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25 YEAR WARRANTY
Wrexham Mineral Cables
25 Year System Warranty
Warranty Available. See website for details.
www.wrexhammineralcables.com
MINERALINSULATED
COPPERCABLES
Product & SpecificationCATALOGUE
Wrexham Mineral Cable...
...The True Fire Survival Cable
02
Established in 1989 Wrexham Mineral Cables developed a totally new and unique process for the continuous manufacture of Mineral Insulated Cables - the only True Fire Survival Cable.
Now celebrating 25 years in business we have marked our success with the addition of a completely brand new £6m manufacturing line & factory extension to compliment our existing plant. Our new manufacturing line will provide the facility to manufacture much longer lengths of the heavy duty sizes such as 1H240mm² & 4H25mm², never before available.
The specially designed equipment is housed in our 5,000 square metre purpose built factory located in Ruabon, Wrexham, North Wales, United kingdom. Our success is due to our continued investment and commitment to manufacturing a quality product while providing comprehensive customer service, making us the largest UK manufacturer of Mineral Insulated Cables.
The quality and reliability of Wrexham Mineral Cables is recognised world wide and throughout the electrical industry. Our cables are manufactured to meet British and European standards, achieving endorsements & certifications from many regulatory bodies including BRE - LPCB, the world renowned approvals body for fire performance products, Warrington Fire Research Centre and London Underground. The termination glands and increased safety seals are SIRA - ATEX EExd approved.
ManufacturingPurpose built and occupying 5,000 square metres with vast stock warehousing.
5,000 square meters of purpose built factory allow us to produce all our products in the UK ensuring 100% quality and security of supply. Cables can be made to your requirements in longer lengths than any other Mineral Insulated Cable manufacturer.
NEW PIC OF PRODUCTION LINE TO BE ADDED TO THIS BOX
MADE IN THE UK
Introduction
“Over 135million metresmanufactured
to date”
“The largest UK manufacturer of
Mineral Insulated Cables”
Applications
Features and Benefits
Fire Performance
Specification
Standards and Approvals
Cable Supply
Cable & Accessory Selection
08-09
04-07
10-13
14-15
16-17
18-19
20-23
Accessories & Tools24-25
Installation Practice26-31
Projects & Special Products32-33
Training & Middle East Approvals34-36
Contents
04
Mineral Insulated Cables are used to provide circuit integrity for power and control circuits of critical equipment in the following applications:
Car Parking Multi-storey & Underground
Moving Walkways/Travelators/Escalators Metrolinks
• General Lighting• Fire Alarm System• Fire Pumps• Emergency Lighting System• Exhaust Fume Extraction• Security Cameras
• General Lighting• Handrail Lighting• Recess Illumination• Emergency Stop Start
Controls• Fire Detection and Smoke
Extraction
• General Lighting• Emergency Lighting• Fire Protection Systems• Public Address System • Fire Telephones
Hotels Power Generation & Distribution Petrol Stations
• General Lighting and Power• Stairwell Pressurisation
System • Fire Alarm System • Emergency Lighting• Elevator Motor Supply• Mains Distribution
• General Lighting and Power• Emergency Lighting• Fire Alarm and Security
Systems• Smoke Extraction Fans• Air Conditioning
• Pump Circuits• Fire Alarm and Security
Circuits• General Lighting
PHOTO PHOTO PHOTO
Railway Tunnels/Stations Road Tunnels & Mines Shopping Centres
• General Lighting• Emergency Lighting• Fire Detection and Smoke
Extraction• Fire Telephones• Public Address System
• General Lighting• Emergency Lighting • Fire Detection• Fire Telephones• Fume & Ventilation Systems
• General Lighting and Power• Emergency Lighting • Fire and Security Circuits• Public Address System
PHOTO PHOTO PHOTO
Applications
Building Services Education Buildings Building Exteriors
• Rising Main and Lateral Distribution Systems
• Underfloor Mains Distribution Systems
• Fire Alarm System• Smoke Extraction System• Emergency Lighting• Elevator Motor Power Supply
• Perimeter • Feature & Security Lighting
PHOTO PHOTO PHOTO
Offshore Petrochemicals Airports
• High Integrity Circuits• Accommodation Blocks• Lighting and Power• Safety Systems
• Hazardous Area and Safety System Wiring
• Water Treatment• General Lighting• Emergency Lighting and Fire
Protection• Motor Operated Valves (MOV)
• General Lighting and Power• Emergency Lighting• Fire Protection Systems• Public Address System
PHOTO PHOTO PHOTO
Public Buildings; Theatres, Libraries & Cinemas Hospitals Transport/Interchanges
• General Lighting and Power• Emergency Lighting• Fire Alarm and Security
Systems• Mains Distribution• Smoke Extraction Fans
• Fire Alarm System• Smoke Extraction System• Emergency Lighting• Elevator Motor Power Supply• Theatre Critical Power Supply
• Public Lighting• Fire Alarm• Emergency Lighting• Public Address
PHOTO PHOTO PHOTO
Grand Opening of Our New FactoryWrexham Mineral Cables had the great pleasure of receiving the First Minister of Wales, the Right Honorable Carwyn Jones AM, for the purpose of opening our new £6m factory extension in Ruabon, Wrexham.
Our new line has revolutionised the manufacture of large diameter MICC cable with the capability to make the largest sizes of MICC cable in one piece long enough to supply power from the basement to the roof of the worlds tallest building, guaranteeing power supply to critical circuits in a fire situation.
06
Applications
General Electrical Services Emergency Power & Lighting Systems
• Small Power - Ring and Radial Circuits
• Low Voltage Distribution - Rising and Lateral Mains
• External Lighting Circuits
• Fire Alarm Equipment• Smoke Dampers and Curtains• Fire Door’s and Shutters• Smoke Extract Units• Voice Alarm Systems• CCTV Systems
• Emergency Lighting• Sprinkler Control Systems• Emergency Power Supply• Control Centre• Lifts and Escalators• Fire Telephones
Wiring in Potentially Explosive AtmospheresWrexham Mineral Insulated Copper Cables (MICC) are constructed using solid copper sheath, solid copper conductors and highly compacted powdered magnesium oxide (MgO) insulation, totally preventing the passage of flames, gasses or vapours via the cable to appliance (Reference BS EN 60079-14:2008).
Wrexham brand MICC wiring system fully meets the requirements for wiring zones 1 and 2 when using Ex (d) flameproof & Ex(e) Increased Safety apparatus. Sira approval to BS EN 60079-0 & BS EN 60079-1 (GLANDS EX (d). BS EN 60079-0 & BS EN 60079-7 (Seals) Ex (e).
Potentially explosive atmospheres may be found in locations such as petrol stations, chemical plants, gas production and processing plants, paint works, oil refineries and depots, oil drilling and production platforms.
