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CABLE INSTALLATIONMAN UAL

SEVENTH EDITION

1600 West Main StreetWillimantic, CT 06226-1128

(800)338-0901FAX (860) 450-7019

Division of:BICC Cables Corporation / One Crosfield Avenue West Nyack, NY 10994


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BICC CABLESCABLE INSTALLATION MANUAL

TABLE OF CONTENTS1. Introduction ................................................. 411.Preinstallation ............................................... 5

A. Overview ................................................. 5B. Cable Inspection ........................................... 5C. Cable Handling ......................... 5D. Cable Storage ............................................. 7E. Preinstallation Checklist ..................................... 7Ill. Installation .................................................. 8A. Overview ........ 8B. Ambient Temperatu're' 8C . Equipm ent ................................................ 91. Checklist .............................................. 9

2. Diagram s ............................................. 10D. Conduit Fill .............................................. 131. Overview ............................................. 132. Form ulae ............................................. 133. Raceway Data ......................................... 13

a. Rigid Conduit Information ............................ 15b. Duct Inform ation ................................... 16c. Sweep Elbow Radius ................................. 17d. Conduit Spacing ................................... 18e. Durasheath EP , 600v ................................ 19f. Unicon FREP, 600v .................................. 22g. Durasheath EP, 5kv ................................. 24h. EP - Lead ......................................... 26i. UniBlend .......................................... 30j. UniShield ......................................... 34E. Mechanical Fit of Cable in Raceway .... ..................... 38

1. Configuration .......................................... 382. W eight Correct Factor ................................... 383. Clearance ............................................. 404. Jam Ratio ............................................. 405. Coefficient of Dynamic Friction. ........................... 41F. Physical Limitations of Cables ............ .................. 421. Overview ............................................. 422. Maximum Pulling Tensions .................. ............ 42

a. O verview ...................... ..... ............. 42b. On Pulling Device ............ ...................... 42c. On Conductor ....................................... 431. Form ulae ....................................... 432. Conductor Data .................................. 443. Si Units ......................................... 454. In Parallel or in Assemblies ......................... 465. Multiconductor Cables ............................. 476. Verticle Bend, Pulling Up ........................... 487. Verticle Bend, Pulling Down ......................... 488. Horizontal Pull ................................... 48

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TABLE OF CONTENTS9. Inclined Pull ...................................... 48

10. Horizontal Bend ................................... 4811. Around Bends ..................................... 4912. Calculation Correlation .............................. 4913. Bend M ultiplier .................................... 49

3. Sidewall Loading ....................................... 514. Training and Bending .................................... 525. Calculation Examples ................................... 556. Installation Checklist .................................... 58IV. Splicing &Terminating ........................................ 60

A. Why Shield Power Cables? ................................. 60B. Splicing & Terminating Overview ............................. 61C. Precautions .............................................. 62D. Equipment ............................................... 62E. Medium Voltage Cable Components .......................... 63F. Cable Preparation ......................................... 65G. Tape Termination ......................................... 67H. Tape Splice .............................................. 691.Tape Construction Materials ................................ 71J. Accessory Manufacturers .................................. 72k. Splicing and Terminating Checklist ........................... 73

V. Testing .................................................... 74A. Overview ................................................ 74B. Equipment ............................................... 74C. Procedures ............................................... 74D. High Potential (HiPot) Testing ................................ 75E. Common Problems ........................................ 76F. Equipment Suppliers ....................................... 76G. ICEA, NEMA and IEEE Standard 400 .......................... 77H. AEIC CS5 & CS6-87, Section K .............................. 771.Test Report Format ........................................ 78J. Fault Testing ............................................. 79

K.- ac Testing ............................................... 79L. Insulation Testing ......................................... 79M .Testing Checklist .......................................... 79IV. Appendix .................................................. 80A. Circuit Design Considerations ............................... 801. Calculation Procedures .................................. 80

2. Calculation Input ....................................... 813. Pull Box Sizing ......................................... 824. Dynamometer Correction ................................ 835. Suspending Cable ...................................... 846. Overall Diameter of Multiconductor Assemblies .............. 85

B. Purging Water from Strand or Shield .......................... 86C. Symbols ................................................ 88D. Cable Installation Data Sheet ................................ 89


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1. NTRODUCTIONA power cable and its components are governed by the fundamental laws of physics, chemistry andmechanics. Thus, these laws must be considered during installation if your cable investment is to be protected.This manual provides installation methods based on these laws and should be used in conjunction with thecircuit designer's installation specifications and all applicable codes. The methods are valid for all types ofcable: power, control, instrumentation, and telecommunication.This manual is intended for the installer's use in the field and is not a text on power system design or electricalcircuit analysis. The information given is concise, but should be sufficient for the majority of installations. If yourequire additional information, please contact BICC Cables at (800) 338-0901.

Th dataand recommendations hat follow are basedon information currently availableandbeli ved to be reliable.BICC Cablesmakes no guaranteeof the resultsand assumes no obligatioor liability whatsoever n connection with these recommendations.

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11 . PREINSTALLATIONA. OVERVIEW

To ensure safety during cable installation and reliability once the cable is installed, you should confirmthe following prior to installation.* The cable selected is proper for your application* The cable has not been damaged in transit or storage.

Review all applicable, state and national codes to verity that the cable chosen is appropriate fo r the joAlso, consult your local building authority.Next, you must identify any existing cable damage and prevent any further damage from occuring. This done through proper cable inspection, handling and storage.

B. CABLE INSPECTIONInspect every cable reel fo r damage before accepting the shipment. Be particularly alert fo r cable damage

* A reel is laying flat on its side* Several reels are stacked* Other freight is stacked on a reel* Nails have been driven into reel flanges to secure shipping blocks* A reel flange is damaged* Acable covering is removed, stained or damaged* Acable end seal is removed or damaged* A reel has been dropped (hidden damage likely)C.CABLE HANDLING

Remove al l nails and staples from the reel flanges before moving a reel, and avoid al l objects that coucrush, gouge or impact the cable when moving. NEVER use the cable as a means to move a reelWhen unreeling, observe recommended bending radii, use swivels to prevent twisting and avoid overrun


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PREINSTALLATION (CONT.)

How to Handle Cable Reels

Cradle both reel flanges between Upended heavy reels will oftenforks. arrive damaged. Refuse orreceive subject to inspection forhidden damage.

F,

Reels can be hoisted with a shaft Do not lift by top flange. Cable orextending through both flanges. reel will be damaged.

Never allow forks to touch cableLower reels from truck using surface or reel wrap.hydraulic gate, hoist or fork lift.LOWER CAREFULLY.

Always load with flanges on edge Never drop reels.and check and block securely.

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PREINSTALLATION (CONT.)D. Cable Storage

Cables should be stored on hard surfaces so that reel flanges cannot sink. Small reels may weigh severalhundred pounds while large reels can exceed 1000 pounds.Prevent impact damage by:

Aligning reels flange to flange Using guards across flanges when different reel sizes are stored together* Maintaining adequate aisles and barricades to prevent equipment from hitting the cable.

Seal the ends of all cable stored outdoors, and reseal both ends when a length is cut from the reel.E. Preinstallation Checklist

Code ReviewReview local, state and national codes relating to cable installationConsult local inspection authority

Cable InspectionCheck for shipping damage before accepting shipmentConfirm tlat the cable specified was receivedReseal cable ends

Cable HandlingRemove nails and staples from reel flangesCalculate and observe recommended bending radiiUse swivels and avoid overruns when unreeling

Cable StorageProvide firm support for reelsProtect cable from mechanical damage and from liquid spillsCheck cable end seals periodicallyAdvise all splicers, installers and handlers of all special instructions

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111. INSTALLATIONA. Overview

A survey of customer complaints revealed that 92 % of the cables in question failed due to mechanicaldamage. When does mechanical damage usually occur? During installation.In tact, most cables are subjected to more mechanical stress during installation than they ever experiencein actual operation. Needless to say, handling and pulling your cable according to manufacturer's recom-mendations is extremely important.There are five main considerations in any cable installation:

* Ambient Temperature* Equipment* Conduit Fill* Mechanical Fit in Raceway* Physical Limitations

These considerations were developed and refined by installers of paper-lead cables. Tw o excellent refer-ences are the "Underground Systems Reference Book" and "Pipeline Design for Pipe Type FeedersThe former was published by Edison Electric Institute in 1931 and was last revised in 1957. The latterwas an AIEE paper (#53-389) by R.C. Rifqnburg, published in POWER APPARATUS &SYSTEMS in De-cember, 1953.

B. Ambient TemperatureLo w temperatures are a cause for concern when installing cable. The following are temperatures belowwhich cable should not be installed.CP/EP - 1/C - 31 OF FREP, PE, XLPIE - 1 /C - 58OFCPE Jacket - 31OFCPE/EP - 1/C - 31OF PV C + 14OFCIP = Chlorosulfonated Polyethylene (HypalonO), CPE = Chlorinated Polyethylene,EP = Ethylene Propylene. FREP = Flame Retardant EPPV C = Polyvinyl Chloride.During cold weather installation, cable should be pulled more slowly and trained in place the same dayit is removed from storage. Do not impact, drop, kink or bend cable sharply in low temperatures.


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INSTALLATION (CONT.)B. EQUIPMENT

The proper use of appropriate equipment is crucial to a successful cable installation. The equipment neededfor most installations is detailed in the following checklist.

CHECK LISTM portable electric generator M shackles/clevisE] extension cords & GFCl M gang rollers; with at least 4 11effective radiusM pump, diaphragm M hand winces (come-a-long)F] make-up air blower & hose manhole edge sheave[:] manhole cover hooks pulling ropeE] warning flags, signs swivels

electrostatic kV tester E] basket grip pullerselectric safety blankets and clamps M 0-1/5/10 kip dynamometerradios or telephonesgloves M reel arborflood lamps M ree1jacks

reel brakesfishtape or string blower/vacuum E] cable cutterhand line lint free rags

M duct cleaning mandrels cable pulling lubricantM duct testing mandrels prelubing devicesF1 capstan type puller plywood sheetsEj snatch blocks M diameter tape

short ropes for temp tie-offs M 50 ft measuring tapeM silicone caulking (to seal cable ends)M guide-in flexible tubing (elephant trunks)

several wire rope slings of various lengths

The following diagrams illustrate various cable feed-in setups.


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INSTALLATION (CONT.)EOUIPMENT CABLE FEED-IN SETUPS

PPLY LUBE HERE

GUIDE IN TUBE

Reels on truck

11111111777 PISetup for duct close to floor

Setup for overhead. into tray

The feed-in setup should unreel the cable with a natural curvature (Fig. 1) as opposed to a reverse "S"curvature (Fig. 2).

IMPROPER PROPER

(Fig.,2) (Fig. 1)


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INSTALLATION (CONT.)EQUIPMENT I CAPSTAN

I PULLING ROPE

-

Setup withtimber becauseof no pullingeyes

-

&K

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INSTALLATION (CONT.)EQUIPMENTSINGLE SHEAVE

Single Sheaves may be used only for GUIDING cables.Arrange multiple blocks to hold bending radii whenever cableis deflected.

