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CABLE INSTALLATION
MAN UAL
SEVENTH EDITION
1600 West Main Street

Willimantic, CT 06226-1128
(800) 338-0901
FAX (860) 450-7019
Division of:
BICC Cables Corporation / One Crosfield Avenue West Nyack, NY 10994
BICC CABLES
CABLE INSTALLATION MANUAL
TABLE OF CONTENTS
1. Introduction ................................................. 4
11. Preinstallation ............................................... 5
A. Overview ................................................. 5
B. Cable Inspection ........................................... 5
C. Cable Handling ......................... 5
D. Cable Storage ............................................. 7
E. Preinstallation Checklist ..................................... 7
Ill. Installation .................................................. 8
A. Overview ........ 8
B. Ambient Temperatu're' 8
C . Equipm ent ................................................ 9
1. Checklist .............................................. 9
2. Diagram s ............................................. 10
D. Conduit Fill .............................................. 13
1. Overview ............................................. 13
2. Form ulae ............................................. 13
3. Raceway Data ......................................... 13
a. Rigid Conduit Information ............................ 15
b. Duct Inform ation ................................... 16
c. Sweep Elbow Radius ................................. 17
d. Conduit Spacing ................................... 18
e. Durasheath EP, 600v ................................ 19
f. Unicon FREP, 600v .................................. 22
g. Durasheath EP, 5kv ................................. 24
h. EP - Lead ......................................... 26
i. UniBlend .......................................... 30
j. UniShield ......................................... 34
E. Mechanical Fit of Cable in Raceway .... ..................... 38
1. Configuration .......................................... 38
2. W eight Correct Factor ................................... 38
3. Clearance ............................................. 40
4. Jam Ratio ............................................. 40
5. Coefficient of Dynamic Friction. ........................... 41
F. Physical Limitations of Cables ............ .................. 42
1. Maximum
2. Overview .............................................
Pulling Tensions .................. ............ 42
42
a. O verview ...................... ..... ............. 42
b. On Pulling Device ............ ...................... 42
c. On Conductor ....................................... 43
1. Form ulae ....................................... 43
2. Conductor Data .................................. 44
3. Si Units ......................................... 45
4. In Parallel or in Assemblies ......................... 46
5. Multiconductor Cables ............................. 47
6. Verticle Bend, Pulling Up ........................... 48
7. Verticle Bend, Pulling Down ......................... 48
8. Horizontal Pull ................................... 48
2
BICC CABLES
TABLE OF CONTENTS
9. Inclined Pull ...................................... 48

1 0. Horizontal Bend ................................... 48
11. Around Bends ..................................... 49
12. Calculation Correlation .............................. 49
13. Bend M ultiplier .................................... 49
3. Sidewall Loading ....................................... 51
4. Training and Bending .................................... 52
5. Calculation Examples ................................... 55
6. Installation Checklist .................................... 58
IV. Splicing &Terminating ........................................ 60
A. Why Shield Power Cables? ................................. 60
B. Splicing & Terminating Overview ............................. 61
C. Precautions .............................................. 62
D. Equipment ............................................... 62
E. Medium Voltage Cable Components .......................... 63
F. Cable Preparation ......................................... 65
G. Tape Termination ......................................... 67
H. Tape Splice .............................................. 69
1.Tape Construction Materials ................................ 71
J. Accessory Manufacturers .................................. 72
k. Splicing and Terminating Checklist ........................... 73
V. Testing .................................................... 74
A. Overview ................................................ 74
B. Equipm ent ............................................... 74
C. Procedures ............................................... 74
D. High Potential (HiPot) Testing ................................ 75
E. Common Problems ........................................ 76
F. Equipment Suppliers ....................................... 76
G. ICEA, NEMA and IEEE Standard 400 .......................... 77
H. AEIC CS5 & CS6-87, Section K .............................. 77
1. Test Report Format ........................................ 78
J. Fault Testing ............................................. 79
K.- ac Testing ............................................... 79
L. Insulation Testing ......................................... 79
M .Testing Checklist .......................................... 79
IV. Appendix .................................................. 80
A. Circuit Design Considerations ............................... 80
1. Calculation Procedures .................................. 80
2. Calculation Input ....................................... 81
3. Pull Box Sizing ......................................... 82
4. Dynamometer Correction ................................ 83
5. Suspending Cable ...................................... 84
6. Overall Diameter of Multiconductor Assemblies .............. 85
B. Purging Water from Strand or Shield .......................... 86
C. Sym bols ................................................ 88
D. Cable Installation Data Sheet ................................ 89
BICC CABLES
1.INTRODUCTION
A power cable and its components are governed by the fundamental laws of physics, chemistry and
mechanics. Thus, these laws must be considered during installation if your cable investment is to be protected.
This manual provides installation methods based on these laws and should be used in conjunction with the
circuit designer's installation specifications and all applicable codes. The methods are valid for all types of
cable: power, control, instrumentation, and telecommunication.
This manual is intended for the installer's use in the field and is not a text on power system design or electrical
circuit analysis. The information given is concise, but should be sufficient for the majority of installations. If you
require additional information, please contact BICC Cables at (800) 338-0901.
Th data and recommendationsthat follow are based on information currently availableand

beli ved to be reliable.BICC Cables makes no guaranteeof the results and assumes no obligation
or liability whatsoever in connection with these recommendations.
4
11. PREINSTALLATION
A. OVERVIEW
To ensure safety during cable installation and reliability once the cable is installed, you should confirm
the following prior to installation.
* The cable selected is proper for your application

* The cable has not been damaged in transit or storage.
Review all applicable, state and national codes to verity that the cable chosen is appropriate for the job.
Also, consult your local building authority.
Next, you must identify any existing cable damage and prevent any further damage from occuring. This
is done through proper cable inspection, handling and storage.
B. CABLE INSPECTION
Inspect every cable reel for damage before accepting the shipment. Be particularly alert for cable damage if:
* A reel is laying flat on its side
* Several reels are stacked
* Other freight is stacked on a reel
* Nails have been driven into reel flanges to secure shipping blocks
* A reel flange is damaged
* A cable covering is removed, stained or damaged
* A cable end seal is removed or damaged
* A reel has been dropped (hidden damage likely)
C. CABLE HANDLING
Remove all nails and staples from the reel flanges before moving a reel, and avoid all objects that could
crush, gouge or impact the cable when moving. NEVER use the cable as a means to move a reel
When unreeling, observe recommended bending radii, use swivels to prevent twisting and avoid overruns.
PREINSTALLATION (CONT.)
How to Handle Cable Reels
Cradle both reel flanges between Upended heavy reels will often
forks. arrive damaged. Refuse or
receive subject to inspection for
hidden damage.
F,
Reels can be hoisted with a shaft Do not lift by top flange. Cable or
extending through both flanges. reel will be damaged.
Never allow forks to touch cable

Lower reels from truck using surface or reel wrap.
hydraulic gate, hoist or fork lift.
LOWER CAREFULLY.
Always load with flanges on edge Never drop reels.

and check and block securely.
6
PREINSTALLATION (CONT.)
D. Cable Storage
Cables should be stored on hard surfaces so that reel flanges cannot sink. Small reels may weigh several
hundred pounds while large reels can exceed 1000 pounds.
Prevent impact damage by:
• Aligning reels flange to flange

• Using guards across flanges when different reel sizes are stored together
* Maintaining adequate aisles and barricades to prevent equipment from hitting the cable.
Seal the ends of all cable stored outdoors, and reseal both ends when a length is cut from the reel.
E. Preinstallation Checklist
Code Review
Review local, state and national codes relating to cable installation
Consult local inspection authority
Cable Inspection
Check for shipping damage before accepting shipment
Confirm tlat the cable specified was received
Reseal cable ends
Cable Handling
Remove nails and staples from reel flanges
Calculate and observe recommended bending radii
Use swivels and avoid overruns when unreeling
Cable Storage
Provide firm support for reels
Protect cable from mechanical damage and from liquid spills
Check cable end seals periodically
Advise all splicers, installers and handlers of all special instructions
7
111. INSTALLATION
A. Overview
A survey of customer complaints revealed that 92% of the cables in question failed due to mechanical
damage. When does mechanical damage usually occur? During installation.
In tact, most cables are subjected to more mechanical stress during installation than they ever experience
in actual operation. Needless to say, handling and pulling your cable according to manufacturer's recom-
mendations is extremely important.
There are five main considerations in any cable installation:
* Ambient Temperature
* Equipment
* Conduit Fill
* Mechanical Fit in Raceway
* Physical Limitations
These considerations were developed and refined by installers of paper-lead cables. Two excellent refer-
ences are the "Underground Systems Reference Book" and "Pipeline Design for Pipe Type Feeders
The former was published by Edison Electric Institute in 1931 and was last revised in 1957. The latter
was an AIEE paper (#53-389) by R.C. Rifqnburg, published in POWER APPARATUS & SYSTEMS in De-
cember, 1953.
B. Ambient Temperature
Low temperatures are a cause for concern when installing cable. The following are temperatures below
which cable should not be installed.
CP/EP - 1/C - 31 OF FREP, PE, XLPIE - 1 /C - 58OF

CPE Jacket - 31OF
CPE/EP - 1/C - 31OF PVC + 14OF
CIP = Chlorosulfonated Polyethylene (HypalonO), CPE = Chlorinated Polyethylene,

EP = Ethylene Propylene. FREP = Flame Retardant EP
PVC = Polyvinyl Chloride.
During cold weather installation, cable should be pulled more slowly and trained in place the same day
it is removed from storage. Do not impact, drop, kink or bend cable sharply in low temperatures.
INSTALLATION (CONT.)
B. EQUIPMENT
The proper use of appropriate equipment is crucial to a successful cable installation. The equipment needed
for most installations is detailed in the following checklist.
CHECK LIST
M portable electric generator M shackles/clevis

E] extension cords & GFCl M gang rollers; with at least 4 11effective radius
M pump, diaphragm M hand winces (come-a-long)
F] make-up air blower & hose manhole edge sheave
[:] manhole cover hooks pulling rope
E] warning flags, signs swivels
electrostatic kV tester E] basket grip pullers
electric safety blankets and clamps M 0-1/5/10 kip dynamometer
radios or telephones
gloves M reel arbor
flood lamps M ree1jacks
reel brakes
fishtape or string blower/vacuum E] cable cutter
hand line lint free rags
M duct cleaning mandrels cable pulling lubricant
M duct testing mandrels prelubing devices
F1 capstan type puller plywood sheets
Ej snatch blocks M diameter tape
short ropes for temp tie-offs M 50 ft measuring tape

M silicone caulking (to seal cable ends)
M guide-in flexible tubing (elephant trunks)
several wire rope slings of various lengths
The following diagrams illustrate various cable feed-in setups.

