IEC 60502-2 3 Core Basic Construction

10/12/23, 2:32 PM Medium Voltage Cables to IEC 60502|caledonian Medium Voltage Cables|Three Core Cables to IEC 60502
Medium Voltage Cables

Alarm & Audio & Electronic Medium Voltage Cables to BS 6622 Medium Voltage Cables to IEC 60502 Medium Voltage Cables to VDE 0276
Cables
Automotive Cables Medium Voltage Cables to IEC 60502
Airport Cables Three Core Cables to IEC 60502

Application
Aerial Bundled Cables
The three core cables are designed for distribution of electrical power with nominal voltage Uo/U ranging from
Belden Equivalent Cables
1.8/3KV to 26/35KV and frequency 50Hz. They are suitable for installation mostly in power supply stations,
Bus Cables
indoors and in cable ducts, outdoors, underground and in water as well as for installation on cable trays for
Coaxial Cables industries, switchboards and power stations.
Cables for Oil Industry Standards
Control Cables IEC 60502 Part 1(1.8/3KV)
Composite Cables IEC 60502 Part 2(3.6/6KV to 18/30KV)

Construction
Elevator Cables
Conductor: Plain annealed copper or aluminium complying with IEC 60228 class 1 or 2.
Fiber Optic Cables
Conductor Screen:
Flexible Cables The conductor screen consists of an extruded layer of non metallic, semi-conducting compound applied on top of
Fire Resisting Cables(Fireflix) a semi-conducting tape. The conductor screen is applied under triple extrusion process over the conductor along
Fire Retardant Cables(FIRETOX) with the insulation and the insulation screen. The extruded semi-conducting compound is firmly bonded to the
Flame Retardant Cables insulation to exclude all air voids and can be easily hand stripped on site. The conductor screen is not necessary
(FIREGUARD) for both PVC and EPR/HEPR insulated 1.8/3.6KV and 3.6/6KV cables.
High Temperature Cables Insulation:
Highway Cables Insulation is of polyvinyl chloride (PVC) intended for 1.8/3.6KV and 3.6/6KV cables, cross-linked polyethylene
compound (XLPE) or ethylene propylene rubber (EPR/ HEPR).
Instrumentation Cables
Table 1. Insulation Thickness Of XLPE Or EPR/HEPR Insulation
Industrial Cables
Insulation Thickness at Nom. Voltage
Nom. Cross
Lan Cables/Data Cables 1.8/3kV 3.6/6kV 6/10KV 8.7/15KV 12/20KV 18/30KV
Section Area
(Um=3.6)kV (Um=7.2)kV (Um=12KV) (Um=17KV) (Um=24KV) (Um=36KV)
Mining Cables
mm² mm mm mm mm mm mm
Military Cables XLPE EPR
XLPE/EPR Unscr Scre XLPE/EPR XLPE/EPR XLPE/EPR XLPE/EPR
Medium/High Voltage Cables
eened ened
NEK606 Offshore & Marine 10 2.0 2.5 3.0 2.5 - - - -
Cables 16 2.0 2.5 3.0 2.5 3.4 - - -
25 2.0 2.5 3.0 2.5 3.4 4.5 - -
Marine, OIL,GAS & Petrochemical
35 2.0 2.5 3.0 2.5 3.4 4.5 5.5 -
Cables
50 – 185 2.0 2.5 3.0 2.5 3.4 4.5 5.5 8.0
https://www.caledonian-cables.net/product/Medium-Voltage-Cables/three-core-cables-iec60502.html 2/9
Power Cables 240 2.0 2.6 3.0 2.6 3.4 4.5 5.5 8.0
