Building Wire and Cable Installation Instructions

18 March 2014

Page 2 of 23

Table of Contents 1. Scope ......................................................................................................................................................................... 3 2. Packaging and Handling ............................................................................................................................................ 3 

2.1. Packaging ........................................................................................................................................................... 3 2.2. Handling ............................................................................................................................................................. 4 

3. Installation of Cables ................................................................................................................................................. 6 3.1. Maximum Allowed Conduit Fill ......................................................................................................................... 6 3.2. Jam Ratio Calculation ......................................................................................................................................... 6 3.3. Maximum Pulling Tension Calculation .............................................................................................................. 7 3.4. Pulling Tension Calculation ............................................................................................................................. 10 3.5. Sidewall Bearing Pressure Calculation ............................................................................................................. 11 3.6. Minimum Bend Radius ..................................................................................................................................... 12 3.7. Use of Pulling Lubricants ................................................................................................................................. 14 

4. Low Temperature Installation .................................................................................................................................. 14 4.1. Cables Marked “-40C” ..................................................................................................................................... 14 4.2. Cables Not Marked “-40C” .............................................................................................................................. 15 

5. Vertical Installation ................................................................................................................................................. 15 6. Hazardous Location Installations............................................................................................................................. 15 7. Terminating and Splicing ........................................................................................................................................ 15 

7.1. Splicing CORFLEX® RA90 or DRIVERX® VFD RA90 Cables ................................................................... 16 8. Removing Armour ................................................................................................................................................... 16 

8.1. Removing Interlocked Armour ......................................................................................................................... 16 8.2. Removing Aluminum Sheath Armour .............................................................................................................. 16 

9. Connectors ............................................................................................................................................................... 17 9.1. Aluminum Sheath Armoured Cables ................................................................................................................ 17 

9.1.1. Terminating Dry-Type CORFLEX® Connectors: ..................................................................................... 17 9.1.2. Terminating Wet-Type CORFLEX® Connectors: .................................................................................... 17 

10. Field Testing .......................................................................................................................................................... 17 11. Abnormal Chemical Exposure of Wire and Cable ................................................................................................. 18 

11.1. Cable repair ..................................................................................................................................................... 18 

References 1. EEMAC 201 / NEMA WC26 “Binational Wire and Cable Packaging Standard” 2. IEEE Paper 84 T&D 365-3 3. EPRI EL-3333, Volume 2 “Maximum Safe Pulling Lengths for Solid Dielectric Insulated Cables – Cable

User’s Guide” 4. AEIC CG5-2005 “Underground Extruded Power Cable Pulling Guide” 5. NEMA WC70 “Power Cables Rated 2000 Volts or Less for the Distribution of Electrical Energy” 6. NEMA WC71 “Standard for Nonshielded Cables Rated 2001-5000 Volts for use in the Distribution of

Electric Energy” 7. CSA C22.1 Canadian Electrical Code 8. Nexans Insulation Resistance Testing of Low Voltage Cables in the Field 9. CSA Standard C22.2 No. 0.2 “Insulation Coordination”

18 March 2014

Page 3 of 23

1. Scope This set of installation instructions covers the safe handling and installation of the following cable constructions:

Residential cables o CANADEX® or HEATEX® NMD90 o SUPERVEX® NMWU

Single conductors for use in conduit or direct burial o TW(-40C), TW75 and TWU(-40C) o INSTAGLIDE® T90 Nylon / TWN75 o RW90 and RWU90 o RPV90 and RPVU90

Jacketed, armoured, and armoured with an overall jacket commercial and industrial cables o SECUREX®-II FAS / LVT o AC90 and ISO-BX o ACWU90 o FIREX®-II TECK90 o CORFLEX® RA90 o DRIVERX® VFD RA90

Many of these cables are available in single as well as multiple conductor constructions, ranging from 300 V to 5 kV (unshielded), depending on the cable type and construction. The conductor materials used are either copper or an 8000 series aluminum alloy (ACM), the availability of which depends on the cable type and construction. Note that the data presented within this document apply only to Nexans wire and cable. This data may not apply to wire and cable produced by other manufacturers.

2. Packaging and Handling

2.1. Packaging It is important that wire and cable products are packaged in a manner that allows for the safe, damage-free storage and installation of the product. Proper selection of the drum diameter is essential to prevent overbending of the cable and damage to the cable components.