Petrol stations
Chemical plants
Gas production and
processing plants
Paint Works
Oil refineries and depots
Oil drilling and production
platforms
Potentially explosive atmospheres may be
found in locations such as:
Why Mineral Insulated Cable?Mineral Insulated Cable (MICC) has been in use commercially since 1937, the fact that it is still widely used today is evidence that it has not been bettered by any other cable system. Soft skinned polymeric cables are a compromise in safety, fire performance and longevity when comparisons are made to MICC cables.Any cable system that relies on polymers for conductor insulation will burn and will be very likely to fail in a real fire situation, MICC cable does not rely on polymers for insulation.
Mineral Insulated Cable is totally Inorganic and Silicone free in construction. The main construction consists of solid copper conductors (cores), highly compressed magnesium oxide (MgO) insulation and a solid copper sheath. This unique construction gives melting points of 1083°C and 2800°C for the copper and insulation respectively. This provides fire survival whilst continuing to safely carry a load for 3 hours at 950°C and for short periods of time in temperatures in excess of 1000°C.
MICC cables can also be considered to be non-aging as copper and MgO will not deteriorate with age in most situations. Cables normally need to be replaced as the polymers used for insulation breakdown causing the insulation resistance (IR) to fall thus creating an unsafe system. The total life cycle costs of MICC cables in a building with a typical 40 - 50 year design expectancy would be considerably less than those using an XLPE steel wire armored LSZH fire resistant cable, thus off-setting any initial capital expenditure.
For the majority of modern installations, bare copper sheathed cable will suffice requiring no additional outer covering. In this state the cable is resistant to oil, water and many other gases and liquids.
Where the natural corrosion resistance of the copper sheath is not sufficient, it can be augmented with an additional LSZH (low smoke zero halogen) outer covering. This outer covering can also be used for coloured circuit identification or visual appearance.
08
Heysham 1 Nuclear Power Station
Houses of ParliamentKensington PalaceSt. James’ PalaceBuckingham PalaceWindsor Castle
Edinburgh CastleHeathrow AirportManchester Airport
University of WalesManchester University
Loughborough University
Chesterfield Royal Hospital
Memorial Hospital London
Iron Bridge Power Station
British Museum
Millennium Dome
Lowry Centre
Claridges Hotel
Harrods
Marks & Spencer
Sainsburys
Tesco
Asda
National Trust
London Underground
New Amex Building Brighton
John Muir CentreTollcross Aquatic Centre (2014 Commonwealth Games Venue)
Baker Street Station Re-developement (LUL)Kings Cross StationRe-development
Isle of Grain LNG FacilityNostel Priory
Hardwick Hall
Current installations include:
Features and Benefits
Airtight Small Overall Diameter Earth Continuity
Impervious to water, oil and gas.
MICC cables have a smaller diameter than soft skinned fire resistant cables of equivalent ratings.
MICC cables do not require a separate earth continuity conductor as the outer copper sheath serves this purpose providing excellent low resistance earth continuity.
Fire Resistant High Operation Temps Inherent Flameproof Barrier
Will neither burn nor support combustion.
Continuous maximum operating temperature up to 250°C for the life of the cable, and for shorter periods up to 1083°C, the melting point of copper.
With a non-flammable copper sheath the highly compacted MgO insulation will resist the transmission of vapours, gases and flames between items of equipment connected by the cable.
High Mechanical Strength None Ageing Pliable
Withstand considerable stresses such as bending, twisting and flattening.
Mineral insulated cable is permanent and does not usually weaken or degrade with age under normal conditions offering longer and safer lifespans.
Wrexham Mineral Insulated Cable is annealed using a fully controlled in-line process and consequently is extremely ductile and easily manipulated to follow existing wiring routes and irregular shapes.
Warranty Available. See website for details.The Wrexham Mineral Cable 25 Year System Warranty
With Consultants, Project Engineers and Specifiers requesting detailed and extended warranty for electrical components and cabling systems, Wrexham Mineral Cables have introduced a 25 year system warranty. This is available to all customers and is at no extra charge.
To qualify for the extended warranty simply register the installation, exclusively use Wrexham Mineral Cable and Accessories and test the installation once completed. See our website for full details www.wrexhammineralcables.com
25 YEAR WARRANTY
Wrexham Mineral Cables
25 Year System Warranty
The True Fire Survival CableWhether you are involved in designing, specifying, planning, installation, operation or maintenance, safety is paramount. MICC is the best choice of cable having a direct bearing on life and/or property, the safest cable is the one which can not burn!
The terminology used to describe cables claiming a degree of fire protection is often misinterpreted. The terms; ‘fire resistance and fire performance’ are often applied to a wide range of products. However, because they are not defined clearly and imply fire protection, it’s surprising how little protection is offered. Wrexham Mineral Insulated Cable will survive for over 3 hours at 950 Deg C while receiving a direct mechanical impact and water spray on the same sample of cable.
It’s worth remembering that compliance with the relevant fire safety standards is the minimum requirement, MICC cables surpass BS 6387 C,W & Z, BS EN 50200 PH120 Enhanced, BS 8434-2. If you were in a real fire situation would you feel safer knowing the cables used to protect the critical circuits exceed the standards, and not just a laboratory controlled fire test? If the answer is yes then you can rely on Wrexham Mineral Insulated Cables.
10
OFFOFF
“Mineral Insulated Cables
save lives”
Circuit IntegrityBS 6387: 1994 Performance Requirements for Cables Required to Maintain Circuit Integrity under Fire Conditions.
The standard details the following tests to categorise cable according to their fire withstand capabilities:
Fire Performance
PERFORMANCE TABLE SYMBOL WREXHAM MIRESISTANCE TO FIRE650⁰C for 3 hours A SURPASSES750⁰C for 3 hours B SURPASSES950⁰C for 3 hours C SURPASSES950⁰C for 20 minutes S SURPASSESRESISTANCE TO FIRE WITH WATER650⁰C W SURPASSESRESISTANCE TO FIRE WITH MECHANICAL SHOCK650⁰C X SURPASSES750⁰C Y SURPASSES950⁰C Z SURPASSES
Resistance to fire
Exposure to Gas Burner Flames
Resistance to fire with water
spray
Exposure to Flames at 650 for 15
minutes then exposure to Water
Spray and Fire for 15 minutes
(One survival category “W” is
defined. See table below).
Resistance to fire with
mechanical impact
Exposure to Flames whilst
Mounting Panel is struck with a
Steel Bar at 30 second intervals
for 15 minutes.
Circuit integrity
Circuit integrity maintained
after exposure to fire, water and
impact.
Soft Skin Polymeric CableBS 6387 category C demands that cables perform safely for 3 hours at 950 Deg C. BS EN 50200 PH120 Enhanced demands 2 hours fire resistance at 850 Deg C. The soft skin polymeric fire resistant cables shown below have been subjected to only 10 minutes at 850 Dec C, as you can see the majority of the polymers used for primary and secondary insulation have been consumed by the fire.
These cables claim to meet both BS 6387 CWZ and BS EN 50200 PH120, what would be left to protect them in a real fire situation? One direct impact on any of these cables would most likely cause the conductors to touch and short out rendering the appliance useless.
