLES CONFORMING TO IS : 1554 (PART I) AMENDED UPTO DATE

Nominal Cross Nominal Thickness of Minimum Nominal Approx. Approx. Max. Dc Conductor Current Ratings
Sectional Area Insulation Thickness Thickness Overall Weight of Resistance at 20°C
Main Neutral Main Neutral of Inner of Outer Diameter Cable Main Neutral Direct In In Ducts In Air
Sheath Sheath Ground
Sq. mm Sq. mm Sq. mm Sq. mm mm mm mm Kgs./Km Ohm/Km Ohm/Km Amps. Amps. Amps.
25 16 1.2 1.0 0.3 2.0 22.5 1180 0.727 1.150 99 81 90
35 16 1.2 1.0 0.3 2.0 25.0 1465 0.524 1.150 120 99 110
50 25 1.4 1.2 0.3 2.2 29.0 2040 0.387 0.727 145 125 135
70 35 1.4 1.2 0.4 2.2 33.0 2810 0.268 0.524 175 150 165
95 50 1.6 1.4 0.4 2.2 36.5 3715 0.193 0.387 210 175 200
120 70 1.6 1.4 0.5 2.4 39.0 4680 0.153 0.268 240 195 230
150 70 1.8 1.4 0.5 2.4 42.5 5600 0.124 0.268 270 225 265
185 95 2.0 1.6 0.5 2.6 47.0 6970 0.099 0.193 300 255 305
240 120 2.2 1.6 0.6 3.0 54.0 9000 0.075 0.153 345 295 355
300 150 2.4 1.8 0.6 3.2 58.0 11150 0.060 0.124 385 335 400
400 185 2.6 2.0 0.7 3.4 65.0 14570 0.047 0.099 425 360 455

13
Weight, Dimension data &
Current carrying capacity of cables

TABLE-17 “POLYCAB” 1.1 KV FOUR CORE, ALUMINIUM CONDUCTOR, PVC INSULATED, INNER SHEATHED,
ARMOURED PVC SHEATHED CABLES CONFORMING TO IS : 1554 (PART I) AMENDED UPTO DATE
Nominal Nominal Nominal Armour Minimum Approx. Approx. Max. Dc Current Ratings
Cross Thickness Thickness Galv. Round Galv. Flat Thickness Overall Weight of Conductor Direct In In Ducts In Air
Sectional of Insula- of Inner Steel Wire Steel Strip of Outer Diameter Cable Resistance Ground
Area tion Sheath Nominal Nominal Sheath at 20°C
Dia. Thickness
Sq. mm mm mm mm mm mm mm Kgs./Km Ohm/Km Amps. Amps. Amps.
*1.5 0.8 0.3 1.4 - 1.24 15.0 400 18.100 16 14 13
*2.5 0.9 0.3 1.4 - 1.24 16.5 480 12.100 21 18 18
*4.0 1.0 0.3 1.4 - 1.24 18.0 550 7.410 28 23 23
*6.0 1.0 0.3 1.4 - 1.24 19.5 650 4.610 35 30 30
*10 1.0 0.3 - 0.8 1.40 20.0 660 3.080 46 39 40
16 1.0 0.3 - 0.8 1.40 23.0 750 1.910 60 50 51
25 1.2 0.3 - 0.8 1.40 24.0 950 1.200 76 63 70
35 1.2 0.3 - 0.8 1.40 27.0 1165 0.868 92 77 86
50 1.4 0.4 - 0.8 1.56 31.0 1540 0.641 110 95 105
70 1.4 0.4 - 0.8 1.56 35.0 1800 0.443 135 115 130
95 1.6 0.4 - 0.8 1.72 38.0 2400 0.320 165 140 155
120 1.6 0.5 - 0.8 1.88 42.0 2800 0.253 185 155 180
150 1.8 0.5 - 0.8 1.88 46.0 3350 0.206 210 175 205
185 2.0 0.6 - 0.8 2.04 51.0 4000 0.164 235 200 240
240 2.2 0.6 - 0.8 2.36 58.0 5050 0.125 275 235 280
300 2.4 0.7 - 0.8 2.52 66.0 6200 0.100 305 260 315
400 2.6 0.7 - 0.8 2.84 72.0 7850 0.078 335 290 375
500 3.0 0.7 - 0.8 3.00 80.0 9600 0.061 350 310 410
* If required, these sizes can be offered with standard conductors also

TABLE-18 “POLYCAB” 1.1 KV FOUR CORE, ALUMINIUM CONDUCTOR, PVC INSULATED, INNER SHEATHED,
UNARMOURED PVC SHEATHED CABLES CONFORMING TO IS : 1554 (PART I) AMENDED UPTO DATE
Nominal Nominal Nominal Nominal Approx. Approx. Max. Dc Current Ratings
Cross Thickness of Thickness of Thickness of Overall Weight Of Conductor Direct In In Ducts In Air
Sectional Insulation Inner Sheath Outer Sheath Diameter Cable Resistance at Ground
Area 20°C
Sq. mm mm mm mm mm Kgs./Km Ohm/Km Amps. Amps. Amps.
*1.5 0.8 0.3 1.8 12.5 150 18.100 16 14 13
*2.5 0.9 0.3 1.8 14.0 180 12.100 21 18 18
*4.0 1.0 0.3 1.8 15.5 220 7.410 28 23 23
*6.0 1.0 0.3 1.8 17.0 260 4.610 35 30 30
*10 1.0 0.3 1.8 19.0 340 3.080 46 39 40
16 1.0 0.3 2.0 21.5 460 1.910 60 50 51
25 1.2 0.3 2.0 24.0 600 1.200 76 63 70
35 1.2 0.3 2.0 26.5 800 0.868 92 77 86
50 1.4 0.4 2.2 32.5 1100 0.641 110 95 105
70 1.4 0.4 2.2 33.5 1400 0.443 135 115 130
95 1.6 0.4 2.4 38.5 1850 0.320 165 140 155
120 1.6 0.5 2.4 41.5 2250 0.253 185 155 180
150 1.8 0.5 2.6 46.0 2750 0.206 210 175 205
185 2.0 0.6 2.6 50.5 3400 0.164 235 200 240
240 2.2 0.6 3.0 58.0 4300 0.125 275 235 280
300 2.4 0.7 3.4 64.0 5300 0.100 305 260 315
400 2.6 0.7 3.6 72.0 6900 0.078 335 290 375
500 3.0 0.7 4.0 80.0 8600 0.061 350 310 410
* If required, these sizes can be offered with stranded conductors also