300 2.0 2.8 3.0 2.8 3.4 4.5 5.5 8.0
Railway Cables 400 2.0 3.0 3.0 3.0 3.4 4.5 5.5 8.0
Robotics 500 - 1600 2.2-2.8 3.2 3.2 3.2 3.4 4.5 5.5 8.0
Insulaton Screen:
Rolling Stock Cables
The insulation screen consists of an extruded layer of non metallic, semi-conducting compound extruded over
Rubber & Crane Cables
the insulation of each core. The extruded semi- conducting layer shall consist of bonded or cold strippable semi-
Security Cables conducting compound capable of removal for jointing or terminating. As an option, a semi-conducting tape may
Special Cables be applied over the individual cores or core assembly as a bedding for the metallic layer. The minimum thickness
Shipboard Cables(JIS) is 0.3 mm and the maximum resistivity is 500 Ohm-m at 90°C. The screen is tightly fitted to the insulation to
Spiral Cables exclude all air voids and can be easily hand stripped on site. The insulation screen is not necessary for both PVC
Submarine Cables and EPR/HEPR insulated 1.8/3.6KV and 3.6/6KV cables. The screen may be covered by semi-conductive water
blocking swellable tape to ensure longitudinal watertightness.
Submersible Pump Cables for Oil
Industry Inner Covering & Fillers:
For cables with a collective metallic layer or cables with a metallic layer over each individual cores with additional
Telephone Cables
collective metallic layers, semi-conducting inner covering and fillers shall be applied over the laid up cores. The
Thermocouple Cables
inner covering and fillers are made of non hygroscopic material like polypropylene, except if the cable is to be
Telecommunication cables
made longitudinally watertight. The inner covering is extruded in general but may be lapped if the interstices
VFD Cables between the cores are filled.
Windmill Cables The approximate thickness of extruded inner coverings is given in Table 2:
Other Cabless Table 2. Approximate Thickness Of Extruded Inner Coverings
Customized Products Ficititous Diameter Over Laid Up Cores Approx. Thickress of Extruded Inner Covering
mm mm
Stock Cables
> <
Accessories - 25 1.0
25 35 1.2
35 45 1.4
BS 5308 Cables 45 60 1.6
60 80 1.8
PAS 5308 Cables 80 - 2.0
BS 5467 Cables *The approximate thickness of lapped inner coverings shall be 0.4mm for fictitious diameters over the laid up
BS 6724 Cables cores up to and including 40mm and 0.6mm for larger diameter.
BS 6346 Cables Metallic Layer: The concentric copper screen wire is applied over the insulation, or over the insulation screen or over
an inner covering. As an alternative, copper tape(s) with minimum thickness of 0.1mm can be applied with overlap.
BS 7211 Cables Total cross section of copper wire screen and copper tape screen layer are shown in Table 3a and 3b.
BS 8573 Cables
Table 3a. Total Cross Section and Max. DC Resistance of Copper Wire Screen
IEC 60502-1 Cables