12
Mineral Insulated CableWrexham Mineral Insulated Cable is manufactured and LPCB approved to BS EN 60702-1:2002 and conforms to BS 6387 CWZ and BS EN 50200 PH120 Enhanced. The sample shown in Fig. 1 below has been subjected to 950 Deg C for 10 minutes, the LSZH outer sheath though charred does not effect the overall performance of the cable.
Even after the full 3 hours at 950 Deg C the Wrexham Mineral Insulated cable in Fig. 2 is still fully functional and safely maintaining circuit integrity. In fact there is little change to the copper sheath other than discolouration and slight oxidization and we would be confident that this cable could take many direct impacts during the fire without failing. This is why Wrexham Mineral Insulated Cable is the only true fire survival system.
Fire Performance
Fig. 1
Fig. 2
“Mineral Insulated Cablesmaintain circuit
integrity”
14
Current-Carrying CapacityLSZH covered or bare and exposed to touch(COPPER CONDUCTORS AND SHEATH)
CON
DU
CTO
R CR
OSS
-SEC
TIO
NAL
ARE
A
REFERENCE METHOD C(clipped direct)
REFERENCE METHODS E, F, AND G(in free air or on a perforated cable tray etc, horizontal or vertical)
SINGLE-PHASE
a.c or d.cTHREE-PHASE a.c
SINGLE-PHASE
a.c or d.cTHREE-PHASE a.c
2 SI
NG
LE-C
ORE
CA
BLES
TO
UCH
ING
O
R 1
TWO
-CO
RE
CABL
E
3 SI
NG
LE-C
ORE
CA
BLES
IN T
REFO
IL
OR
1 TH
REE-
CORE
OR
FOU
R-CO
RE C
ABLE
3 SI
NG
LE-C
ORE
CA
BLES
FLA
T AN
D
TOU
CHIN
G, H
ORI
-ZO
NTA
L O
R VE
RTIC
AL
2 SI
NG
LE-C
ORE
CA
BLES
TO
UCH
ING
O
R 1
TWO
-CO
RE
CABL
E
3 SI
NG
LE-C
ORE
CA
BLES
IN T
REFO
IL
OR
1 TH
REE-
CORE
OR
FOU
R-CO
RE C
ABLE
3 SI
NG
LE-C
ORE
CA
BLES
FLA
T AN
D
TOU
CHIN
G
3 SINGLE-CORE CABLES FLAT & SPACED BY ONE CABLE
DIAMETER
VERTICAL HORIZONTAL
(mm²) (AMPS) (AMPS) (AMPS) (AMPS) (AMPS) (AMPS) (AMPS) (AMPS)
LIGHT DUTY CABLE (500 volts)
1 18.5 15 17 19.5 16.5 18 20 23
1.5 23 19 21 25 21 23 26 29
2.5 31 26 29 33 28 31 34 39
4 40 35 38 44 37 41 45 51
HEAVY DUTY CABLE (750 volts)
1.5 25 21 23 26 22 26 28 32
2.5 34 28 31 36 30 34 37 43
4 45 37 41 47 40 45 49 56
6 57 48 52 60 51 57 62 71
10 77 65 70 82 69 77 84 95
16 102 86 92 109 92 102 110 125
25 133 112 120 142 120 132 142 162
35 163 137 147 174 147 161 173 197
50 202 169 181 215 182 198 213 242
70 247 207 221 264 223 241 259 294
95 296 249 264 317 267 289 309 351
120 340 286 303 364 308 331 353 402
150 388 327 346 416 352 377 400 454
185 440 371 392 472 399 426 446 507
240 514 434 457 552 466 496 497 565
Notes:• Ambient temperature: 30⁰C• Sheath operating temperature: 70⁰C• For single-core cables, the sheaths of the circuit are assumed to be connected together at both ends• Fore bare cables exposed to touch, the tabulated values should be multiplied by 0.9
Voltage Drop
Notes:* Spacings larger than one cable diameter will result in a larger voltage dropConductor operating temperature 70⁰C
Specification
CONDUCTOR CROSS-SECTIONAL
AREA
SINGLE PHASE a.c. or d.c THREE-PHASE a.c
2 SINGLE-CORE CABLES TOUCHING 1 TWO-CORE CABLE 1 THREE OR FOUR-
CORE CABLE
3 SINGLE-CORE CABLES IN TREFOIL
FORMATION
3 SINGLE-CORE CABLES FLAT &
TOUCHING
3 SINGLE-CORE CABLES FLAT & SPACED BY ONE
CABLE DIAMETER*
(mm²) (mV/A/m) (mV/A/m) (mV/A/m) (mV/A/m) (mV/A/m) (mV/A/m)
2.5 17 17 14 14 14 14
4 10 10 9.1 9.1 9.1 9.1
6 7 7 6.0 6.0 6.0 6.0
10 4.2 4.2 3.6 3.6 3.6 3.6
16 2.6 2.6 2.3 2.3 2.3 2.3
r x z r x z r x z r x z r x z r x z
25 1.65 0.200 1.65 1.65 0.145 1.65 1.45 0.125 1.45 1.45 0.170 1.45 1.45 0.25 1.45 1.45 0.32 1.50
35 1.20 0.195 1.20 - - - - - - 1.05 0.165 1.05 1.05 0.24 1.10 1.05 0.31 1.10
50 0.89 0.185 0.91 - - - - - - 0.78 0.160 0.80 0.79 0.24 0.83 0.82 0.31 0.87
70 0.62 0.180 0.64 - - - - - - 0.54 0.155 0.56 0.55 0.23 0.60 0.58 0.30 0.65
95 0.46 0.175 0.49 - - - - - - 0.40 0.150 0.43 0.41 0.22 0.47 0.44 0.29 0.53
120 0.37 0.170 0.41 - - - - - - 0.32 0.150 0.36 0.33 0.22 0.40 0.36 0.28 0.46
150 0.30 0.170 0.34 - - - - - - 0.26 0.145 0.30 0.29 0.21 0.36 0.32 0.27 0.42
185 0.25 0.165 0.29 - - - - - - 0.21 0.140 0.26 0.25 0.21 0.32 0.28 0.26 0.39
240 0.190 0.160 0.25 - - - - - - 0.165 0.140 0.22 0.21 0.20 0.29 0.26 0.25 0.36
Approvals
Manufactured and Tested To BS EN 60702 –1: 2002 (Formerly BS6207)Certification of Assessed Quality Assurance No. 333 to BS EN ISO 9001:2008LPCB Product Certification No. 333a/01
Approval Body Standard Reference Description
LPCB IEC 60331-1:2009 Tests for electric cables under fire conditions - Circuit integrity - Part 1: Test method for fire with shock at a temperature of at least 830°C for cables of rated voltage up to and including 0,6/1,0 kV and with an overall diameter exceeding 20mm
LPCB IEC 60331-2 Tests for electric cables under fire conditions - Circuit integrity - Part 1: Test method for fire with shock at a temperature of at least 830°C for cables of rated voltage up to and including 0,6/1,0 kV and with an overall diameter not exceeding 20mm
LPCB IEC 60332-1 Tests on electric cables under fire conditions - Part 1-1: Test for vertical flame propagation
LPCB IEC 60754-1 Test on gases evolved during combustion of materials from cables - Part 1: Determination of the halogen acid gas content
LPCB IEC 61034-2 Measurement of smoke density of cables burning under defined fire conditions
LPCB BS 5839-1:2013 ENHANCED to clause 26.2
Fire detection and fire alarm systems for buildings. Code of practice for system design, installation, commissioning and maintenance
LPCB BS EN 50200:2006 Class Ph120 Resistance to fire of unprotected small cables for use in emergency circuit
LPCB BS 8434-2:2003+A2:2009 Test for unprotected small cables for use in emergency circuits. BS EN 50200 with a 930°C flame and with water spray
LPCB C,W & Z OF BS 6387:1994 Requirements for cables to maintain circuit integrity under fire conditions
LPCB BS EN 50267 Gases evolved during combustion of electrical cables
16
Testing Wrexham Mineral Cables are tested to the following:
Warrington Fire Research B.S 6387:1994 CWZ (to the highest category)Warrington Fire Research To BS 4066 : International standard IEC 60331
London Underground To Specification EME-SP-14-028-A1 (Fire Survival Cables – MICC)
Terminations Manufactured and Tested in accordance with BS EN 60702-2:2002Sira Quality Assurance Notification No. Sira 02 ATEX M170
EC-Type Examination Certificate
EN 50014 amendments A1 & A2 & For use with flameproof equipment in Zones 1 and 2, apparatus, gas sub-groups IIA, IIB and IIC and all general applications.
