The current carrying capacity of a conductor is the maximum amount of electric current it can safely carry without overheating or damaging the insulation. This value depends on various factors such as the material, size, and environmental conditions. When electrical current flows through a conductor, it generates heat, which can affect its performance. The goal is to ensure that the conductor does not exceed its temperature limit, which could lead to melting or degradation of the insulation.
Table of contents
- Key Determinants of Current Carrying Capacity of Copper Conductors
- Annealed Bare Copper Wire Specification
- Bundled Conductors Derating Factors
- Formula for The Current Carrying Capacity
- Current Calculation Formula
- Copper Conductor Ampacity Charts
- Current Carrying Capacity of Copper Wire Per sq mm Chart
- Current Carrying Capacity Of Aluminium Cable
- Class 2 Copper Wire Diameter Chart & Properties
- Amperes Conductor Chart
- Copper Conductor vs Aluminum Conductor
- Applications of Copper Conductors
- Copper Conductor Resistance
- Types of Copper Cable Current Carrying Capacity
Key Determinants of Current Carrying Capacity of Copper Conductors
| Factor | Details |
|---|---|
| Conductor Size | Larger area , Higher current capacity. |
| Heat Generation | Must stay within insulation’s max temperature. |
| Ambient Temperature | Higher temp, Less heat needed for max insulation rating. |
| Conductor Number | More bundled conductors , Less heat dissipation. |
Annealed Bare Copper Wire is Manufactured as Per IEC 60228 Standard
This wire goes through the same forming process as hard-drawn copper and after that it is been heat treated soon after, which is even been considered as a part of manufacturing process. The heat treatment makes it easier to work, bend, and shape, which makes the wire “softer†and less brittle.
IEC 60228 standard is the International Electrotechnical Commission, which is the international standard on conductors of insulated cables. Manufacturing through this standard process sticks to universally known guidelines that guarantees the copper wire quality and performance with security.
It is considered as the trusted choice for engineers and electricians who works with copper wire for their application. The below table detail will provide you all the properties.
Annealed Bare Copper Wire Specification
| Aspect | Details |
|---|---|
| Essential Properties | Excellent electrical conductivity. Ideal for bending and wrapping. Long-lasting and robust. |
| Uses in Industry | Binding and winding. Power transmission. Various industrial uses. Electroplating processes. Copper plating applications. |
| Annealed Bare Copper Wire | – Manufacturing Process: Heated in a vacuum furnace. Superior conductivity and flexibility. Advanced technology and strict guidelines. |
| Quality and Compliance | Adheres to approved standards. Suitable for both industrial and household use. |
| Manufacturer | Known for high-quality annealed bare copper wire. |
Bundled Conductors Derating Factors
| Bundle | Derating Factor (X Amps) |
|---|---|
| 2-5 | 0.8 |
| 16-30 | 0.5 |
| 6-15 | 0.7 |
| These charts as a guide for determining conductor and cable current ratings | |
What methods can be used to find the cable’s current carrying capacity?
| Method | Description | Key Considerations |
|---|---|---|
| Ampacity Calculation | – Calculates the maximum current a cable | – Cross-sectional area – Material – Insulation type – Ambient temperature – Cable grouping – Installation method |
| Thermal Modeling | – Uses heat transfer principles to estimate the maximum current | – Thermal resistance – Heat dissipation – Surrounding environment |
| Measurement and Monitoring | – Directly measures the cable’s temperature rise under load | – Cable’s temperature rise – Rated operating temperature – Performance over time |
| Empirical Data and Standards | – Utilizes industry standards and guidelines . | – National Electrical Code (NEC) – International Electrotechnical Commission (IEC) standards – Size, type, and installation conditions |
| Simulation and Modeling Software | – Uses specialized software tools to model the cable’s behavior under various loading conditions | – Loading conditions – Environmental factors – Software tools |
How much current is a wire capable of carrying?