En 50288-7 Cables Nom. Cross Section Total Cross Section

Area of Conductor Max. DC
NF M 87-202 3.6/6KV 6/10KV 8.7/15KV 12/20KV 18/30KV
Resistance at
(Um=7.2KV) (Um=12KV) (Um=17KV) (Um=24KV) (Um=36KV)
20℃
mm² mm mm mm mm mm Ω
10 10 - - - - 1.075
16 16 16 - - - 1.075
25 16 16 16 16 - 1.075
35 16 16 16 16 - 1.075
50 16 16 16 16 16 1.075
70 16 16 16 16 16 1.075
95 16 16 16 16 16 1.075
120 16 16 16 16 16 1.075
150 25 25 25 25 25 0.688
185 25 25 25 25 25 0.688
240 25 25 25 25 25 0.688
300 25 25 25 25 25 0.688
400 35 35 35 35 35 0.491
500 35 35 35 35 35 0.491
630 35 35 35 35 35 0.491
Table 3b. Total Cross Section and Max. DC Resistance of Copper Tape Screen (0.1mm)
Nom. Cross Total Cross Section & Max. DC Resistance
Section Area
3.6/6KV 6/10KV (Um=12KV) 8.7/15KV 12/20KV 18/30KV
of Conductor
(Um=7.2KV) (Um=17KV) (Um=24KV) (Um=36KV)
Total Max. DC Total Max. DC Total Max. DC Total Max. DC Total Max. DC
Cross Resistance Cross Resistance Cross Resistance Cross Resistance Cross Resistance
Section at 20℃ Section at 20℃ Section at 20℃ Section at 20℃ Section at 20℃
mm² mm Ω mm Ω mm Ω mm Ω mm Ω
10 4.2 4.122 - - - - -
16 4.6 3.778 5.20 3.306 - - - -
25 5.0 3.420 5.68 3.029 6.47 2.657 7.2 2.390 - -
35 5.4 3.161 6.09 2.824 6.89 2.498 7.6 2.261 - -
50 5.9 2.903 6.58 2.616 7.37 2.334 8.1 2.125 9.9 1.738
70 6.6 2.616 7.23 2.380 8.02 2.145 8.7 1.967 10.5 1.630
95 7.3 2.369 7.91 2.174 8.71 1.975 9.4 1.824 11.2 1.531
120 8.0 2.153 8.64 1.991 9.43 1.823 10.2 1.694 12.0 1.438
150 8.5 2.013 9.19 1.871 9.99 1.722 10.7 1.606 12.5 1.374
185 9.4 1.838 9.88 1.741 10.82 1.590 11.4 1.509 13.2 1.303
240 10.4 1.656 10.96 1.569 11.76 1.463 12.5 1.378 14.3 1.204
300 11.4 1.508 11.84 1.452 12.64 1.361 13.4 1.287 15.2 1.134
400 12.6 1.362 12.92 1.332 13.71 1.254 14.4 1.192 16.2 1.059
500 13.9 1.237 14.34 1.199 15.14 1.136 15.5 1.110 17.7 0.974
630 15.3 1.121 16.68 1.031 16.57 1.038 17.3 0.995 19.1 0.901
Separation Sheath (for armoured cable):
The separation sheath comprises a layer of extruded PVC, PE or LSZH applied over the laid up cores under the
armour. PVC is normally of grade ST2 and PE of grade ST7. The nominal thickness is calculated by 0.02Du +
0.6mm where Du is the fictitious diameter under the sheath in mm. For cables without a lead sheath, the
nominal separation sheath thickness shall not be less than 1.2mm. For cables where the separation sheath is
applied over the lead sheath, the nominal separation sheath thickness shall not be less than 1.0mm.
Tabel 4. Separation Thickness
Approx. Thickress of
Cores Diameter
Inner Sheath
mm mm
> <
35 45 1.4
45 60 1.6
60 80 1.8
80 - 2.0
Lapped Bedding (for armoured lead sheathed cable):
The lapped bedding applied to the lead sheath consists of either impregnated/synthetic compounded paper
tapes or a combination of two layers of these paper tapes followed by a few layers of compounded fabulous
materials. The thickness is around 1.5mm.
Armour (for armoured cable):
The armour is applied over the inner covering helically. It consists of either flat galvanized steel wire armour
(strip), round galvanized steel wire armour, and double steel tape armour.
Table 5. Round Armour Wire Diameter
Fictitious Diameter Under the ArmourArmour Wire Diameter
mm mm
> <
- 10 1.25
10 15 1.25
15 25 1.6
25 35 2.0
35 60 2.5
60 - 3.15
Table 6. Armour Tape Thickness