14
Weight, Dimension data &
Current carrying capacity of cables

TABLE-19 “POLYCAB” 1.1 KV FOUR CORE, COPPER CONDUCTOR, PVC INSULATED, INNER SHEATHED,
ARMOURED PVC SHEATHED CABLES CONFORMING TO IS : 1554 (PART I) AMENDED UPTO DATE
Nominal Nominal Nominal Armour Minimum Approx. Approx. Max. Dc Current Ratings
Cross Thickness Thickness Galv. Round Galv. Flat Thickness Overall Weight of Conductor Direct In In Ducts In Air
Sectional of Insula- of Inner Steel Wire Steel Strip of Outer Diameter Cable Resistance Ground
Area tion Sheath Nominal Nominal Sheath at 20°C
Dia. Thickness
Sq. mm mm mm mm mm mm mm Kgs./Km Ohm/Km Amps. Amps. Amps.
*1.5 0.8 0.3 1.4 - 1.24 15.0 440 12.100 21 17 17
*2.5 0.9 0.3 1.4 - 1.24 16.5 550 7.410 27 24 24
*4.0 1.0 0.3 1.4 - 1.24 18.0 650 4.610 36 30 30
*6.0 1.0 0.3 1.4 - 1.24 19.5 800 3.080 45 38 39
*10 1.0 0.3 - 0.8 1.40 20.0 910 1.830 60 50 52
16 1.0 0.3 - 0.8 1.40 23.0 1150 1.150 77 64 66
25 1.2 0.3 - 0.8 1.40 24.0 1570 0.727 99 81 90
35 1.2 0.3 - 0.8 1.40 27.0 2035 0.524 120 99 110
50 1.4 0.4 - 0.8 1.56 31.0 2780 0.387 145 125 135
70 1.4 0.4 - 0.8 1.56 35.0 3540 0.268 175 150 165
95 1.6 0.4 - 0.8 1.72 38.0 4760 0.193 210 175 200
120 1.6 0.5 - 0.8 1.88 42.0 5770 0.153 240 195 230
150 1.8 0.5 - 0.8 1.88 46.0 7065 0.124 270 225 265
185 2.0 0.6 - 0.8 2.04 51.0 8580 0.099 300 255 305
240 2.2 0.6 - 0.8 2.36 58.0 11000 0.075 345 295 355
300 2.4 0.7 - 0.8 2.52 66.0 13625 0.060 385 335 400
400 2.6 0.7 - 0.8 2.84 80.0 17750 0.047 425 360 455
* If required, these sizes can be offered with standard conductors also

TABLE-20 “POLYCAB” 1.1 KV FOUR CORE, COPPER CONDUCTOR, PVC INSULATED, INNER SHEATHED,
UNARMOURED PVC SHEATHED CABLES CONFORMING TO IS : 1554 (PART I) AMENDED UPTO DATE

Nominal Nominal Nominal Nominal Approx. Approx. Max. Dc Current Ratings

Cross Thickness of Thickness of Thickness of Overall Weight of Conductor Direct In In Ducts In Air
Sectional Insulation Inner Sheath Outer Sheath Diameter Cable Resistance at Ground
Area 20° C
Sq. mm mm mm mm mm Kgs./Km Ohm/Km Amps. Amps. Amps.
*1.5 0.8 0.3 1.8 12.5 190 12.100 21 17 17
*2.5 0.9 0.3 1.8 14.0 245 7.410 27 24 24
*4.0 1.0 0.3 1.8 15.5 320 4.610 36 30 30
*6.0 1.0 0.3 1.8 17.0 410 3.080 45 38 39
*10 1.0 0.3 1.8 19.0 590 1.830 60 50 52
16 1.0 0.3 2.0 21.5 860 1.150 77 64 66
25 1.2 0.3 2.0 24.0 1220 0.727 99 81 90
35 1.2 0.3 2.0 26.5 1670 0.524 120 99 110
50 1.4 0.4 2.2 32.5 2340 0.387 145 125 135
70 1.4 0.4 2.2 33.5 3140 0.268 175 150 165
95 1.6 0.4 2.4 38.5 4210 0.193 210 175 200
120 1.6 0.5 2.4 41.5 5220 0.153 240 195 230
150 1.8 0.5 2.6 46.0 6470 0.124 270 225 265
185 2.0 0.6 2.6 50.5 7980 0.099 300 255 305
240 2.2 0.6 3.0 58.0 10250 0.075 345 295 355
300 2.4 0.7 3.4 64.0 12730 0.060 385 335 400
400 2.6 0.7 3.6 72.0 16800 0.047 425 360 455
* If required, these sizes can be offered with stranded conductors also

15
Weight, Dimension data &
Current carrying capacity of cables

TABLE-21 “POLYCAB” 1.1 KV, ANNEALED HIGH CONDUCTIVITY SOLID COPPER CONDUCTOR, 1.5 SQ.MM
PVC INSULATED, INNER SHEATHED, ARMOURED / UNARMOURED PVC SHEATHED CONTROL CABLES
CONFORMING TO IS : 1554 (PART I) AMENDED UPTO DATE
Number Nominal Min. Armour Nominal Minimum Approx. Approx. Max. Dc Current Ratings
of Cores Thickness Thick- Galv. Galv. Sheath Sheath Overall Diameter Weight of Cable Conductor Direct In In
of Insula- ness Round Flat Steel Thickness Thickness Unar- Ar- Unar- Ar- Resistance In Ducts Air
-tion of Inner Steel Wire Strip Nom. Unar- Armoured moured moured moured moured at 20°C Ground
Sheath Nom. Dia Thick moured

mm mm mm mm mm mm mm mm Kgs./Km Kgs./Km Ohm/Km Amps. Amps. Amps.