C-Type Examination Certificate No. Sira 02ATEX3304U(Increased Safety Seals) EN 50014: amendments A1 & A2 & EN 50019:2000
See page 35 for Middle East Approvals
Standards and Approvals
Cable TypeBare Copper sheathed cables are available or with an LSZH (Low Smoke Zero Halogen) outer covering. The standard colours for the LSZH outer covered cables are Orange, Red, Black or White. Other colours are available on request.
ReelsThe popular Light Duty cable sizes are supplied as standard in 100 metre lengths on non-returnable reels as follows:
CableSizes 2L1.5 2L2.5
Length(Metres) 100 100
Typeavailable
Bare Copper or LSZH Outer
Covered
Coloursavailable
Orange, Red, White or Black
ReelDimensions
400mm dia x190mm width
ReelWeight
kg
LSZH 16.9 22.2
Bare 14.6 19.6
CoilsWith the exception of the previous reel sizes, cable is supplied in coil form as standard. The coil diameters are either 500mm, 915mm or 1370mm dependent on the cable diameter.
DrumsThe following cables can be supplied ex-stock on non-returnable drums.
Cabl
e Si
zes
Coil
Leng
th (a
ppro
x)
m.
LSZH
Dru
m fl
ange
dia
mm
.
Ora
nge
Red
Whi
te
Blac
k
2L1.5 500 750
2L2.5 500 750
3L1.5 500 750
4L1.5 500 750
4L2.5 500 1110
2H1.5 500 1110
2H2.5 500 1110
7L1.5 500 1110
Other colours available on request.
18
Cable Supply
Cable TestingThe insulant of all Mineral Insulated Cables has an affinity for moisture. However, the inorganic insulant utilised in the manufacture of Wrexham Cables has a self-blocking characteristic and can be left unsealed during installation and storage without being adversely affected.
During a period of several weeks exposure, atmospheric moisture will only penetrate an unsealed cable to a depth of approximately 100mm (see graph below). Subsequent stripping back during terminating will remove the moisture affected insulant.
It is therefore unnecessary to take costly special precautions when storing or installing Wrexham Wiring Cables and the following important points should be noted:
1. Temporary seals are not required during storage.
2. Installed cable lengths do not require temporary seals pending the fitting of terminations.
3. Extra length should not be allowed on installed cables to allow for shortening back of moisture affected ends. This is an unnecessary and wasteful practice.
4. Wrexham Mineral Insulated Cables are supplied with the ends unsealed. They should be cut to length and terminated at both ends before insulation resistance tests are carried out. (See Installation Practice section for details).
Coil Diameter available in either 500mm, 915mm or
1370mm
DEP
TH O
F PE
NET
RATI
ON
(mm
)
200
150
100
50
0 1 2 3 4 5 6
TIME EXPOSED (MONTHS)
FAILURE TO SEAL CABLE ENDS PRIOR TO TESTING WILL RESULT IN INCORRECT AND MISLEADING READINGS
The unique composition of our cable can withstand temperatures in excess of 1000°C and still operate safely at its rated voltage.
This impressive performance can add vital time to escape a fire and makes it ideal for use in large developments such as hospitals, shopping centres, airports, schools, underground rail systems and factories which house large numbers of people.
Standard Conductor Cable
1Solid Copper Conductors
2Magnesium Oxide Insulation (MgO)
3Solid Copper Sheath
4LSZH Outer Sheath (optional)
TECHNICAL ACCESSORIES
CORE
CABL
E SI
ZERE
FERE
NCE
CONDUCTORS CURRENT RATINGS VOLT DROP
SHEA
TH C
ROSS
SEC
TIO
N
AREA
(EFF
ECTI
VE m
m²)
MAX
SH
EATH
RES
ISTA
NCE
@
20C
0hm
/km
MAX
IMU
M C
ON
DU
CTO
R RE
SIST
ANCE
0hm
s PE
R 10
00 M
ETER
S 20
⁰C CABLE DIAMETER APPROX WEIGHT PER 1000 METERS
GLAND SIZEREF: RGM
CABLE FIXINGS
N0 X SQ MM
CABLES EXPOSED TO TOUCH ONE HOLE CLIPS TWO WAY SADDLES
BARE(AMPS)
COVERED(AMPS)
PER AMP/PER
METRE mV
BARE(mm)
LSZH COVERED
(mm)BARE (KG)
LZSHCOVERED
(KG)
PLAINSEAL(mm)
REF: WRPS
EARTHTAIL SEAL
(mm)REF: WRPSL
BARECOPPERREF: WRC
LZSHCOATED
REF: WRCHL
BARECOPPER REF: WRS
LZSHCOATED
REF: WRSFL
LIGHT DUTY CABLE (500 volts)
2L 1.0 2 1.0 16.5 18.5 42 5.4 3.95 18.1 5.1 6.6 105 124 20 20 20 26 202 272
2L 1.5 2 1.5 20.5 23 28 6.3 3.35 12.1 5.7 7.2 132 156 20 20 22 28 222 302
2L 2.5 2 2.5 28 31 17 8.2 2.53 7.41 6.6 8.1 184 207 20 20 26 32 272 342
2L 4.0 2 4.0 36 40 10 10.7 1.96 4.61 7.7 9.4 253 290 20 20 30 37 302 382
3L 1.0 3 1.0 13.5 15 36 6.7 3.15 18.1 5.8 7.3 132 159 20 20 22 28 242 302
3L 1.5 3 1.5 17 19 24 7.8 2.67 12.1 6.4 7.9 172 199 20 20 24 30 272 342
3L 2.5 3 2.5 23.5 26 14 9.5 2.23 7.41 7.3 9.0 234 270 20 20 28 34 302 342