EOUIPMENT CABLE FEED-IN SETUPS
PPLY LUBE HERE
GUIDE IN TUBE
Reels on truck
11111111777 PI
Setup for duct close to floor
Setup for overhead. into tray
The feed-in setup should unreel the cable with a natural curvature (Fig. 1) as opposed to a reverse "S"
curvature (Fig. 2).
IMPROPER PROPER
(Fig.,2) (Fig. 1)
I
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Setup with
timber because
of no pulling
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11
EQUIPMENT
SINGLE SHEAVE
Single Sheaves may be used only for GUIDING cables.

Arrange multiple blocks to hold bending radii whenever cable
is deflected.
SHEAVE ASSEMBLY
For pulling around bends, use conveyor sheave assemblies of

the appropriate radius series.
The pulleys must be positioned to ensure that the effective curvature is smooth and deflected evenly at
each pulley. Never allow a polygon curvature to occur. (Fig. C)
The fit of the pulley around the cable, is also important when polling heavy weights (ex. pulleys at the top
of a vertical drop).
Fig. C
RADIUS
NEVER ALLOW
Remember to use the radius of the surface over
which the cable is bent, not the outside flange
diameter of the pulley. A "10 inch" cable sheave
typically has an inside (bending) radius of 3
inches,
12
D. CONDUIT FILL
1. Overview
Heat is generated as current passes through conductor. The safe dissipation of this heat to the surrounding
conduit is a major consideration during cable installation and dictates allowable conduit fill.
Conduit fill is the percentage of area inside the conduit occupied by cable. It determines the maximum am-
pacity of the enclosed cables since an increase in the number of current-carrying conductors in the conduit
decreases the amount of current each conductor can carry without exceeding its temperature rating.
Consult the applicable codes for your maximum specified conduit fill and for the influence that fill has on
circuit ampacity.
The effect of conduit fill on jamming, clearance and friction is covered in Section E, Mechanical Fit of Cable
in Raceway.
2. Formulae
Conduit fill is calculated as follows:
% Fill= 1: Conductor Area X 100
Raceway Area
For round conduits and cables with equal diameters:
0/b Fill= (d/D)' n X 100 WHERE': d 1/c cable diameter
D ID of conduit
n number of conductors
3. Data
The following pages contain the data needed to calculate conduit fill for various
BICC cables.
13
INSTALLATION (CONT)
EQUIPMENT
BICC CABLES APPROVAL LIST

CABLE PULLING LUBRICANTS
Name of Lubricant Manufacturer
POLYWATERQD A, G, & J American Polywater Corporation

Stillwater, MN
POLYWATERQD Plus Silicone, American Polywater Corporation

Types NN, WNN, FS Stillwater, MN
Wire LubeO & Aqua-Gel" Ideal Industries, Sycamore, IL
DYNA-BLUEO Cable Lubricant American Polywater Corporation

Stillwater, MN
Wirepull Mac Products, Kearney, NJ
Other lubricants may be suitable for use with BICC Cable designs.
Contact the lubricant manufacturer about the compatibility of their products with specific cables.
Cable lubricants should be currently I.I.L. listed.

Contact lubricant manufacturer for-proof of approval.
14
4. RACEWAY DATA
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16
I INSTALLATION (CONT.)
RACEWAY DATA
SWEEP ELBOW RADIUS
I table lists the inside radius for manufactured rigid steel conduit elbows.
~~~~~This
The inside radius (R,) equals the centerline radius (Rj)less half of the conduit
inside diameter (0).
ELBOW CENTERLINE RADIUS OnChes)

Std. 12 15 18 24 30 36 42 -48
Conduit Conduit
Size Ri: Elbow inside Radius (feet) Size
1 0.44 0.96 1.21 1.46 1.96 2.46 2.96 3.46 3.96 1
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0.62 0.93
~~~~~~~~1/
0.71 0.91
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1.16
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1.91 2.41 2.91 3.41 3.91
l'1/4
l'1/2
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1 3
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0.96
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18
INSTALLATION (CONT),
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co
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RACEWAY DATA
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to
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RACEWAY DATA
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-27
E. MECHANICAL FIT OF CABLE IN RACEWAY
Five parameters influence a cable's mechanical fit in a raceway: its configuration, weight, clearance, jam ratio
and coefficient of friction.
1. Configuration
The configuration of the cable in the raceway is measured by the ratio of the inner diameter of the conduit
to the overall diameter of one of the cables within the conduit (Did).
Acradled configuration occurs when cables with a ratio of 2.5 or greater are pulled in parallel from individual
reels. A triangular configuration occurs when cables with a ratio of less than 2.5 are pulled in parallel from
individual reels or when cables are assembled.
Single Cable Cradled Triplexed

Configuration directly affects drag which is computed as Weight Correction Factor (w) in thefoliowing section.
2. Weight
When making installation calculations, use the total weight per unit length of the cables being pulled. Ca-
bled assemblies will weigh more than paralleled cables unless the cables were specially ordered to have
several paralleled cable wound on a reel.
Weight Correction Factor (w): Due to its geometric configuration, a cable is subjected to uneven force when
it is pulled into a conduit. This imbalance results in additional frictional drag which must be calculated and
allowed for if your installation is to be successful.
No. Conductors Configuration Factor (w)
4 2
dY-d-)
Cradled
3 .(5dJ2
GA
D- Y
Triplexed
The following graph illustrates the Weight Correction Factor (w):
38
MECHANICAL FIT OF CABLES IN RACEWAY
I ~~W
1.55-
WEIGHT CORRECTION FACTOR