2 0.8 0.3 1.4 - 1.80 1.24 10.50 13.50 130 350 12.1 23 20 20
3 0.8 0.3 1.4 - 1.80 1.24 11.00 14.00 160 400 12.1 21 17 17
4 0.8 0.3 1.4 - 1.80 1.24 11.50 15.00 190 450 12.1 21 17 17
5 0.8 0.3 1.4 - 1.80 1.24 12.50 15.50 225 500 12.1 21 17 17
6 0.8 0.3 1.4 - 1.80 1.24 13.00 16.00 250 550 12.1 15 13 13
7 0.8 0.3 1.4 - 1.80 1.24 13.50 16.50 265 565 12.1 14 13 13
10 0.8 0.3 1.4 - 1.80 1.40 16.50 19.00 350 750 12.1 13 11 11
12 0.8 0.3 - 0.8 1.80 1.24 17.50 19.50 400 650 12.1 12 10 10
14 0.8 0.3 - 0.8 1.80 1.40 18.00 20.00 450 760 12.1 11 10 10
16 0.8 0.3 - 0.8 1.80 1.40 19.50 21.00 500 800 12.1 11 9 9
19 0.8 0.3 - 0.8 2.00 1.40 20.00 22.00 600 850 12.1 10 9 9
24 0.8 0.3 - 0.8 2.00 1.40 23.00 25.00 725 1050 12.1 9 8 8
30 0.8 0.3 - 0.8 2.00 1.40 24.50 26.50 860 1200 12.1 9 7 7
37 0.8 0.3 - 0.8 2.00 1.40 26.00 28.00 1050 1400 12.1 8 7 7
61 0.8 0.4 - 0.8 2.20 1.56 33.00 35.00 1650 2100 12.1 7 6 6

TABLE-22 “POLYCAB” 1.1 KV, ANNEALED HIGH CONDUCTIVITY SOLID COPPER CONDUCTOR, 2.5 SQ.MM
PVC INSULATED, INNER SHEATHED, ARMOURED / UNARMOURED PVC SHEATHED CONTROL CABLES
CONFORMING TO IS : 1554 (PART I) AMENDED UPTO DATE
Number Nominal Min. Armour Nominal Minimum Approx. Overall Approx. Weight Max. Dc Current Ratings
of Cores Thickness Thick- Galv. Galv. Sheath Sheath Diameter of Cable Conductor Direct In In
of Insula- ness Round Flat Steel Thickness Thickness Unar- Ar- Unar- Ar- Resistance In Ducts Air
-tion of Inner Steel Wire Strip Nom. Unar- Armoured moured moured moured moured At 20°C Ground
Sheath Nom. Dia Thick moured

mm mm mm mm mm mm mm mm Kgs./Km Kgs./Km Ohm/Km Amps. Amps. Amps.

2 0.9 0.3 1.4 - 1.8 1.24 11.00 14.50 160 425 7.41 32 27 27
3 0.9 0.3 1.4 - 1.8 1.24 11.50 15.50 225 475 7.41 27 24 24
4 0.9 0.3 1.4 - 1.8 1.24 11.50 16.50 250 530 7.41 27 24 24
5 0.9 0.3 1.4 - 1.8 1.24 14.00 17.50 300 600 7.41 27 24 24
6 0.9 0.3 1.4 - 1.8 1.24 15.50 18.50 340 675 7.41 20 18 18
7 0.9 0.3 1.4 - 1.8 1.24 15.50 18.50 375 700 7.41 20 17 17
10 0.9 0.3 - 0.8 1.8 1.40 19.00 21.00 500 780 7.41 18 15 15
12 0.9 0.3 - 0.8 2.0 1.40 20.00 22.00 600 850 7.41 17 14 14
14 0.9 0.3 - 0.8 2.0 1.40 21.00 23.00 650 950 7.41 16 13 13
16 0.9 0.3 - 0.8 2.0 1.40 22.00 24.00 750 1050 7.41 15 13 13
19 0.9 0.3 - 0.8 2.0 1.40 23.00 25.00 850 1150 7.41 14 12 12
24 0.9 0.3 - 0.8 2.0 1.40 27.00 29.00 1050 1400 7.41 13 11 11
30 0.9 0.3 - 0.8 2.0 1.56 28.50 30.50 1250 1700 7.41 12 10 10
37 0.9 0.4 - 0.8 2.2 1.56 31.00 33.00 1550 2000 7.41 11 10 10
61 0.9 0.4 - 0.8 2.2 1.56 38.50 41.00 2450 3100 7.41 9 8 8

16
Weight, Dimension data &
Current carrying capacity of cables

TABLE-23 CONDUCTOR RESISTANCE OF PLAIN COPPER CONDUCTORS

USED FOR HEAVY DUTY CABLES AS PER IS : 8130-1984

Size in sq.mm Conductor Max.cond. Size in sq.mm Conductor Max. cond.

Construction resistance in Construction resistance in
Ohm/Km at 20°C Ohm/Km at 20°C
Single Core & Single Core &
Multi Core Multi Core
1.5* 1/1.38 12.100 120 37/2.03 0.153
2.5* 1/1.78 7.410 150 37/2.24 0.124
4.0* 1/2.24 4.610 185 37/2.50 0.099
6.0* 1/2.76 3.080 240 61/2.24 0.075
10.0 7/1.35 1.830 300 61/2.50 0.060
16.0 7/1.70 1.150 400 61/2.85 0.047
25.0 7/2.14 0.727 500 61/3.20 0.037
35.0 7/2.50 0.524 630 91/3.00 0.028
50.0 7/3.00 0.387 - - -
70.0 19/2.14 0.268 800 127/2.83 0.022
95.0 19/2.50 0.193 1000 127/3.16 0.018

TABLE-24 CURRENT RATING OF ‘“POLYCAB” COPPER ARMOURED / UNARMOURED CABLES

650 / 1100 V GRADE IN AIR.