| Factor | Description | Example |
|---|---|---|
| Gauge | Thickness of the wire. Thicker wires carry more current. | 14-gauge: up to 15 amps; 12-gauge: up to 20 amps |
| Insulation | Type and rating of insulation affect current capacity. | Rated for temperatures like 60°C or 90°C |
| Length | Longer wires have higher resistance, reducing capacity. | Increased length may lower current capacity |
| Temperature | Higher temperatures decrease capacity and can cause overheating. | Higher ambient temps reduce safe current limits |
What is copper Conductor current density?
| Condition | Current Density | Description |
|---|---|---|
| Standard Conditions | 1 to 1.5 A/mm² | Typical range for general applications. |
| High-Temperature Applications | Up to 2 A/mm² or more | Can be higher depending on cooling and insulation. |
Formula for The Current Carrying Capacity
| Factor | Details |
|---|---|
| Formula | I=KALI = \frac{KA}{L} |
| I | Maximum current load (amps) |
| K | Constant based on material type |
| A | Cross-sectional area (mm²) |
| L | Length (meters) |
| Example | Standard annealed copper wire |
| Cross-sectional Area | 1 mm² |
| Length | 10 meters |
| K Value | 0.0175 Ω/m |
| Calculation | I=0.0175×110=0.00175 ampsI = \frac{0.0175 \times 1}{10} = 0.00175 \text{ amps} or 1.75 mA |
| Result | Maximum current load = 1.75 milliamps (mA) |
What is the Current Capacity of an Aluminium and Copper Conductor?
| Features | Aluminum Conductors | Copper Conductors |
|---|---|---|
| Max Current Density | Up to 3.5 A/mm² | Up to 3.5 A/mm² |
| Cooling Medium | Essential for heat dissipation; affects capacity. | Essential for heat dissipation; affects capacity. |
| Resistivity | Higher resistivity | Lower resistivity |
| Specific Gravity | Lower, making it lighter | Higher, making it heavier |
| Current-Carrying Area | Requires larger cross-sectional area | Requires smaller cross-sectional area |
Current Calculation Formula
| Details | |
|---|---|
| Formula | Current (I)=Voltage (V)Resistance (R)\text{Current (I)} = \frac{\text{Voltage (V)}}{\text{Resistance (R)}} |
| Known as | Ohm’s Law |
| Current (I) | Measured in Amperes (A) |
| Voltage (V) | Measured in Volts (V) |
| Resistance (R) | Measured in Ohms (Ω) |
| Relationship | Current is directly proportional to Voltage and inversely proportional to Resistance |
Benefits of Using Copper Conductors
| Benefits | Description |
|---|---|
| Superior Conductivity | High electrical conductivity, second only to silver. |
| Heat Resistance | High melting point and heat resistance, ideal for heat-related components. |
| Corrosion Resistance | Good resistance to corrosion, enhancing durability. |
| Overloading Risk | High heat resistance helps reduce the risk of overloading issues. |
| Versatility | Available in various forms (bare, stranded) and compatible with other metals. |
| Thermal and Electrical Conductivity | High thermal and electrical conductivity ensures efficient performance. |
Refer Ampacity Charts of Bare Copper Ground Conductor
It has mentioned the maximum ratio of electric current that bare copper ground conductor can tolerate safely without beating its temperature level. The below given chart has mentioned the list of gauge sizes of copper and next to it different conditions and temperature are given.
This chart is vital for engineers and electricians for safety system which will prevent excessive heating which protects the durability of bare copper ground conductor.