for quantities shown, of cables of equal diameters and weights, for
1.50 all others, use ME= 1.4,
except for one cable, then w =1 .0
I ~~~~~~1.45
I ~~~~~1.40.
1.35-
1.30
I~~~~~~~~~IM
I I~~~~~~~~~~~~~~~I
~~~~~1.156
I K II
1.10~~~~~~~~~~~~~11
12.2.3.0K35 . 4 .5 5.
EmI I/ 13.680.1 =1 3.37,

II I 1.1
TI = rip d CRI rde
I~~~~~~~~~~~~~~~~~~~-R
MECHANICAL FIT IN RACEWAY (CONT.)
When computing Weight Correction Factor, ensure

all cable diameters are equal. When in doubt, use
cradled configuration formula. the
The cables may be in either a single or multiple conductor

construction. But, when only one cable (whether
single conductor or multiple conductor under common
jacket) is being pulled, no weight correction factor
is needed.
3. Clearance
Clearance refers to the distance between the uppermost

cable in the conduit and the inner top of the con-
duit. Clearance should be 1/4 inch at minimum and up
to one inch for large cable installations or installations
involving numerous bends. It is calculated as follows:
Of Conductors/Cables Configuration Formula
1
D-d
D DA _d
3
1.366d + 2 _d
TRIPLEXED
3 d2
6-d _
D-cl
CRADLED
When calculating clearance, ensure all cable diameters

are equal. Use the triplexed configuration formula
if you are in doubt. Again, the cables may be of single
or multiple conductor construction.
4. Jam Ratio
Jamming is the wedging of three cables lying side

by side in a conduit. This usually occurs when cables
are being pulled around bends or when cables twist.
Jam Ratio is calculated by slightly modifying the ratio

used to measure configuration (D/d). A value of 1.05D
is used for the inner diameter of the conduit because
bending a cylinder creates an oval cross-section in
the bend (1.05D/d).
* If 1.05D/d is larger than 3.0, jamming is impossible.

* If 1.05D/d is between 2.8 and 3.0, serious jamming
is probable.
* If 1.05D/d is less than 2.5 jamming is impossible
but clearance should be checked.
Since there are manufacturing tolerances on cable,
the actual overall diameter should be measured prior
to computing jam ratio. 40
MECHANICAL FIT IN RACEWAY (CONT.)
5. Coefficient of Dynamic Friction

The coefficient of dynamic friction is a measure of the
friction between the cable and the conduit or roller,
and can vary from 0.03 to 0.8, even with lubrication.
Typical values are shown in Table below:
TYPICAL COEFFICIENTS OF DYNAMIC OF FRICTION
(f) WITH ADEQUATE
CABLE LUBRICATION AT TIME OF PULL
TYPE OF CONDUIT
CABLE EXTERIOR M PVC FIB ASB
PVC - Polyvinyl Chloride
.4 .35 .5 .5
PE - Low Density HMW Polyethylene
.35 .35 .5 .5
CPE - Chlorinated Polyethylene
.35 .35 .5 .5
HypalonO -CSPE (Chlorosulfonated PE)
.5 .5 .7 .6
NeopreneO - N (Chloroprene)
.5 .5 .7 .6
FREP - Flame Retardant EP
.4 .4 .5 .5
XLPE - Cross Linked PE
.35 .35 .5 .5
LEAD
.5 .5 .5 .5
M = Metallic, Steel or Aluminum

PVC Polyvinyl Chloride, Thinwall or Heavy Schedule 40
FIB Fiber Conduit - Orangeburg or Nocrete
ASB Asbestos Cement - Transite or Korduct
The coefficient of friction of a duct or conduit varies
with the type of cable covering, condition of duct or
conduit internal surface, type and amount of pulling
lubricant used and ambient installation temperature.
High ambient temperatures (8010F and over) can increase
the coefficient of dynamic friction for cable having
a nonmetallic jacket.
Pulling lubricants must be compatible with the cable's
components and be applied while the cable is being
pulled.
Note: These values may be conservative and lubricant manufacturer

should be consulted for recommended
coefficients of friction.
41
F. Physical Limitations of Cables
1. Overview
The fifth and final consideration in any cable installation
is the physical limitations of a cable as it is being
pulled into position. Pulling subjects cable to extreme
stress and, if done improperly. can displace a ca-
ble's components. Thus, it is important that the followin
g guidelines be observed:
• Calculate and stay within the cable's maximum
pulling tension, maximum sidewall load and mini-
mum bending radii.
• Ensure that the raceway joints are aligned and that
the wiring space is sufficient.
• Train the cable to avoid dragging on the edge of
the raceway.
• It using a basket grip, secure it to the cable with
steel strapping and cut well behind the area it
covers once the cable is in place.
• Ensure that the pull rope's elongation minimizes
jerking.
• Pull NO FASTER than 40 feet per minute.
• Pull with a capstan, if possible.
• Do not stop a pull unless absolutely necessary.
• NEVER pull the middle of the cable.
• Seal the cable ends with high voltage putty or
silicon caulking and overwrap with tape.
2. Maximum Pulling Tensions
a. Overview
Excessive pulling tension can cause delamination and
displacement of a cable's components. This can
cause voids which become the focal, points for corona
deterioration.
Pulling Tension should NOT EXCEED the SMALLER
of these values:
* Allowable Tension on Pulling Device.
* Allowable Tension on Conductor.
* Allowable Sidewall Load.
1. Allowable Tension on Pulling Device.
Do not exceed the working load stated by the manufacturer

of the pulling devices (pulling eyes, ropes,
an'chors, basket grips, etc.). If catalog information is
not available, work at 10% of the rated braking
tensile strength.
Basket Grip - The allowable tension with a basket grip
must not exceed the lbs/cmil value (as shown
in the Table on page 47) or 1000 lbs, whichever is smaller.
Exceptions to this rule are the following
Cablec products, for which the upper limit is 1250
lbs.
Single Conductor - Durasheath EPR, Durasheath XLPE,
Unicon FREP
Multiple Conductor - Flame-Guard Durasheath EPR.
42
PHYSICAL LIMITATIONS OF CABLES
2. Allowable Tension on Conductor
The metallic phase conductors are the tensile members

of the cables and should bear all pulling forces.
Shielding drain wires or braids should never be used
for pulling.
Conductor pulling tension should not exceed:
Material Cable Type Temper lb/cmil

Copper All Soft 0.008
Aluminum Power Hard 0.008
Aluminum Power 3/4 Hard 0.006
Aluminum Power 'AWM' 0.005
Aluminum URD (solid) Soft (112 hard) 0.003
All Thermocouple
0.008
Three-quarter hard aluminum is allowed for power
cable. AWM is required for UL labeled 600V aluminum
smaller, it may be used in larger sizes. Soft is sometimes solid wire 8 AWG and
used for large solid aluminum. AWM is a UL designated
aluminum.
Reduce the maximum pulling tension by 20% to 40%
if several conductors are being pulled
simultaneously since the tension is not always evenly
distributed among the conductors.
While BIGC Cables does not recommend the practice,
we recognize that some users pull a combination of
conductor sizes simultaneously, observing the maximum
pulling tension of the largest conductors. During
such a pull, the smaller cables may get crushed at bends
or may have the pulling forces transf rred to them
momentarily (which greatly exceeds their tensile strength).
Maximum pulling tension is calculated as follows:
TENSION MAXIMUM, single conductors, pulled in

parallel:
n < = 3: TM = TI/c n
n > 3: TM = TI/c n 0.8

lead sheath: Trrr = 471 2 t (d-t) t = sheath thickness
TENSION MAXIMUM: multiple conductors:
For cables 8 AWG and larger, and over

3 conductors:
TM = 0.8 ETI/c
For cables smaller than 8 AWG, and having

no twisted subassemblies, and over 6 conductors:
TM = 0.8 ET1/c
For cables having twisted subassemblies:
TM= 0.6 ET1/c
The following charts provide the data necessary

for calculating allowable tensions:
43
INSTALUIXION (CON-1.)
PHYSICAL LIMITATIONS OF CAB't..ES
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V COCDL; 0V C)
IT 0000
C'j (D 0) 00 0000 CD =1080 080
E CO_ (0 V). Ln M0 800 08 0 U)
0 -N CD 0 cn CD C,4r, -M
(D:; C14 CDM 9D to co w E
PI - McLq
Q 04 Oul- WoLn a
CIALn EDCO M V Lo; x VI PI r- 0) 0 co
- 0
co C u U) 0
E
N 0 OD (Dv C-40 M OD (D -cr C-) N E coo
C-4(14- 0000 Ch U
CZ4
C-i;4 0 C
(3
44
INSTALLATION (CONT)
E
E
LU cli
co
FE
uE
CU, 0
N
a6 - tn m Ln - ui r-: c
CD o C-) U3,m - 0 0
F, N C,, m m r w Ln
C
ucn
zN a cm mv
cq"q:"CY 'p1pal
COin M V r- CM W CO
M Ln CM r- N WA W mmo M cao0
-j N m
cm m
cmm v;w 4 0 wN 0 a cm
V) , 0, EN v
CC
Wwsv mmo N co . . . . . . . . . . .
c .4 r-: C6 cj N in 0 cV Ln le in CM 00 0 0 002
CY
0) 1-t
04
c 00 CO
V)
'D N N kg)00 10H
It cb
04 CY cl V) C!
.5 i
CD C4
le ci
in rl(D U . . co. - . w. C.) w Cy 0 ov 0 a--
. . . . ODLn
t- CDCY)40 cmC-)it . to. co. 0). &I"
. CY
. CY
CY . .
40 IC04
0
In
E Z
-W r.- a N cq to r. co
lao m W) 0 w r.. w ci 6 oi C
6 4 ui cd vi r-
z
co
Q
0
M.2
0 ro RN o
E (I u? cR N C
E cc'mE w 0 4)
co m 0- to 0
0 C4 cm 04
.0 E o
im3C
C4 w 0 w 04
00 en in cn
4m o;z r- Cc
W 4m (D
0 CIAm -W
-W -a PI (D a, t 0 C) V) W)W r, P. W)m co C.) C 0E G
C; "i 4 4 uid z .6 i ci ".: ci Z 6 : 'd C5 : Q -4 wi f.
CD
- - - - - - - cl CY N 0A
Cm Cm
r- #A CL
0 E
tm.2 in 0
>
0 cV
0 CM M 0ID Lo
C4 0 Im 0
CY
MW M in in r. Wu > 0
M CM CQ -4 f,
C4 c ci 4 ui ui (a r--:cd ci 6 w
0 co
Co
CM
CM
CMCO40 MN ui
Ecl ou oOR q v) c4
cj Ln to
'P co
cl v)
N c4
&wr:
ei
X
Cj 'P
c-)
en cq
"Q:
v m
w? N oli
'TEo
Ln Co CDr.:
0 CD
N CyP, N
0 t, 0CYCl
V) CO
#- -T
0M It
W)0CD (D
0V 0W
Cli CY V) V3 - .2 0
g -Z E
=
P
E
Oil
C4 0 00 W.WC4 ochco wqrr) C4-0 .08 cull00 8 -on 8 C)
ul 0
0 E
0 cis 2
Mm IV Ln Ln to g r CD0 U)
Ar,
PHYSICAL LIMITATIONS
CHARTS CONDUCTORS INPARALLEL OR AS ASSEMBLIES
SOFT DRAWN COPPER OR HARD DRAWN ALUMINUM
The following maximum tensions are for direct
attachment to the conductor. However, the pulling
must not exceed the smallest value of 1) conductor force
tension, or 2) pulling device tension, or 3) sidewall
load. #CDR 2 3 4' 5 6
AWG/kcrnil MAXIMUM ALLOWABLE CONDUCTOR TENSION
(LBS) AWG/kcmil
20 8 16 24 26 33 39 20
18 13 26 39 41 52 62 18
16 21 41 62 66 83 99 16
14 33 66 99 100 .130 150 14
12 52 100 150 160 200 250 12
11 66 130 190 210 260 310 11
10 83 160 240 260 330 390 10
9 100 200 310 330 410 500 9
8 130 260 390 420 520 630 8
6 210 420 630 670 840 1000 6
4 330 660 1000 1060 1330 1600 4
3 420 840 1260 1340 1680 2020 3
2 530 1060 1590 1690 2120 2540 2
1 670 1330 2000 2140
1/0 2670 3210 1
840 1690 2530 2700 3370 4050 1/0
2/0 1060 2130 3190 3400 4250 5110 2/0
3/0 1340 2680 4020 4290 5370 6440 3/0
4/0 1690 3380 5070 5410 6500 6500 4/0
250 2000 4000 6000 6400
300 6500 6500 - 250
2400 4800 6500 6500
350 6500 6500 300
2800 5600 6500 6500 6500 6500 350
400 3200 6400 6500 6500 6500 6500 400
-450 3600 6500 6500 6500 6500 6500 450
500 4000 6500 6500 6500 6500 6500 500
600 4800 6500 6500 6500 6500 6500 600
700 5000 6500 6500 6500 6500 6500 700
750 5000 6500 6500 6500 6500 6500 750
800 5000 6500 6500 6500 6500 6500 800
900 5000 6500 6500 6500 6500 6500 900
1000 5000 6500 6500 6500 6500 6500 1000
T = 0.008 x CM x N, if N < = 3.
T = 0.008 x CM x, N x 0.8, if N > 3.
This chart may also be used for hard temperature aluminum
conductors. However, use 1/2 of these chart values
for all other UL labeled cables having aluminum conductors.
46
I ~INSTALLATION (CONT.)

I ~CHARTS MULTICONDUCTOR CABLES
HAVING EOUAL SIZED CONDUCTORS; WITHOUT SUBASSEMBLIES
SOFT DRAWN COPPER
The following maximumn tensions are for direct attachment to the cable jacket. However, the pulling force
must not exceed the smallest value of 1) conductor tension, or 2) pulling device tension or 3) sidewall load.
AWG-= 20 is 16 14 12 11 10 9
I ~ ~~CDR MAXIMUM ALLOWABLE CONDUCTOR TENSION (LBS) CDR
I ~
2
4
~
16
~~3
24
33
26
39
52
41
62
83
66
99
130
100
150
200
130
190
260
160
240
330
200
310
410
3
4
2
5 41 65 100 160 260 320 410 520 5

7 49
478 78 120
1090 190 310
30 390
90 490
90 620
606
8 52 83 130 210 330 420 530 670 8

9 ~~~ ~~~
93 140 ~~~~~~~59
~~~ 230 370 470 590 7509
10 65 100 160 260 410 520 660 830 10
11 72 110 180 280 460 570 730 920 11