Area Twin Core 3, 3 1/2, 4 Core Area Twin Core 3, 3 1/2, 4 Core

sq.mm Amp. Amp. sq.mm Amp. Amp.

1.5 20 17 70 195 165
2.5 27 24 95 230 200
4.0 35 30 120 265 235
6.0 45 39 150 305 265
10.0 60 52 185 350 305
16.0 78 66 240 410 355
25.0 105 90 300 465 400
35.0 125 110 400 530 455
50.0 155 135 - - -

17
Weight, Dimension data &
Current carrying capacity of cables

TABLE-25 ESTIMATED A.C RESISTANCE, REACTANCE, CAPACITANCE, IMPEDANCE, VOLTAGE DROP

AND SHORTCIRCUIT RATING FOR PVC INSULATED, ALUMINIUM CONDUCTOR,
ARMOURED SINGLE CORE CABLES.

Nominal area of A.C Resistance at Reactance at 50 Hz Capacitance Impedance at 70°C Voltage Drop Short circuit ratings of
Conductor 70°C conductor for 1 second
thickness of
Outersheath
mm² Ohm/Km Ohm/Km µF/Km Ohm/Km V/Km/A kA
16 2.3000 0.1250 0.81 2.3000 3.980 1.22
25 1.4400 0.1200 0.83 1.4500 2.510 1.90
35 1.0400 0.1140 0.95 1.0500 1.820 2.66
50 0.7700 0.1120 0.95 0.7780 1.350 3.80
70 0.5330 0.1040 1.13 0.5430 0.940 5.32
95 0.3850 0.0970 1.17 0.3970 0.688 7.22
120 0.3050 0.0926 1.32 0.3180 0.552 9.12
150 0.2480 0.0916 1.30 0.2650 0.459 11.41
185 0.1980 0.0895 1.35 0.2170 0.377 14.07
240 0.1520 0.0876 1.40 0.1750 0.303 18.25
300 0.1220 0.0863 1.44 0.1500 0.259 22.81
400 0.0961 0.0845 1.48 0.1280 0.222 30.41
500 0.0761 0.0835 1.47 0.1130 0.196 38.02
630 0.0606 0.0833 1.45 0.1030 0.178 47.90
800 0.0495 0.0816 1.61 0.0954 0.165 60.83
1000 0.0416 0.0797 1.81 0.0899 0.156 76.03

TABLE-26 ESTIMATED A.C RESISTANCE, REACTANCE, CAPACITANCE, IMPEDANCE, VOLTAGE DROP

AND SHORT CIRCUIT RATING FOR PVC INSULATED,
ALUMINIUM CONDUCTOR, ARMOURED MULTI CORE CABLES.
Nominal area of A.C Resistance at Reactance at 50 Hz Capacitance Impedance at 70°C Voltage Drop Short circuit ratings of
Conductor 70°C conductor for 1 second
thickness of
Outersheath
mm² Ohm/Km Ohm/Km µF/Km ohm/Km V/Km/A kA
1.5 21.7000 0.1120 0.38 21.700 37.700 0.11
2.5 14.5000 0.1100 0.41 14.500 25.200 0.19
4.0 8.9000 0.1050 0.45 8.900 15.400 0.30
6.0 5.5400 0.0988 0.52 5.540 9.600 0.46
10.0 3.7000 0.0938 0.60 3.700 6.410 0.76
16.0 2.3000 0.0862 0.80 2.300 3.980 1.22
25.0 1.4400 0.0854 0.84 1.440 2.500 1.90
35.0 1.0400 0.0827 0.96 1.050 1.810 2.66
50.0 0.7700 0.0825 0.98 0.775 1.340 3.80
70.0 0.5330 0.0771 1.12 0.538 0.932 5.32
95.0 0.3850 0.0767 1.16 0.393 0.680 7.22
120.0 0.3050 0.0744 1.28 0.314 0.543 9.12
150.0 0.2490 0.0745 1.26 0.259 0.449 11.41
185.0 0.1980 0.0744 1.28 0.212 0.367 14.07
240.0 0.1520 0.0740 1.31 0.169 0.293 18.25
300.0 0.1220 0.0732 1.35 0.142 0.247 22.81
400.0 0.0961 0.0727 1.40 0.121 0.209 30.41

18
Weight, Dimension data &
Current carrying capacity of cables

TABLE-27 ESTIMATED A.C RESISTANCE, REACTANCE, CAPACITANCE, IMPEDANCE, VOLTAGE DROP

AND SHORT CIRCUIT RATING FOR HR PVC INSULATED, ALUMINIUM CONDUCTOR,
ARMOURED SINGLE CORE CABLES.