Figure 1: Reel dimensions

Flange Diameter

Drum Diameter

Overall Width

Traverse

18 March 2014

Page 4 of 23

The acceptable minimum reel drum diameter for all cables is calculated as a multiple of the outside diameter of the cable. This multiplying factor varies with the cable construction. The minimum reel drum diameter for unarmoured building wire and cable is 10x the outer diameter of the cable. The minimum reel drum diameter for interlocked armoured cable (using aluminum or steel interlocked armour) is 14x the outer diameter of the cable. The minimum reel drum diameter for aluminum sheath armoured cable is 17x the outer diameter of the cable. The minimum reel drum diameter factors for each wire and cable type are shown in Table 1, below. Table 1: Minimum Reel Drum Diameter Cable Type Minimum Reel Drum Diameter CANADEX® or HEATEX® NMD90 10x SUPERVEX® NMWU 10x TW(-40C), TW75 and TWU(-40C) 10x INSTAGLIDE® T90 Nylon / TWN75 10x RW90 and RWU90 10x RPV90 and RPVU90 10x SECUREX-II FAS / LVT 10x (without armour) / 14x (with armour) AC90 and ISO-BX 14x ACWU90 14x FIREX-II TECK90 14x CORFLEX® RA90 17x DRIVERX® VFD RA90 17x Note: The minimum reel drum diameter factor is applied to the overall cable diameter unless otherwise stated. These values are based on EEMAC 201 / NEMA WC26 data.

2.2. Handling The following provides reel storage, loading / unloading, and handling guidelines to help ensure an undamaged wire and cable product at time of installation and use.

18 March 2014

Page 5 of 23

How to Handle Cable Reels

Reel Storage and Loading

Always load and store large reels upright on their flanges and block securely.

Upended heavy reels will often be damaged. Small diameter or light reels may be flopped and stacked.

Reel Handling

Reels can be hoisted with a properly secured shaft extending through both flanges.

Do not lift by the top reel flange. Cable or reel may be damaged. Fork under bottom flange is acceptable.

Cradle both reel flanges between fork tines.

Never allow fork tines to touch the cable surface or reel wrap.

Reel Loading and Unloading

Lower reels from a truck using a hydraulic gate, hoist or fork lift. LOWER CAREFULLY.

Never drop reels.

18 March 2014

Page 6 of 23

3. Installation of Cables Certain installations require the pulling of cable into ducts or trays. These installations require careful planning and execution. The following provides information on how to calculate tensions developed during pulling and what precautions to take to prevent damage to the cable. The maximum tension applied to a cable is limited to prevent damage or distortion of cable components which could reduce the life or reliability of the cable. The method of pulling is significant in that different methods will result in different stresses on critical cable components for the same overall tension. Nexans recommends that, wherever possible, cables be pulled by means of the conductors, aided with a basket-type grip over the inner jacket, armour (interlocked metal tape armour, or aluminum sheath armour) and outer jacket (if present). This ensures all cable components are pulled as a unit. Tape should be applied to the trailing end of the basket-type grip to avoid slippage of the grip and also to reduce the potential of damage to ducts or being caught on rollers, when being pulled into cable trays. When designing the duct layout, it is suggested that the bends be concentrated near the end from which the cable is pulled. This practice will result in lower tensions. In some cases, the tensions resulting from alternative pulling directions should be calculated. Where high tensions are calculated it may be necessary to consider two or more pulls and splicing the cables. For the installation of cable in trays, rollers are normally used. Using well lubricated rollers and large radius sheaves at bends will result in a lower coefficient of dynamic friction when compared to duct. For long pulls with bends it may be necessary to install assist pullers to reduce the risk of damage from excessive Sidewall Bearing Pressure (SWBP). The recommendations given above are intended to cover a wide variety of pulling conditions. It is possible, under ideal conditions, and with experienced installers, to exceed the pulling tension and SWBP limits provided in this document (see Table 1 and Section 2.3, below). For further guidance, see the IEEE Paper 84 T&D 365-3, or contact Nexans. See the example of a pulling tension calculation at the end of these instructions. NOTE: Wherever possible cables with an aluminum sheath armour (such as CORFLEX® or DRIVERX® cables) should be laid out and then lifted into position rather than being pulled.

3.1. Maximum Allowed Conduit Fill The Canadian Electrical Code, Rule 12-1014, Subrule (4) limits the maximum conduit fill to 53% for a single conductor in a conduit, 31% for 2 conductors in a conduit, or 40% for 3 to 200 conductors in a conduit. All conductors (including the bonding conductor) are included in the conduit fill calculation.

3.2. Jam Ratio Calculation When the ratio of the inside diameter of the conduit, to the cable diameter is exactly equal to 3, one of the cables in a 3 or 4 cable pull may slip between the other cables, causing a cable jam in the conduit. To reduce the likelihood of a cable jam in a conduit during a pull, one of the following 2 expressions should be satisfied:

9.205.1

nd

D

18 March 2014

Page 7 of 23

1.303.1

nd

D

Where: D = conduit inner diameter (mm)

nd = nominal cable outer diameter (mm)

For further guidance, see EPRI EL-3333 Volume 2, or contact Nexans.

