This section covers several categories pertaining to the installation and use of our cable. Including:

  • Jamming
  • Minimum Bending Radii
  • Maximum Pulling Tensions
  • Cable Sidewall Pressure
  • Cable Preparation and D.C. Hi-Pot Testing Procedure
  • Cable End Preparation
  • Cable Storage Procedure

JAMMING
Jamming is the wedging of three or more cables as they are pulled into a conduit. This usually occurs as a result of cross-overs when the cables are twisted or are pulled around bends in the conduit. Jam ratio is defined as the ratio of conduit inner diameter (D) to the cable outside diameter (d).



Probability of Jamming
Jamming Probability Using Jam Ratio




The oval cross section of conduit bends was accounted for with a 5% factor.
Note: Measured cable diameters should be used to determine the jam ratio since actual cable diameters vary from published values.

MINIMUM BENDING RADII
These factors apply to the minimum values for the radii to which insulated cables may be bent for permanent training during installation. These limits do not apply to conduit bends, sheaves, or other curved surfaces around which the cable may be pulled under tension while being installed. In all cases the minimum radii specified referes to the inner surface of the cable and not to the axis of the cable. These factors apply only as noted. Additional constructions are covered under the appendix of ICEA S-93-639, ICEA S-95-658, and ICEA S-96-659.

A. Power Cables Without Metallic Shielding or Without Armor
The minimum bending radii for both single and multi-conductor cables with or without lead sheath and without metallic shielding are as follows:
Thickness of Conductor Insulation in Mils 155 and Less
Overall Diameter of Cable Inches
1.000 and Less 1.001 to 2.000 2.001 and Over
4 5 6


Power Cables Over 600 Volts, Non-Shielded, Non-Armored:
The minimum bending radius for all cables is eight times the overall cable diameter.
Power Cables Over 600 Volts, Shielded or Lead Covered:
The minimum bending radius for all cables is twelve times the overall cable diameter.
Interlocked Armored Cables, All Voltages:
For Non-Shielded cables, the minimum bending radius is seven times the armor O.D. - For Shielded cables, the minimum bending radius is twelve times the diameter of one phase conductor or seven times the armor O.D., whichever is larger.

MAXIMUM PULLING TENSIONS
The following recommendations are based on a study sponsored by the ICEA. These recommendations may be modified if experience and more exact information so indicate.

  1. Maximum Pulling Tension on a Cable:
    1. With pulling eye attached to copper conductors:

      WHEN MORE THAN THREE CONDUCTORS ARE PULLED TOGETHER, THE MAXIMUM PULLING TENSION SHOULD BE REDUCED BY 20%.

    2. With cable grip over lead sheath:
    3. With cable grip over non-leaded cable:
      The maximum pulling tension is determined per grip manufacturer's specification.
  2. Maximum Permissible Pulling Length:
  3. Maximum Tension Requirement in Ducts:
    1. For straight duct sections, the pulling tension equals the length of the duct multiplied by the weight per foot of cable and the coefficient of friction (per type of lubricant).
    2. For curved sections, the following formula applies:

CABLE SIDEWALL PRESSURE
The maximum pulling tension in pounds shall not exceed the following factor times the radius of curvature of the bend expressed in feet.

Cable Type Factor
Low voltage 16 -10 AWG 300
Low voltage 8AWG & larger 500
5KV non-shielded 500
5 KV - 35KV shielded 500
Interlocked Armor (all) 300


CABLE PREPARATION AND D.C. HI-POT TESTING PROCEDURE

600 to 5000 Volt Non-shielded Cables
Common Cable Preparation (See Diagram A below)

  1. Remove 18" of the overall jacket from the end of the cable.
  2. Clean the insulation with the proper cable cleaner.
  3. Remove 1" of the insulation from the end of the cable.
  4. Repeat the procedure for each conductor in the cable.


D.C. High Voltage Test
Note: If the cable to be tested is a multi-conductor cable, the conductor(s) not under test must be connected to each other and to the other metallic components (if applicable). The cable's grounding conductor must be connected to the metallic components of the cable.