Fictitious Diameter Under the ArmourGalvanized Steel / SteelAluminum / Aluminium Alloy
mm mm mm
> <
- 30 0.2 0.5
30 70 0.5 0.5
70 - 0.8 0.8
For flat wire armour and fictitious diameter under the armour greater than 15mm, the nominal thickness of the
flat steel wire diameter shall be 0.8mm.Cables with fictitious diameter under the armour up to and including
15mm, flat wire armour will not be used. The tape armour is applied helically in two layers so that the outer tape
is approximately central over the gap of the inner tape. If tape armour is used, the inner covering shall be
reinforced by taped bedding.
Over Sheath:
Overall sheath comprises a layer of extruded either thermoplastic compound (PVC ST3 type or PE ST7 type) or
elastomeric compound (polychlorprene CSP or chlorosulfonated PE). The nominal oversheath thickness is
calculated by 0.035D+1 where D is the fictitiuous diameter immediately under the oversheath in mm. For
unarmoured cables and cables with the oversheath not applied over the armour, metallic screen or concentric
conductor, the nominal oversheath thickness shall not be less than 1.4mm. And for cables with oversheath
applied over the armour, metallic screen or concentric conductor, the nominal oversheath thickness shall not be
less than 1.8mm.
PHYSICAL PROPERTIES:
Operating Temperature: up to 70°C (PVC insulation); up to 90°C (XLPE or EPR insulation)
Temperature Range: -5°C ( PVC sheath ); -20°C ( PE sheath )
Short Circuit Temperature( 5 seconds maximum duration ): 140-160 °C (PVC insulation);
250°C (XLPE or EPR insulation)
Bending Radius: 15 x OD
Table 7. Nominal /Operating /Testing Voltages
Rated Voltage Uo/UOperating Voltage (Um)Testing Voltage (rms)
1.8/3KV 3.6KV 6.5KV
3.6/6KV 7.2KV 12.5KV
6/10KV 12KV 21KV
8.7/15KV 17.5KV 30.5KV
12/20KV 24KV 42KV
18/30KV 36KV 63KV
*21/35KV and 26/35kV power frequency voltage test can be made under the following conditions: 2.5Uo x
30mins or 3.0Uo x 15mins. Numbers in brackets refer to the test values for 3.0Uo x 1.5mins.
Three Core 1.8/3KV (Um=3.6KV) Dimensional Data

Unarmoured Cables Steel Round-Wire Armoured Cables
Nom. Nom. Nom. Approx. Approx. Nom. Armour Nom. Approx. Approx.
Cross- Insulation Sheath Overall Weight Bedding Wire Sheath Overall Weight
Section Thickness Thickness Diameter Thickness Size Thickness Diameter
Area CU AL CU AL
mm² mm mm mm kg/km mm mm mm mm kg/km