SHEAVE ASSEMBLY

For pulling around bends, use conveyor sheave assembliesthe appropriate radius series.

The pulleys must be positioned to ensure that the effective curvature is smooth and deflected evenly ateach pulley. Never allow a polygon curvature to occur. (Fig. C)The fit of the pulley around the cable, is also important when polling heavy weights (ex. pulleys at the topof a vertical drop).

Fig. CRADIUS

NEVER ALLOWRemember to use the radius of the surface overwhich the cable is bent, not the outside flangediameter of the pulley. A "10 inch" cable sheavetypically has an inside (bending) radius of 3inches,

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INSTALLATION (CONT.)D. CONDUIT FILL

1. OverviewHeat is generated as current passes through conductor. The safe dissipation of this heat to the surroundingconduit is a major consideration during cable installation and dictates allowable conduit fill.Conduit fill is the percentage of area inside the conduit occupied by cable. It determines the maximum am-pacity of the enclosed cables since an increase in he number of current-carrying conductors in he conduitdecreases the amount of current each conductor can carry without exceeding its temperature rating.Consult the applicable codes for your maximum specified conduit fill and for the influence that fill has oncircuit ampacity.The effect of conduit fill on jamming, clearance and friction is covered in Section E, Mechanical Fit of Cablein Raceway.

2. FormulaeConduit fill is calculated as follows:

% Fill= 1: Conductor Area X 100Raceway AreaFor round conduits and cables with equal diameters:

0/ b Fill= (d/D)' n X 100 WHERE': d 1/c cable diameterD ID of conduitn number of conductors3. DataThe following pages contain the data needed to calculate conduit fill for variousBICC cables.

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INSTALLATION (CONT)EQUIPMENTBICC CABLES APPROVAL LISTCABLE PULLING LUBRICANTS

Name of Lubricant Manufacturer

POLYWATERQD A, G, &J American Polywater CorporationStillwater, MN

POLYWATERQD Plus Silicone, American Polywater CorporationTypes NN, WNN, FS Stillwater, MN

Wire LubeO &Aqua-Gel" Ideal Industries, Sycamore, IL

DYNA-BLUEO Cable Lubricant American Polywater CorporationStillwater, MN

Wirepull Mac Products, Kearney, NJ

Other lubricants may be suitable for use with BICC Cable designs.Contact the lubricant manufacturer about the compatibility of their products with specific cables.Cable lubricants should be currently I.I.L. listed.Contact lubricant manufacturer for-proof of approval.

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INSTALLATION (CONT.)4. RACEWAY DATA

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INSTALLATION (CONT.)RACEWAY DATA

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I INSTALLATION (CONT.)RACEWAY DATA

SWEEP ELBOW RADIUSI ~~~~~Thisable lists the inside radius for manufactured rigid steel conduit elbows.The inside radius (R,) equals the centerline radius (Rj)ess half of the conduitinside diameter (0).ELBOW CENTERLINE RADIUS OnChes)Std. 12 15 18 24 30 36 42 -48

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EXAMPLE: Find inside radius of 15 inch sweep elbow for 2-C.Ri (Rc - 0.5D)/12I. =~~~~~~~~~~5S - 0.5(2.067)] - 12

=1.16 ft

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INSTALLATION (CONT),RACEWAY

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CDc\j 0 z (DjB = cn 2EE um2 cn c\l IM CM 04 C-4-tr 0 c\1 (M CD CV co cn J Lo CMM V M CM it M r- 0) 04 Ln2 'r- - .. 'o (,2 Cm\!Cc"?) C-'? Cl:' Ln Ccq cw C7) to 'j Lo 0 U) U) 0 Lo C'j P' S) cq cm m - 'd'0 - U -'a . p 1,-: Cq CIR C4 Cl Cl 114: Lq LO CD f- OD Q C14LO - U')4) 0 4) 0 0 U) ci ci 6 0 O 0 C, 0 C) 0 0 a a C) CD 6 d 6 ci c c0) 0):2 0 0C 'cn:,- 0 E0 0 - -6 >E CD0 Z gn O X LLILn C\j - Lo CY) CT V) C) Ln U) m co IT x P- cm t- (D 0 IT 0) CD .) v to 0 0'IT Iq LO (D (D CO rl- OD o) V COW 1 CO00 CD 0 0 CMV ODZ cp . 9 Cl U?> M M 6 6 b O' 0, O' c5pO' 0 O- a 6 ci c; ci ci 6 6a 0-0 C co0

1='= IC 0)MZ M.r Smu 'tooZU E ELA q) Lo E OE :0 EZ.r M 0 0 a 0 -)U.) 0 tn 0 kg a a 0 0 Oa 0 a coU A 4 U')U"C" InX to CO (o CM CV M V C\j M Ln r in co(DT C\,-;:: i4t CY V) Ln r-

24


27/95


COW T 0 C) C) C) CD 0 C) 0 CD aocoT N-a 000 000 00& C; Ln U)0 V)0 'n Lo 0 Lo 0cm CO Lo r- 0 cm MLn r- a

0 cn cow C\l..Zco

0 to co aC

co 0 p- U) cq 004 M Cl) 04 U)C0 co a) co r- W \J 0) CMU3 cli c\j Cl 'T 4C M C.) M U)M N0 Z vir0 w -It C) r C) 0 C) -T r- M - 0M CM\l co V) co c\j CY\l C.) Lo

0'T m c\j 0 0 cm T F- cm W Ln,.CrE en CM M o -* Ul N N N cn M Iq Ln

LU 0 5az0 Q Co w m r- M 0) m co a M rl- 0) D04 CM c\j CM CM V) lw Itt CM N V) m m Low Z &

ir & C) N CD CMM Kr 0) cn cn rl co 0)U cm cm V) m IT Ul cq CM m Lo Ln0z

Z CD -T rl- M 0) P, Locm " cn Ln co Ln

CL+ 0) tn CDN co Lo0LUuj Ccc 0

LLJ-i 4 C t a 0 cJ - -T 0 CM U) Lr) 0 CO 0) 0 _j V 0) CD C.) V CD CO - M 0 0) com uj,- M Cl 0) CD 00 CV - 00 L0 U') M CD - CV -J CD U) V a) CD 00 M CK) 0) - Lf) CO CD


28/95


N-0 000 000 0 C\A-a 000 000 0- LO Ln 0 Ln 0 Ln to 0 Ln aq N cn in r, 5 N M Ln rl- 0

114, 'T CDC\l N

CO LO N co U)cv M N N M

N f, Ln ;T cv U, co 0 ;T ;ncq N M IT cq cm cm M 't tn

M rl- M 'IT to N cn co - Ln ;n knW z cm cQ M v Ul) N N N M co 'IT Ln10 0c40 lot

CD cm t, M Ln ;n r- 'n Ln Go o Ln tr) WM 0 cn cm cm cu cm cn I-T In N 04 N M M Iq VI0U) ui& M M0 U ac 0 cm U) f- 0) to Zb ; r-co qc v- v oLU z CO) 04 N 04 CV M CO) V LO M M CO IT Ln W

-i 0CM

ai & I Lu ;D Zv Zn Lo 4 r,co 0 C-4 M 0) v I-T Ln Ln Ln Ln;a -0 LUw r Woeu Er 0 X10 Ln -v a,coo N In LOn'a .0 CCY 3: 30 coE -5 M < - ,q co u) ,t Cl co C) C) r cn cn tD Ln aj r- m mt cD0 10'ra c Ln 0 CD CV CD r4D Ln CD LO C15 M CO CO 04 r- M Cj 0c 0 in (DCD t- CD0) CID M COCO CY) M "T 00M CO- - ciCD CZ 6 6 C5 6 6 6 C ci ci 0 6 c"i c0 CD cU.E

f- Ul 'COD 0r Im C 'ro- li U 0 V CD CV CO W V U-) c') M c') co C%4Y r, M Ci 0)cn - z U P,: 9 C! 9 cl CT U f- CIR U)8 00 CD 0) 0) 0 M (A> 0 C5 6 6 o - 0

0 z (LZ 20 .G co 6 0E EE U) E bg 000 0 0 5t?20 coo 0 E0 3::" - 4 L U')) Lon 0 tn Ln 0 tn 0 M

N CV CM M Ln r- - CM t N M to r- -

26


29/95


C"J-o 000 000 0 _ao aoo a0a 000 000& 4 in Ln 0 Ln 0 Lo 0 0 Lo 0 4Lnin CLOON M Lo r- 0 cmM Lo I,- 0 Ncn tnfo

'-T 0 QD cv W o f" ;nW lcov N co m N " m cn Itt

Ln 0 ;o to 0- -wo Lo Zo zq " ;o ;n mLn mm CmNcn cn I-T W co m m I-T Ln

U. W rl ;D ;O r- in Lo r.- - cm ;T q -aV cm m cn -It Ln "CM" mmcn IRr n cn -q tn

W z0C.) '-T CD (3)r 0 0) clJ C.) OD r- U) zy) -- oCl C\j C\l cm cn cn * (D N M cv) M 1-cr L0 Iq Lf) toz0

cn 0 C,) ;D ;-- Zq b) 4M CM ) cn cn 1 4 Ln M V IV 'T V)LUz 0

to -4 co U-) W M V) "T Ln U') Lc)c) LnLUW

Co loc4z N f 'o, Lo t- a- F- co C;) C" a W Ln rl- IT W Lo 0 Lnu) cm cm r- "t '-T N CM W mmm W v m M Lnyo o q q q cl (P r, '0 POR 0 -: Iq ORp .7cn 0 CM cn - - - - - - - CM CO (A CM CM N N cn V

C EOROx CO elC CD V -T O 0) cn C\] 0 cy (pL) V) 0 V V 0) 0 L0 CD 0 CD (D CM Cl q V Ln C) (D CD 00 Cb - M U)Z '7 -7 7 7 C? C! '11p OR 0- - - - - - - - - - C\i C\i C\i oEL

CDCEE20 00 CDOO r.200 aLn Ln 0 In 0 4U)LO 000 C, W U) 0 Lo 0cm cm V cm C.)U)r- - a CM CYM W)r, - V N M in r, -

97


30/95


CM-0 C)oo 000 0 M-0 000 CDOCD aE - - Ln Ln 0 Ln a tn Ln a Ln 00 CMle Cj Cn Ln r- a C-i cr) U-) 0

CO a Lo 0QD cm " cn

cm cl m cn Itt0

v m co CD m W Q r- co U,)V cn v 04 CJ M V) -T Le)C) ZZci 0m N Lf 0 Co r co Q 0 CM '-T CY) M f- (D flLU x V CM CM MM Ln CIJ 04 CIJ 04 04 Cv) M V Ln

V)cmC 0 c, 0

z M CY) 04 CD CD CD CD 0) - P, V) aD 0)0 C.) CM CM CM M M v 04 cli 04 M m Ul(D C).0 zV o0 '-T (o 00 - CD CY - LI) Le) CY) cli 0 r-U Lu M CM CM CM C.) cv) IV U,) V) cr) cr) IT Ul U,)a) zC,,