3.3. Maximum Pulling Tension Calculation The maximum pulling tension on a cable, where pulled by means of the conductor(s) using pulling eyes, should not exceed:

For copper conductors:

AnT 70max

For aluminum conductors:

AnT 50max

Where:

maxT = maximum pulling tension when the copper conductors are under tension (N)

n = 1 for single conductor cable; = 1.5 for 2c cable; = 2 for 3c cable (triplexed); = 3 for 4c cable; or = The number of conductors multiplied by 0.8, rounded down to the nearest whole number, for cables with more than 4 conductors (e.g. 4 for 5c cable, 4 for 6c cable, 5 for 7c cable).

A = cross-sectional area of one conductor (mm2)

18 March 2014

Page 8 of 23

Table 2: Maximum Pulling Tension (N) – 20 AWG to 10 AWG – Copper

Number of Conductors

Tension Factor

Conductor Size 20 AWG 18 AWG 16 AWG 14 AWG 12 AWG 10 AWG

1 1 36 58 92 146 232 369 2 1.5 54 86 138 219 349 554 3 2 73 115 184 293 465 739 4 3 109 173 275 439 697 1108 5 4 145 231 367 585 930 1478 6 4 145 231 367 585 930 1478 7 5 181 288 459 731 1162 1847 8 6 218 346 551 878 1394 2216 9 7 254 404 643 1024 1627 2586 10 8 290 461 734 1170 1859 2955 11 8 290 461 734 1170 1859 2955 12 9 327 519 826 1316 2091 3324 13 10 363 576 918 1463 2324 3694 14 11 399 634 1010 1609 2556 4063 15 12 436 692 1102 1755 2789 4433 16 12 436 692 1102 1755 2789 4433 17 13 472 749 1194 1901 3021 4802 18 14 508 807 1285 2048 3253 5171 19 15 544 865 1377 2194 3486 5541 20 16 581 922 1469 2340 3718 5910 21 16 581 922 1469 2340 3718 5910 22 17 617 980 1561 2486 3950 6279 23 18 653 1038 1653 2633 4183 6649 24 19 690 1095 1744 2779 4415 7018 25 20 726 1153 1836 2925 4648 7388 26 20 726 1153 1836 2925 4648 7388 27 21 762 1211 1928 3071 4880 7757 28 22 799 1268 2020 3218 5112 8126 29 23 835 1326 2112 3364 5345 8496 30 24 871 1384 2203 3510 5577 8865 31 24 871 1384 2203 3510 5577 8865 32 25 907 1441 2295 3656 5809 9235 33 26 944 1499 2387 3803 6042 9604 34 27 980 1557 2479 3949 6274 9973 35 28 1016 1614 2571 4095 6507 10343 36 28 1016 1614 2571 4095 6507 10343 37 29 1053 1672 2663 4241 6739 10712 38 30 1089 1729 2754 4388 6971 11081 39 31 1125 1787 2846 4534 7204 11451 40 32 1162 1845 2938 4680 7436 11820 50 40 1452 2306 3672 5850 9295 14775 60 48 1742 2767 4407 7020 11154 17730 70 56 2033 3228 5141 8190 13013 20685 80 64 2323 3690 5876 9360 14872 23640 90 72 2613 4151 6610 10531 16731 26595

100 80 2904 4612 7345 11701 18590 29550

18 March 2014

Page 9 of 23

Table 3: Maximum Pulling Tension (N) – 8 AWG to 1000 kcmil – Copper

Conductor Size Number of Conductors / Tension Factor 1 / 1 2 / 1.5 3 / 2 4 / 3

8 AWG 588 881 1175 1763 6 AWG 934 1401 1868 2801 4 AWG 1476 2214 2951 4427 3 AWG 1873 2809 3745 5618 2 AWG 2361 3542 4723 7084 1 AWG 2978 4467 5956 8935

1/0 AWG 3758 5637 7516 11274 2/0 AWG 4736 7105 9473 14209 3/0 AWG 5971 8957 11943 17914 4/0 AWG 7530 11295 15060 22590 250 kcmil 8896 13345 17793 26689 300 kcmil 10676 16014 21351 32027 350 kcmil 12455 18683 24910 37365 400 kcmil 14234 21351 28469 42703 500 kcmil 17793 26689 35586 53379 600 kcmil 21351 32027 42703 64054 700 kcmil 24910 37365 49820 74730 750 kcmil 26689 40034 53379 80068 800 kcmil 28469 42703 56937 85406 900 kcmil 32027 48041 64054 96082

1000 kcmil 35586 53379 71172 106757

18 March 2014

Page 10 of 23

Table 4: Maximum Pulling Tension (N) – 12 AWG to 1000 kcmil – Aluminum

Conductor Size Number of Conductors / Tension Factor 1 / 1 2 / 1.5 3 / 2 4 / 3

12 AWG 174 261 349 523 10 AWG 277 416 554 831 8 AWG 441 661 881 1322 6 AWG 700 1050 1401 2101 4 AWG 1107 1660 2214 3320 3 AWG 1404 2107 2809 4213 2 AWG 1771 2657 3542 5313 1 AWG 2234 3350 4467 6701