Copper Conductor Ampacity Charts
| Copper (Wire Size & Amp Ratings) | |||
|---|---|---|---|
| Wire Gauge Size | 60°C (140°F) NM-B, UF-B |
75°C (167°F) THW, THWN, SE, USE, XHHW |
90°C (194°F) THWN-2, THHN, XHHW-2, USE-2 |
| 14 | 15 | 20 | 25 |
| 12 | 20 | 25 | 30 |
| 10 | 30 | 35 | 40 |
| 8 | 40 | 50 | 55 |
| 1 | — | 130 | 145 |
| 1/0 | — | 150 | 170 |
| 2/0 | — | 175 | 195 |
| 3/0 | — | 200 | 225 |
| 6 | 55 | 65 | 75 |
| 4 | 70 | 85 | 95 |
| 3 | 85 | 100 | 115 |
| 2 | 95 | 115 | 130 |
| 4/0 | — | 230 | 260 |
| 250 | — | 255 | 290 |
| 300 | — | 285 | 320 |
| 750 | — | 475 | 535 |
| 1000 | — | 545 | 615 |
| 350 | — | 310 | 350 |
| 500 | — | 380 | 430 |
| 600 | — | 420 | 475 |
Why is the Size of a Conductor Depending on Its Current?
| Aspect | Description |
|---|---|
| Current-Size Relationship | The size of a conductor depends on the amount of current it will carry. |
| Power Loss | Loss of power as heat due to resistance, given by P=I2×RP = I^2 \times R. |
| Resistance and Area | Power loss is proportional to the square of the current. |
| Larger Conductors | Required for higher currents to reduce resistance and minimize power loss. |
| Smaller Conductors | Suitable for lower currents as they have lower power loss and resistance. |
| Safety and Efficiency | Larger conductors help prevent overheating |
Current Carrying Capacity of Copper Wire Per sq mm Chart
| Nominal CrossSection (mm²) | Group 1 | Group 2 | Group 3 | |||
|---|---|---|---|---|---|---|
| Current Carrying Capacity(A) Copper Wire | Protective Fuse(A) | Current Carrying Capacity(A) Copper Wire | Protective Fuse(A) | Current Carrying Capacity(A) Copper Wire | Protective Fuse(A) | |
| 0,75 | Â | Â | 12 | 6 | 15 | 10 |
| 1 | 11 | 6 | 15 | 10 | 19 | 16 |
| 1,5 | 15 | 10 | 18 | 16 | 24 | 20 |
| 6 | 33 | 25 | 44 | 32 | 54 | 50 |
| 10 | 45 | 32 | 61 | 50 | 73 | 63 |
| 16 | 61 | 50 | 82 | 63 | 98 | 80 |
| 25 | 83 | 63 | 108 | 80 | 129 | 100 |
| 2,5 | 20 | 16 | 26 | 20 | 32 | 25 |
| 4 | 25 | 20 | 34 | 25 | 42 | 32 |
| 35 | 103 | 80 | 135 | 100 | 158 | 125 |
| 50 | 132 | 100 | 168 | 125 | 198 | 160 |
| 120 | 235 | 200 | 292 | 250 | 344 | 315 |
| 150 | Â | Â | 335 | 250 | 391 | 315 |
| 185 | Â | Â | 382 | 315 | 448 | 400 |
| 70 | 165 | 125 | 207 | 160 | 245 | 200 |
| 95 | 197 | 160 | 250 | 200 | 292 | 250 |
| 240 | Â | Â | 453 | 315 | 528 | 400 |
| 300 | Â | Â | 504 | 400 | 608 | 500 |
| 400 | Â | Â | Â | Â | 726 | 630 |
| 500 | Â | Â | Â | Â | 830 | 630 |
Current Carrying Capacity Of Aluminium Cable
2.5 Sq MM Cable Specification
| Guage | Volts Support | Amp | Load | Suitable For |
| 2.5 Sq MM | 250 | 110 | 500 Watts | Normal Load |
4.0 Sq MM Cable Details
| Guage | Volts Support | Amp | Load | Suitable For |
| 4.0 Sq MM | 250 | 110 | 800 Watts | Normal Load |
6.0 Sq MM Cable Specification
| Guage | Volts Support | Amp | Load | Suitable For |
| 6.0 Sq MM | 250 | 110 | 1200 Watts | Normal Load |
8.0 Sq MM Cable Load Capacity
| Guage | Volts Support | Amp | Load | Suitable For |
| 8.0 Sq MM | 250 | 110 | 1800 Watt | Heavy Load |
10 Sq MM Cable Load Specification
| Guage | Volts Support | Amp | Load | Suitable For |
| 10 Sq MM | 250 | 110 | 2500 Watt | Heavy Load |
Check Diameter Chart and Properties of Class 2 Copper Wire
Class 2 copper wire is often used for high temperature condition. It has better properties than class 1 copper wire. It offers exceptional conductivity and longetivity. It is highly demanded due to its properties to handle average levels of mechanical pressure at the same time sustaining its ductility and this feature makes it desirable product. Its heat resistant properties makes it protected against high temperature conditions without failing its execution and this makes it an ideal choice for electrical applications.