CL v co 0)cis tu 04 V) V Ln Ln Lo (D+E.U EC) x-0 U) ul CM fl-Oa too U s 04 Ln Ln3: 0-gZ; -,ia r- xcm 0 :3 4) LUW= -i 4 C CO CD (D C-4 CYM Vj "W em Lg;Ln 0 Ln CO W r, CM co0 13 C co W- - 0) 0) M M CD CD 0) OD CDCD in r- 0) U') IV 0 v00 -- ,O ;5 W 0 9 N 104 U c C! U U? OR q 'R r-- ORV P4) 0 CL U) - CMCM cn M V Ln P, CMM\l V) V) V V in I- 0001 0 0 C0 CoE 00 U.e -,air . (D> 0 0.00 I? -- W n cm q m N CM-C.- 11 - z0 Q

CD 0=rJ Em C) o 000 000 0 0 CD 0 CD CD 0 0P U') Ln 0 Lo 0 in U) U) 8 LnCD 0 CY cm v CY M Ln r- - W. C4 CM cr) f-

28


31/95


"-o 000 00 00 _Q0 coo 000 000 000to to C Lo 0 - - V) Ln 0 V) 0 4 Ln in 0 Ln 0CO Ln r- 0 cq V cQ V) a) r- 0 m Lo rl- a

Co P- cn CO - cogcq cm m cq V)cn cv cv m m 'T

M t- cq 0 P- cm Ln f.- r- Lo 'T "Vo Lnv)N cm V) V IT cm " CM cn V tn Co m IT l4t LnU. C

L.00 w C4WW VO Q C D V w r" " V Q Co t- 0 C-i 0 r-z V CM m CY m V Lo to cli cm 04 m m m V tn V VW) W)Z I0 X lu0 I.- 0-"R - 4c0 M Ln tn fl- cn w cm 0 0 V) IT 0 04 0) OD 0 cr)x cc V 01 01 CY C-4 C.) M le Lf) C.) M 0) It IV V Ln Lo Loui m a0 E t=MS z p a cm cj in CM w V 0) cJ V - LnX a - 0 Ln cn V Ict Ln Ln

1= z30 . 0a V) M r- CD c\l (D CDCO) V "cr qtr Lo W) Lo W)LU

I ZIL C4ul CL C4+ 05.

0

UJ C cmLU 0M C C CU 't Co N cucmw W"Wci 0 r- Co V w cn V "t w m w in a V 0 (D.2 0) .* 0 Lo r.. cm in 0 w w cv V Ln r.. 0) 40 CD I'- CMW - Cm0)m uj M-- V-U) cn Co 0) cn OD- M C) M C4 Cq OD m P- m 0 a) f-cu cn c6 6 44 ui,6 r,: ai vi 4 4 6,66 PZoi 6 -9 6 c6 r- ai ci C-,iCL f's

C ON0U.

o0a 000 o 0 o cooz V .1 m cm;:: =,v mcmz0E 40 in (R2 - Ln Lg-) 0 Ln -Lnu) Soo 114 tn U- ) L(W. N clJ V " 0) U) II- - C4 C\, IV cm V) r, C4 v cm 0)

2P


32/95

INSTALLATION (CONT)RACEWAY DATA

(DNtN -!20 000 000 0 CQ - oocD 000 000_ o L O O L O 0 __ _tnul) otnoE C'i m t cm MLo r- 0 c"J cO "4' v m Ln r-. o

cm Nw N cm N

w cm IT - 0to N m cm cn m

411 I-* cn 0 - Lo 0 COOcm m .4, cq N m m .0,LLci I-0i 5 w'a 0 0 cm I'll w N co co0 CM CMcr) 19t Lf) CM CM CM cm cv) cv) ITz (awi 0 wCNA40 cv 14, rl- N CD C) CM cn CD CO cn CDo J! CO) CY CV 04 Cr) Cf) 04 CM CIJ NC M CO V),Rt ctZV ui E CM4t 0) cl) CD cf) r-) - 'RTI'- Lf)06 ED z c4) N CM 04 CO Cr) 'q* c\l c\l cr) cr) cl) 1-cr05 z

0'c 'Itt 00 0 CO r,- Lf) 0 00C4 04 04 CY Cl) Cl) Cr) q:r Lf)

U)co W0 w W0 (7) IV 0 cl) co0u E m CM CY cv) V It0 c x4D - 'n0 = q3:U) CDe E W P.o 0 m m ;iCM; coE 3 > 0 r- cl) Lr) Cl) 0 cr) 04 cl) N aD 0) P- (D 0) (D 0 cl) V 002 r Id cri re CD Cr) 0) CM 0 00 LQ CD LO V 0 Ln 0 (D cr) OV U,),qtro- .2 Qd M cl) qt V Ln Ln t, CO 00 0 C14 - a CD r, N GO 0) 0 CO (D o(od)0 "o U) 00 c; 6 ci 6 ci c; c; 6 6 c C66 66c; CctM (M:2 00 CDr- S 'ro >, 0E 00 0 to .-,D c 0 EQ a -. 003 0 "o 0 9, CO Cl) (.0 mt I'- COr- 0 CD LO Cl) - CLOO 00 N C11 q4, CD V) rl- W.0 qT CY) n CO 04 CD LO (D U) CD 0) tQ 9- LO OD CO 00 cl) CO 0 Cl) COECD 0 CD z (P IP P.: r': OR OR (7 q 9 C4 'le: IR G 0 cy q 9 q 'Id: IR OR0 0.0 000 000 0 0 0 CD0 zU C-0 r 0cd0r_ 1= r_ 'CMM'o 0 coICe0E 'o >U, -Cc 9 0ffi E "Al 000 0'-_ :E m 0 00 000 000 aoo 000Z.. Ln tn 0 Ln 0 in - Q L O U ) O L n okn CD V CM cr)CM l4t CM cl) to fl- CY CM cr) V CM cr) to f,-

30


33/95


CIJ 0 CD 0 0 C) 0 C) 0 Cl0 E -Z;5- L n L o o Lnc:,c.J "4' cj m Lo rZ a

CIAw C- i cl)

co co 'It win " " cn

cm V O L O McoU.

wN C> cm -.- coin c> to cocsi cm co coz011 to co 0 cn to CD I-cn co m cn m vCO)'-,q 00O) cr) cr) cv) v let v0

z0

U C4V-Wuicc 04x

cw 0IX2E 0.ot 'Rt CD cl) "I CO r- 0) cr) r.- aDotn 0 CD co co m m m .0-0 Coco m qo Lo Co " o

c; ci c; c vi

cl)0 X cr)V 00 Cv) CD Cr) CD 0 Cr) - t--z q q 7 -: 04 C\! q U r, (3

>(D 000 C) 0 0 0 00 In Q U0 Ln 0 Ul 0Cj CY Cl) V 01 Cr) Lf) r-

31


34/95


-aa 000 coc CD CM- 000 000 cooo U,)OLO o Lotn O L n oc') "'t m Cn In I.- 5 C'J C'3 cm M In F- a

cm 04 cm

_j CO 04 W CY -CM04 M cm cm cn ItU.

CM(D U,) CM 0 CM I- CYV CM 03 cr) It CM CM CM M ql'z z

ci 0 x tuN 0 cl) r- cl) Q) Le) 00 lqtc x U) C\I CM C\J Cr)O CM CM CM N Cr) 'qt If)

LQ Ulc-i mc 0tv) (D CD Lc) CV) 04 r- (7) cl) (D q1tCO) CJ CIJ 04 Cv) V' CM N cm N cm V) cr)ziu t

U3 -i z4) m 0 0IL) - cl) CD tf) 0) r- 430 0 cr) (D 0) cor- E z cv) 04 CM CM Cv) CO) Cr) 4T CM Cr) Cr) Cr) (w) q0 T 0W IL)

co01 z CMU) 0 CM (D 0) 00 CO (D 0Q cm 04 CM CM M M V) Co) V U,)

0.+CDZ 0 .5 LO C14 ID

ti - 0 E 04 cr) CO IRT Re Inc 0 xLo LULuU)Z -T. 0 $ c'a c .0 Ir 4) 0 0c', .2 3: MCD g m uj 0E -J4 r- M V U) 0 CM 0 to V) In U) 0 cr) cv) co co 0) cm cm qr wMUJ - co , 'cr o 0) cm 0) N 0) cm OD U.) 2 (0 004 Cl) In N 0) r-E. .2 & > V, LO N OD Cl) It) OD -qt CQ In f,- e 0 04 '4t (0 M CIJ U) V) qt 040 0) 0 c\i c c 6 4L6 6 C c c c c c vi vi -j wi c6 c60:2 0S 0 E cr)0 0 Co :5 s-r- o E Q 003 -6 - =- IOD LIL, 00, r- 'ro- q li 's - %1- U) -'s 0 J! OR 000 C) '"' O!R a 0000.0 0 z V) CDCD,.t *-C,)Cm " cm 4 'Rt 'Rt '%t It 14t cl) CM 0 -- c\I It "it0 0 cq z

0co 0 5 E >Q U a > co he 0CD 0 E < 0 a ooc c c q o0oCD 00 oao tn 0 In In"' t c\I U,) CT In U) 0 Inin w CM Cl) IRT CM M LO r- v- 04 cl) ,it 04 cl) ID r-

32


35/95


04 C) CD 0 0 C) 0 0 0 0E - - - Lo Lo 0 to 0u C\l c') "o, C\j C'S Lo r-- 6

0 Ln CM(D c\j cm co

0 Ln CD w (DCM 04 cl m leLL 3

lo..a ll CM CO - r- U')0 z le C\l CMl) CY)z0 ui - Cf) Ln r- 0 CMD CDx v 04 C\J CM C\J V) M V) ItE LU

0Lo r- m Cm Lo CY) - Om CMC\l 04 M CO Cr) IT LOzLu t-j ZI! Z)m om 0= Z 't CO 0) CJ r- C4M 0 Cl)'-d'CV) Mt l4t LoF u

z co C\j04 04 L0

CL+12 -0LUui ccc 0 0UAU) (mcr)- co O (7)O r- C\lto LU'- a co co a C\Jqt co U,),Rt NJ 0)m & la ", lp () 7 ',I: CR 9 (3 CR " N0. U) c cm C\l cm c) m m cr If th r- Cyi

Fcl) 000 co.4. v c)z c\, 04 Vco aoc:l 000 00in LO O 0 LO 0C\l Cr)'RT CM Cr) LO r v-

33


36/95


N-0 000 oc>o CICDO 000 000 Lntn O L O O LnLo OtnoE c\l 14,0 c\I Cf) Inr- 0 C\j cm C) U.) , o

Into C\j c\I cm

1q, - cm 0 coIn N cn " cn cn

mom cq w f Incv cn cn cm cm cnU.ciPi10 m co co CD cn Ift m to r-V cm " m cm cm cm m 10,zcm 0 m LID r- D Q CM > fl, InC* cm N m cn It cq cmmm 'IctUAU)CD U)UC -Z z 0 C\l OD V) 0 0) cr) I,- 0) cr) 00 2 0 cri c\l cli C\l V) T C\l N N m v In13) z