12 78 120 190 310 500 630 790 1000 12
13 85 130 210 340 540 680 860 1000 13
I ~~~~14
15
91
98
140
150
230
240
360
390
580
620
730
790
930
990
1000
1000
14
15
I~ ~~~1
16
17
1
100
110
7 8 40 70 8010 00 1
160
170
260
280
420
440
660
710
840
8940
1000
1000
1000
1000
16
17
19 120 190 310 500 790 1000 1000 1000 19
20 130 200 330 520 830 1000 1000 1000 20

22 140 220 360 570 910 1000 1000 1000 22
24 150 240 390 630 1000 1000 1000 1000 24
26 170 270 420 680 1000 1000 1000 1000 26
I ~
28
~
10
~~30
190
290
310
460
490
730
780
1000
1000
1000
1000
1000
1000
1000
1000
28
30
32 200 3330 520 840 1000 1000 1000 1000 32
34 220 350 560 890 1000 1000 1000 1000 34
36 230 370 590 940 1000 1000 1000 1000 36
38 240 390 620 1000 1000 1000 1000 1000 38

40 260 410 660 1000 1000 1000 1000 1000 40
42 270 430 690 1000 1000 1000 1000 1000 42
44 280 450 720 1000 1000 1000 1000 1000 44

46 300 470 760 1000 1000 1000 1000 1000 46
48 310 490 790 1000 1000 1000 1000 1000 48
50 320 510 820 1000 1000 1000 1000 1000 50

THE MAXIMUM LIMIT IS 1000 LBS.
I ~
T =0.O8 x CM xN,ifN<=6.
T
=~~~T
=
0.008 x CM x N x 0.8, if N>6.
0.008 x CM x N x 0.6, if twist d subassembli s.
I ~~~~~~~~~~~~~~47
CALCULATION FORMULAE
These tension formulas are for estimating the forces due to dynamic frfiction. THEY DO NOT ACCOUNT FOR BENDINGI
FORCES. The bending forces will vary with cable construction and material stiffness, especially with conductor hardness.
If T0~, < 0, use zero as tension for next section of raceway.I

TENSIONS, VERTICAL BEND, PULLING UP
Large concave down angle (VUCD)I

Tout = Ti +WRM [2ytfe fsinO +(1 1f2 wf VC
Large concave up angle (VUCU)I

vuCu
OD T0 ~ T eWfO. iiWRv [2wf sinO-(l-w 2I2) (et -coso)]I
TENSIONS, VERTICAL BEND, PULLING DOWN
Large concave down angle (VDCD)I

wlO WR _2 2( f) AleDCD
T0 Te
T~ +rf
+ 1+ [2.vif sine (O . (e - cosO)I
Larg concave up angle (VDCU)TI
OT
0 ~TineklfO~- +WR [2yife-wf0 sino + (1- _Wf2) (1-e Wf0cosOE)] VC
OIf T,,, < WR. use formulatfor concave down.T

TENSIONS, HORIZONTAL PULLI
Straght
ecton' = wfWL + (Prior tension) See the Chart Bend Multiplier on page 59
Straightsection
__ ~~~~~~~~~~~~~~~~~to
find et"'.
Maximum length Lm = TM/(WfW) Symbol meanings shown on pag 8

TENSIONS, INCLINE PULL
Upward T =WL(sin 0 + wf cos 0) + (Prior tension)
Downward T - WL (sin 0 - wf cos 0) + (Prior tension)
TENSIONS HORIZONTAL BEND2I
Tout = Tin cosh wf 6 + (sinI~wf 0) \/(Tin) + (WR)
TENSIONS, BEND, APPROXIMATION
if Tin > 1O0WR then Tout =Tin f I
ARCHES
Z2 +
41- 2
8H
o- 360 si'Z -----
2R K'
S 2R cos R
tan~'2-
48
CALCULATION DISCUSSON
PULLING AROUND BENDS

The preceding formulae for vertical bends assumes that the cable is sliding on the INSIDE SURFACE of the
bend. This would not occur on concave up bends when the sidewall loading is less than the weight of the
cable.
-Cable
--- Duct
Standard formulae are valid Standard formulae not valid

W<T/R W>T/R
Typical installation having cable dragging the bottom of the duct are river crossings or up and downhill
pulls of long lengths.
BENDS MULTIPLY INCOMING TENSION.
STRAIGHT RUNS ADD TENSION.
The difference:
where: Mt = 1.1 W = 2 f 0.5 Tn = 500 lb
pull 100 It horizontally- Tc),,t wfWL + T.n = 61 0 lb
pull around 90' ell: T out Tn e 12001b (See page 59)
Thus for the given conditions, one 90' bend increased the tension almost double that of 1 00 ft of straight
duct!
Because of this multiplying effect, it is better to feed into the duct end having the greater number of bends. But
calculate the tensions for pulling either direction to determine which will be easier.
CALCULATIONS CORRELATION
Even though the foregoing parameters and formulae give exact answers, because of variances in installation
techniques, these answers may not correspond to facts. THESE CALCULATIONS MUST BE USED ONLY AS
GUIDELINES TO PREDICT "NORMAL" OR "DIFFICULT" CABLE PULLS.
The stated parameters and formulae do not consider forces required to bend the cables, and the coefficient of
friction is arbitrarily selected - in fact it may change during the pull it the lubricant is not spread evenly. Seldom
are the bends located exactly as shown on the designer's drawing, nor are the exact bends' angle or radius
known. Nevertheless, one major engineeringcontracting firm states that for 90% of the pulls at a given project,
the actual was within 10% of the predicted pulling tension.
CAUTION The formulae do not take into account:

1) Weight Correction Factor when there are more than 6 cables (use w = 1.4);
2) Sidewall Loading when there are more than 3 cables;
3) Bending forces in short pulls of large cables through several bends.
To better correlate tensions: 1) read just before the pulling head starts into a bend, 2) read just after the head exits
a bend, 3) read just after the cable exits the raceway, 4) the meters should have range switches so that the
readings are made at half to full scale of the meter, 5) the main reading is the last when the pulling head and rope
have minimum influence, 6) record the relative position of the pulling head for any unusual surges.
49
BEND MULTIPLIER
Wfe e
1800 90,
BEND MULTIPLIER
7
This isthe multiplier used incomputing ten - - - - - -
sions around bends.
6
70'
I1JqI
19
- - - - - - - -
-I0440- 7
1xi I 01
40,
I 1XI I A
IZI I
- - - - - - - - - - - - - 00 0,100,I -.1, -.411
- - - - - - - - - I I Lo, I so,
- - - - - - - - - 1L4 i1o,I I 14ol
100' I
- - - - - - - - - - - - - Yi I v yo, 1.100 70 --
3- Pq -45'
/I v Yl 000 .0
'01 ly LOO 00.1
0,11 AV 40
O v I, I 'IO' LK I
00,XA 41 .0e 41 1 1
I XII Ik, I Yo, I --- LLo.
ol I X IKIY
00 11?, IL
30-
o, oo ooo
01,
01
10I.
)ooq
ooI oo
OOV, 00 oo e .22.5'
010 20'
o" " ." -, I I
oo, oo,- loo,
01 ol
140
/ 00
i :a 4 L I01
010
0,0n S IT[ iI
ol
o- -t7T
Ii Lu
-'4
0.2 0.4 0.6 0.8 1.0 1.2 1.4
Wf
examol The line for 9'fffO when wt-0-55 and e-30- is 1.33.
50
F. PHYSICAL LIMITATIONS OF CABLE (CONT.)
3. Sidewall Loading (Sidewall Bearing Pressure)
a. Overview
Sidewall load is the radial force exerted on a cable being pulled around a conduit bend or sheave. Exces-
sive sidewall loading can crush a cable and is, therefore, one of the most restrictive factors in installations
having bends or high tensions.
TENSION
LOAD
Sidewall loading is reduced by increasing the radius of bends. To illustrate, a 15 kv 350 kcmil cable instal-
lation dropping six feet vertically underground, traveling horizontally, then rising to a motor should have
bends at least six feet in radius to maximize the horizontal distance and still be within the sidewall limit
of 500 lbs./ft.
Sidewall loading is calculated as follows:
SIDEWALL LOADING
Where T is tension out of a bend, in pounds and R is radius of a bend, in feet
1 /C per conduit: SW T
R
3-1 /C cradled: SW 3w-2 ] T

3 R
3-1 /C triangular: SW T
Laboratory tests conducted on standard BICC cables after they had been subjected to conduit
,pull tests through 900 elbows of appropriate radii, indicate no significant change in the cabi 's
electrical parameters at the following sidewall loads:
Cable type SWIL (lb/ft)

