Conductors and Cables Course

Lesson 1 • Conductor Physical Properties

Covers resistivity, tensile strength, thermal expansion, and ductility. These properties directly influence conductor sizing and installation method choices.

Lesson 2 • Electricity and Conductor Basics

Introduces electric charge, current flow, and the role of conductors in circuits. Establishes the physical basis for all subsequent conductor and cable topics.

Lesson 3 • Conductor Sizing and Gauges

Explains wire gauge systems, cross-sectional area, and ampacity relationships. Proper sizing prevents overheating and ensures safe current-carrying capacity.

Lesson 4 • Stranded vs. Solid Conductors

Compares solid and stranded conductor construction, flexibility, and application suitability. Guides selection decisions based on installation environment and mechanical demands.

Lesson 1 • Cable Anatomy Overview

Identifies every layer of a cable from conductor core to outer jacket. Understanding anatomy enables accurate specification reading and fault diagnosis.

Lesson 2 • Reading Cable Markings and Datasheets

Teaches interpretation of cable markings, part numbers, and manufacturer datasheets. Accurate reading prevents misapplication and supports procurement decisions.

Lesson 3 • Insulation Materials and Ratings

Covers PVC, XLPE, EPR, and other insulation types with their temperature and voltage ratings. Insulation selection determines cable suitability for specific environments.

Lesson 4 • Jacket Materials and Functions

Reviews outer jacket compounds including PVC, LSZH, polyethylene, and neoprene. Jacket selection governs flame, chemical, and UV resistance performance.

Lesson 1 • Data and Communication Cables

Reviews structured cabling categories, coaxial cables, and fibre optic cables. Data cables prioritise bandwidth, attenuation, and crosstalk performance over current capacity.

Lesson 2 • Low-Voltage Power Cables

Covers cables rated for distribution and branch-circuit power up to 1 kV. Establishes the baseline cable category used in most commercial and industrial installations.

Lesson 3 • Specialty and Harsh-Environment Cables

Covers cables for mining, marine, high-temperature, and hazardous-area use. Specialty cables meet extreme mechanical, chemical, or regulatory requirements.

Lesson 4 • Medium- and High-Voltage Cables

Examines cables rated above 1 kV including shielded and screened designs. Higher voltage cables require specialised insulation systems and installation practices.

Lesson 1 • Practical Sizing Workflow

Integrates ampacity, voltage drop, and short-circuit checks into a unified sizing procedure. A structured workflow reduces errors and supports design documentation.

Lesson 2 • Derating Factors and Corrections

Applies ambient temperature correction and conduit fill derating to ampacity values. Derating ensures conductors operate safely under real installation conditions.

Lesson 3 • Voltage Drop Calculations

Calculates resistive and reactive voltage drop for single-phase and three-phase circuits. Voltage drop limits protect equipment performance and energy efficiency.

Lesson 4 • Ampacity Calculation Methods

Explains continuous and non-continuous load ampacity requirements and base ampacity tables. Correct ampacity calculation is the primary step in conductor sizing.

Lesson 1 • Pre-Installation Planning

Covers route surveys, pulling tension calculations, and material staging. Thorough planning prevents cable damage and costly rework during installation.

Lesson 2 • Conduit and Raceway Systems

Reviews rigid, flexible, and liquid-tight conduit types along with cable tray systems. Raceway selection affects protection level, heat dissipation, and future expandability.

Lesson 3 • Underground and Direct-Burial Installation

Covers trenching, bedding, burial depth, and duct bank construction for underground cables. Underground methods protect cables from physical damage and environmental exposure.

Lesson 4 • Cable Support and Securing

Addresses support spacing, clamps, hangers, and seismic bracing requirements. Adequate support prevents sag, mechanical stress, and long-term insulation damage.

Lesson 1 • Termination Fundamentals

Explains contact resistance, connection integrity, and the consequences of poor terminations. Sound termination practice is critical to system reliability and safety.

Lesson 2 • Mechanical and Compression Connectors

Covers set-screw, compression lug, and split-bolt connector types and installation methods. Connector selection must match conductor material, size, and application environment.

Lesson 3 • Insulation Displacement and Push-In Connectors

Reviews IDC and push-in connector technology for low-voltage and data applications. These connectors enable fast, tool-reduced terminations in appropriate applications.

Lesson 4 • Cable Termination Kits and Stress Control

Explains stress cones, termination kits, and end-sealing for medium- and high-voltage cables. Stress control prevents electrical field concentration at termination points.

Lesson 1 • Continuity and Resistance Testing

Addresses conductor continuity verification and low-resistance measurement methods. These tests confirm correct wiring and identify high-resistance joints before energisation.

Lesson 2 • High-Potential and Withstand Testing

Explains DC and AC high-potential test methods and their application to cable systems. Hi-pot testing stresses insulation to confirm it can withstand operating voltage.

Lesson 3 • Insulation Resistance Testing

Covers megohmmeter operation, test voltage selection, and result interpretation. Insulation resistance testing detects moisture ingress, contamination, and insulation degradation.

Lesson 4 • Time-Domain Reflectometry and Fault Location

Introduces TDR principles and fault-location techniques for installed cable systems. Accurate fault location minimises excavation and repair time on buried or concealed cables.

Lesson 1 • Common Cable Failure Modes

Analyses insulation breakdown, mechanical damage, water treeing, and termination failures. Understanding failure modes guides targeted inspection and corrective action.

Lesson 2 • Systematic Fault Diagnosis

Applies a structured diagnostic process to isolate and identify cable faults efficiently. Systematic diagnosis reduces mean time to repair and minimises unnecessary cable replacement.

Lesson 3 • Cable Repair and Replacement Decisions

Evaluates repair options against replacement economics and remaining service life. Sound repair/replace decisions optimise capital expenditure and system reliability.

Lesson 4 • Thermal Imaging and Partial Discharge

Covers infrared thermography and partial discharge testing as condition-monitoring tools. These non-invasive methods detect developing faults before catastrophic failure occurs.