4L 1.0 4 1.0 13.5 15 36 7.7 2.71 18.1 6.3 7.8 164 191 20 20 24 30 272 342
4L 1.5 4 1.5 17.5 19.5 24 9.1 2.33 12.1 7.0 8.5 209 243 20 20 28 34 302 342
4L 2.5 4 2.5 23.5 26 14 11.3 1.85 7.41 8.1 9.8 288 333 20 20 32 37 342 422
7L 1.0 7 1.0 9 10 42 10.2 2.06 18.1 7.6 9.3 237 271 25 25 30 37 302 382
7L 1.5 7 1.5 11.5 13 28 11.8 1.78 12.1 8.4 10.1 310 351 25 25 32 40 342 422
7L 2.5 7 2.5 15.5 17.5 17 15.4 1.36 7.41 9.7 11.4 433 475 25 25 37 43 382 462
20
Cable & Accessory SelectionTECHNICAL ACCESSORIES
CORE
CABL
E SI
ZERE
FERE
NCE
CONDUCTORS CURRENT RATINGS VOLT DROP
SHEA
TH C
ROSS
SEC
TIO
N
AREA
(EFF
ECTI
VE m
m²)
MAX
SH
EATH
RES
ISTA
NCE
@
20C
Ohm
/km
MAX
IMU
M C
ON
DU
CTO
R RE
SIST
ANCE
0hm
s PE
R 10
00 M
ETER
S 20
⁰C CABLE DIAMETER APPROX WEIGHT PER 1000 METERS
GLAND SIZEREF: RGM
CABLE FIXINGS
N0 X SQ MM
CABLES EXPOSED TO TOUCH ONE HOLE CLIPS TWO WAY SADDLES
BARE(AMPS)
COVERED(AMPS)
PER AMP/PER
METRE mV
BARE(mm)
LSZH COVERED
(mm)BARE (KG)
LZSH COVERED
(KG)
PLAIN SEAL (mm) REF: WRPS
EARTHTAIL SEAL
(mm)REF: WRPSL
BARECOPPERREF: WRC
LZSHCOATED
REF: WRCHL
BARECOPPER REF: WRS
LZSHCOATED
REF: WRSFL
HEAVY DUTY CABLE (750 volts)
1H2.5 1 2.5 39 43 13.5 6.44 3.71 7.41 5.3 6.6 111 128 20 20 20 26 202 272
1H4 1 4 51 56 8.3 7.7 3.09 4.61 5.9 7.2 143 166 20 20 22 28 222 272
1 H6 1 6 47 52 6 8 2.67 3.08 6.4 7.7 173 213 20 20 24 30 272 342
1 H10 1 10 63 70 3.6 9 2.23 1.83 7.3 9.0 241 274 20 25 28 34 302 342
1 H16 1 16 83 92 2.3 12 1.81 1.15 8.3 10.0 327 364 20 25 32 37 342 422
1 H25 1 25 108 120 1.45 15 1.4 0.727 9.6 11.3 458 500 20 32 37 43 382 462
1 H35 1 35 132 147 1.05 18 1.17 0.524 10.7 12.4 600 650 20 32 40 47 422 502
1 H50 1 50 163 181 0.79 22 0.96 0.387 12.1 13.8 760 812 25 40 47 54 502 542
1 H70 1 70 199 221 0.55 27 0.77 0.268 13.7 15.4 1019 1080 25 - 54 59 542 632
1 H95 1 95 237.5 264 0.41 32 0.65 0.193 15.4 17.7 1326 1416 25 - 59 67 632 702
1 H120 1 120 272.5 303 0.33 37 0.56 0.153 16.8 19.1 1615 1713 32 - 63 75 702 752
1 H150 1 150 311 346 0.29 44 0.48 0.124 18.4 20.7 1952 2059 32 - 71 79 752 812
1 H185 1 185 353 392 0.25 54 0.41 0.101 20.4 23.2 2425 2570 32 - 79 88 812 932
1 H240 1 240 411 457 0.21 70 0.34 0.0775 23.3 26.1 3146 3312 40 - 88 101 932 1042
1H300 1 300 795 883 0.31 84.6 0.28 0.0775 26 28.8 3791 3972 n/a n/a 101USE WRSHL18 OR WRSZL18 AS REQUIRED 1H400 1 400 948 1053 0.28 106 0.22 0.044 30 32.8 5004 5211 n/a n/a n/a
2 H1.5 2 1.5 22.5 25 28 11 1.9 12.1 7.9 9.6 247 284 20 20 30 37 342 382
2 H2.5 2 2.5 30.5 34 17 13 1.63 7.41 8.7 10.4 280 335 20 20 34 40 342 422
2 H4 2 4 40.5 45 10 16 1.35 4.61 9.8 11.5 365 415 20 25 37 43 422 462
2 H6 2 6 51 57 7 18 1.13 3.08 10.9 12.6 463 510 20 25 43 47 462 502
2 H10 2 10 69 77 4.2 24 0.887 1.83 12.7 14.4 653 725 25 32 47 54 502 592
2 H16 2 16 92 102 2.6 30 0.695 1.15 14.7 16.4 855 918 25 40 54 63 592 702
2 H25 2 25 119.5 133 1.65 38 0.546 0.727 17.1 19.4 1185 1285 32 40 67 75 702 752
3 H1.5 3 1.5 19 21 24 12 1.75 12.1 8.3 10.0 265 310 20 20 32 37 342 422
3 H2.5 3 2.5 25 28 14 14 1.47 7.41 9.3 11.0 345 390 20 25 37 43 382 462
3 H4 3 4 33 37 9.1 17 1.23 4.61 10.4 12.1 452 495 20 25 40 47 422 502
3 H6 3 6 43 48 6 20 1.03 3.08 11.5 13.2 562 602 25 25 43 51 462 542
3 H10 3 10 58.5 65 3.6 27 0.783 1.83 13.6 15.3 758 817 25 32 54 59 542 632
3 H16 3 16 77 86 2.3 34 0.622 1.15 15.6 17.9 1039 1130 25 40 59 71 632 752
3 H25 3 25 101 112 1.45 42 0.5 0.727 18.2 20.5 1451 1557 40 40 71 79 752 812
4 H1.5 4 1.5 19 21 24 14 1.51 12.1 9.1 10.8 330 370 20 20 37 43 382 462
4 H2.5 4 2.5 25 28 14 16 1.29 7.41 10.1 11.8 412 445 20 25 40 47 422 462
4 H4 4 4 33 37 9.1 20 1.04 4.61 11.4 13.1 530 608 25 25 43 51 462 542
4 H6 4 6 43 48 6 24 0.887 3.08 12.7 14.4 740 790 25 32 47 54 502 592
4 H10 4 10 58.5 65 3.6 30 0.69 1.83 14.8 16.5 916 979 25 32 54 63 592 702
4 H16 4 16 77 86 2.3 39 0.533 1.15 17.3 19.6 1292 1393 32 40 67 75 702 752
4 H25 4 25 101 112 1.45 49 0.423 0.727 20.1 22.9 1813 1956 40 40 79 88 812 932
7 H1.5 7 1.5 13 14.5 28 18 1.15 12.1 10.8 12.5 435 482 25 25 43 47 462 502
7 H2.5 7 2.5 17.5 19.5 17 22 0.959 7.41 12.1 13.8 563 616 25 25 47 54 502 542
12 H1.5 12 1.5 10.5 12 28 29 0.744 12.1 14.1 15.8 710 770 32 - 54 59 592 632
12 H2.5 12 2.5 14.5 16 17 34 0.63 7.41 15.6 17.9 910 1001 32 - 59 71 632 752
19 H1.5 19 1.5 9 10 28 37 0.57 12.1 16.6 18.9 989 1086 40 - 63 71 702 752
Twisted Conductor Cable
22
2 Core
3 Core
4 Core
Twisted Conductor Cable
Our Twisted Conductor Cables are designed for use where enhanced fire survival is required such as fire alarm and detection systems.