Nominal area of A.C Resistance at Reactance at 50 Hz Capacitance Impedance at 85°C Voltage Drop Short circuit ratings
Conductor 85°C of conductor for 1
second thickness of
Outersheath
mm² Ohm/Km Ohm/Km µF/Km Ohm/Km V/Km/A kA
16 2.4100 0.1250 0.81 2.4100 4.180 1.01
25 1.5100 0.1200 0.83 1.5200 2.630 1.72
35 1.0100 0.1140 0.95 1.1000 1.910 2.40
50 0.8090 0.1120 0.95 0.8170 1.410 3.43
70 0.5590 0.1040 1.13 0.5690 0.985 4.80
95 0.4040 0.0970 1.17 0.4160 0.720 6.52
120 0.3200 0.0926 1.32 0.3330 0.577 8.23
150 0.2610 0.0916 1.30 0.2760 0.479 10.29
185 0.2080 0.0895 1.35 0.2260 0.392 12.69
240 0.1590 0.0876 1.40 0.1820 0.315 16.46
300 0.1280 0.0863 1.44 0.1540 0.267 20.58
400 0.1010 0.0845 1.48 0.1310 0.228 27.44
500 0.0796 0.0835 1.47 0.1150 0.200 34.30
630 0.0632 0.0833 1.45 0.1050 0.181 43.21
800 0.0515 0.0816 1.61 0.0964 0.167 54.88
1000 0.0431 0.0797 1.81 0.0906 0.157 68.59

TABLE-28 ESTIMATED A.C RESISTANCE, REACTANCE, CAPACITANCE, IMPEDANCE, VOLTAGE DROP

AND SHORT CIRCUIT RATING FOR HR PVC INSULATED, ALUMINIUM CONDUCTOR,
ARMOURED MULTI CORE CABLES.
Nominal area of A.C Resistance at Reactance at 50 Hz Capacitance Impedance at 85°C Voltage Drop Short circuit ratings
Conductor 85°C of conductor for 1
second thickness of
Outersheath
mm² Ohm/Km Ohm/Km µF/Km Ohm/Km V/Km/A kA
1.5 22.800 0.1120 0.38 22.800 39.600 0.10
2.5 15.300 0.1100 0.41 15.300 26.400 0.17
4.0 9.350 0.1050 0.45 9.350 16.200 0.27
6.0 5.820 0.0988 0.52 5.820 10.100 0.41
10.0 3.890 0.0938 0.60 3.890 6.730 0.69
16.0 2.410 0.0862 0.80 2.410 4.180 1.01
25.0 1.510 0.0854 0.84 1.520 2.630 1.72
35.0 1.010 0.0827 0.96 1.010 1.900 2.40
50.0 0.809 0.0825 0.98 0.813 1.41 3.43
70.0 0.559 0.0771 1.12 0.565 0.978 4.80
95.0 0.404 0.0767 1.16 0.412 0.713 6.52
120.0 0.320 0.0744 1.28 0.329 0.569 8.23
150.0 0.261 0.0745 1.26 0.271 0.470 10.29
185.0 0.208 0.0744 1.28 0.221 0.383 12.69
240.0 0.159 0.0740 1.31 0.176 0.304 16.46
300.0 0.128 0.0732 1.35 0.148 0.256 20.58
400.0 0.101 0.0727 1.40 0.124 0.215 27.44

19
Weight, Dimension data &
Current carrying capacity of cables

TABLE-29 ESTIMATED A.C RESISTANCE, REACTANCE, CAPACITANCE, IMPEDANCE, VOLTAGE DROP

AND SHORT CIRCUIT RATING FOR PVC INSULATED, COPPER CONDUCTOR,
ARMOURED SINGLE CORE CABLES.

Nominal area of A.C Resistance at Reactance at 50 Hz Capacitance Impedance at 70°C Voltage Drop Short circuit rat-
Conductor 70°C ings of conductor
for 1 second
thickness of
Outersheath
mm² Ohm/Km Ohm/Km µF/Km Ohm/Km V/Km/A kA
16 1.3800 0.1250 0.81 1.3800 2.390 1.84
25 0.8700 0.1200 0.83 0.8780 1.520 2.88
35 0.6270 0.1140 0.95 0.6380 1.100 4.03
50 0.4630 0.1120 0.95 0.4770 0.830 5.75
70 0.3210 0.1040 1.13 0.3370 0.585 8.05
95 0.2320 0.0970 1.17 0.2510 0.435 10.93
120 0.1840 0.0926 1.32 0.2060 0.357 13.80
150 0.1500 0.0916 1.30 0.1760 0.304 17.25
185 0.1200 0.0895 1.35 0.1500 0.260 21.28
240 0.0928 0.0876 1.40 0.1280 0.221 27.60
300 0.0751 0.0863 1.44 0.1140 0.198 34.50
400 0.0604 0.0845 1.48 0.1040 0.180 46.00
500 0.0490 0.0835 1.47 0.0968 0.168 57.50
630 0.0401 0.0833 1.45 0.0925 0.160 72.45
800 0.0339 0.0816 1.61 0.0883 0.153 92.00
1000 0.0297 0.0797 1.81 0.0850 0.147 115.00

TABLE-30 ESTIMATED A.C RESISTANCE, REACTANCE, CAPACITANCE, IMPEDANCE, VOLTAGE DROP

AND SHORT CIRCUIT RATING FOR PVC INSULATED, COPPER CONDUCTOR,
ARMOURED MULTI CORE CABLES.
Nominal area of A.C Resistance at Reactance at 50 Hz Capacitance Impedance at 70°C Voltage Drop Short circuit rat-
Conductor 70°C ings of conduc-
tor for 1 second
thickness of
Outersheath
mm² Ohm/Km Ohm/Km µF/Km Ohm/Km V/Km/A kA
1.5 14.5000 0.1140 0.37 14.500 25.100 0.17
2.5 8.9000 0.1100 0.40 8.900 15.400 0.29
4.0 5.5200 0.1060 0.44 5.520 9.560 0.46
6.0 3.6900 0.1001 0.51 3.690 6.390 0.69
10.0 2.1900 0.0907 0.67 2.190 3.800 1.15
16.0 1.3800 0.0862 0.80 1.380 2.390 1.84
25.0 0.8700 0.0854 0.84 0.870 1.510 2.88
35.0 0.6300 0.0827 0.96 0.630 1.010 4.03
50.0 0.4640 0.0825 0.98 0.471 0.815 5.75
70.0 0.3210 0.0771 1.12 0.331 0.572 8.05
95.0 0.2320 0.0767 1.16 0.244 0.423 10.93
120.0 0.1840 0.0744 1.28 0.199 0.344 13.80
150.0 0.1500 0.0745 1.26 0.168 0.290 17.25
185.0 0.1210 0.0744 1.28 0.142 0.246 21.28
240.0 0.0930 0.0740 1.31 0.119 0.206 27.60
300.0 0.0750 0.0732 1.35 0.105 0.182 34.50
400.0 0.0604 0.0727 1.40 0.095 0.164 46.00