0s (D - to cn CD cm U,)cm cn m cnCm w co vE m c4i CO v0ggAL CLU 0 0C\I CD 0= m 2iE :)-a r- 0'4- 'q PI In 00 (D t'- r LO V OD t- CO CO U)e o 0) tr) 0) OD O O O D CD CO 04 CO 04 CIJ 0 OD 0C) V -V LO CD OD 0) N CO 0 tn CO t- 4M 0 04 T Cb -qCDC.) CD U) C; C; 6 Cs C; 6 c A ci C; C; cicm ,:2 8 iE 1.CFa.c 2 >,0 E'o

o o -0 OXV '02 q 'a C-4 Cblt V 04 04 "qr Cl V) V, In C\I CO -'.4, U) aD 0) InID U t. tZ P, co mo cJ CD '00 CY)M 04 M In r-o 0.0 Z V) - -o o C) 6 6 z 6 6 60 m Sr = IrM Cs w2 a = > >-53 E 10 Y.E CMD E op poo o 0 o to Q Q !Roo 000co U') U') 0 If> 0 In In 000P 0 CM C-4 C\l M W P- v- C\ l v- C\J e 04 M U) t-


37/95


clJoc 000 C:)Oc) coo oc)cD 00 CDCDQ 000 00E -LoLn C:)Lno -- 4 LoLoc) Lo a - Ln 0 0 Lo 0C\, "'tm C.) U-) a CM CM CO Lo rl_ 0 cQ Itt N CV) Lo r 0

co co - U)0 CM ) - co0 C\l C14 CM CM CO CM CM CO cv)

- to CO 0 -,.t C) co cv) CMV) 00 - W IT CMin CM CMco 110, ""m m 114t CMCY " co co It tn

M P- cq cq C) - Lo CO 0 r- co co I- CM Lo CD toCM " m Nt Lo N CM "MM CM " co co co V.LL

co CY)t 0 '-t to - V)OD- CMcr 0 ITCM \l CMO I-T CM c\j V) CO V) IT cv) m v v0 LU

Lc)r- I P- co M 0 CMCY) C,4,qtM N c\j c\l M V) qt V) V) M v v Ir t V, tr )LU 0

CC) CO (D Lo 0z V) CMCO CO V Lf) V-0z0

CMujLU C-4

C CLLI Co2i 4.r- CM CM -- 00 P 0) V r M CO ID M LO -! 00 M t-- c,) r, C,) cod-- OD 04 CO (3) - Ln Z CQ G) 0 (30 0 CC) CO Cr) z Co Lf) CY) CD co co Ln tofa CP cxog c It wcvw to 0 0 co co co (n -I-w to CO V CO CO 0 V M VC 0 0 0 c c C\i c C\C\i c C6

a? 0It cV (D M Ln V) r-, w -, t w m co co m w cv CMw r- m to lo. a0 q 9 7 C\! M CD 00 - " co 't Lo r- M M M -* Lo W f 0 -z . . . . . . . . . . . . . . . .0 - - - - - - - z - - - - - - - - z CM

o ou to 00 OCIC, c1clo anooo CC)o oc M) C) 0 C) 0 0- Lf) LI) 0 U) 0 R - - - U) Lr) 0 U-) c - - - Lc) Lf) 0 Lr) 0cm , Cm T 64 in Li.)- - CQ Iq CMM LO r- CM9t Cli M to r-

,is


38/95


C\l c) c o o a a o o C\100 C:)C:)o 000IO to C) U) 0 - -1.01.0 01.00CM CM V) L O N O C\, " N m US F- o

Lo CM04 c\j cq

to CMIN M CMM cv)

t= LIa 0 '-cr CM N1)L IN CM M t CM CM M Mza0 M(3 iuN CD to C>mo U) 0 P- wC, X CM cm M CO In CM N m M CTEacm

M CD c'J CY) CO CM a) 00C3 cf ) CM Mf) cv) In c\I c\j CO M COw oemz!

V coo I- cr) C) U) M 00 0 Mz CO) 04 CMM cn 'At CM MMto0 2 0

toC ZU) (. 0 C\J CID 10 to CO N5 C-A N c\ l cv) m CC) ',CT ItCL

+ LaC) CO Lr)LI E N co 1-41 IOo C 0

Ln CY) - V cl r- V U) 0 (D

m It M cj- 4cm i c c\i ri 6 4 ui .6 c6 CO 6 6 4 4 ui 6 r, c6 4 4 Lei 6 c6 r-- oi 6U 4 00LL V)

a o c) 000 000 00 0 000 ocDz -d' cr) CM 04 V V, V 'Rt z cr) CM CM V, it V V z M EV CY V 'q;r

> > >E in 000 !Ro 00 000 000 in 000 00 0 0 Co 0 0 0 0U= - In Lo C Lo C) Lo U) a Ln 0 , - U') tn 0 Ul 04.9 IL v- 04 C\l q 04 M Ln N - CM - CMV CMM Ln r- 1 cli V 01 M Ln N

-27


40/95

INSTALLATION (CONT.)E. MECHANICAL FIT OF CABLE IN RACEWAY

Five parameters influence a cable's mechanical fit ina raceway: its configuration, weight, clearance, jam ratioand coefficient of friction.1 Configuration

The configuration of the cable in the raceway is measured by the ratio of the inner diameter of the conduitto the overall diameter of one of the cables within the conduit (Did).Acradled configuration occurs when cables with a ratio of 2.5 or greater are pulled inparallel from individualreels. A triangular configuration occurs when cables with a ratio of less than 2.5 are pulled in parallel fromindividual reels or when cables are assembled.

Single Cable Cradled TriplexedConfiguration directly affects drag which is computed as Weight Correction Factor (w) in hefoliowing section.

2. WeightWhen making installation calculations, use the total weight per unit length of the cables being pulled. Cabled assemblies will weigh more than paralleled cables unless the cables were specially ordered to haveseveral paralleled cable wound on a reel.Weight Correction Factor (w): Due to its geometric configuration, a cable is subjected to uneven force whenit is pulled into a conduit. This imbalance results in additional frictional drag which must be calculated andallowed for if your installation is to be successful.

No. Conductors Configuration Factor (w)

4 2dY-d-)

Cradled

3 .(5dJ2GA YD-Triplexed

The following graph illustrates the Weight Correction Factor (w):

38


41/95

INSTALLATION (CONT.)MECHANICAL FIT OF CABLES IN RACEWAYI ~~W

1.55-

WEIGHT CORRECTION FACTORfor quantities shown, of cables of equal diameters and weights, for1.50 all others, use ME 1.4,except for one cable, then w =1 .0I ~~~~~~1.45I ~~~~~1.40.

1.35-

1.30

I~~~~~~~~~IMI~~~~~~~~~~~~~~~II ~~~~~1.156I 1.10~~~~~~~~~~~~~11 K II12.2.3.0K35 . 4 .5 5.

EmI I/ 1 .680.1 =1 3.37,I I 1.1TI = rip d CRI rdeI~~~~~~~~~~~~~~~~~~~-R


42/95

INSTALLATION (CONT.)MECHANICAL FIT IN RACEWAY (CONT.)

When computing Weight Correction Factor, ensure all cable diameters are equal. When in doubt, use thecradled configuration formula.The cables ma y be in either a single or multiple conductor construction. But, when only one cable (whethersingle conductor or multiple conductor under common jacket) is being pulled, no weight correction factoris needed.

3. ClearanceClearance refers to the distance between the uppermost cable in the conduit and the inner top of the con-uit. Clearance should be 1/4 inch at minimum and up to one inch for large cable installations or installationsinvolving numerous bends. It is calculated as follows:

Of Conductors/Cables Configuration Formula1 D-d

D DA _d 1.366d + 2 _d

TRIPLEXED

d23 6-d _ D-clCRADLED

When calculating clearance, ensure all cable diameters are equal. Use the triplexed configuration formulaif you are in doubt. Again, the cables may be of single or multiple conductor construction.4. Jam Ratio

Jamming is the wedging of three cables lying side by side in a conduit. This usually occurs when cablesare being pulled around bends or when cables twist.Jam Ratio is calculated by slightly modifying the ratio used to measure configuration (D/d). A value of 1.05Ds used for the inner diameter of the conduit because bending a cylinder creates an oval cross-section inthe bend (1.05D/d).

* If 1.05D/d is larger than 3.0, jamming is impossible.* If 1.05D/d is between 2.8 and 3.0, serious jamming is probable.* If 1.05D/d is less than 2.5 jamming is impossible but clearance should be checked.Since there are manufacturing tolerances on cable, the actual overall diameter should be measured priorto computing jam ratio. 40


43/95

INSTALLATION (CONT.)MECHANICAL FIT IN RACEWAY (CONT.)

5. Coefficient of Dynamic FrictionThe coefficient of dynamic friction is a measure of the friction between the cable and the conduit or roller,and can vary from 0.03 to 0.8, even with lubrication. Typical values are shown in Table below:TYPICAL COEFFICIENTS OF DYNAMIC OF FRICTION (f) WITH ADEQUATECABLE LUBRICATION AT TIME OF PULL

TYPE OF CONDUITCABLE EXTERIOR M PV C FIB ASBPVC - Polyvinyl Chloride .4 .35 .5 .5E - Low Density HMW Polyethylene .35 .35 .5 .5PE - Chlorinated Polyethylene .35 .35 .5 .5ypalonO -CSPE (Chlorosulfonated PE) .5 .5 .7 .6eopreneO - N (Chloroprene) .5 .5 .7 .6REP - Flame Retardant EP .4 .4 .5 .5LPE - Cross Linked PE .35 .35 .5 .5EAD .5 .5 .5 .5M = Metallic, Steel or AluminumPVC Polyvinyl Chloride, Thinwall or Heavy Schedule 40FIB Fiber Conduit - Orangeburg or NocreteAS B Asbestos Cement - Transite or KorductThe coefficient of friction of a duct or conduit varies with the type of cable covering, condition of duct oronduit internal surface, type and amount of pulling lubricant used and ambient installation temperature.High ambient temperatures (8010F and over) can increase the coefficient of dynamic friction for cable havinga nonmetallic jacket.Pulling lubricants must be compatible with the cable's components and be applied while the cable is beingpulled.Note: These values ma y be conservative and lubricant manufacturer should be consulted for recommendedcoefficients of friction.

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INSTALLATION (CONT.)F. Physical Limitations of Cables

1. OverviewThe fifth and final consideration in any cable installation is the physical limitations of a cable as it is beingpulled into position. Pulling subjects cable to extreme stress and, if done improperly. can displace a ca-ble's components. Thus, it is important that the followin g guidelines be observed:

Calculate and stay within the cable's maximum pulling tension, maximum sidewall load and mini-mum bending radii. Ensure that the raceway joints are aligned and that the wiring space is sufficient. Train the cable to avoid dragging on the edge of the raceway. It using a basket grip, secure it to the cable with steel strapping and cut well behind the area itcovers once the cable is in place. Ensure that the pull rope's elongation minimizes jerking. Pull NO FASTER than 40 feet per minute. Pull with a capstan, if possible. Do not stop a pull unless absolutely necessary. NEVER pull the middle of the cable. Seal the cable ends with high voltage putty or silicon caulking and overwrap with tape.2. Maximum Pulling Tensions

a. OverviewExcessive pulling tension can cause delamination and displacement of a cable's components. This cancause voids which become the focal, points for corona deterioration.Pulling Tension should NO T EXCEED the SMALLER of these values:* Allowable Tension on Pulling Device.* Allowable Tension on Conductor.* Allowable Sidewall Load.1. Allowable Tension on Pulling Device.