Other applications include fire telephone systems, CCTV and public address systems. Our Twisted Conductor Cables have reduced electromagnetic interference and signal corruption, reducing system malfunction and improved electrostatic screening.
CABLE SIZE REFERENCE CONDUCTORS CONDUCTOR
RESISTANCE
MAX SHEATH RESISTANCE
@20C Ohm/km
CAP-C/C@10k-Hz
CAP-C/SH@10kHz
IND-LOOP@10kHz
CHARACTERIMP
DIAMETEROVER SHEATH
DIAMETEROVER LSZH
CONDAREA
FREQUENCYOF TWIST
(PER METRE)
LSZH 2T1 2 18.1ohms/Km 3.95 144
pF/m219
pF/m443
uH/Km55
ohms 5.1mm 6.6mm 1.0mm² 20
LSZH 2T1.5 2 12.1ohms/Km 3.35 164
pF/m243
pF/m436
uH/Km52
ohms 5.7mm 7.2mm 1.5mm² 20
LSZH 2T2.5 2 7.4ohms/Km 2.53 170
pF/m270
pF/m410
uH/Km49
ohms 6.6mm 8.1mm 2.5mm² 20
LSZH 3T1.5 3 12.1ohms/Km 2.67 160
pF/m260
pF/m450
uH/Km50
ohms 6.4mm 7.9mm 1.5mm² 20
LSZH 4T1.5 4 12.1ohms/Km 2.33 180-216
pF/m290
pF/m520
uH/Km48
ohms 7.0mm 8.5mm 1.5mm² 20
Cable & Accessory Selection
Reduced electromagnetic interference and signal corruption
Accessories
Fixing Clips & Saddles Brass Glands
Earth Tail Seal Kit Plain Seal Kit Copper Fixing Strap
Gland Shrouds Brass Locknuts Serrated Washers
For use with the installation of the gland.Sizes: 20mm, 25mm, 32mm, 40mm.PRODUCT CODE: WRLWS
To complement the cable,Wrexham Mineral Cablehas developed a range ofaccessories and tools, andcan therefore supply acomplete wiring system to suitthe requirements of a widevariety of installations andapplications where only MICC cables are suitable.
24
For use when making your own special size cable groupings. All colours available.Size: 12mm, 18mm. Sold as 5Mtr Roll.PRODUCT CODE: WRSZL - WRSHL (covered)PRODUCT CODE: WRSZ - WRSH (bare strap)
Zero halogen shroud available in all standard colours with special colours available on request. Sizes: 20mm, 25mm, 32mm, 40mm.PRODUCT CODE: WRHGMM - (LSZH), WRHG - (PVC) Available in 20mm & 25mm only
For use with the RGM glands to secure the gland to the power supply box.Sizes: 20mm, 25mm, 32mm, 40mm.PRODUCT CODE: WRLM
A full range of clips and saddles are avail-able in Bare Copper, Red, Orange, Black, & White. Other colours available on request.PRODUCT CODE: WRCHL (clips)PRODUCT CODE: WRSFL (saddles)
ATEX certified brass compression glands for EExd and general applications.Sizes: 20mm, 25mm, 32mm, 40mm.
PRODUCT CODE: WRGM + cable size in mm
Termination seals with built in earth tail for easy use. Kit comprises of E/T pots, WRMX sealing compound, Stub caps, Conductor and earth sleeving. Sizes: 20, 25, 32, 40mm
PRODUCT CODE: WRPSL
Termination seals without built in earth tail. Kit comprises Seal pots, WRMX sealing compound, Stub caps, Conductor sleeving.Sizes: 20mm, 25mm, 32mm, 40mm.
PRODUCT CODE: WRPS
Our cable fixings are fire rated and meet the requirements of BS 7671 fire resitant cable fixings in escape routes.
Tools
Pot Wrench
Plate Type Crimper Bending Lever Rotary Stripper
Joistripper Ringing Tool Wrench
A quick and easy tool for crimping the stub caps into the pots. The ‘T’ bar avoids the need for spanners.PRODUCT CODE: WZDC20
Uses a 3 point crimping plate to lock the stub cap into the pot.PRODUCT CODE: WZDD + 20mm, 25mm, 32mm, 40mm
To assist in the dressing of cables or when using the larger cables. The bending lever will help save time.PRODUCT CODE: WZBLA (cables 10-16mm) WZBLB (cables 16-27mm)
Strips cables sheathsPRODUCT CODE: WZSUS (<8mm dia. cable) WZSU (>8mm dia. cable)SPARE BLADES: WZSUSB (pack of 5) WZSUB (pack of 5)
Easy to set tool for fast and efficient stripping of: 2L1, 2L1.5, 2L2.5, 3L1, 3L1.5, 4L1, 4L1.5PRODUCT CODE: WZSJSPARE BLADES: WZSJB (sold individually)
Used to score a light groove around the cable sheath to neatly stop the stripping action.PRODUCT CODE: WZR
Quick and easy ratchet tool for screwing on 20mm brass pots to the cable.PRODUCT CODE: WZRP (20mm pots only)
Hand Crimper
Tool ensures quick and accurate screwing on of the brass pot. Sizes: 20mm, 25mm, 32mm, 40mm.
PRODUCT CODE: WZPM + Pot Size in mm
Accessories & Tools
For further information on
our tools and components
please call our sales team
on +44 (0)1978 810789
BendingAll normal bending may be carried out without the use of tools, however, two sizes of bending levers are available for use with the larger diameter cables or when multiple bends are required - WZBLA (small) and WZBLB (large). These levers are specially designed to prevent cable damage during bending (see Fig. 3).
The bending radius is normally recommended to be limited to six times the diameter of the bare copper cable, which permits further straightening and re-bending if required. If more severe bends are unavoidable, they should be limited to a minimum bending radius of three times the bare cable diameter, and any further straightening and bending must be done with care to avoid damage to the cable.