20
Weight, Dimension data &
Current carrying capacity of cables

TABLE-31 ESTIMATED A.C RESISTANCE, REACTANCE, CAPACITANCE, IMPEDANCE, VOLTAGE DROP

AND SHORT CIRCUIT RATING FOR HR PVC INSULATED, COPPER CONDUCTOR,
ARMOURED SINGLE CORE CABLES.
Nominal area of A.C Resistance at Reactance at 50 Hz Capacitance Impedance at 85°C Voltage Drop Short circuit ratings
Conductor 85°C of conductor for 1
second thickness of
Outersheath
mm² Ohm/Km Ohm/Km µF/Km Ohm/Km V/Km/A kA
16 1.4400 0.1250 0.81 1.4500 2.510 1.66
25 0.9130 0.1200 0.83 0.9210 1.590 2.59
35 0.6580 0.1140 0.95 0.6680 1.160 3.63
50 0.4860 0.1120 0.95 0.4990 0.864 5.19
70 0.3370 0.1040 1.13 0.3530 0.611 7.26
95 0.2430 0.0970 1.17 0.2620 0.453 9.86
120 0.1930 0.0926 1.32 0.2140 0.371 12.45
150 0.1570 0.0916 1.30 0.1820 0.315 15.57
185 0.1260 0.0895 1.35 0.1550 0.268 19.20
240 0.0971 0.0876 1.40 0.1310 0.226 24.91
300 0.0785 0.0863 1.44 0.1170 0.202 31.13
400 0.0630 0.0845 1.48 0.1050 0.183 41.51
500 0.0509 0.0835 1.47 0.0978 0.169 51.89
630 0.0416 0.0833 1.45 0.0931 0.161 65.38
800 0.0351 0.0816 1.61 0.0888 0.154 83.02
1000 0.0306 0.0797 1.81 0.0853 0.148 103.78

TABLE-32 ESTIMATED A.C RESISTANCE, REACTANCE, CAPACITANCE, IMPEDANCE, VOLTAGE DROP

AND SHORT CIRCUIT RATING FOR HR PVC INSULATED, COPPER CONDUCTOR,
ARMOURED MULTI CORE CABLES.
Nominal area of A.C Resistance at Reactance at 50 Hz Capacitance Impedance at 85°C Voltage Drop Short circuit ratings
Conductor 85°C of conductor for 1
second thickness of
Outersheath

mm² Ohm/Km Ohm/Km µF/Km Ohm/Km V/Km/A kA

1.5 15.2000 0.1140 0.37 15.2000 26.300 0.16
2.5 9.3000 0.1100 0.40 9.3000 16.100 0.26
4.0 5.7900 0.1060 0.44 5.7900 10.000 0.42
6.0 3.8700 0.1001 0.51 3.8700 6.700 0.62
10.0 2.3000 0.0907 0.67 2.3000 3.980 1.04
16.0 1.4400 0.0862 0.80 1.4500 2.510 1.66
25.0 0.9130 0.0854 0.84 0.9170 1.590 2.59
35.0 0.6580 0.0827 0.96 0.6630 1.150 3.63
50.0 0.4860 0.0825 0.98 0.4930 0.854 5.19
70.0 0.3370 0.0771 1.12 0.3460 0.599 7.26
95.0 0.2430 0.0767 1.16 0.2550 0.442 9.86
120.0 0.1930 0.0744 1.28 0.2070 0.359 12.45
150.0 0.1570 0.0745 1.26 0.1740 0.301 15.57
185.0 0.1260 0.0744 1.28 0.1470 0.254 19.20
2400. 0.0972 0.0740 1.31 0.1220 0.212 24.91
300.0 0.0787 0.0732 1.35 0.1070 0.186 31.13
400.0 0.0630 0.0727 1.40 0.0962 0.167 41.51

21
 Rating Factors

1 ) F O R A I R A N D GRO UND TE MPE R ATU RE

A. Rating factors for variation in ambient air temperature
Ambient Temp (°C) 25 30 35 40 45 50
Rating Factors 1.25 1.16 1.09 1.00 0.90 0.80
B. Rating factors for variation in ground temperature
Ground Temp (°C) 15 20 25 30 35 40 45
Rating Factors 1.17 1.12 1.06 1.00 0.94 0.87 0.79
C. Rating factors for variation in ground temperature (for Cables in Ducts)
Ground Temp (°C) 15 20 25 30 35 40 45
Rating Factors 1.17 1.12 1.06 1.00 0.94 0.87 0.79

2 ) F O R D EP T H O F LAYING (CA BLE S LAID DIRECT IN T HE G ROUND) .

Depth of laying Size
Cm Upto 25 mm 2
Above 25 mm2 Upto 300 mm2 Above 300 mm2
75 1.00 1.00 1.00
90 0.99 0.98 0.97
105 0.98 0.97 0.96
120 0.97 0.96 0.95
150 0.96 0.94 0.92
180 or more 0.95 0.93 0.91