Do not exceed the working load stated by the manufacturer of the pulling devices (pulling eyes, ropes,an'chors, basket grips, etc.). If catalog information is not available, work at 10% of the rated brakingtensile strength.Basket Grip - The allowable tension with a basket grip must not exceed the lbs/cmil value (as shownin the Table on page 47) or 1000 lbs, whichever is smaller. Exceptions to this rule are the followingCablec products, fo r which the upper limit is 1250 lbs.Single Conductor - Durasheath EPR, Durasheath XLPE, Unicon FREPMultiple Conductor - Flame-Guard Durasheath EPR.

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INSTALLATION (CONT.)PHYSICAL LIMITATIONS OF CABLES

2. Allowable Tension on ConductorThe metallic phase conductors are the tensile members of the cables and should bear all pulling forceShielding drain wires or braids should never be used for pulling.Conductor pulling tension should not exceed:Material Cable Type Temper lb/cmilCopper All Soft 0.008Aluminum Power Hard 0.008Aluminum Power 3/4 Hard 0.006Aluminum Power 'AWM' 0.005Aluminum URD (solid) Soft (112 hard) 0.003All Thermocouple 0.008Three-quarter hard aluminum is allowed for power cable. AWM is required for UL labeled 600V aluminum solid wire 8 AW Gmaller, it may be used in larger sizes. Soft is sometimes used for large solid aluminum. AW M is a UL designated aluminu

Reduce the maximum pulling tension by 20% to 40% if several conductors are being pulledsimultaneously since the tension is not always evenly distributed among the conductors.While BIGC Cables does not recommend the practice, we recognize that some users pull a combinatioonductor sizes simultaneously, observing the maximum pulling tension of the largest conductors. Duuch a pull, the smaller cables may get crushed at bends or may have the pulling forces transf rred tomomentarily (which greatly exceeds their tensile strength).

Maximum pulling tension is calculated as follows:TENSION MAXIMUM, single conductors, pulled in parallel:n < = 3: TM = TI/c n

n > 3: TM = TI/c n 0.8lead sheath: Trrr = 471 2 t (d-t) t = sheath thickness

TENSION MAXIMUM: multiple conductors:For cables 8 AW G an d larger, an d over 3 conductors:

TM = 0.8 ETI/cFor cables smaller than 8 AWG, and having no twisted subassemblies, and over 6 conduct

TM = 0.8 ET1/cFo r cables having twisted subassemblies:

TM = 0.6 ET1/cTh e following charts provide the data necessary for calculating allowable tensions:

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INSTALUIXION (CON-1.)PHYSICAL LIMITATIONS OF CAB't..ES

coLn 0 to Ln w mr - WM- ow4v W Omw CDCNmr, w C) Amm 0 rv Iq w m -q w a eq 0 a 066 C14TLn 0 co 0 r, W ;; tO rl C4 M OD IT lzOO coo D000 00- Ul w rl- cn C00 000 coo 000 000 000 C O O 000 000 0- coCDL)(D CDo V Ln V mCNI 6 CDV r., Ln 0 C4 CDCNVm Lo - a) Ln (D CD(D U) V C.) C14 0 CD _ Cn CDCN Ln V as N 00 0 IT rl 00 V 00 in Ch w M r- V V m08 8 0 8 C14 W - C) rj Lo M M rld r, co (D n 0 0 0 0 0 000 - - - C,4 cn c-) v Ln 0 r- co a00 000 000 000 000 000 Ocio cicio 000 Oa m

U, D CYr- Lnim C) -8 V C) OM VI 0) V CO m (n cn mL m 'No C400 -covy w 00 U'l 0 co m ;z w 0- Ln V co m CY)c8 0 C, C.) r Ln o C14 D0 Ln CN Ln r-j m v cm Ln cn cc00 0;; ZC d CNM W M CN n W OD Coo Ocio doo 000 000 00- C14 N C'yM 00r, CD M Ln co v cD (n ? C., WH O r. w 'n C-) ao 4m C.) C14 r, cn LO r-j m co c,4 0 V Ln C, 0ft CldC-i mmlw -a kn co CO W M ch 0 N ff) 0 0co 0to C) 000 000 coo coo dOo - co

r- c-J r 0 M N Lnw (n C) ao 0) K,, C) 't 0 0 Cq It? . I- -r ci cioo coo coo 0 00 ci 0 - cd w 0E im 0z 0 WIM C)IT 0 C14 0r- CMm m Tq Ln Ln CD co .0 r 0 0 000 o b o 0 58 0C0U W wmvq wow v CN N m C-) aj 0 co Ln 0 00 Ln M V co V N CLU 0v srF r-j Ln Cn W CD.! ? m w m m , CN cn E2. 0 a 0 N C14 f m cn n Ln Ln CD Co Co Co M CD Z 0 C CMcoo Ocia, 000 OOO 000 coo O O d Ocio 00E - CL

CMCoSi Eh: 12C,) 17 u) 0 M VfD M M COW r- > 4)o r1l a V ODM IT 0) r- M V 4) to ID

(3

vL n tO 8 0 0 cli V)CON CD 000 0 0 N ry C14%, m lq v U) r4OO OOO OOO 000 O co 000 o 0) 4)000 000 000 0 C) 0000 0008 C14OD:: M CO D ; V IT C'j (D 0) 00 0 CD =1080 080 800 08 0 U) CO (0 V). Ln M 0 C,4, -M 9D to co w E McLq Oul- WoLn a0 -N CD 0 cn CD (D:; C14 CDM PI - Q 04 M V VI PI r- 0) 0 coIA n EDCO Lo; x - 0

co C u U) 0EE cooN 0 OD (Dv C-40 M OD (D -cr C-) N 0000 Ch 0 C-414 CZ4-i;4 U

44


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INSTALLATION (CONT)PHYSICAL LIMITATIONS OF CABLES

EELU clico CU, 0FEuE N a6 - tn m Ln - ui r-: cCDo C-) U3,m - 0 0F, N C,, m m r w LnCucn

zN a cm m vcq"q:" 'p1palCY CO n M V r- CMW COCM r- N WA W mmo M caoLn N m cmm v;w V) , 0, EN-j cm m 4 0 wN 0 a cmCCWwsv mmo N co . . . . . . . . . . .c .4 r-: C6 cj N in 0 cV Ln le in CM 00 0 0 002Y) 1-t c 00 CO N kg) 0D N 10H4 V) It cb C!4 CY cl V)

.5 ico - w C.) w Cy 0 ov 0 a-- ODLnD C4 ci rl U . . . . . . . . . . . . . . . . .e in (D t- CDCY)0 cmC-)t to co 0) CY YCYI" 40 IC04 0In

E Z r.- a N cq to r. coW Cao m W)0 w r.. w ci 6 oi 6 4 ui cd vi r-z co

Q0M.2 o ro RN

C (I u? cR N w 0 4) cc' co m 0 to 0 - C4 cm 04 .0 E oim3CC4 w 0 w 04 in o;z r- 4m 0 CIAm PI0 en 4m cn W Cc (D -W -a -W co C.) C 0 GDa, t 0 C) V) W)W r, P. W)m E CDC; "i 4 4 uid z .6 i ci ".: ci Z 6 : 'd C5 Q -4 wi f.- - - - - - cl CY N 0A Cm Cm

r- #A CL0 Etm.2 in 0>Wu > 0V CM ID Im 0 M M in in r. 0 C4 0 0 Lo CY W M CM CQ -4 f, w4 c ci 4 ui ui (a r--: d ci 6 0 coCouiCMMMCO0 MN eicl u OR q c4 'P cl N c4 r: 'P "Q:? 'TEoo cj v) Ln to co v) & w c-) cq m N oli r.: CDCyP, N Cl CO -T It 0 (Dj en v Ln Co CD0 N 0 t, 0 V) #- 0 W)CD 0 0 .2 0 EY li CY M V) V3 V W - g -Z =PEC)0 E cis 24 0 00 W.WC4 ochco wqrr) C4-0 .08 cull0 8 -on 8 ul 0 0il M m IV Ln Ln to g r CD U)

Ar,


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INSTALLATION (CONT.)PHYSICAL LIMITATIONSCHARTS CONDUCTORS IN PARALLEL OR AS ASSEMBLIESSOFT DRAWN COPPER OR HARD DRAWN ALUMINUMThe following maximum tensions are fo r direct attachment to the conductor. However, the pulling forceust not exceed the smallest value of 1) conductor tension, or 2) pulling device tension, or 3) sidewallload. #CDR 2 3 4' 5 6

AWG/kcrnil MAXIMUM ALLOWABLE CONDUCTOR TENSION (LBS) AWG/kcmil20 8 16 24 26 33 39 208 13 26 39 41 52 62 186 21 41 62 66 83 99 1614 33 66 99 100 .130 150 142 52 100 15 0 160 200 250 121 66 130 19 0 210 260 310 1110 83 160 240 260 330 390 10 100 200 310 330 410 500 9 130 260 390 420 520 630 86 210 420 630 670 840 1000 6 330 660 1000 1060 1330 1600 4 420 840 1260 1340 1680 2020 32 530 1060 1590 1690 2120 2540 2 670 1330 2000 2140 2670 3210 1/0 840 1690 2530 2700 3370 4050 1/02/0 1060 2130 3190 3400 4250 5110 2/0/0 1340 2680 4020 4290 5370 6440 3/0/0 1690 3380 5070 5410 6500 6500 4/0250 2000 4000 6000 6400 6500 6500 - 25000 2400 4800 6500 6500 6500 6500 30050 2800 5600 6500 6500 6500 6500 350400 3200 6400 6500 6500 6500 6500 400450 3600 6500 6500 6500 6500 6500 45000 4000 6500 6500 6500 6500 6500 500600 4800 6500 6500 6500 6500 6500 60000 5000 6500 6500 6500 6500 6500 70050 5000 6500 6500 6500 6500 6500 750800 5000 6500 6500 6500 6500 6500 80000 5000 6500 6500 6500 6500 6500 900000 5000 6500 6500 6500 6500 6500 1000

T = 0.008 x CM x N, if N < = 3.T = 0.008 x CM x, N x 0.8, if N > 3.This chart may also be used for hard temperature aluminum conductors. However, use 1/2 of these chart valuesfor all other UL labeled cables having aluminum conductors.