When offsetting the cable to enter an enclosure via a gland, 25 - 50mm of straight cable should be left between the gland and the final bend to facilitate withdrawal of the gland from the enclosure.
Spacing of fixingsAs a general guide, horizontal fixings should be spaced at not more than 100 times the cable diameter which may be increased by 50% for vertical runs. The following table is given for guidance:
OVERALL DIAMETER OF CABLE
MAX. SPACING OF FIXINGS FOR MI CABLE
mmHORIZONTAL VERTICAL
mm mm
Not exceeding 9 600 800
Exceeding 9 and not exceeding 15 900 1200
Exceeding 15 and not exceeding 20 1500 2000
Exceeding 20 and not exceeding 40 2000 3000
Preparation for strippingCutting the Cable to Length
The cable should be cut squarely to the length required allowing for the appropriate length of conductor tails (Fig. 4).
For Cables with LSZH Coverings
When a gland shroud is to be used, cut the cable end square, and then offer up the shroud to the cable end in reverse to determine the amount to be cut off, to ensure a tight fit over the outer LSZH covering (Fig. 5).
It will be necessary to remove an appropriate length of the outer covering prior to stripping the copper sheath. Mark the covering to the required tail length, plus an additional amount as indicated in the table.
Gland Size 20 25 32 40
Length of tail plus 70mm 70mm 80mm 90mm
It is important when removing the LSZH covering with a knife, not to nick the under-lying copper sheath (Fig. 6).
Fig. 4
Fig. 5
Fig. 3
26
Hold the knife blade flat on the sheath so that the edge does not cut into the copper (Fig. 7). Then mark and strip the copper as follows:
Stripping the Cable SheathThe sheath and insulant should be stripped back to expose the conductors using one of the methods described later. Allow for the required length of tail, plus the measurement indicated below according to the size of seal being fitted.
Pot Size 20 25 32 40
Length of tail plus 11mm 17mm 20mm 25mm
Using the Large and Small Rotary Strippers(WZSU & WZSUS)
The large Rotary Stripper reference WZSU will accommodate all sizes of cable by adjustment of the knurled screw and locknut. The small ‘V’ of the reversible block will accommodate cables up to 8·5mm diameter, for cable above this size the larger ‘V’ must be used.
Positioning of the appropriate ‘V’ is achieved by unscrewing the retaining screw, reversing the block (ensuring that the chamfered edge is on opposite side to cutting wheel) and then retightening the retaining screw (see Fig. 8 and Fig. 9).
The small Rotary Stripper reference WZSUS is suitable for use on cables up to 8.00mm diameter. The tool has a fixed v block and is adjusted by means or the knurled screw. The large Rotary Stripper WZSU is illustrated here, the operations are identical for the small Rotary Stripper WZSUS. Spare blades for these tools are available, Ref. WZSUB or WZSUSB.
Having previously marked the sheath at the point stripping is to stop (point A Fig. 10), add a second pencilmark one tool width further along the sheath to indicate stop position and location of pliers (point B, Fig. 10).
Insert the cable into the tool as far as the face of the cutting wheel (Fig. 11). Tighten knurled screw untilthe tool can just support its own weight in a horizontal position. Slightly release screw until tool can just fall under its own weight and finger tighten locknut. (No locknut is fitted to the small Rotary Stripper).
Fig. 8 Fig. 9
Fig. 11
Fig. 10AB
Fig. 6
Fig. 7
Installation Practice
Rotate tool in a clockwise direction applying slight pressure in the direction of stripping until sufficient swarf has been formed, to allow it to be bent round the adjacent post, (Fig. 12 and Fig. 13). This will prevent the tool snagging on the swarf and swarf coils from damaging the exposed conductors. When making long tails it is advisable to cut off the surplus swarf as the stripping proceeds.
Continue turning the tool which will feed itself along the cable. When sufficient sheath has been strippedthe operation is terminated by gripping the cable with pliers at the point marked B and allowing the toolto rotate against the jaws (Fig. 14). Remove the tool.
After removal of any remaining insulant from the conductors, the cable is now ready for sealing.
Note:
1. The strippers will not self feed satisfactorily if:a. The cable is flattened or distortedb. The blade is not free to rotate or is blunt or chipped
The Joistripper is the sheath stripping tool specially recommended for 2L1, 2L1·5, 2L2.5, 3L1, 3L1·5, 4L1 and 4L1·5 light duty Wrexham Cables. It is quick and easy to use, taking off more sheath per revolution than any othertool of its type (Fig. 15).
The tool has a robust steel guide block which is easilypositioned to accommodate the different cable sizes.
Setting the guide block
Unscrew the guide block retaining screw in the back of the guide block, in order to clear the block from thelocating pin in the handle assembly.
The block can then be rotated to align the appropriate cable guide hole with the cutting blade and then engage the locating pin. Finger pressure only to be used. Do not force the guide block by tightening the retaining screw. Ensure no dirt is blocking the locating hole. Then tighten the retaining screw and the tool is ready for use. Do not adjust the blade.
Changing the blade
Unscrew the retaining screws (Fig. 15) holding the clamping plate and remove blade. Ensure cleanliness of the slot before inserting replacement blade. Slide blade down the slot until it rests against the face of the guide block, whilst still lying flat in the slot.
Replace and secure clamping plate, tighten the two retaining screws without undue force. The blade is sharpened at both ends so that a spare cutting edge is available.
Note:The Joistripper will not self-feed along the cable if:a. The cable is flattened or bentb. The blade is chipped or bluntc. The cable guide hole diameter is reduced by copper
accumulated from the cable sheath. This can be avoided by periodic cleaning with a rag dipped in solvent. e.g. white spirit
Fig. 14
Fig. 12 Fig. 13
Fig. 15
Using the Joistripper Tool Ref WZSJ
Retaining screws
28
Pencil mark the sheath at the point where stripping is to stop, point A. Add a second pencil mark one tool width further along the sheath to indicate stop position and location of pliers, point B. Place the tool over the end of the cable and with a slight initial forward pressure, rotate the tool (Fig. 16).
The tool will feed itself along the cable ~ removing the sheath in a continuous spiral. If the tool does not feed itself due to minor distortion of the cable, a continuous slight forward pressure to assist the feed will enable thestripping to be carried out. When making long tails it is advisable to cut off the surplus swarf as the strippingproceeds.
When sufficient sheath has been removed, the operation is terminated, by gripping the cable with pliers at point B allowing the tool to rotate against the jaws (Fig. 17). Remove the tool and any remaining insulant from the conductors, The cable is now ready for sealing.
Using the WZPM Pot Wrench
Recommended for all types of seal when using externally threaded WRGM glands, available for all four gland sizes.
If the sheath stripping operation has left any roughness around the end of the sheath, this can be removed by lightly running pliers around the cable end, ensuring that no resultant metal particles adhere to the insulant.
Place gland shroud (if required), gland nut and compression ring on stripped end of cable.