600V nonshielded control 300
600V & 1 kV nonshielded EP power 500
5-35 kV Unishield & Uniblend, 5 kV Durasheath EP 500
Interlocked & Philsheath armored cable (All Voltage Classes) 300
4. Training and Bending
a. Overview
Training is the positioning of cable which is not under tension. Bending is the positioning of cable which
is under tension. When installing cable, the object is to limit these forces so that the cable's physical
and electrical characteristics are maintained for the expected service life. The recommended limits are:
b. Tables per National Electric Code (Page 57)
c. Tables per ICEAMEMA (Page 58)
d. A nonshielded cable can tolerate a sharper bend than a shielded cable can. This is especially true for
cables having helical metal tapes which, when bent too sharply, can separate, buckle and cut into the
insulation.
The problem is compounded by the fact that most tapes are under jackets which conceal such damage.
The shielding bedding tapes or extruded polymers have sufficient conductivity and coverage initially to
pass acceptance testing, then fail prematurely due to corona at the shield/insulation interface.
Remember that offsets are bends.
52
4. Training and bending (cont.)
b. Applications in accordance with the NATIONAL ELECTRICAL CODE.
Table I
Shielded or Lead-Covered Cable

(Non-Armored)
Single and Multiple Conductor -
All Voltages Over 600 Volt Nominal
12 x Overall Diameter
Table 11
Non-Shielded and Non-Armored
Single and Multiple Conductor -

All Voltages Over 600 Volt Nominal
8 x Overall Diameter
Table III
Armored Cable - Type MC
Interlocked or Corrugated Sheath
Multiple Conductors - Non Shielded
7 x External Diameter of Armor
Multiple Conductors - Shielded
12 x Diameter of One Shielded Conductor
or
7 x External Diameter of Armor
Whichever is Greater
In all cases the minimum bending radius specified refers to the inner surface of the cable and not to axis of the cable.
4. Training and Bending (Cont.)
c. Applications in Accordance With ICEA/NEMA STIDS. (Non-Code)
Table I
Non-Shielded, Non-Armored Power & Control Cable
Thickness of Overall Diameter of Cable, Inches

Conductor Insulation Up to 1.000 1.001 To 2.000 Over 2.000
Inches Min. Bend Radius As A Multiple of Cable O.D.
.155 and less 4 5 6

.1 70 to .31 0 5 6 7
.325 and Over - 7 8
Table 11
Metallic Shielded and/or Armored Power & Control Cable
Minimum Bending Radius

Type of Cable As A Multiple of Cable O.D.
Flat Tape or Wire Armored 12

Armored, Interlocked (Duralox ) or (PhilflexO ) - ------ 12
Armored, Welded Corrugated Sheath (Philsheath 12
*Non-Armored, Tape Shielded UniBlendO - 12
*Non-Armored, Wire Shielded or UniShieldO - Table I Above
'Includes 12 x Single Conductor O.D. in Cabled Assemblies, i.e. Triplexed, Quadruplexed, etc.
The above Tables contain the minimum values for the radii to which insulated cables may be bent for perman nt
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. Larger radii bends are required for such condi-
tions due to the limitation of sidewall bearing pressure. In all cases the minimum radii specified refers to the inner
surface of the cable and not to the axis of the cable.
54
CALCULATION EXAMPLE
EXAMPLE 1 - Maximum length
_____ __ __ __ __
Problem: Find the maximum manhole spacing for a feeder.

I Cable: 3-1IC, 350 kcmil Cu, 15 kV GN, 0.175 " EP - Lead; to be
inparallel.
~~~~~~~~~~~~~installed
Cable Size: Weight = 3180 lb/MFT for I1/C, d =1.39 in
I ~~~~~~~~~Conduit
Selection = 4 in (see Chart '3/C % fill
This avoids jamming and conforms with NEC
-EP-Lead'
I 0~~~~~~~~~~~
= 4.026 in, Sld Ri = 1.17 ft (see Chart 'Conduit').
I ~~~~~~~~Clearance = 0.5D - 1.366d + 0.5 (D-d) 1( )
=0.5 (4.03) - (1.366) (1.39)
=1.24 in. =0OK
Maximum pulling length
I Lm
~~~~~~~~~~TmTm
Mf i~ d 2
find Tm =6500 lb Per Installation, Physical Limitations Chart
m1 + -
3
((0.5) 6500
40-.9i1000/
(3
-= 995 feet
55
INSTALLATION (CONT.)I
CALCULATION EXAMPLE
EXAMPLE 2 - I
10 ft
vertical
7~~~~
5 6~~~~~
Probem:Insall15
V fede beteen1 ad 8in igi codui 4I 0tt 9
Prolensal k Cu (gedrounding); cabld nrgd odi I

UniShield weight = 673 lb/IVFT. d = 0.92 in
Per "Conductor Data": Class B bare = 128.9 lb/MFT, d = 0.232"
area = 0.0423 in2
Per Conductor Tension, Tm = 2530 for 3/C
Conduit Selection:I
Cable Area = 3.irl/4*0.922 + 0.0423 =2.04 in2
For fill < 400/ use 3"1C (see "Conduit Info" - 3"C has 40% area of 2.96 in2)
Conduit Info 3"C: 0 = 3.068 in, stid R1 0.96 ftI
Jam: 1.05D/d = 1.05 (3.068/0.92) = 3.5 =OK
Clearance; check if # 4 fits interstice of phase cdrs.I