1/0 AWG 2818 4228 5637 8455 2/0 AWG 3552 5329 7105 10657 3/0 AWG 4478 6718 8957 13435 4/0 AWG 5647 8471 11295 16942 250 kcmil 6672 10008 13345 20017 300 kcmil 8007 12010 16014 24020 350 kcmil 9341 14012 18683 28024 400 kcmil 10676 16014 21351 32027 500 kcmil 13345 20017 26689 40034 600 kcmil 16014 24020 32027 48041 700 kcmil 18683 28024 37365 56048 750 kcmil 20017 30025 40034 60051 800 kcmil 21351 32027 42703 64054 900 kcmil 24020 36031 48041 72061

1000 kcmil 26689 40034 53379 80068 Notes forTable 2, Table 3, and Table 4: 1. These are the tensions allowed on the conductor(s). Consideration must be given to the maximum tension that

may be allowed based on other conditions of the installation where the cable is being pulled. 2. To obtain the maximum pulling tension in pounds of force (instead of Newtons), multiply the tabulated value

(in Newtons) by 0.22481: 22481.0 Newtonslbf TT

3. When cables are being pulled using a basket-type grip, these maximum pulling tensions are limited to 8896 N (2000 lbf).

3.4. Pulling Tension Calculation The tension resulting from a given duct installation is calculated as follows: a) For the tension developed in a straight section:

fWLT 8.9

Where: T = pulling tension (N) L = length of duct section (m) W = linear mass of cable (kg / m)

f = coefficient of dynamic friction, typically 0.35

b) For the tension developed in a bend:

faeTT 1

18 March 2014

Page 11 of 23

Where: T = tension coming out of bend (N)

1T = tension at bend entrance (N)

e = 2.71828

f = coefficient of dynamic friction

a = angle of bend (radians) fae = tension multiplier for bend angle and friction

Note that to convert the angle of the bend from degrees to radians:

180deg

a

arad

fae is given in Table 5 for common conditions.

Table 5: Multiplication Factors for Various Conduit Bends

Bend Angle

efa f = 0.15 f = 0.30 f = 0.40 f = 0.45 f = 0.50 f = 0.55 f = 0.60 f = 0.65 f = 0.70

15º 1.04 1.08 1.11 1.13 1.14 1.15 1.17 1.19 1.20 30º 1.08 1.17 1.23 1.27 1.30 1.33 1.37 1.41 1.44 45º 1.13 1.27 1.37 1.42 1.48 1.54 1.60 1.67 1.73 60º 1.17 1.37 1.52 1.60 1.69 1.78 1.87 1.98 2.08 90º 1.27 1.60 1.87 2.03 2.19 2.37 2.57 2.78 3.00

Coefficients of dynamic friction with lubricant are given in Table 6 for conductors and cables with an outer PVC or XLPE covering pulled into common duct materials. These coefficients can be used for calculation of pulling tensions. Table 6: Coefficient of Dynamic Friction with Lubricant

Duct Type

Conductor or Cable Outer Covering PVC or Nylon XLPE

One Cable Per Duct

Three Cables Per Duct

One Cable Per Duct

Three Cables Per Duct

PVC 0.50 0.60 0.40 0.60 PE 0.30 0.45 0.45 0.55

Fiber 0.40 0.45 0.30 0.65 Transite 0.70 0.70 0.70 0.70

Steel 0.65 0.65 0.60 0.65 Note: A coefficient of dynamic friction of 0.15 can be used when calculating pulling tension using rollers.

3.5. Sidewall Bearing Pressure Calculation Consideration must be given to SWBP when pulling cable through a bend. The SWBP is calculated as follows:

r

TSWBP

Where: SWBP = sidewall bearing pressure (N / m) T = pulling tension on cable end exiting bend (N) r = radius of the conduit bend (m)

18 March 2014

Page 12 of 23

Note that to convert SWBP from N / m to lbf / ft:

06852.0// mNewtonsftlbf SWBPSWBP

For unarmoured cables, Nexans recommends a maximum SWBP of 7290 Newtons per meter of bend radius (500 lbf / ft). For interlocked armoured cables, Nexans recommends a maximum SWBP of 4400 Newtons per meter of bend radius (300 lbf / ft). For corrugated aluminum sheath armoured cables, Nexans recommends a maximum SWBP of 7290 Newtons per meter of bend radius (500 lbf / ft). Maximum sidewall bearing pressure are shown in Table 7, below. Table 7: Maximum Sidewall Bearing Pressure