10 2.0 1.8 23 650 460 1.2 1.6 1.8 28 1480 1290
16 2.0 1.8 24 840 540 1.2 1.6 1.9 29 1720 1410
25 2.0 1.8 26 1160 680 1.2 1.6 1.9 32 2130 1650
35 2.0 1.8 29 1490 820 1.2 2.0 2.1 36 2810 2140
50 2.0 1.9 32 1900 1000 1.2 2.0 2.2 39 3340 2450
70 2.0 2.0 36 2580 1290 1.2 2.0 2.3 42 4200 2910
95 2.0 2.2 40 3440 1640 1.3 2.5 2.4 47 5620 3820
120 2.0 2.3 43 4220 1950 1.3 2.5 2.5 51 6580 4310
150 2.0 2.4 46 5090 2290 1.4 2.5 2.7 54 7680 4870
185 2.0 2.5 50 6240 2730 1.5 2.5 2.8 58 9060 5560
240 2.0 2.7 56 8030 3430 1.6 2.5 3.0 64 11200 6600
300 2.0 2.8 60 9890 4100 1.6 2.5 3.1 69 13590 7500
400 2.0 3.1 68 12530 5150 1.8 3.15 3.4 78 17260 9880
500 2.2 3.3 75.7 16680 7510 1.8 3.15 3.5 84.3 21780 13025
630 2.4 3.5 84.9 21770 10040 1.8 3.15 3.8 94.6 27400 16050
Steel Flat Wire Armoured Cables Double Steel Tape Armoured Cables
Nom. Approx. No of Approx.
Cross- Weight Steel Weight
Nom. Armour Nom.Sheath Approx. Nom. Nom. Approx.
Section Bedding Wire Thickness Overall Bedding Tapes x Sheath Overall
Area Thickness Size Diameter Thickness Nom Tape Thickness Diameter
CU AL Thickness CU AL
mm² mm mm mm mm kg/km mm mm mm mm kg/km
10 1.2 0.8 1.8 24.5 1245 1065 1.2 2 x 0.2 1.8 23.6 925 750
16 1.2 0.8 1.8 27.1 1565 1280 1.2 2 x 0.2 1.8 26.2 1205 925
25 1.2 0.8 1.8 29.7 1975 1525 1.2 2 x 0.2 1.9 29.0 1590 1145
35 1.2 0.8 1.9 32.5 2420 1805 1.2 2 x 0.2 1.9 31.6 1985 1370
50 1.2 0.8 2.0 35 2860 2080 1.2 2 x 0.2 2.0 34.1 2400 1605
70 1.2 0.8 2.1 38.7 3685 2525 1.2 2 x 0.5 2.2 39.5 3570 2410
95 1.3 0.8 2.2 42.9 4695 3080 1.3 2 x 0.5 2.3 43.7 4570 2950
120 1.3 0.8 2.3 46.4 5650 3585 1.3 2 x 0.5 2.4 46.1 5510 3440
150 1.4 0.8 2.4 49.6 6630 4085 1.4 2 x 0.5 2.6 50.6 6500 3955
185 1.5 0.8 2.6 54.1 7990 4820 1.5 2 x 0.5 2.7 54.9 7825 4650
240 1.6 0.8 2.7 59.2 10060 5790 1.6 2 x 0.5 2.8 60.0 9825 5600
300 1.6 0.8 2.9 64.6 12230 6865 1.6 2 x0.5 3.0 65.4 12030 6660
400 1.8 0.8 3.1 71.0 15200 8280 1.8 2 x 0.5 3.2 71.8 14970 8055
500 1.8 0.8 3.3 79.5 19090 10255 1.8 2 x 0.8 3.5 80.5 18880 10035
630 1.8 0.8 3.6 89.8 24400 12920 1.8 2 x 0.8 3.8 92.3 25070 13620
Electrical Data
Nom. Cross- D C Resistance A C Resistance Short Circuit Rating of Capaci- Charging ReactanceInductance
Section Area CU / AL CU / AL Conductor CU / AL tance Current
1 sec
mm² µΩ/m µΩ/m kA pF/m mA/m µΩ/m nH/m
10 1830/3080 2330/3920 1.4/0.9 160 0.25 101 390
16 1150/1910 1460/2420 2.2/1.4 180 0.27 98 370
25 727/1200 929/1538 3.6/2.3 220 0.29 95 350
35 524/868 668/1113 5.0/3.2 250 0.31 92 330
50 387/641 494/822 6.8/4.4 270 0.33 88 310
70 268/443 343/568 9.8/6.3 310 0.35 84 290
95 193/320 248/410 13.3/8.5 350 0.38 81 270
120 153/253 196/325 17.2/11.0 380 0.46 79 250
150 124/206 159/265 21.2/13.5 420 0.50 77 260
185 99/164 128/211 26.6/17.0 460 0.56 76 250
240 75/125 98/161 34.9/22.3 510 0.61 74 240
300 60/100 80/130 43.8/28.0 570 0.68 73 250
400 47/78 64/102 57.3/36.6 590 0.70 71 240
500 37/60 57/81 72.3/46.2 610 0.72 69 230
630 28/47 42/64 91.2/58.3 630 0.74 67 220
Three Core 3.6/6KV (Um=7.2KV)
Three Core 6/10KV (Um=12KV)
Three Core 8.7/15KV (Um=17.5KV)
Current Rating for Three Core 3.6/6KV(Um=7.2 )KV to 18/30KV(Um=36KV)
Current Rating Conditions:

Ground Temperature: 20°C
Ambient Temperature (air): 30°C
Depth of Soil: 0.8 m
Thermal Resistance of Soil: 1.5K•m/W
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IEC 60502-2 3 Core Basic Construction

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10/12/23, 2:32 PM Medium Voltage Cables to IEC 60502|caledonian Medium Voltage Cables|Three Core Cables to IEC 60502

Medium Voltage Cables

Airport Cables Three Core Cables to IEC 60502

Composite Cables IEC 60502 Part 2(3.6/6KV to 18/30KV)

IEC 60502-1 Cables

En 50288-7 Cables Nom. Cross Section Total Cross Section

Table 6. Armour Tape Thickness

Three Core 1.8/3KV (Um=3.6KV) Dimensional Data

mm² mm mm mm kg/km mm mm mm mm kg/km

Current Rating Conditions:

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