Interstice factor = 0.483 (see Appendix)
Fit =0.483*0.92 =0.44I
0.44>0.23 so we can use the 3/C "cbl" factor of 2.155:
Cl = D - 2.155d = 3.068- 2.155*0.92 =1.11 inch
Bending: (See NEC 300-34)
Training radius:
1/C = 0.92* 12 = 11 inches
cable 0.92*2.155(12 23.5 in 2 ft
I
= = =
Bending radius: we must use conduit elbow having at least 30-inch radius (R =2.37 ft) because we must
xceed 2 ft training limitation.
56
I ~CALCULATION EXAMPLE
I ~EXAMPLE 2
See Weight Correction Chart, for Did = 3.068/0.92_ w -1.1
wf -1.1.0.5 = 0.55 W = 0.68-3.03 +1.01-0.129 =2.19 lb/ft
K = WfW=0.55*2.19 = 1.20 10WR = 10.2 19.2.37 = 52
PM 500 lb/ft w/2R =1. 1/(2-2.37) = 0.232
30., eAI'0
I
See chart: for Al = 0.55. 0 = 1 .33 (see Bend Multiplier chart)
~~~~~for
wf = 0.55. 0 = 90., ettfO zz2.37
Pulling from 1 to 8:'
T2= wfWL = KL -=1 .20*320 = 384 lb

since T2 >1OWR then T3 ztT 2 e~~0, likewise for T5 &T7
I ~P
T3 zzT 2 e~f U= 384.1.33 =51 1 lb
3 =Iw/2R1
T4 z KL +T 3
T3 =0.232-51 1 = 119 lb /ft
859 lb
=OK since 119<-500.
I
=1.20.290+511 =
~ 5 ~T 4 ewt() =
:~:T 859*1.33 = 1142 lb
P5 = [w/2RJT 5 = 0.232-1 142 = 265 lb/ft = OK
T6 z~. KL +T 5 ==1.20.140+1142 = 1310 lb
T7 .zT 6 e~O = 1310*2.37 = 3100 lb = NO because-.TM
P7 = [&/2R]T 7 = 0.232-31 00 = 719 lb/ft = NO because >Pm
Thus we cannot pull from 1 to 8 because both maximum tension and sidewall load are exceeded at 7.
Pulling Example 2
Pulling from 8 to 1
I ~
Because the calculated tension will be negative at 6 & 7, compute from 6 to 1.
5~T
:zLKL = 1.20.140 = 168 lb
T4 z:T 5 e~ t = 168*1.33 =223 lb
I,~ ~P = [W/2R]T 4 = 0.232*223 =52 lb/ft = OK
I
T3 :z:KL + T 4 = 1.20-290+ 223 = 571 lb
~ 2 ~T
:-,T 3 e =751 *1.33=759 lb
P2 = [ml/2RJT 2 = 0.232*759 = 1 76 lb/ft =OK
T 1 :~:KL +T 2 = 1.20*320+ 759 =1 1 43 lb =0OK

Using the exact formulae, pulling from 1 to 7 calculations give T7 =31 65 lb .P 7 =736 lb pulling from
6 tol1giveT = 11 56 lb P 2 =1 79 lb
I ~~~~~~~~~~~~~~~57
CHECKLIST
RACEWAYS
E] Bending - Check sidewall loads; the use of long sweeps (over 6 ft) allows longer shielded medium voltage
cable pulls.
- Avoid bends and offsets at the 'pulling' end of a raceway section.
Training - Make sure to meet or exceed the minimum training radius.
E] Size - Consider weight correction factor and clearance.
El Jam Ratio - Avoid a conduit to cable ratio which may cause jamming; elbows may be out of round.
El Conduit Fill - Raceways that are too full create pull-in problems and possible cable damage.
E] H at Transfer - Route raceways to avoid high ambient temperatures and high thermal resistivity locations.
- Separate cables in raceway seals and fire stops.
Abrasion - Use duct end-bells, conduit bushings,'and rack saddles to prevent abrasion.
n Grounding - Be sure metallic raceways are grounded.
Expansion - Thermal expansion of raceways should be considered in duct layout.
Spacing - Heat dissipation improves with greater spacing between raceways.
Manhole/Spli6e Box - Allow enough working space for pulling and splicing.
- Install anchor bolts and grounding electrode during box fabrication.
- Provide cable supports.
- Chamfer concrete edges at openings.
- Provide drainage holes in bottom of boxes, adequate lips on covers.
E] Supports - Support raceway system, during system and cable installation, especially trays.
- Provide for gang rollers' insertion to be used during pulling.
E] Ties - Allow for radial expansion of cable during electrical loading.
DIRECT BURIED
C] Backfill - Use screened backfill to keep rocks, and debris from damaging cables.
r7 Crossovers - Do not lay one cable on top of another.
Cable Slack - Allow for earth movement due to freezing, drying or settlement.
D pth - Stay below frost-line, check Code requirements.
Protection - Use marker tape, and post warning signs.
58
CHECKLIST
PULLING
El Conduit Cleanout - Provide clean, SMOOth COncentric inner duct surface; test with a mandrel for obstructions.
R Bending -- Bends during pulling must be larger than those permitted for final training; ESPECIALLY THE
LAST BEND, WHICH MAY BE TEMPORARY FOR INSTALLATION!
F1 Edges - Install temporary guides, tubes, sheaves, etc., as necessary to prevent cutting of cable on sharp
edges, such as at panelboards.
E] Maximum Tension - Keep sidewall loads below specified maximum.
- Check maximum allowable pulling tension.
- Check limitation for type of pulling attachment used.
M Lubrication - Use pulling compound liberally. Be sure itis compatible with the particular cable being installed.
Prelube just before making a difficult pull.
Temperature - Check for minimum allowable installation temperature. Allow for change of the coefficient of
friction with temperature.
El End Seals - Keep moisture out of cable.
R Special Instructions - Check shipping container for special instructions.
59
IV SPLICING AND TERMINATING
1. Why Shield Power Cables?
All electrically insulated conductors are capacitors. When a changing voltage is applied across a capaci-
tor a charging current will flow through that capacitor.
In most cable installations the cable's surface makes only random casual contacts with its grounded phys-
ical supports or with the surfaces of other cables. Except at these points of actual physical contact there
are air gaps which are also capacitors. The result is a series circuit consisting of the capacitance of the
cable and the capacitance of the air gap. The surface of the cable then becomes the "floating" tap of
a capacitive voltage divider. Consequently, the voltage on the cable surface can vary from almost zero
to nearly the phase-to-ground voltage of the insulated conductor, depending upon the size of these exter-
nal air gap capacitors.
If the voltage along the cable surface or across the air gap capacitors is sufficiently high, the surface of
the cable may be deteriorated by surface tracking, and/or there can be corona and sparking discharges
across the air gaps, and the surface may be a shock hazard.
Shielded Cables
INSULATION SHIELDING PROPERLY APPLIED AND GROUNDED,' ELIMINATES ELECTROSTATIC

CHARGES EXTERNAL TO THE CABLE SHIELD AND PROVIDES A FIXED KNOWN PATH TO GROUND
FOR THE CHARGING CURRENT SHIELDS ARE RECOMMENDED ON CABLES ENERGIZED OVER
2 KV.
The shield of a power cable, by providing a fixed electrical path to ground that is in intimate contact with
the external surface of the cable insulation, eliminates the surface discharge problems associat d with
nonshielded cables.
In addition, shielding assures uniform electrical stress distribution within the cable insulation; and because
of the fixed conductor-to-ground capacitance per unit length of cable, shielding minimizes voltage surge
reflections along the cable.
Carefully designed and grounded shields provide personal safety by eliminating surface potential, minimizing
shield loss, and minimizing insulation stress.
60
SPLICING AND TERMINATING (CONT.)
Ov rview
A shielded power cable termination must be properly designed and properly applied or the termination may fail
within a short time. Remember that a splice in the middle of a cable is in effect two shield terminations!
As described in the section "Why Shielded Cables" the shield is always grounded. The shield must be removed
for a distance when making splices and terminations to provide sufficient dielectric strength to prevent voltage
breakdown along the insulation surface. The length of cable from which the shield is removed is usually called
the "creepage length."
P nciling the insulation relieves the gradient at the insulation end. Voltage breakdown or flashover from
the bare conductor over the insulation surface to a grounded shield is prevented by maintaining creepage
I ngths, and reinsulation at splices
Splices introduce the problem of heat dissipation. Minimize connection resistance. control insulation
thickness and provide surface area to help solve this problem. That is, use high quality connectors
designed for medium voltage, insulated cables: do not add more insulation tape than the drawings
specify; do not cram several splices together.
About 75% of the conductor-to-shield voltage gradient is concentrated along the first longitudinal inch of insulation
surface:
(If
1 = conductor
2 = stress control layer
3 = insulation
4 grounded shield
5 creepage length
O
This gradient may be controlled with a stress cone by altering the relative capacitance and insulation
thickness; much as an optical lens retracts light:
1= conductor
2= stress control layer
3= insulation
4= grounded shi Id
5= creepage length
6= stress cone
7= flared shield
Lik wise, special tapes or paints may be used to alter the relative capacitance
C. PRECAUTIONS
When splicing and terminatingmedium voltage cable:
* Keep both the cable and the work area clean and dry.
* Do not cut the insulation.
* Completely remove the semi-conducting insulation shield, but do not lift it at the cut-off point.
* Support the cable near its splices, never under them.
* Keep nonshielded conductors away from ground and from other phase conductors.
* Keep stress cones aligned.
* Ensure bends in nonshielded conductors are smooth.
* Use skirted terminators outdoors or in contaminated areas.
* Keep nonblack insulation out of direct sunlight by using a tube or track resistant tape.
* Use shielded cables in all applications requiring 2 kV and higher.
* Use a minimum amount of cleaning solvent.
* Consider lead sheathing for hostile environments (oils, water, solvents, chemicals, etc.)
Tape: Half-lap and stretch per manufacturer's recommendations - usually 3/4 original width; over-stretch
ends and roll each layer to prevent voids; use fresh tape only; remove separator backing, start and end
taping at the middle of the splice or termination.
Grounding: Except in unusual installations, ground shields at every opportunity; grounding leads should
be copper, solid 6 AWG minimum and insulated outside of splice or termination to resist corrosion; con-
nect outdoor termination grounds directly to lightning arrestor grounds; span splices with grounding lead
for fault ampacity.
TOOLS/SUPPLIES
Diameter Tape Linesmen's Pliers Scissors

Knife & Stone Hacksaw Hose Clamp
Soldering Iron Screwdriver Rat-tail File
Crimping Tool Ruler, Grease Pencil Concave Roller (tape roller)
Plastic Pipe Cutter Splicing Separators Wire, solid copper, Nos. 12 & 6 AWG
(tie wire, gn bond)
62
I SPLICING AND TERMINATING (CONT.)
* ~~~~~~MEDIUM VOLTAGE CABLE COMPONENTS
CONDUCTOR (ANAPACT)*
CONDUCTOR STRESS CONTROL-