3) FOR VARIATION IN THERMAL RESISTIVITY OF SOIL

(TWO AND THREE AND MULTICORE CABLES LAID DIRECT IN THE GROUND).
Nominal area of Two cables touching for values of Thermal Resistivity of soil in °C cm / W
conductor mm2 100 120 150 200 250 300
1.5 1.10 1.05 1.00 0.92 0.86 0.81
2.5 1.10 1.05 1.00 0.92 0.86 0.81
4.0 1.10 1.05 1.00 0.92 0.86 0.81
6.0 1.10 1.05 1.00 0.92 0.86 0.81
10.0 1.10 1.06 1.00 0.92 0.85 0.80
16.0 1.12 1.06 1.00 0.91 0.84 0.79
25.0 1.14 1.08 1.00 0.91 0.84 0.78
35.0 1.15 1.08 1.00 0.91 0.84 0.77
50.0 1.15 1.08 1.00 0.91 0.84 0.77
70.0 1.15 1.08 1.00 0.90 0.83 0.76
95.0 1.15 1.08 1.00 0.90 0.83 0.76
120.0 1.17 1.09 1.00 0.90 0.82 0.76
150.0 1.17 1.09 1.00 0.90 0.82 0.75
185.0 1.18 1.09 1.00 0.89 0.81 0.75
240.0 1.18 1.09 1.00 0.89 0.81 0.75
300.0 1.18 1.09 1.00 0.89 0.81 0.75
400.0 1.19 1.10 1.00 0.89 0.81 0.75

22
Group Rating Factors

F O R S I N GL E C O R E CA BLE S
A) Cables laid direct in the ground in horizontal formation.
Distance between Trefoils
No. of Trefoils in Group
Touching 15 cm 30 cm 45 cm
2 0.78 0.81 0.85 0.88

3 0.68 0.71 0.77 0.81

4 0.61 0.65 0.72 0.76

5 0.56 0.61 0.68 0.73

B) Cables laid in ducts in horizontal formation.

Distance between Trefoils
No. of Trefoils in Group
Touching 45 cm 60 cm

2 0.87 0.90 0.91

3 0.79 0.83 0.86

4 0.74 0.79 0.82

5 0.71 0.76 0.80

C) Cables laid on racks / Trays in covered trench with having restricted air circulation, Trefoils are separated by two cable
diameter horizontally and the trays are in tiers having 30 cm distance.
No. of Trefoils in Horizontal Formation
No. racks / trays in tiers
1 2 3

1 0.95 0.90 0.88

2 0.90 0.85 0.83

3 0.88 0.83 0.81

6 0.86 0.81 0.79

D) as above C. but cables laid in open air.

No. of Trefoils in Horizontal Formation
No. racks / trays in tiers
1 2 3

1 1 0.98 0.96

2 1 0.95 0.93

3 1 0.94 0.92

6 1 0.93 0.90

23
 Group Rating Factors

F O R M U LT I C O R E CA BLE S

A) Cables laid on cable trays exposed to air, the cables spaced by one cable diameter and trays are in tiers spaced by
30 cm. The clearance between the wall and the cable is 25 mm.
No. of cables trays in No. of Cables per Tray
tier 1 2 3 6 9
1 1 0.98 0.96 0.93 0.92
2 1 0.95 0.93 0.90 0.89
3 1 0.94 0.92 0.89 0.88
6 1 0.93 0.90 0.87 0.86

B) Cables laid inside concrete trench with removable covers on cable trays having restricted circulation. The cables spaced
by one cable diameter and trays are in tiers spaced by 30 cm. The clearance of the cable from the wall is 25 mm.
No. of cables trays in No. of Cables per Tray
tier 1 2 3 6 9
1 0.95 0.90 0.88 0.85 0.84
2 0.90 0.85 0.83 0.81 0.80
3 0.88 0.83 0.81 0.79 0.78
6 0.86 0.81 0.79 0.77 0.76

C) Cables laid on cable trays exposed to air, the cable touching and trays are in tiers spaced by 30 cm. The clearance
between the wall and the cable is 25 mm.
No. of cables trays in No. of Cables per Tray
tier 1 2 3 6 9
1 1 0.84 0.80 0.75 0.73
2 1 0.80 0.76 0.71 0.69
3 1 0.78 0.74 0.70 0.68
6 1 0.76 0.72 0.68 0.66

D) Cables laid direct in ground in horizontal formation.

Distance of Cables
No. of cables in Group
Touching 15 cm 30 cm 45 cm
2 0.79 0.82 0.87 0.90
3 0.69 0.75 0.79 0.83
4 0.62 0.69 0.74 0.79
5 0.58 0.65 0.72 0.76
6 0.54 0.61 0.69 0.75

E) Cables laid in single way ducts / pipes in horizontal formation.

Distance of Cables
No. of cables in Group
Touching 30 cm 45 cm 60 cm
2 0.88 0.90 0.92 0.94
3 0.82 0.84 0.87 0.89
4 0.77 0.80 0.84 0.87
5 0.74 0.78 0.82 0.85
6 0.71 0.76 0.81 0.84

24
Selection of Cables

Power Cables are generally selected considering the application. However, following
factors are important for selection of suitable cable construction required to transport
electrical energy from one end to the other.
1) Maximum operating voltage,
2) Fault Level,
3) Load to be carried,
4) Possible overloading duration & magnitude,
5) Route length and voltage drop.
6) Mode of installation considering install-lation environment such as ambient & ground
temperature chemical & physical properties of soil.
7) Flame retardant properties.
All sizes of POLYCAB PVC cables are designed to standard operating conditions in India and
abroad. The standards adopted are considering the geographical/ climatical conditions
and general applications of power for utilities, distribution and generation purposes.
The cables are manufactured conforming to Indian & International cables specifications
for PVC Insulated cables. Customer specific requirements can also be met.