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I ~INSTALLATION (CONT.)PHYSICAL LIMITATIONS OF CABLESI ~CHARTS MULTICONDUCTOR CABLESHAVING EOUAL SIZED CONDUCTORS; WITHOUT SUBASSEMBLIESSOFT DRAWN COPPERThe following maximumn tensions are for direct attachment to the cable jacket. However, the pulling forcemust not exceed the smallest value of 1) conductor tension, or 2) pulling device tension or 3) sidewall load.

AWG-= 20 is 16 14 12 11 10 9I ~ ~~CDR MAXIMUM ALLOWABLE CONDUCTOR TENSION (LBS) CDR2 16 26 41 66 100 130 160 200 2I ~ ~ ~~34 39 62 99 150 190 240 310 34 33 52 83 130 200 260 330 41 0 45 41 65 100 160 260 320 410 520 57 49 78 120 19 0 310 390 490 62078 1090 30 90 90 606

8 52 83 130 21 0 33 0 420 530 670 89 ~~~ ~~~ ~~~ ~~~~~~~593 140 23 0 370 47 0 590 750910 65 100 16 0 26 0 410 520 660 830 1011 72 110 18 0 280 460 570 730 920 1112 78 120 19 0 310 50 0 630 79 0 1000 1213 85 130 210 340 540 680 860 1000 13I ~~~~14 91 140 230 360 580 730 930 1000 1415 98 150 24 0 390 620 79 0 990 1000 1516 100 160 26 0 420 66 0 840 1000 1000 16I~~~1 1 7 8 40 70 8010 00 117 110 170 280 440 710 8940 1000 1000 1719 120 190 310 50 0 790 1000 1000 1000 1920 130 200 330 520 830 1000 1000 1000 2022 140 22 0 360 57 0 910 1000 1000 1000 2224 150 24 0 390 63 0 1000 1000 1000 1000 2426 170 270 420 680 1000 1000 1000 1000 2628 10 290 460 730 1000 1000 1000 1000 28I ~ ~ ~~3090 310 490 780 1000 1000 1000 1000 3032 200 33 0 520 840 1000 1000 1000 1000 3234 220 350 560 890 1000 1000 1000 1000 3436 230 370 590 940 1000 1000 1000 1000 3638 240 390 620 1000 1000 1000 1000 1000 3840 260 410 660 1000 1000 1000 1000 1000 4042 270 430 690 1000 1000 1000 1000 1000 42

44 280 450 720 1000 1000 1000 1000 1000 4446 300 470 760 1000 1000 1000 1000 1000 4648 310 490 790 1000 1000 1000 1000 1000 48

50 320 510 820 1000 1000 1000 1000 1000 50THE MAXIMUM LIMIT IS 1000 LBS.T =0.O8 CM xN, f 6.T = 0.008 x CM x N x 0.6, if twist d subassembli s.

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INSTALLATION (CONT.)CALCULATION FORMULAEThese tension formulas are for estimating the forces due to dynamic frfiction. THEY DO NOT ACCOUNT FOR BENDINGIFORCES. The bending forces will vary with cable construction and material stiffness, especially with conductor hardness.

If T0~, < 0, use zero as tension for next section of raceway.ITENSIONS, VERTICAL BEND, PULLING UP

Large concave down angle (VUCD)ITout = Ti +WRM [2ytfe fsinO +(1 1f2 wf VC

Large concave up angle (VUCU)I vuCuOD T0 ~ T eWfO. i iWRv [2wf sinO-(l-w 2I2) (e t -coso)]ITENSIONS, VERTICAL BEND, PULLING DOWN

Large concave down angle (VDCD)IwlO WR 2(2 f) AleDCDT0 T~e + 1+ rf [2.vif sine (O . (e - cosO)I

Larg concave up angle (VDCU)TIOT ~TineklfO~ +WR [2yife-wf0 sino + (1- _Wf2) (1-e Wf0cosOE)] VCOIf T,,, < WR. use formulatfor concave down.TTENSIONS, HORIZONTAL PULLIStraghtcton' = wfWL + (Prior tension) See the Chart Bend Multiplier on page 59Straight ection_ ~~~~~~~~~~~~~~~~~toind et"'.

Maximum length Lm = TM/(WfW) Symbol meanings shown on pa g 8TENSIONS, INCLINE PULLUpward T =WL(sin 0 + wf cos 0) + (Prior tension)Downward T - WL (sin 0 - wf cos 0) + (Prior tension)

TENSIONS HORIZONTAL BEND2ITout = Tin cosh wf 6 + (sinI~wf 0) \/(Tin) + (WR)

TENSIONS, BEND, APPROXIMATIONif Tin > 1O0WR then Tout =TinARCHES

Z2 + 41- 28Ho- 360 si'Z -----2R K'

S 2Rcos Rtan~'2-

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CALCULATION DISCUSSONPULLING AROUND BENDSThe preceding formulae for vertical bends assumes that the cable is sliding on the INSIDE SURFACE of thebend. This would not occur on concave up bends when the sidewall loading is less than the weight of thecable.

-Cable--- Duct

Standard formulae are valid Standard formulae not validWT/R

Typical installation having cable dragging the bottom of the duct are river crossings or up and downhillpulls of long lengths.BENDS MULTIPLY INCOMING TENSION.STRAIGHT RUNS ADD TENSION.The difference:

where: Mt = 1.1 W = 2 f 0.5 Tn = 500 lbpull 100 It horizontally- Tc),,t wfWL + T.n = 61 0 lbpull around 90' ell: T Tn e 12001b (See page 59)ou tThus for the given conditions, one 90' bend increased the tension almost double that of 100 ft of straightduct!

Because of this multiplying effect, it is better to feed into the duct end having the greaternumber of bends. Butcalculate the tensions for pulling either direction to determine which will be easier.CALCULATIONS CORRELATIONEven though the foregoing parameters and formulae give exact answers, because of variances in installationtechniques, these answers may not correspond to facts. THESE CALCULATIONS MUST BE USED ONLY ASGUIDELINES TO PREDICT "NORMAL" OR "DIFFICULT" CABLE PULLS.The stated parameters and formulae do not consider forces required to bend the cables, and the coefficient ofriction is arbitrarily selected - in fact it may change during the pull it the lubricant is not spread evenly. Seldomare the bends located exactly as shown on the designer's drawing, nor are the exact bends' angle or radiusknown. Nevertheless, one major engineeringcontracting firm states that for 90% of the pulls at a given projectthe actual was within 10% of the predicted pulling tension.CAUTION The formulae do not take into account:1) Weight Correction Factor when there are more than 6 cables (use w = 1.4);

2) Sidewall Loading when there are more than 3 cables;3) Bending forces in short pulls of large cables through several bends.

To better correlate tensions: 1) read just before the pulling head starts into a bend, 2) read just after the head exitsa bend, 3) read just after the cable exits the raceway, 4) the meters should have range switches so that thereadings are made at half to full scale of the meter, 5) the main reading is the last when the pulling head and ropehave minimum influence, 6) record the relative position of the pulling head for any unusual surges.

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INSTALLATION (CONT.)BEND MULTIPLIER

W fe e1800 90,

BEND MULTIPLIER

7 This is he multiplier used in omputing ten - - - - - -sions around bends.6

70'I 1Jq190

-I0440 40,- - - - - - - - 1xi I 017 I 1X I I AIZI I- - - - - - - - - - - - - 00 0,100,I -.1, -.41 1- - - - - - - - - I I Lo, I so,- - - - - - - - - 1 4 i1o, I 14ol100' I- - - - - - - - - - - - - Yi I v yo , 1.100 70 --3- Pq -45'/I v Yl 000 .0'01 ly LOO 00.1

0,11 AV 40O v I, I 'IO' LK00,XA 41 .0 e 41 11I XII Ik, I Yo , I --- LLo.I X IKIY 11?,ol 00 IL0-

o, oo ooo01,10 .ooIoo q ooOOV 00 oo e .22.5'010 20'o" " ." -, Ioo,-oo, loo,ol01

14000/ i :a 4 L I01010,0n S IT[ iol I Luo- -t7T-'40.2 0.4 0.6 0.8 1.0 1.2 1.4

Wfexamol The line for 9'fffO when wt-0-55 and e-30- is 1.33.

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INSTALLATION (CONT.)F. PHYSICAL LIMITATIONS OF CABLE (CONT.)

3. Sidewall Loading (Sidewall Bearing Pressure)a. Overview

Sidewall load is the radial force exerted on a cable being pulled around a conduit bend or sheave. Exces-sive sidewall loading can crush a cable and is, therefore, one of the most restrictive factors in installationshaving bends or high tensions.

TENSION

LOADSidewall loading is reduced by increasing the radius of bends. To illustrate, a 15 kv 350 kcmil cable instal-lation dropping six feet vertically underground, traveling horizontally, then rising to a motor should havebends at least six feet in radius to maximize the horizontal distance and still be within the sidewall limitof 500 lbs./ft.Sidewall loading is calculated as follows:SIDEWALL LOADING

Where T is tension out of a bend, in pounds and R is radius of a bend, in feet1 /C per conduit: SW T

R3-1 /C cradled: SW 3w-2 ] T3 R3-1 /C triangular: SW T

Laboratory tests conducted on standard BICC cables after they had been subjected to conduit,pull tests through 900 elbows of appropriate radii, indicate no significant change in the cabi 'selectrical parameters at the following sidewall loads:

Cable type SWIL (lb/ft)600V nonshielded control 300600V & 1 kV nonshielded EP power 5005-35 kV Unishield & Uniblend, 5 kV Durasheath EP 500Interlocked & Philsheath armored cable (All Voltage Classes) 300


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INSTALLATION (CONT.)4. Training and Bending

a. OverviewTraining is the positioning of cable which is not under tension. Bending is the positioning of cable whichis under tension. When installing cable, the object is to limit these forces so that the cable's physicaland electrical characteristics are maintained for the expected service life. The recommended limits are:

b. Tables per National Electric Code (Page 57)c. Tables per ICEAMEMA (Page 58 )d. A nonshielded cable can tolerate a sharper bend than a shielded cable can. This is especially true for

cables having helical metal tapes which, when bent too sharply, can separate, buckle and cut into theinsulation.

The problem is compounded by the fact that most tapes are under jackets which conceal such damage.The shielding bedding tapes or extruded polymers have sufficient conductivity and coverage initially topass acceptance testing, then fail prematurely due to corona at the shield/insulation interface.Remember that offsets are bends.

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INSTALLATION (CONT.)4. Training and bending (cont.)

b. Applications in accordance with the NATIONAL ELECTRICAL CODE.

Table I

Shielded or Lead-Covered Cable(Non-Armored)

Single and Multiple Conductor -All Voltages Over 600 Volt Nominal

12 x Overall Diameter

Table 11

Non-Shielded and Non-Armored

Single and Multiple Conductor -All Voltages Over 600 Volt Nominal

8 x Overall Diameter

Table IIIArmored Cable - Type MC

Interlocked or Corrugated SheathMultiple Conductors - Non Shielded

7 x External Diameter of ArmorMultiple Conductors - Shielded

12 x Diameter of One Shielded Conductoror

7 x External Diameter of ArmorWhichever is Greater

In all cases the minimum bending radius specified refers to the inner surface of the cable and not to axis of the cable


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INSTALLATION (CONT.)4. Training and Bending (Cont.)

c. Applications in Accordance With ICEA/NEMA STIDS. (Non-Code)Table I

Non-Shielded, Non-Armored Power & Control CableThickness of Overall Diameter of Cable, Inches

Conductor Insulation Up to 1.000 1.001 To 2.000 Over 2.000Inches Min. Bend Radius As A Multiple of Cable O.D.