Cable Type Maximum Sidewall Bearing Pressure

Newtons per meter Pounds force per foot CANADEX® or HEATEX® NMD90 7290 500 SUPERVEX® NMWU 7290 500 TW(-40C), TW75 and TWU(-40C) 7290 500 INSTAGLIDE® T90 Nylon / TWN75 7290 500 RW90 and RWU90 7290 500 RPV90 and RPVU90 7290 500

SECUREX-II FAS / LVT Unarmoured: 7290 Armoured: 4400

Unarmoured: 500 Armoured: 300

AC90 and ISO-BX 4400 300 ACWU90 4400 300 FIREX-II TECK90 4400 300 CORFLEX® RA90 7290 500 DRIVERX® VFD RA90 7290 500

3.6. Minimum Bend Radius During installation of the cable it is recommended that the radius of bends be 1.5x that of the minimum bending radius for the final training. The minimum bend radius for wire and cable under tension, as well as final training are shown in Table 8 and

18 March 2014

Page 13 of 23

Table 9, below. Table 8: Minimum Bend Radius – Unarmoured Cables

Cable Type

Minimum Bend Radius Overall Cable Diameter

25.4 mm (1”) or Less Overall Cable Diameter

Greater than 25.4 mm (1”) Under Tension Final Training Under Tension Final Training

CANADEX® or HEATEX® NMD90 6x 4x 7.5x 5x SUPERVEX® NMWU 6x 4x 7.5x 5x TW(-40C), TW75 and TWU(-40C) 6x 4x 7.5x 5x INSTAGLIDE® T90 Nylon / TWN75 6x 4x 7.5x 5x RW90 and RWU90 6x 4x 7.5x 5x RPV90 and RPVU90 6x 4x 7.5x 5x SECUREX®-II FAS / LVT 6x 4x 7.5x 5x

18 March 2014

Page 14 of 23

Table 9: Minimum Bend Radius – Armoured Cables

Cable Type Minimum Bend Radius

Under Tension Final Training SECUREX®-II FAS / LVT 7.5x 5x AC90 and ISO-BX 10.5x 7x ACWU90 10.5x 7x FIREX®-II TECK90 10.5x 7x CORFLEX® RA90 14x (sheath diameter) 9x (sheath diameter) DRIVERX® VFD RA90 14x (sheath diameter) 9x (sheath diameter) Note: The minimum bending radius factor is applied to the overall cable diameter unless otherwise stated. These values are based on NEMA WC70, WC71, and the Canadian Electrical Code (CSA C22.1). The bending radius is that of the inner surface of the cable at the bend (see Figure 2, below).

Figure 2: How to measure cable bend radius

3.7. Use of Pulling Lubricants It is extremely important for the success of any pull in duct to use approved lubricants. Lubricants must be compatible with the conductor insulation or cable jacket, and the duct material. Lubricating the pulling rope will decrease the tension on the pulling equipment and more importantly will reduce the risk of damage to the inside of the duct. This duct damage could in turn damage the cable. Lubricating systems from ARNCO or POLYWATER are highly recommended.

4. Low Temperature Installation

4.1. Cables Marked “-40C” A number of Nexans cables meet CSA cold bend and impact requirements at minus 40°C. These cables are easily identifiable, as the print on the cable contains the term “-40C”. These cold bend and cold impact tests are conducted under carefully controlled laboratory conditions to ensure comparability of results from different laboratories and does not necessarily indicate that the cable can be safely installed at minus 40°C. These cables may be handled and installed at temperatures lower than minus 10°C, however, appropriate care must be taken. Appropriate care in this circumstance includes:

(a) minimize flexing of the conductor; (b) when flexing the conductor, bend the conductor slowly; and (c) work with an increased minimum bend radius.

Bend Radius

Cable

18 March 2014

Page 15 of 23

Since actual field conditions are not subject to such control it is recommended that, wherever possible, provision be made to keep the cable in a warm environment (warmer than 15°C for at least 24 hours) prior to installation. This cable should be handled and installed in the cold environment within the same day of being removed from the warm environment. This will minimize the risk of damaging cables in very cold weather. Once a conductor is installed in a fixed position, it may operate safely at much lower ambient temperatures. Currently the following cables pass the CSA cold bend and impact requirements to be marked “-40C”:

TW(-40C) and TWU(-40C) RW90 and RWU90 ACWU90 FIREX®-II TECK90 CORFLEX® RA90 DRIVERX® VFD RA90

4.2. Cables Not Marked “-40C” Cables not marked “-40C” may be handled and installed at temperatures down to minus 10°C. Once a conductor is installed in a fixed position, it may operate safely at much lower ambient temperatures.

5. Vertical Installation For vertical installations, the use of a messenger may be necessary to support the cable during installation. In order to prevent slippage of the cable’s core, offsets may be necessary for final positioning of the cable. The Canadian Electrical Code has some guidelines for the distance between these offsets or another suitable means of cable core support (see Rule 12-120, as well as Table 21 of the Canadian Electrical Code). Nexans also has recommendations for vertical installations of standard TECK90 as well as information on a special design called VERTEK®. Please consult your nearest Nexans Sales Office for recommendations and information on VERTEK® cable.