Flame Retardant Low Smoke Cables

The behaviour of Electric Cables in presence of fire has been a matter of great concern
to all Electrical Engineers involved in Generation, Transmission and Utilisation of electric
power. Normally all XLPE / PVC Cables have an outer sheath of PVC. Although PVC by itself
is flame retarding, it does produce highly toxic and corrosive fumes in the event of fire.
As a matter of fact, in closed and crowded places such as power stations, subways,
railways with long sections in tunnels, road tunnels, ships, hospitals, schools, hotels,
cinema theatres, museums and public premises in general, besides the obvious danger
represented by fire propagation, also fume toxicity and opacity are particularly important
as they may cause, with equally serious consequences for human safety, suffocation
intoxication and panic due to reduced visibility.
FRLS PVC compound should ensure the following :
1) Minimum smoke emission.
2) Very low toxic and corrosive fumes emission.
3) Fire Retardant characteristics.
Our laboratory is well equipped with latest test equipments to carry out following
test requirements.
a) The oxygen index and temperature index of sheath as per ASTM-D 2863.
b) Flammability characteristics of cable as per IEC-332 ( Pt. I ) & IEC-332 ( Pt. III )
c) Flammability characteristics of cables as per Swedish Standard SS 424 14 75, Class F3.
d) Determination of the amount of halogen acid gas evolved during combustion of
outersheath materials as per per IEC 754 ( Pt. I ).
e) Determination of smoke generation of outersheath material under fire as per ASTM-D 2843
f) The measurement of smoke density as per IEC 61034.

25
‘Polycab’ Overload & Short Circuit Ratings

Normal current rating of POLYCAB cable as given in the tables takes into account temporary
overloading which often occurs in use. However, to safeguard against excessive thermal damage,
it is essential that protective switchgear of a proper rating is used in circuit.
Cables laid in air or in ducts can safely be overloaded to 1.5 times the amount given in
the current rating tables for four hours provided the protective system uses a class P fuse
designed to operate at a 50% overload.
In case the protective circuit has a different fuse rating, select a cable by multiplying
the tripping current by 0.67 to arrive at a suitable size of cable. For example, for
carrying 200 amps current in the air 70 sq.mm. single core cable is suitable (current
rating is 230 amps.) This cable can therefore be overloaded to the extent of 230 x
1.5 = 345 amp. provided that the protective fuse rating is 230 x 1.5 = 345. However,
if the protective fuse rating is 400 amps. normal rating 400 x .67 = 268 amps., 95
sq. mm cable should be used. Similarly current rating for cables in the ground
can safely used for an overload factor of 1.3 for four hours. It is essential that the
protection is designed to operate at a 30% overload. In case this is different, select
a cable to carry 0.77 times the current at which protection is designed to operate.

SHORT CIRCUIT RATING FOR ALUMINIUM CONDUCTOR CABLES

With a high increase in KVA capacity of the power distribution system, cable are
expected to carry short circuit currents of high magnitude. Normally rated at 70° C,
our insulating materials permit a short circuit temperature of 160° C. With the high
interrupting capacity expected of a cable under short circuit, it is essential that
protective fuses in the system are designed to minimise the duration as far as possible.
Short circuit rating of a cable can be calculated as under

Where lsh = 75.8 x A lsh : Short circuit current in r. m. s. amps.

√ t t : Duration of short circuit in seconds.
A : Area of conductor in sq. mm
Constants are tabulated below for different duration of short circuit.
10 25 50
Duration of 1 cycle 2 cycle 5 cycle
cycle cycle cycle 2 3 4 5
short circuit =0.02 =0.04 =0.01
=0.02 =0.02 =0.02 seconds seconds seconds seconds
in seconds seconds seconds seconds
seconds seconds seconds
Short circuits
constant 536 378 239 169 107 75.7 53.0 43.6 37.8 34.0
per unit area

Example : Short circuit rating of 150 sq.mm. conductor area with a short circuit duration of
0.5 seconds = 150 x 107 = 16050 amps.

S HO R T CIRCUIT RAT ING FOR COPPER CONDUCTOR CAB LES

The following formula gives the Short Circuit Rating of Copper conductor, PVC insulated
cables

Where lsh = 113 x A lsh : Short circuit current in r. m. s. amps.

√ t t : Duration of short circuit in seconds.
A : Area of conductor in sq. mm

26
Handling, Storage and Laying of Polycab Cables

A . CA BLE INS PECT ION B. CABLE HANDLING & STORAGE

Inspect every cable reel for damage before Damage to cables can occur due to the
accepting the shipment.Be particularly incorrect handling to which the drums
alert for cable damage if: and cables may be subjected; causing
breakdown of the drum flanges and in
1. A reel is lying flat on its side
exceptional cases, movement of the drum
2. Several reels are stacked barrel takes place. Once this breakdown of
the drum occurs, the cable is immediately
3. Other freight is stacked on a reel exposed to damage. Cables damaged during
4. Nails have been driven into reel flanges handling & storage can cause service
to secure shipping blocks failures when the subject cable is put to
use.
5. A reel flange is damaged
Thus the following is a list of Do’s and
6. A cable covering is removed, stained or Don’ts that should be followed while
damaged handling and storing the cables before it
7. A cable end seal is removed or is put to use.
damaged. A reel has been dropped
(hidden damage likely)

Do’s Don’ts
When off loading reels from a truck, lower Never drop reels. If reels must be rolled, roll in
reels carefully using a hydraulic gate, hoist opposite direction of the cable wraps to keep
or forklift truck cable from loosening on the reel.

If a fork lift is used, approach the reel from Do not allow the lift forks to contact the cable.
the flange side. Position the forks such that Care must be taken by the fork lift operator not
the reel is lifted by both reel flanges. Also to make sudden turns or stops.
Consideration should be given to, Traffic
patterns during off-loading & damage dur-
ing the time in storage

Cable reels should be stored on hard sur- Multiple reels stacked on top of each other
faces resting on the flanges edge (flanges (“Pancake” storage) is not recommended for
vertical). Align reels flange to flange and, cable drums. The weight of the stack can total
if possible, arrange so that first in is first thousands of kgs. creating an enormous load on
out. the bottom reel. Also, damage to the reel and/
or cable will likely occur when the reel is flipped
for transit. A concentration of stress on the reel
flange may cause it to break and subsequently
damage the cable.

When using a hoist, install a mandrel This may lead to the bending of the reel flanges
through the reel arbor holes and attach a and mashing the cable
sling. Use a spreader bar approximately 6
inches longer than the overall reel width
placed between the sling ends just above
the reel flanges.

27