(ESS)"*
K
I ~~INSULATION~
~~~~~~~~~~~~~~SHIELD
DRAIN WIRES*
INSULATION SHIELD (EXTRUDED
LEAD SHEATH*
JACKET
JACKET I INSULATION SHIELD*M
UnIShIeId*8 EP- Lead
'Electrically Conducting
I~~~~~~~~~~~~~~~~~~~~~~~~~~~~~A1
MEDIUM VOLTAGE CABLE COMPONENTS
(ANAPACTi - CDUTRCONDUCTOR
CONDUCTOR STRESS CTRLCONDUCTOR STRESS CONTROL

(ESS)* (ESS)*
I.. ~~INSULATION INSULATION
SHIELD BEDDING * INSULATION SHIEILD*
TAPE OR EXTRUDED)- (EXTRUDED)
iLlINSULATION SHIELD
(TAPE)* CONCENTRIC NEUTRAL*
WIRE SHIELD*
Tape Shielded Wire Shielded URD

Unibi nd
'Electrically Conducting
5 kV Nonshielded Cables
For splices and end seals, follow the same dimensions and procedure as for shielded cables, only delete the
shield portions. Do apply conducting tape over the connector or lug to make a smooth configuration. Stress relief
cones are not necessary.
2 kV or less
No special terminations are necessary, unless they are to be in wet environments. Then it is suggested
that the outdoor ends be sealed against moisture entry into the conductor, and multiconductor cables be
sealed at the jacket cut-off. Heat shrink tubing is compatible with either type.
For both splices and terminations use HV insulating tape for the best seal, for high temperature use
silicone tape. Overlap the original cable insulation by at least one inch applying two half-lapped layers of
tape.
Identify Cable Shield System
TAPE SHIELD - UNIBLEND6 - This cable has copper-tape shields and between these tapes and the
insulation surface will be a layer of electrically conducting material. This cable has an overall jacket.
WIRE SHIELD - UNISHIELDO - This cable shield consists of longitudinally applied corrugated wires
embedded in a conducting jacket. This conducting jacket adheres to the cable insulation.
WIRE SHIELD-URD - This cable shield consists of wires wrapped around a conducting polymer jacket which
adheres to the cable insulation.
EP-LEAD - This cable shield consists of a lead sheath over a conducting polymer which adheres to the cable
insulation.
Cabi Preparation
Be sure the splice/termination is the correct one for your specific cable type
Review cable manufacturer's instructions. Review and follow splice/termination manufacturer's instruc-
tions.
Determine proper dimensions.
Train cable into final position Cut off excess cable.
Remove overall jacket. Remove single conductor jacket for all except those constructions having drain wires
emb dded within the jacket, such as UniShield.
METALLIC Component of Shield:
Concentric Neutral (URD): bind wires (but not tightly); unwrap and twist into pigtail-, tie back out
of way.
Drain Wires (or UniShleld): mark pull-out point with two wraps of PVC tape; unwrap wires or pull out
UniShield wires and twist into pigtail; tie back odt of way; remove PVC tape.
Tapes (Uniblend): tack solder at cut off; apply hose clamp; score; unwrap and tear tape against knife
edge.
Tube (EP-Lead): apply hose clamp; score.- make one or more longitudinal cuts-, roll back and
t ar.
65
Cable Preparation (continued)
Extruded Conducting Layer (EIS)-.

Conducting Tapes: apply clamp; score; unwrap and tear against knife edge.
The circumferential cut may be made using a plastic pipe cutter, a knife in conjunction with a hose
clamp for its guide, or a file - rat-tail or triangular - when a taper is desired.
The longitudinal cuts are made in UniShield by pulling out the drain wires. For other cables, use a
guarded tip knife - such as Stanley No. 199 - which has had the tip or guard ground to give a tip long
enough to just cut 85-95% through the conducting layer. Make longitudinal cuts 0.625-0.75 inch apart.
Heat may be applied to soften the conducting layer. Excess heat will be indicated by smoking of the
material. Roll or pull the longitudinal strips back to the cut-off point.
Penciling (when required)
Mark pencil area with two wraps of PVC tape on each side: slice the insulation into a taper using a
4-inch knife; smooth with abrasive cloth (nonconducting); then remove PVC tapes and insulation stub
which has served as a handle and guard unless solder connectors are to be used, then part of the stub
may be left temporarily as a heat shield. Charrifer insulation edge slightly if penciling is not required
(penciling is done also to provide a long bonding area for taping.)
Cleaning
Wipe the insulation towards the shield with a solvent-dampened cloth to remove conducting
particles on the surface. Loosen remaining conducting material with a nylon solvent-dampened
scouring pad backed with a cloth. Buff only if absolutely necessary with a 240 grit nonconduc-
tive abrasive cloth. Wipe clean with a solvent-dampened lint-free cloth DO NOT POUR SOL-
VENTS OVER CABLE
Protecting
Seal and protect insulation with a single layer of PVC tape during a temporary splice/termination stop-
page - i.e. for lunch. Rewipe with lint-free solvent-dampened cloth after tape is removed just prior to
splicing/terminating.
NOTES Minor scratches on the insulation must be buffed. Cuts or gouges into the insulation necessi-
tate removal of insulation to that point and restarting. All conducting material must be
removed from the creepage area. Do not loosen remaining shield beyond the cut-off point
either by allowing flaring or by solvent flowing under the shield. Make cuts square, trim away
raveling or jagged edges
Insulation without a conducting layer is lighter in color, its surface resistance is higher.
Remember that black rubber has carbon black as a constituent, so it will also discolor a solvent-
dampened cloth. Follow the solvent manufacturer's handling precautions. Use a minimum
amount of solvent and buff ing on the "creepage" area. The 1/4 inch of insulation adjoining the
shield cut-off need not be perfectly clean, since this area is reshielded during the splice or ter-
mination installation.
66
TAPE TERMINATION
Stress Cone
Apply half-lapped tightly-stretched layers of high voltage (HV) insulating tape back and forth to build a
tapered stress cone. Keep 1/4 inch away from any shield component
Grounding Attachment
UniShield: Twist drain wires together; cut to 1 1/2 inch; splice to 6 AWG solid copper grounding bond.
Uniblend & EP-LEAD:- Apply a 3/4 inch tack of solder longitudinally to hold the 6 AWG solid copper
grounding bond to the metal shield component.
Shi Iding
For all cable types, apply one half-lapped tightly stretched layer of conducting tape overlapping the cable
shield to within 1/8 inch of the stress cone peak. NO VOIDS
If it is desired to 'beef-up' the stress cone shield, apply one half-lapped layer of shielding braid 1/8 inch
from the edge of the conducting ta0e (near the cone peak) to 1 inch beyond the conducting tape overlap-
ping the cable shield.
Jacketing
Apply two slightly-stretched half-lapped layers of HV insulating tape over stress cone, overlapping the
cable jacket and onto the insulation creepage area by 1/4 inch maximum. Make a good sea[ at the ground-
ing bond exit. Apply two half-lapped layers of PVC tape over this HV tape just applied, overlapping it by
1/4 inch.
Connecting - see that prior page.
Sealing
For outdoor terminations seal the conductor against moisture entry at the lug. It is not necessary, nor desirable, to
seal the cable ends in dry locations just against water vapor. However, it may be desirable to seal against other
corrosive environments.
Fill any indents in the lug with conducting tape strips after burrs have been removed. Apply one half-lap-
ped slightly stretched layer of conducting tape overlapping the lug barrel and just 1/1 6 inch onto the pen-
ciled insulation. Apply HV insulating tape in half-lapped slightly stretched layers to fill in the penciled
area, then overlapping the lug barrel and insulation. Apply two layers of PVC tape over the sealed end. (Do
NOT apply PVC over the insulation between the lug seal and stress cone.)
Grounding
URD: Wrap neutral back into place to the bottom of the stress cone. With slight tension apply three turns
of 6 AWG solid copper around the neutral wires leaving a lead. The solid copper should be coated if the
n utral wires are coated.
For all: Connect the shield grounding bond to the system ground. UNGROUNDED SHIELDS ARE DAN-
GEROUS. Keep the distance between the termination and its surge protector as short as possible.
NOTE: When the circuit designer designates that the shield is not to be grounded, particular attention
must be given to keep the shield isolated from ground, which is only practical with Uniblend type cables.
Tracking Protection
For areas exposed to sunlight or airborne contaminants (i.e. dust) apply two half-lapped layers of track-
resistant silicone rubber tape, starting at the highest part of the exposed insulation (usually the lug end)
wrapping down over the entire stress cone, then back up to the starting point.
A7
UNISHIELD & URD
CONDUCTING JACKET CUT -OFF
E ~~~~~~~~~~~~~~GROUN
PECI
ENB AKTOVELAD
CODCIGTP OELP CNUTIGAPSE-CK ,B
E~~~~~~~~~~~~~~~~~~~WR
CONDUC N CONDUCT#~~~~~~~~~~~~~~ONUCIN TP
PVC Y PENCIL PVC TAPE
E ~~~~~~~~~OVELAPKTOVRA
CONDUCTING TAPE OV
STRESSSTOESSPCONE -
ZIRE~~
CONDUCTIGROUNDIN
SHILDNGLVELA
STRESS
PEASTESSCON
CONE
UNBRADLSOPINA PLEASHIMELDOS S ICEDGEG BEDDING
THICKNESS
MATHACE ETA WIUTHCONFEA
LUGHOLE~~~~~~~~~~~RMPLG /
25Kv
0.260 1 75 25 33 5.25~~0.5LOLDERLU
CON~~~~uC ING CONDPLSTIUINULC

T PI
28Kv
2.25 0.280
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Data
ndrCOmmNDaTIoNs TArE bRAsePnifraincurnl vial adblee ob
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ISOPTIONALSHIELD BEDING
information
INSLAIO
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TAPE SPLICE
Pr paration - see that prior page
Connecting - see that prior page
Stress Control
Remove any burrs from the conductor connector
Fill any connector indents with conducting tape
Apply one half-lapped tightly stretched layer of conducting strips
tape across the connector to provide a smooth
configuration, overlapping the penciling as shown.
Dimension
Measure and record the diameter over the taped
connector (DOC). Compute what will be the diameter
high voltage (HV) insulating tape: DOI = DOC + over the
21 (see drawing for dimension 1).
Insulating
Do not start or end application of insulating tape
tightly-stretched, half-lapped high voltage (HV) at a splice end, ie - stagger the tape endings.
insulating Apply
back and forth across splice to within 1/4 inch tape back and forth between penciling, then
diameter over the connector, with a gradual taper of the shield bedding at each end Build up to proper
at both ends as shown Roll each second layer
CAUSE FAILURE. VOIDS
Shielding
Apply onetightly-stretched, half-lapped layer of
conducting tape across-the splice, overlapping
ing cable shield at both ends as shown. NO VOIDS. the exist-
For all but URD cables, apply one halt-lapped layer
of braid tape across the splice as shown Fasten
braid by tucking its ends under the last wrap: the
soldering is not necessary.
Grounding Attachment
UniShield: Twist the drain wires together; splice
to 6 AWG solid copper grounding bond, spanning
splice. the
Uniblend: span the splice with 6 AWG solid copper
grounding bond and tack solder 3/4 inch of the
longitudinally to the metal shield component at bond
each end.
All: bend the grounding bond at a right angle to
the cable axis. Apply a spiral wrap of tape to hold
in place. the wire
Jacketing
Apply two half-lapped slightly-stretched layers
of HV insulating tape across the splice, overlapping
cable jacket as shown. Make good seal at grounding the
bond exit.
Apply two layers of PVC or jacketing tape as shown
Grounding
URD: span splice with concentric neutral wires
and splice to grounding bond.
All: Connect grounding bond to system ground.
UNGROUNDED SHIELDS ARE DANGEROUS
NOTE: When circuit designer designates that the
made to keep the shield insulated from ground, shield is not to be grounded, particular attention must be