6. Hazardous Location Installations All Nexans ACWU90, FIREX®-II TECK90, CORFLEX® RA90, and DRIVERX® VFD RA90 cables are CSA approved to be installed in hazardous locations up to and including Class I, Division (Zone) 1. Cables must be installed in accordance with the requirements of Section 18 of the Canadian Electrical Code. Cable connectors or fittings must be approved for the Class and Division (Zone) involved.

7. Terminating and Splicing All of the building wire and cable that Nexans manufactures (from 300 V up to and including 5 kV) is non-shielded. This means it has no insulation shields and therefore electrical stress relief is not typically required for terminations or splices, where proper clearances between phases, as well as between phase and ground are maintained. Terminations require no special kits. However, additional clearances between phases and between phase and ground are required for 5 kV rated cable, where electrical stress relief systems are not installed. See CSA Standard C22.2 No. 0.2 “Insulation Coordination” for more information regarding minimum acceptable termination clearances for various installation environments. 600 V and 1 kV cable are terminated using normal good workmanship for these voltage levels. Splice kits are available from several companies that specialize in this type of equipment. Nexans suggests that these manufacturers be consulted for kits suitable for any particular cable and installation condition.

18 March 2014

Page 16 of 23

7.1. Splicing CORFLEX® RA90 or DRIVERX® VFD RA90 Cables While splicing of CORFLEX® RA90 cables is common and permitted by Nexans, splicing of DRIVERX® VFD RA90 cables is not recommended, as the electromagnetic shielding performance of the aluminum sheath armour, as well as its high frequency impedance would be compromised, potentially yielding sub-standard performance in a VFD system.

8. Removing Armour

8.1. Removing Interlocked Armour These instructions give the procedure to remove interlocked armour from the cable.

1. Determine the amount of armour and overall jacket required to be removed. The amount of jacket to be stripped depends on connector type and will vary with size. Follow connector manufacturer's instructions.

2. Straighten cable for required length. 3. Remove overall jacket for required length. 4. At the point required make a diagonal cut across the armour strip using a fine-tooth hacksaw (24T). This

cut should just go through the armour and not damage the insulated conductors in the cable core. Alternatively, the armour can be cut with a commercially available armour slitting tool. The manufacturer of these tools can make recommendations for tool selection and directions for its safe use.

5. Flex armour several times to break it apart, then twist in the direction of the insulated conductors of the cable core, and slide the armour off of the core.

6. If required by the connector manufacturer, install an anti-short bushing between the armour and the cable core.

7. The cable is now ready for connector installation.

8.2. Removing Aluminum Sheath Armour These instructions give the procedure to remove aluminum sheath armour from the cable.

1. Cut and remove a small section of the jacket at desired location of cable sheath end. 2. Pencil indicates relative location to cut the sheath. Score line with knife “squarely” around cable where the

sheath is to be cut. 3. Carefully cut through the raised helix using a fine-tooth hacksaw (24T). This cut should just go through the

armour and not damage the insulated conductors in the cable core. Alternatively, the armour can be cut with a commercially available armour slitting tool. The manufacturer of these tools can make recommendations for tool selection and directions for its safe use.

4. Crack scored sheath by gently bending back and forth. Remove any burrs with knife edge. Pull off the sheath, slightly rotating in direction of conductor lay.

5. The cable is now ready for connector installation.

18 March 2014

Page 17 of 23

9. Connectors Connectors used to affix wire and cable to cabinets, enclosures and so on, are available from many companies. Connector information for cables that Nexans manufactures is available on our website and is listed in our catalogues. All Nexans ACWU90, FIREX®-II TECK90, CORFLEX® RA90, and DRIVERX® VFD RA90 cables are HL rated (approved for installation and use in hazardous locations). If there are special installations such as this, Nexans suggests a connector supplier be consulted.

9.1. Aluminum Sheath Armoured Cables For CORFLEX® RA90 and DRIVERX® VFD RA90 cables it is strongly recommended that Nexans CORFLEX® connectors be used in the installation. This is primarily due to low cable armour to connector interface resistance, maintaining the low impedance bonding / grounding path required for many applications, such as VFD systems.

9.1.1. Terminating Dry-Type CORFLEX® Connectors: 1. If the cable has a PVC jacket, cut the jacket back to the length of the connector barrel. See Table 10, below,

for strip length. 2. Slip the body over the cable. Carefully thread the connector onto the sheath and turn by hand until the end

of the sheath binds against the internal shoulder. Tighten by hand only. 3. Type “D” connector has a “one unit” body with internal threading matched to the profile of the sheath.

