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Function of soft copper wire in cable trays

Fiber and communications infrastructure knowledge brief Published 31 Aug 2023

Prepared for preliminary research by the METRA knowledge desk. Confirm optical interfaces, port or core capacity, electrical input and output, enclosure protection, thermal design and installation limits against current standards and product documentation.

Soft copper wire, typically annealed and stranded, is widely used in cable trays for its flexibility, durability, and compliance with NEC standards.

Types and Standards

Soft copper wires used in cable trays are generally annealed, stranded conductors that conform to ASTM standards such as ASTM B3 for bare copper and ASTM B8 for Class B concentric stranding. For larger sizes, compressed annealed copper per ASTM B8 is used. These conductors are designed to be flexible, making them easier to pull through cable trays and around bends without damage.

Insulation and Jacket

Soft copper tray cables are insulated with high dielectric strength, heat- and moisture-resistant PVC, rated for continuous use at 90°C dry and 75°C wet to meet UL 83 standards for THHN or THWN wire. The conductors are often cabled together with non-hygroscopic fillers and wrapped with a binder to form a compact core.

A PV

C jacket provides additional protection against abrasion, oil, chemicals, sunlight, and water, ensuring durability in industrial and commercial environments.

Flexibility and Installation

Soft annealed copper, especially with fine stranding (e.g., 24 AWG Class I), offers superior flexibility, which reduces labor effort during installation and prevents twisting or torsion of conductors. Many modern tray cables are designed for direct burial and can be installed in both indoor and outdoor cable trays, ducts, or wireways. Some constructions include tin-coated copper for enhanced corrosion resistance.

Ampacity and Temperature Considerations

The ampacity of soft copper wires in cable trays is based on ambient temperature of 30°C (86°F) according to NEC Table 310. 15(B)(16). Correction factors must be applied if the ambient temperature differs.

Conductor sizes and temperature ratings are selected to comply with NEC requirements, including overcurrent protection limits for smaller gauges.

Applications

Soft copper tray cables are suitable for power, control, and instrumentation circuits in commercial, industrial, and data center installations. They are UL listed and meet flame test requirements such as UL 1277, IEEE 383, and ICEA vertical tray flame tests, ensuring safety in exposed tray installations. In summary, soft copper wire in cable trays provides a combination of flexibility, durability, and compliance with electrical codes, making it ideal for a wide range of commercial and industrial applications.

Proper selection of conductor size, insulation type, and ampacity ensures safe and efficient operation.

Function of soft copper wire in cable trays - METRA FIBER MARKET [PDF]

Function of soft copper wire in cable trays

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Technical note

This reference is intended for preliminary fiber and communications infrastructure research. Optical interface, fiber type, port or core capacity, electrical input and output, enclosure protection, cooling, installation limits and applicable standards must be verified for the specific project.

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