.155 and less 4 5 6.170 to .31 0 5 6 7.325 and Over - 7 8

Table 11Metallic Shielded and/or Armored Power & Control Cable

Minimum Bending RadiusType of Cable As A Multiple of Cable O.D.

Flat Tape or Wire Armored 12Armored, Interlocked (Duralox ) or (PhilflexO ) - ------ 12Armored, Welded Corrugated Sheath (Philsheath 12

*Non-Armored, Tape Shielded UniBlendO - 12*Non-Armored, Wire Shielded or UniShieldO - Table I Above

'Includes 12 x Single Conductor O.D. in Cabled Assemblies, i.e. Triplexed, Quadruplexed, etc.

The above Tables contain the minimum values fo r the radii to which insulated cables may be bent fo r perman nttraining during installation. These limits do not apply to conduit bends, sheaves or other curved surfaces aroundwhich the cable may be pulled under tension while being installed. Larger radii bends are required fo r such condi-tions due to the limitation of sidewall bearing pressure. In al l cases the minimum radii specified refers to the innersurface of the cable and not to the axis of the cable.

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INSTALLATION (CONT.)CALCULATION EXAMPLE

EXAMPLE 1 - Maximum length_____ __ __ __ __

Problem: Find the maximum manhole spacing for a feeder.Cable: 3-1IC, 350 kcmil Cu, 15 kV GN, 0.175 " EP - Lead; to beI ~~~~~~~~~~~~~installednarallel.Cable Size: Weight = 3180 lb/MFT for I1/C, d =1.39 inI ~~~~~~~~~Conduitelection = 4 in (see Chart '3/C % fill -EP-Lead'This avoids jamming and conforms with NECI 0~~~~~~~~~~~4.026 in, Sld Ri = 1.17 ft (see Chart 'Conduit').I ~~~~~~~~Clearance = 0.5D - 1.366d + 0.5 (D-d) 1( )

=0.5 (4.03) - (1.366) (1.39)

=1.24 in. =0OKMaximum pulling lengthI ~~~~~~~~~~TmTmLm Mf i~ d 2

find Tm =6500 lb Per Installation, Physical Limitations Chart6500 -= 995 feet

m + - ((0.5) (33 40-.9i1000/

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58/95

INSTALLATION (CONT.)ICALCULATION EXAMPLEEXAMPLE 2 -

10 ftvertical

7~~~~56~~~~~Probem:Insall15fede beteen1 ad 8in igi codui 4I 0tt 9

Prolesal Cu (gedrounding); cabld rgd odi

UniShield weight = 673 lb/IVFT. d = 0.92 inPer "Conductor Data": Class B bare = 128.9 lb/MFT, d = 0.232"

area = 0.0423 in2Per Conductor Tension, Tm = 2530 for 3/CConduit Selection:ICable Area = 3.irl/4*0.922 + 0.0423 =2.04 in2For fill < 400/ use 3"1C (see "Conduit Info" - 3"C has 40% area of 2.96 in )Conduit Info 3"C: 0 = 3.068 in, stid R1 0.96 ftIJam: 1.05D/d = 1.05 (3.068/0.92) = 3.5 =OKClearance; check if # 4 fits interstice of phase cdrs.I

Interstice factor = 0.483 (see Appendix)Fit =0.483*0.92 =0.44I0.44>0.23 so we can use the 3/C "cbl" factor of 2.155:Cl = D - 2.155d = 3.068- 2.155*0.92 =1.11 inch

Bending: (See NEC 300-34)Training radius:

1/C = 0.92* 12 = 11 inchescable = 0.92*2.155(12 = 23.5 in = 2 ft

Bending radius: we must use conduit elbow having at least 30-inch radius (R =2.37 ft) because we mustxceed 2 ft training limitation.

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INSTALLATION (CONT.)I ~CALCULATION EXAMPLEI ~EXAMPLE 2See Weight Correction Chart, for Did = 3.068/0.92_ w -1.1wf -1.1.0.5 = 0.55 W = 0.68-3.03 +1.01-0.129 =2.19 lb/ftK = WfW=0.55*2.19 = 1.20 10WR = 10.2 19.2.37 = 52

PM 500 lb/ft w/2R =1. 1/(2-2.37) = 0.232See chart: for Al = 0.55. 0 = 30.,eAI'0 1 33 (see Bend Multiplier chart)I ~~~~~forf =.55. 0 = 90.,ettfO zz2.37Pulling from 1 to 8:'

T2= wfWL = KL -=1 .20*320 = 384 lbsince T2 >1OWR then T3 ztT 2e~~0, likewise for T5&T7T3 zzT2e~f U= 384.1.33 =51 1 lbI ~P 3=w/2R1 T3 =0.232-51 1 = 119 lb /ft =OK since 119PmThus we cannot pull from 1 to 8 because both maximum tension and sidewall load are exceeded at 7.Pulling Example 2Pulling from 8 to 1Because the calculated tension will be negative at 6 & 7, compute from 6 to 1.I ~ ~T:zLKL = 1.20.140 = 168 lbT4 z:T 5e~ t = 168*1.33 =223 lbI,~~P = [W/2R]T 4 = 0.232*223 =52 lb/ft = OKT3 :z:KL + T4 = 1.20-290+ 223 = 57 1 lbI ~ ~T:-,T 3e = 51 *1.33=759 lbP2 = [ml/2RJT 2 = 0.232*759 = 176 lb/ft =OKT1 :~:KL +T 2 = 1.20*320+ 759 =1 143 lb =0OKUsing the exact formulae, pulling from 1 to 7calculations give T7 =31 65 lb .P 7 =736 lb pulling from6 tol1giveT = 11 56 lb P 2 =1 79 lb

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INSTALLATION (CONT.)CHECKLIST

RACEWAYSE] Bending - Check sidewall loads; the use of long sweeps (over 6 ft) allows longer shielded medium voltagecable pulls.

- Avoid bends and offsets at the 'pulling' end of a raceway section.Training - Make sure to meet or exceed the minimum training radius.E] Size - Consider weight correction factor and clearance.El Jam Ratio - Avoid a conduit to cable ratio which may cause jamming; elbows may be out of round.El Conduit Fill - Raceways that are too full create pull-in problems and possible cable damage.E] H at Transfer - Route raceways to avoid high ambient temperatures and high thermal resistivity locations.- Separate cables in raceway seals and fire stops.

Abrasion - Use duct end-bells, conduit bushings,'and rack saddles to prevent abrasion.n Grounding - Be sure metallic raceways are grounded.

Expansion - Thermal expansion of raceways should be considered in duct layout.Spacing - Heat dissipation improves with greater spacing between raceways.Manhole/Spli6e Box - Allow enough working space for pulling and splicing.- Install anchor bolts and grounding electrode during box fabrication.- Provide cable supports.- Chamfer concrete edges at openings.- Provide drainage holes in bottom of boxes, adequate lips on covers.

E] Supports - Support raceway system, during system and cable installation, especially trays.- Provide for gang rollers' insertion to be used during pulling.E] Ties - Allow for radial expansion of cable during electrical loading.DIRECT BURIEDC] Backfill - Use screened backfill to keep rocks, and debris from damaging cables.r7 Crossovers - Do not lay one cable on top of another.

Cable Slack - Allow for earth movement due to freezing, drying or settlement.D pth - Stay below frost-line, check Code requirements.Protection - Use marker tape, and post warning signs.

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INSTALLATION (CONT.)CHECKLISTPULLINGEl Conduit Cleanout - Provide clean, SMOOth COncentric inner duct surface; test with a mandrel for obstructionsR Bending -- Bends during pulling must be larger than those permitted for final training; ESPECIALLY THELAST BEND, WHICH MAY BE TEMPORARY FOR INSTALLATION!F1 Edges - Install temporary guides, tubes, sheaves, etc., as necessary to prevent cutting of cable on sharpedges, such as at panelboards.E] Maximum Tension - Keep sidewall loads below specified maximum.- Check maximum allowable pulling tension.- Check limitation for type of pulling attachment used.M Lubrication - Use pulling compound liberally. Be sure it s compatible with the particular cable being installedPrelube just before making a difficult pull.

Temperature - Check for minimum allowable installation temperature. Allow for change of the coefficient ofriction with temperature.El End Seals - Keep moisture out of cable.R Special Instructions - Check shipping container for special instructions.

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IV SPLICING AND TERMINATING1. Why Shield Power Cables?

All electrically insulated conductors are capacitors. When a changing voltage is applied across a capaci-tor a charging current will flow through that capacitor.In most cable installations the cable's surface makes only random casual contacts with its grounded phys-ical supports or with the surfaces of other cables. Except at these points of actual physical contact thereare air gaps which are also capacitors. The result is a series circuit consisting of the capacitance of thecable and the capacitance of the air gap. The surface of the cable then becomes the "floating" tap ofa capacitive voltage divider. Consequently, the voltage on the cable surface can vary from almost zeroto nearly the phase-to-ground voltage of the insulated conductor, depending upon the size of these exter-nal air gap capacitors.If the voltage along the cable surface or across the air gap capacitors is sufficiently high, the surface ofthe cable may be deteriorated by surface tracking, and/or there can be corona and sparking dischargesacross the air gaps, and the surface may be a shock hazard.Shielded CablesINSULATION SHIELDING PROPERLY APPLIED AN D GROUNDED,' ELIMINATES ELECTROSTATICCHARGES EXTERNAL TO TH E CABLE SHIELD AN D PROVIDES A FIXED KNOWN PATH TO GROUNDFOR THE CHARGING CURRENT SHIELDS ARE RECOMMENDED ON CABLES ENERGIZED OVER2 KV.The shield of a power cable, by providing a fixed electrical path to ground that is in intimate contact withthe external surface of the cable insulation, eliminates the surface discharge problems associat d withnonshielded cables.In addition, shielding assures uniform electrical stress distribution within the cable insulation; and becauseof the fixed conductor-to-ground capacitance per unit length of cable, shielding minimizes voltage surgereflections along the cable.Carefully designed and grounded shields provide personal safety by eliminating surface potential, minimizingshield loss, and minimizing insulation stress.