9.1.2. Terminating Wet-Type CORFLEX® Connectors: 1. If the cable has a PVC jacket, cut the jacket back to the length of the connector body only. See Table 10,

below, for strip length. 2. Place the packing nut and sealing grommet onto cable, ensuring that the grommet is completely over the

PVC jacket. 3. Thread the connector body onto the sheath and turn by hand only until the sheath binds against the internal

shoulder. Tighten by hand only. 4. Thread the packing nut onto the body and tighten sufficiently to begin squeezing the grommet out from

under the packing nut. When connecting to a plate, ensure a rubber gasket is placed between the connector and the outside surface of the plate.

Table 10: CORFLEX® connector hub size and cable jacket strip length

Cat. No. Hub Size Strip Length 13D2 / 13W2 ½" 1 ¼" 16D3 / 16W3 ¾" 1 ¼" 20D3 / 20W3 ¾" 1 ¼" 25D3 / 25W3 ¾" 1 ¼" 30D4 / 30W4 1" 1 ¾" 35D5 / 35W5 1 ¼" 1 ¾" 40D5 / 40W5 1 ¼" 1 ¾" 45D6 / 45W6 1 ½" 1 ¾" 50D8 / 50W8 2" 1 ¾"

10. Field Testing Voltage tests after installation should be made as soon as possible after installation and before cables are placed in service. Before applying the test voltage, ensure that the cable to be tested is disconnected completely from all other equipment. Also ensure that there is sufficient clearance between the cable ends and any grounded surfaces, objects or persons. We recommend that only qualified persons familiar with the process and associated safety precautions perform field testing.

18 March 2014

Page 18 of 23

For non-shielded cables rated up to and including 5 kV, an insulation resistance test at not more than the cable’s rated voltage is recommended. See: “Nexans Insulation Resistance Testing of Low Voltage Cables in the Field” for more information on this topic. Alternatively, 5 kV non-shielded cables may be subjected to a DC hi-pot test of 25 kV for 5 minutes. After any hi-pot test is conducted all metallic components, including the phase conductors, ground or bonding conductor and armour must be grounded long enough to discharge charges that are developed by the test. Insulation resistance testing may be performed on a maintenance schedule, but Nexans recommends that the 25 kV hi-pot test be performed only on new cable before being placed in service.

11. Abnormal Chemical Exposure of Wire and Cable Nexans’ wires and cables are designed and manufactured to meet industry standards for safety and reliability. Our products are designed for use in a variety of environments and will provide exceptional service and reliability when installed and maintained appropriately. However, wires and cables may be occasionally exposed to materials, or environmental conditions that may have a detrimental impact on their performance and expected lifetime. When questions arise regarding abnormal exposure of our products to potentially harmful chemicals or conditions, Nexans Applications Engineering will provide assistance. As every situation is unique, providing details related to the exposure will help Nexans make an accurate assessment and provide recommendations in a timely manner. Details of the exposure should include:

Cable type Installation conditions (e.g. indoor, outdoor, buried) Identity of the chemical agent (e.g. Technical Datasheet and/or MSDS if possible) Specific conditions of exposure (e.g. duration of exposure, frequency, temperature) Extent of exposure (e.g. overall covering, underlying cable components, auxiliary equipment, terminations,

connectors) Indicators of degradation (e.g. blistering, swelling, embrittlement, corrosion of metallic cable components,

terminations or connections) Results of any tests performed after exposure (e.g. insulation resistance) Related incidents (e.g. user experience with similar exposures)

11.1. Cable repair When cable damage does occur, replacement may be recommended, especially if exposure is likely to occur again. When replacing the cable is not required, or is not an option, follow the general suggestions below for repair:

1. Before the repair, protect the damaged cable from the ingress of water or other chemicals. 2. Make the repair water tight. Use an approved shrinkable covering and electrical tape. 3. Examine the cable to ensure that conductor insulation and the conductor material have not been damaged.

If the conductors are damaged then reconsider replacement of the cable. 4. Examine the cable to ensure that the jacket(s) and / or the cable armour have not been damaged (if present).

If the jacket(s) and / or the cable armour are damaged then remove the damaged components and replace with suitable material for the installation conditions. A cable splice kit may be necessary.

5. It is suggested that theauthority having jurisdiction be informed in order to obtain the appropriate approval for repairs.