Class 2 Copper Wire Diameter Chart & Properties
| NO. OF WIRES | NOMINAL CROSSSECTIONAL AREA (mm²) | DIAMETER OFCONDUCTORSmm | DIAMETER OF WIRES (mm) | MECHANICAL PROPERTIES OFPLAIN COPPER WIRE | MAXIMUM DCRESISTANCEAT 20°(ohms/km) | NOMINALWEIGHT(kg/km) | |
|---|---|---|---|---|---|---|---|
| Minimum Elongation% | Minimum TensileStrength(N/mm2) | ||||||
| 7 | 16 | 4.8 | 1.74 | 28 | 200 | 1.15 | 137 |
| 7 | 25 | 5.8 | 2.19 | 28 | 200 | 0.727 | 215 |
| 7 | 1.5 | 1.59 | 0.53 | 24 | 200 | 12.1 | 13 |
| 7 | 10 | 3.85 | 1.35 | 26 | 200 | 1.83 | 87 |
| 7 | 35 | 6.9 | 2.62 | 28 | 200 | 0.524 | 300 |
| 10 | 50 | 8.2 | 2.62 | 28 | 200 | 0.387 | 410 |
| 7 | 2.5 | 2.01 | 0.67 | 24 | 200 | 7.41 | 21 |
| 7 | 4 | 2.55 | 0.85 | 24 | 200 | 4.61 | 35 |
| 7 | 6 | 3.15 | 1.05 | 26 | 200 | 3.08 | 52 |
| 14 | 70 | 9.7 | 2.62 | 28 | 200 | 0.268 | 595 |
| 19 | 95 | 11.4 | 2.62 | 28 | 200 | 0.193 | 820 |
| 48 | 240 | 18.6 | 2.62 | 28 | 200 | 0.0754 | 2100 |
| 61 | 300 | 20.4 | 2.62 | 28 | 200 | 0.0601 | 2700 |
| 19 | 120 | 13.1 | 2.62 | 28 | 200 | 0.153 | 1040 |
| 37 | 150 | 14.2 | 2.62 | 28 | 200 | 0.124 | 1280 |
| 37 | 185 | 15.8 | 2.62 | 28 | 200 | 0.0991 | 1600 |
| 61 | 400 | 26 | 3 | 33 | 200 | 0.047 | 3400 |
| 61 | 500 | 30 | 3 | 33 | 200 | 0.0366 | 4400 |
Amperes Conductor Chart
| Insulation Materials: | Copper Temp. | 30 AWG | 28 AWG | 26 AWG | 24 AWG | 22 AWG | 20 AWG | 18 AWG | 16 AWG | 14 AWG | 12 AWG | 10 AWG | 8 AWG | 6 AWG | 4 AWG | 2 AWG |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Polyethylene Neoprene Polyurethane Polyvinylchloride (Semi-Rigid) |
80°C | 2 | 3 | 4 | 6 | 8 | 10 | 15 | 19 | 27 | 36 | 47 | 65 | 95Perfume Spray Bottle
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