  1. The D.C. High Voltage Test is performed by increasing the voltage to the test voltage and holding the cable at the test voltage for 5 minutes. The leakage current is then recorded.
  1. The test voltage is determined by the conductor size and the type of insulation, and is listed in Table I, II or III.

Termination
Termination should be made in accordance with the termination kit manufacturer's procedure.

TABLE I


Thermoset material, i.e. XLP, EPR, Types XHHW-2, RHH or RHW-2 or USE-2. Testing is currently for multiple conductors.
Conductor Size (AWG or KCMIL) DC Test Voltage (KV)*
Cable Voltage Rating
600V 1000V 2000V
14,12,10 12.0 15.0 16.5
8-2 16.5 18.0 21.0
1-4/0 21.0 22.5 24.0
250-500 24.0 27.0 28.5
600-1000 30.0 33.0 34.5
* - Test Voltage per ICEA.



TABLE II



PVC insulated conductors

Conductor Size (AWG or KCMIL) DC Test Voltage (KV)*
14,12,10 2.0
8-2 3.5
1-4/0 4.0
250-500 4.5
600-1000 6.0
* - Test Voltage per ICEA.



TABLE III



5000V Non-shielded MV-90 Cable

Conductor Size (AWG or KCMIL) DC Test Voltage (KV)*
8-2 25.0
1-4/0 25.0
250-500 25.0
600-1000 25.0
* - Test Voltage per ICEA.



Shielded MV-90 (or EPR MV-105) Cables
Common Cable Preparation (See Diagram B below)

  1. Remove 22" of the overall jacket from the end of the cable.
  2. Remove the metallic shield to within 2" of the jacket.
  3. Remove the semi-conducting insulation shield layer to within 1" of the metallic shield:
    1. Score the extruded semi-con around the cable to within 1" of the metallic shield.
    2. Score longitudinally 3/8" wide around the cable.
    3. Grasp the end of the semi-conducting layer with needle-nose pliers and peel back.
  4. Clean the insulation with an appropriate, commercially available cable cleaner.
  5. Remove 1" of the insulation and conductor shield from the end of the cable.
  6. Repeat the procedure for each conductor in the cable.

D.C. High Voltage Test
Note: If the cable to be tested is a multi-conductor cable, the conductors(s) not under test must be connected to each other and to the other metallic components. The cable's grounding conductor must be connected to the metallic components of the cable.

  1. The D.C. High Voltage Test is performed in steps of 5KV to reach the test voltage. The leakage current is recorded at each 5KV step. The test voltage is then held for a period of 15 minutes, and the final leakage current is then recorded.
  1. The test voltage is specified by the voltage and insulation level of the cable. See Table IV for the appropriate test voltage.
TABLE IV



Shielded MV-90 (or EPR MV-105) Cable

Voltage & Insulation Level DC Test Voltage*
5KV 100% & 133% 25KV
8KV 100% OR 133% 35KV
15KV 100% 55KV
15KV 133% 65KV
25KV 100% 80KV
25KV 133% 100KV
28KV 100% 85KV
35KV 100% 100KV
* - Test Voltage per ICEA.



Termination
Termination should be made in accordance with the termination kit manufacturer's procedure.

CABLE END PREPARATION
Diagram A - 600 to 5000 Volt Non-Shielded Cables:


Diagram B - Shielded MV-90 (or EPR MV-105)Cables:

CABLE STORAGE PROCEDURE
The cable reel should be securely fastened to a suitable stationary object to prevent mechanical damage. A tarp or other equivalent protective covering should be used to protect cable that will be exposed to weather during storage. Aetna cable is shipped with end caps, which provide mechanical and moisture protection during shipment. The end caps on this cable should not be removed till the cable is tested according to the warranty requirements. Also, if the cable will not be installed shortly after testing is completed, the end caps should be replaced to avoid moisture accumulation in the ends of the cable. Moisture accumulation in the cable can be detrimental to cable performance, cable life and personnel. Any moisture, which has accumulated in the cable, should be purged prior to energizing the cable. For installation below -10C preheating the wire is recommended 24hrs before installation.

 

 

 
       
   

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