18 March 2014

Page 19 of 23

Appendix A: Example of a Pulling Tension Calculation Assuming the illustrated duct layout (see Figure 3, below) and the following details:

3 x 1c 4/0 AWG copper 5 kV (unshielded) FIREX®-II TECK90 cable Diameter of each cable = 33.38 mm Linear mass of each cable = 2.103 kg / m PE duct type with PVC jacketed TECK90 cable – Coefficient of friction (f) = 0.45 (from Table 3, above, on

the “PE” (duct type) row, under the “Three Cables Per Duct” column) Our cable pulling tension and SWBP limitations are as follows:

NAnT 749010717070max

mNSWBP /7290max

Figure 3: Duct Layout

r = 610 mm 45º

E F

G

H

K

L

60 m

20 m

30 m

r = 610 mm 90º

30 m

r = 610 mm 90º

r = 610 mm 90º

A B

C

D

30 m

120 m

I

J

r = 610 mm 45º

18 March 2014

Page 20 of 23

Pulling from A to L: Tension at B:

NfWLTB 27845.0103.2308.98.9

Tension at C:

NeTT faBC 56403.2278

SWBP through bend B-C:

mNr

TSWBPBC /925

610.0

564

Tension at D:

NfWLTT CD 167745.0103.21208.95648.9

Tension at E:

NeTT faDE 340403.21677

SWBP through bend D-E:

mNr

TSWBPDE /5580

610.0

3404

Tension at F:

NfWLTT EF 396045.0103.2608.934048.9

Tension at G:

NeTT faFG 562342.13960

SWBP through bend F-G:

mNr

TSWBPFG /9218

610.0

5623

Tension at H:

NfWLTT GH 580845.0103.2208.956238.9

Tension at I:

NeTT faHI 1179003.25808

SWBP through bend H-I:

mNr

TSWBPHI /19328

610.0

11790

Tension at J:

NfWLTT IJ 1206845.0103.2308.9117908.9

Tension at K:

NeTT faJK 1713742.112068

SWBP through bend J-K:

mNr

TSWBPJK /28093

610.0

17137

Tension at L:

NfWLTT KL 1741545.0103.2308.9171378.9

18 March 2014

Page 21 of 23

Pulling from L to A: Tension at K:

NfWLTK 27845.0103.2308.98.9

Tension at J:

NeTT faKJ 39542.1278

SWBP through bend K-J:

mNr

TSWBPKJ /648

610.0

395

Tension at I:

NfWLTT JI 67345.0103.2308.93958.9

Tension at H:

NeTT faIH 136603.2673

SWBP through bend I-H:

mNr

TSWBPIH /2239

610.0

1366

Tension at G:

NfWLTT HG 155145.0103.2208.913668.9

Tension at F:

NeTT faGF 220242.11551

SWBP through bend G-F:

mNr

TSWBPGF /3610

610.0

2202

Tension at E:

NfWLTT FE 275845.0103.2608.922028.9

Tension at D:

NeTT faED 559903.22758

SWBP through bend E-D:

mNr

TSWBPED /9179

610.0

5599

Tension at C:

NfWLTT DC 671245.0103.21208.955998.9

Tension at B:

NeTT faCB 1362503.26712

SWBP through bend C-B:

mNr

TSWBPCB /22336

610.0

13625

Tension at A:

NfWLTT BA 1390345.0103.2308.9136258.9

18 March 2014

Page 22 of 23

Table 11: Summary of Pulling Tensions and SWBP for Example

Point Pull from A to L Pull from L to A

Tension N

SWBP N / m

Tension N

SWBP N / m

A 13903 B 278

925 13625

22336 C 564 6712 D 1677

5580 5599

9179 E 3404 2758 F 3960

9218 2202

3610 G 5623 1551 H 5808

19328 1366

2239 I 11790 673 J 12068

28093 395

648 K 17137 278 L 17415

Comparing the results of the calculations for the forward (pull from A to L) and reverse (pull from L to A) pulling tensions and sidewall bearing pressures, it is clear that the reverse pull yields more favorable results. The pulling tension, however, grossly exceeds the maximum recommended cable pulling tension of 7530 N. As well, the sidewall bearing pressure exceeds the maximum recommended limit of 7290 N / m. One way to resolve the problem is to add a pull box between points E and F. Preferably it should be located closer to E (if pulling from L to A), so as to keep the conduit bends closer to the beginning of the cable pull, and help reduce the SWBP. The addition of the pull box will allow the cable pull to be broken up into 2 sections: (1) from L to E; and (2) from E to A. A rough calculation results in the following:

Tension (from L to E) of about 2750 N (maximum SWBP of about 3600 N / m) Tension (from E to A) of about 2500 N (maximum SWBP of about 3700 N / m)

IMPORTANT NOTICE: This document is provided for informational purposes only in order to illustrate typical product constructions, applications and/or methods of installation. Because conditions of actual installation and use are unique and will vary, Nexans makes no representation or warranty as to the reliability, accuracy or completeness of this document or the information contained herein, even if Nexans is aware of the product's intended use or purpose. Furthermore, this document does not constitute, nor should it be regarded or relied upon, as professional engineering advice. Installation of cable should only be done by qualified personnel and in conformance with all safety, electrical and other applicable codes, standards, rules or regulations. Appropriate and correct product selection, installation and use, and compliance with all such codes, standards, rules and regulations, is a customer/end-user responsibility.