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SPLICING AN D TERMINATING (CONT.)Ov rviewA shielded power cable termination must be properly designed and properly applied or the termination may failwithin a short time. Remember that a splice in the middle of a cable is in effect two shield terminations!As described in the section "Why Shielded Cables" the shield is always grounded. The shield must be removedfor a distance when making splices and terminations to provide sufficient dielectric strength to prevent voltagebreakdown along the insulation surface. The length of cable from which the shield is removed is usually calledthe "creepage length."P nciling the insulation relieves the gradient at the insulation end. Voltage breakdown or flashover fromthe bare conductor over the insulation surface to a grounded shield is prevented by maintaining creepageI ngths, and reinsulation at splicesSplices introduce the problem of heat dissipation. Minimize connection resistance. control insulationthickness and provide surface area to help solve this problem. That is, use high quality connectorsdesigned fo r medium voltage, insulated cables: do not add more insulation tape than the drawingsspecify; do not cram several splices together.About 75% of the conductor-to-shield voltage gradient is concentrated along the first longitudinal inch of insulationsurface:

(I1 = conductor2 = stress control layer3 = insulation4 grounded shield5 creepage length

OThis gradient may be controlled with a stress cone by altering the relative capacitance and insulationthickness; much as an optical lens retracts light:

1= conductor2= stress control lay3= insulation4= grounded shi Id5= creepage length6= stress cone7= flared shield

Lik wise, special tapes or paints may be used to alter the relative capacitance


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SPLICING AND TERMINATING (CONT.)C. PRECAUTIONS

When splicing and terminatingmedium voltage cable:* Keep both the cable and the work area clean and dry.* Do not cut the insulation.* Completely remove the semi-conducting insulation shield, but do not lift it at the cut-off point.* Support the cable near its splices, never under them.* Keep nonshielded conductors away from ground and from other phase conductors.* Keep stress cones aligned.* Ensure bends in nonshielded conductors are smooth.* Use skirted terminators outdoors or in contaminated areas.* Keep nonblack insulation out of direct sunlight by using a tube or track resistant tape.* Use shielded cables in all applications requiring 2 kV and higher.* Use a minimum amount of cleaning solvent.* Consider lead sheathing for hostile environments (oils, water, solvents, chemicals, etc.)Tape: Half-lap and stretch per manufacturer's recommendations - usually 3/4 original width; over-stretchends and roll each layer to prevent voids; use fresh tape only; remove separator backing, start and endtaping at the middle of the splice or termination.Grounding: Except in unusual installations, ground shields at every opportunity; grounding leads shouldbe copper, solid 6 AWG minimum and insulated outside of splice or termination to resist corrosion; con-nect outdoor termination grounds directly to lightning arrestor grounds; span splices with grounding leadfo r fault ampacity.TOOLS/SUPPLIESDiameter Tape Linesmen's Pliers ScissorsKnife & Stone Hacksaw Hose ClampSoldering Iron Screwdriver Rat-tail FileCrimping Tool Ruler, Grease Pencil Concave Roller (tape roller)Plastic Pipe Cutter Splicing Separators Wire, solid copper, Nos. 12 & 6 AWG

(tie wire, gn bond)

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I PLICING AND TERMINATING (CONT.)

* ~~~~~~MEDIUM VOLTAGE CABLE COMPONENTS

CONDUCTOR (ANAPACT)*

CONDUCTOR STRESS CONTROL-(ESS)"*K ~~INSULATION~I ~~~~~~~~~~~~~~SHIELDRAIN WIRES*

INSULATION SHIELD (EXTRUDEDLEAD SHEATH*

JACKET

JACKET I INSULATION SHIELD*M

UnIShIeId*8 EP- Lead

'Electrically Conducting


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SPLICING AND TERMINATING (CONT.)

MEDIUM VOLTAGE CABLE COMPONENTS

(ANAPACTi - CDUTRCONDUCTOR

CONDUCTOR STRESS CTRLCONDUCTOR STRESS CONTROL(ESS)* (ESS)*I.. ~~INSULATION INSULATION

SHIELD BEDDING * INSULATION SHIEILD*TAPE OR EXTRUDED)- (EXTRUDED)

iLlINSULATION SHIELD(TAPE)* CONCENTRIC NEUTRAL*WIRE SHIELD*

Tape Shielded Wire Shielded URDUnibi nd'Electrically Conducting


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SPLICING AND TERMINATING (CONT.)5 kV Nonshielded CablesFor splices and end seals, follow the same dimensions and procedure as for shielded cables, only delete theshield portions. Do apply conducting tape over the connector or lug to make a smooth configuration. Stress reliefcones are not necessary.

2 kV or lessNo special terminations are necessary, unless they are to be in wet environments. Then it is suggestedthat the outdoor ends be sealed against moisture entry into the conductor, and multiconductor cables besealed at the jacket cut-off. Heat shrink tubing is compatible with either type.For both splices and terminations use HV insulating tape for the best seal, fo r high temperature usesilicone tape. Overlap the original cable insulation by at least one inch applying two half-lapped layers oftape.

Identify Cable Shield SystemTAPE SHIELD - UNIBLEND6 - This cable has copper-tape shields and between these tapes and theinsulation surface will be a layer of electrically conducting material. This cable has an overall jacket.WIRE SHIELD - UNISHIELDO - This cable shield consists of longitudinally applied corrugated wiresembedded in a conducting jacket. This conducting jacket adheres to the cable insulation.WIRE SHIELD-URD - This cable shield consists of wires wrapped around a conducting polymer jacket whichadheres to the cable insulation.EP-LEAD - This cable shield consists of a lead sheath over a conducting polymer which adheres to the cableinsulation.

Cabi PreparationBe sure the splice/termination is the correct one fo r your specific cable typeReview cable manufacturer's instructions. Review and follow splice/termination manufacturer's instruc-tions.Determine proper dimensions.Train cable into final position Cut off excess cable.Remove overall jacket. Remove single conductor jacket for all except those constructions having drain wiresem b dded within the jacket, such as UniShield.METALLIC Component of Shield:

Concentric Neutral (URD): bind wires (but not tightly); unwrap and twist into pigtail-, tie back ou tof way.Drain Wires (or UniShleld): mark pull-out point with tw o wraps of PV C tape; unwrap wires or pull ou tUniShield wires and twist into pigtail; tie back odt of way; remove PV C tape.Tapes (Uniblend): tack solder at cut off; apply hose clamp; score; unwrap and tear tape against knifeedge.Tube (EP-Lead): apply hose clamp; score.- make one or more longitudinal cuts-, roll back andt ar.

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SPLICING AND TERMINATING (CONT.)

Cable Preparation (continued)Extruded Conducting Layer (EIS)-.

Conducting Tapes: apply clamp; score; unwrap and tear against knife edge.The circumferential cut may be made using a plastic pipe cutter, a knife in conjunction with a hoseclamp for its guide, or a file - rat-tail or triangular - when a taper is desired.The longitudinal cuts are made in UniShield by pulling out the drain wires. For other cables, use aguarded tip knife - such as Stanley No. 199 - which has had the tip or guard ground to give a tip longenough to just cut 85-95% through the conducting layer. Make longitudinal cuts 0.625-0.75 inch apart.Heat may be applied to soften the conducting layer. Excess heat will be indicated by smoking of thematerial. Roll or pull the longitudinal strips back to the cut-off point.Penciling (when required)

Mark pencil area with two wraps of PVC tape on each side: slice the insulation into a taper using a4-inch knife; smooth with abrasive cloth (nonconducting); then remove PVC tapes and insulation stubwhich has served as a handle and guard unless solder connectors are to be used, then part of the stubmay be left temporarily as a heat shield. Charrifer insulation edge slightly if penciling is not required(penciling is done also to provide a long bonding area for taping.)

CleaningWipe the insulation towards the shield with a solvent-dampened cloth to remove conductingparticles on the surface. Loosen remaining conducting material with a nylon solvent-dampenedscouring pad backed with a cloth. Buff only if absolutely necessary with a 240 grit nonconduc-tive abrasive cloth. Wipe clean with a solvent-dampened lint-free cloth DO NOT POUR SOL-VENTS OVER CABLE

ProtectingSeal and protect insulation with a single layer of PVC tape during a temporary splice/termination stop-page - i.e. for lunch. Rewipe with lint-free solvent-dampened cloth after tape is removed just prior tosplicing/terminating.

NOTES Minor scratches on the insulation must be buffed. Cuts or gouges into the insulation necessi-tate removal of insulation to that point and restarting. All conducting material must beremoved from the creepage area. Do not loosen remaining shield beyond the cut-off pointeither by allowing flaring or by solvent flowing under the shield. Make cuts square, trim awayraveling or jagged edgesInsulation without a conducting layer is lighter in color, its surface resistance is higher.Remember that black rubber has carbon black as a constituent, so itwill also discolor a solventdampened cloth. Follow the solvent manufacturer's handling precautions. Use a minimumamount of solvent and buff ing on the "creepage" area. The 1/4 inch of insulation adjoining thshield cut-off need not be perfectly clean, since this area is reshielded during the splice or temination installation.

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SPLICING AND TERMINATING (CONT.)TAPE TERMINATION

Stress ConeApply half-lapped tightly-stretched layers of high voltage (HV) insulating tape back and forth to build atapered stress cone. Keep 1/4 inch away from any shield componentGrounding AttachmentUniShield: Twist drain wires together; cut to 1 1/2 inch; splice to 6 AWG solid copper grounding bond.Uniblend & EP-LEAD:- Apply a 3/4 inch tack of solder longitudinally to hold the 6 AW G solid coppergrounding bond to the metal shield component.Shi IdingFor al l cable types, apply one half-lapped tightly stretched layer of conducting tape overlapping the cableshield to within 1/8 inch of the stress cone peak. NO VOIDSIf it is desired to 'beef-up' the stress cone shield, apply one half-lapped layer of shielding braid 1/8 inchfrom the edge of the conducting ta0e (near the cone peak) to 1 inch beyond the conducting tape overlap-ping the cable shield.JacketingApply two slightly-stretched half-lapped layers of HV insulating tape over stress cone, overlapping thecable jacket and onto the insulation creepage area by 1/4 inch maximum. Make a good sea[ at the ground-ing bond exit. Apply two half-lapped layers of PV C tape over this HV tape just applied, overlapping it by1/4 inch.Connecting - see that prior page.SealingFo r outdoor terminations seal the conductor against moisture entry at the lug. It is not necessary, no r desirable, toseal the cable ends in dry locations just against water vapor. However, it may be desirable to seal against othercorrosive environments.Fill any indents in the lug with conducting tape strips after burrs have been removed. Apply one half-lap-ped slightly stretched layer of conducting tape overlapping the lug barrel and just 1/1 6 inch onto the pen-ciled insulation. Apply HV insulating tape in half-lapped slightly stretched layers to fill in the penciledarea, then overlapping the lug barrel and insulation. Apply two layers of PVC tape over the sealed end. (DoNO T apply PV C over the insulation between the lug seal and stress cone.)GroundingURD: Wrap neutral back into place to the bottom of the stress cone. With slight tension apply three turnsof 6 AW G solid copper around the neutral wires leaving a lead. The solid copper should be coated if then utral wires are coated.For all: Connect the shield grounding bond to the system ground. UNGROUNDED SHIELDS ARE DAN-GEROUS. Keep the distance between the termination and its surge protector as short as possible.NOTE: When the circuit designer designates that the shield is not to be grounded, particular attentionmust be given to keep the shield isolated from ground, which is only practical with Uniblend type cables.Tracking ProtectionFor areas exposed to sunlight or airborne contaminants (i.e. dust) apply two half-lapped layers of tr

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19915458 Cable Installation Manual