Position the pot into gland body and screw into tool (Fig. 18). Finger tightness is not sufficient. The assembly must be lightly nipped up using pliers or a spanner.
Slide the WZPM Pot Wrench onto the cable, turning it in a clockwise direction while applying sufficient forward pressure to engage internal screw thread of the pot onto the cable sheath.
Continue rotating the tool until the sheath is level with the shoulder inside the pot (Fig. 19).
In the case of the Increased Safety Seal, it is necessary to screw the pot onto the sheath until 2mm of cable protrudes beyond the shoulder inside the pot (Fig. 20).With the small diameter cables it is advisable to grip the cable sheath with pliers just behind the gland to preventtwisting of the cable.
Fig. 18
Fig. 16
Fig. 17
Fig. 19
AB
Fig. 20
Installation Practice
Do not reverse the screwing motion whilst fitting the pot, as this can cause slackness of the pot, which can affect sealing performance. When using earth tail seals the earth continuity may also be adversely affected. When fitting an earth tail pot, the pot should be further turned until the earth tail is midway between two conductors, to ensure alignment with the cap or disc (Fig. 21). The fitting operation may be assisted by applying a light smear of petroleum jelly to the sheath. However, petroleum jelly must not be used with Increased Safety Seals.
Remove the WZPM Pot Wrench from the gland body. When unscrewing the WZPM Pot Wrench grip the gland body with pliers or a spanner to prevent the pot unscrewing from the sheath.
Taking care to avoid facial contact with the conductor ends. Examine the pot interior and remove any metal slivers or loose powder that may have resulted from the screwing.
The conductor lengths should be staggered as follows:
. Twelve core - shorten the nine outer conductors by 10mm
. Nineteen Core - shorten the twelve outer conductors by 20mm and the inner six conductors by 10mm (Fig. 22)
Spread the outer conductors and keeping the thumb between the wrapping and the compound to ensure cleanliness, push the compound around the innerconductors and down to the cable insulant (Fig. 23).
Pull the inner conductors straight using pliers. Reposition the next layer of conductors and apply more compound as necessary, before restraightening the conductors by pulling gently with pliers. In the case of nineteen conductor cables repeat the above repositioning, filling and restraightening operations for the outermost layer of conductors. Taking care to avoid cavities, slightly overfill the pot. Care should be taken to avoid contamination of the sealing compound.
Enter the conductors into the stub cap one at a time, starting with the inner conductors and taking care to achieve correct alignment. When all conductors havebeen entered, push the cap into the pot recess with the aid of a pair of pliers or other suitable tool. The seal is now ready for crimping.
For Twelve and Nineteen Conductor Standard Seal
Fig. 21
Fig. 23
Fig. 22
30
“Over 135million metresmanufactured
to date”
“Over 140 million metres of MICC manufactured
to date”
Two types of crimping tool are available and are used as follows:
Plate Crimp Tool Ref. WZDD 20,25.32 40 (Fig. 24)
Fully unscrew the two screws, slide the crimping plate over the conductors and up to the pot. Swivel the slotted base up around the cable behind the pot and evenly tighten the two screws, which will drive the stub cap or disc fully into the pot recess and secure it in position by means of three indent crimps. Unscrew thescrews and remove the tool.
Hand Crimp Tool Ref WZDC20 (Fig. 25)
Fully unscrew the drive screw by means of the handle. Slide the conductors through the hole in the crimping plate and through the hollow drive screw.
Place the pot into the seating in the brass body and tighten the screw until it is fully hand tight which will drive the stub cap or disc fully into the pot recess and secure it in position by means of three indent crimps. Then unscrew and remove the tool. When using stub caps cut the conductor insulating sleeving to the required length and slide it over the conductors and onto the stubs(Fig. 26).
PTFE headed sleeves for the increased safety seal are supplied in 100mm lengths as standard. Longer lengths are available to special order.
Testing
Insulation testing should never be carried out on cables which have unsealed ends because this will result in false and misleading readings. Moisture in the atmosphere can be recorded across the face of the exposed magnesium oxide insulation resulting in false low insulation resistance readings.
After both ends have been terminated with permanent seals, the cable should be tested for insulation resistance at a d.c. voltage appropriate to the intended operating voltage, as per regulations. This initial test is to check for major faults, (Short circuits within the seal pot) in which case the fault can be located and rectified.
The insulation resistance reading should be noted and compared with the value measured twenty-four hours later. The insulation resistance should be at least 100 meg ohms and have risen from the initial test.
Completing the Seals - Crimping the Pot Closure
Fig. 24
Fig. 25
Fig. 26
Fig. 27
Installation Practice
ProjectsWrexham Mineral Cables have provided true fire survival cable systems for many industries and businesses, exporting to approximately 20 countries around the world including:
• Qatar
• Kuwait
• Saudi Arabia
• Bahrain
• Oman
• Australia
• United Arab Emirates
• India
• Indonesia
• Sri Lanka
• Sudan
• USA
• Malaysia
• Canada
• Thailand
• Hong Kong
Lusail City Multipurpose Stadium
Building Includes: Field of Play, Warm up halls, Changing rooms, Lounges, Medical center, Concourses, Spectator seating, VIP/VVIP area, Ticketing offices, Food and Beverage service, Restaurants, Cafes, Rentable spaces, Office spaces, Event & Competition supporting facilities, Media and Broadcasting facilities, and Prayer rooms.
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Special ProductsWrexham Mineral Cables have used their expertise in engineering, ceramics and manufacturing of mineral insulated (MI) cables to develop bespoke cables to suit client’s special applications.
One area is long line MI heating cables requiring the optimum of product performance in the most demanding environments.
Our technical team have called upon sound engineering experience combined with product knowledge to manufacture MI cables with a range of conductor and sheath materials such as nickel-copper alloy, stainless steel and many other alloy based materials to provide a range of MI heating cables to our client’s specifications.
Our success in this field has led to us being approached by several international corporations to find solutions to their requirements where other manufacturers have failed.
Due to our initial investment and commitment into continuous manufacturing techniques for general wiring MI cables we have been able to build on this technology to manufacture larger diameter cables with multiple sheaths producing individual lengths in excess of 2km.
Projects & Special Products
TrainingWrexham Mineral Cables regularly train students and experienced contractors in terminating MICC cables either at our factory or if suitable we can come to your site. We also issue a step by step training session on DVD.
Please enquire for more details on +44 (0)1978 810789.
+44 (0)1978 810789
www.wrexhammineralcables.com
34
Wrexham Mineral Cables Middle East Approvals• Kuwait Oil Company (KOC)
• Qatar Civil Defence
• Qatar General Electricity & Water Corporation (Kahramaa)
• Dubai Civil Defence
• Saudi Arabian Electrical Company (SEC)
SUCCESSFULLY EXPORTING
TO OVER 20 COUNTRIES
AROUND THE WORLD
Middle East Approvals
WMC OO3/H
Wrexham Mineral CablesWynnstay Technology Park
RuabonWrexham
LL14 6ENUnited Kingdom
Tel: +44 (0)1978 810789
Contents are subject to change without notice