which is only practical with Uniblend type cables.
Protection
When a splice must endure a continually wet environment,
tape over the prior tape to span the splice and apply one half-lapped layer of electrical filler
overlap the cable jacket 2 inches at each end.
layers of PVC tape. Apply two
69
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70
MATERIALS FOR CONVENTIONAL TAPE CONSTRUCTION
BICC Cables does not make individual recommendations.

Below is a partial listing of available materials
construction of cable terminations and splices for field
by conventional tape techniques.
Tapes Mac Products 3M Plymouth

Conducting TAPSCN
Fireproofing 13 Plyshield
AP 77
Insulating Plyarc
High Voltage TAPRUB 23,130C Plyvolt/Plysafe
High Temp, 600V
glass, 1300C GCT
silicone, 180'C 27 Plyglas
ST1 030 70
teflon,2600C Plysil
PVC-Cold Weather MAC 85 33+/88 Premium CW

PVC-Heavy Duty Premium Grey (or Black)
22 HD2
Jack t
23,130C Plytuff
Track Resistant ST1 030 70 Plysil
MISCELLANEOUS
C m nt Splice Cement
Color Tape
Filler 35 37
MACSEAL Scotchfill
Grounding Strap Slipknot Filler
SA582 25
Shielding Braid Plystrap
SA121 24 Plybraid
Caution- Some sealing compounds may have
detrimental effects on components of power and
These materials at the time of testing were found control cables.
to be compatible with most conducting cable polymers:
3M Company "Scotchfil", Mac Products "Mac
Seal".
Data and recommendations are based on information
currently available and believed to be reliable.
BICC Cables makes no guaranteeof resultsand
assumes no obligation or liability whatsoever
in connection with this information.
71
CLEANING SOLVENTS
Follow the solvent manufacturer's precautions

and instructions!
Consult the current Occupational Safety and
Health Standards for allowable concentrations,
required
ventilation, etc. (Especially § 1910.94).
The following solvents are frequently used
to clean cables. BICC Cables has tested these
with regard to their relative cleaning ability only
on BICC Cables Medium Voltage Insulations
-
EPR, XLP and TRXLPE.
Solvent
Evaporation Cleaning
Low Toxicity and nonflammable
methylene chloride
very fast fair
1,1,1 - trichloroethane
fast excellent
CRC- "Cable Clean"
fast excellent
Dow " Chlorothene Nu"
fast good
3M- "Cable Preparation Kit"
fast excellent
West "Westsafe"
fast good
More Hazardous
acetone
fast good
gasoline, white
fast good
petroleum naptha
slow good
Toluene
slow good
Xylene
very slow good
mineral-spirits
slow fair
lacquer thinner
slow good
Terpolene
slow good
West - "Electros6lve"
slow good
EXERCISE CAUTION WHEN USING SOLVENTS.
PROVIDE ADEQUATE VENTILATION. AVOID
VAPORS. AVOID SKIN CONTACT. PROTECT BREATHING
EYES. DO NOT ALLOW SMOKING, OPEN
FLAMES, OR HOT
METAL IN AREA.
Regard all cleaning solvents as hazardous.
Most are toxic or will decompose into toxic
temperatures. Some are also flammable. Use gases at high
minimum quantities. do not permit solvents
to contact
insulation shielding components.
Data and recommendations are based on
information currentlyavailable and believed
BICC Cab/es makes no guarantee of results to be reliable.
and assumes no obligation or liability whatsoever
in connection with this information.
72
BICC Cables does not make individual recommendations.

Below is a partial listing of suppliers of specific
accessories for installing power and control cables. cable
Amerace Corp, Elastimold Div.

Hackettstown NJ
AMP
Harrisburg PA
Cable Spinning Equip.

New London MN
G&W Electric Specialty
General Electric Company Blue Island IL
Schenectady NY: Hickory NC
Greenlee
Rockford IL
His Business
Hotsplicer San Diego CA
Wauconda IL
ITT Blackburn
St. Louis MO
Joslyn Mfg. & Supply, Electrical Apparatus
Div. Chicago IL
Mac Products
Kearny NJ
3M Company, Electro-Products Div.
Oz/Gedney Austin TX
Terryville CT
PLM Products
Cleveland OH
Plymouth Rubber, High Voltage Products
Raychem, Elec Pwr Products Canton MA
Menlo Park CA
Richmond Screw Anchor
Ft Worth TX
Reliable Electric
Franklin Park IL
Richards Mfg.
Irvington NJ
Sherman & Reilly
Chattanooga TN
Tel-Eye Industries
Cornith MS
SPLICE/TERMINATION
Rating - Record the temperature rating
for each device's terminal and of its cable
for proper overcurrent
protection device coordination.
Drawings and instructions - Be sure these
are proper for the cable involved.
- Follow supplier's instructions.
Cable Size, Type, Rating, Dimensions -
Check these before starting to splice or terminate.
F1 Materials - Be sure materials won't harm
cable components.
Review instructions and have materials on hand before starting to splice or terminate.
'El Tools - R-eview instructions and have proper
tools on hand before starting to splice or terminate.
E] Shelter - Provide clean, dry and safe
work area for splicers
n Grounding - Protect personnel from energized
circuits.
- Be sure termination of a shield is adequate
to meet the short circuit capability of the shield.
n Circuit Identity - Use permanent tags
held with nonmetallic binder.
71
V. TESTING
DC HIGH POTENTIAL (HIPOT) TESTING OF

MEDIUM VOLTAGE POWER CABLES
OVERVIEW
This procedure is intended to provide general
guidelines for high potential dc testing of power
cables.
All tests made after cable installation and during

the guarantee period shall be made in accordance
applicable specifications. with
All safety precautions must be observed during
testing at high voltage.
Read and understand and follow the Operator's
Manual for the particular test set being used!
TEST EQUIPMENT
Dir ct current test equipment is available commercially
ment is necessary to safely conduct high voltage with a wide range of voltages. Accessory
tests such as safety barriers, rubber gloves and equip.
ducting hard hats must be used; consult appropriate noncon
safety officer.
TEST PROCEDURES
See IEEE Standard 400. Acceptable procedures,
although varying slightly in technique, have more
less b en standardized as either a "withstand test"
or a "time-leakage current test".
Befor performing any dc overpotential tests:
All equipment'must be disconnected from the
taps, motors, circuit breakers, surge arrestors, cable circuit, i.e. disconnect transformers, switct
etc. This will preclude damage to such equipmen
and will prevent test interruptions due to flashovers
and/or trip-outs resulting from excessiv(
leakage current.
Establish adequate clearance between the circuit
test ends and any grounded object, and to othe
equipment not under test (about 2.5 feet).
Ground all circuit conductors not under test with
all cable shields including nearby equipment
Consult termination manufacturers for maximum
test voltage recommendations and time limita-
tions.
Th direct current test voltage may be applied
either continuously or in predetermined steps
imum value in accordance with applicable specifications. to the max
Continuous Method - Apply test voltage at an

approximate rise rate of 1 kV per second or 75%
the rated current output of the equipment, whichever o
is less. Some equipment will take longer t(
reach the maximum test voltage because of the
amount of charging current.
Step Method - Apply test voltage slowly in 5
to 7 increments of equal value, to the maximun
specified. Allow sufficient time at each step for
the leakage current to stabilize.
74
TESTING (CONT.)
HIPOT TESTING PROCEDURE
Normally this requires only a few seconds
unless cable circuits of high capacitance
are involved.
Record leakage current at each step.
Maintain the test voltage at the prescribed
value for the time designated in applicable
following times are usually considered specifications. The
adequate-
At the end of the test period, set the test
set voltage control to zero. Allow the residual
cuit to decay then ground the conductor voltage on the cir-
just tested.
Caution - It should be recognized that dc
charges on cable can build up to potentially
grounds are removed too quickly. Maintain dangerous levels if
solid grounds after the test on the cable
times the duration of the test. On exceptionally for at I ast 4
long cable lengths it may be necessary to
grounding time. It is advantageous to maintain increase the
these grounds longer and while reconnecting
circuit
components.
Acceptance Testing - After installation
and before the cable is placed in regular
specified test voltage shall be applied for service the
15 consecutive minutes.
Proof Testing - At any time during the period
of guarantee the cable circuit may be removed
service and tested at a reduced voltage from
(normally 65 percent of the original acceptance
value) for
5 consecutive minutes.
Record the leakage current, at one minute
intervals for the duration of the test time
involved.
COMMENTS
DC overpotential testing of medium voltage
power cables is usually performed with
negative polarity con-
nected to the conductor.
DC overpotential testing is a tool only for determining
insulation resistance at higher voltages. Effective
resistance of the cable system may be calculated insulation
by means of Ohms Law: R = V/1. The relation
is:
Megohms Kilovolts - X 1000

Microamperes
Insulation resistance may also be measured
with standard instruments which give a
volts (or higher, depending on the model). direct reading at 500
IR in general has little or no direct relationship
to dielectric or
breakdown strength.
The significance of conducting dc High
Voltage tests on nonshielded, nonmetallic-sheathed
dependent upon the environment in which cable is
it is installed because the characteristics
are unknown. The environment must be of the return circuits
carefully considered or test results may
these tests can result in damage to the not be significant. In fact
cable insulation.
Humidity, condensation and actual precipitation
on the surface of a cable termination can
leakage current by several orders of magnitude. increase the
Humidity also increases the corona current,
indication is included in the total leakage which
current. Wind prevents the accumulation
bare energized terminals. This results in of space charges at all
an increase of corona. It is most desirable
corona current at the bare metal extremities to reduce or eliminate
of cable or terminations. This may be
covering these areas with plastic envelopes, accomplished by
plastic or glass containers, plastic wrap
'Handiwrap') or suitable electrical putty. (e.g. 'Saran"k or
Routine periodic dc maintenance testing
of cable for the evaluation of the insulation
strength is not a com-
75
TESTING (CONT.)
HIPOT TESTING PROCEDURE (Cont.)

mon practice. Some power cable users
have adopted a program of testing circuits
ages, preferring possible breakdowns during plann d out-
during testing rather than experiencing
a service outage. It is nearly
impossibletorecommendtestvoltagevaluesforthosemaintenancetestswiththehistoryofthecabI
cuit. An arbitrary test voltage level could cir-
breakdown a cable circuit that would otherwise
ble-free service at normal operating ac render long trou-
voltage.
The main usefulness of dc high voltage
testing is to detect conducting particles
during splicing or termination. left on the creepage surface
Test equipment should be supplied from
a stable, constant voltage source. Do not
which is supplying arc welders or othe'r use the same source
equipment causing line voltage fluctuations.
the test set must be filtered and regulated. The output voltage of
Consider using a portable motor driven
alternator to energize
test set.
The gradual decrease or nonincrease
of leakage current with respect to time
the acceptance criteria for dc hipot testing. at maximum test voltage is
TESTING PROBLEMS
Extra Leakage Current-
Environmental Influences.
Failure to guard against corona
Failure to clean insulation surface High Relative Humidity,
Failure to keep cable ends dry Dampness, Dew, Fog,
Wind, Snow
Failure to provide adequate clearance
to ground
Improper shield termination
Erratic Readings
Fluctuating voltage to test set
Improper test leads
RESULTS vs CABLE LIFE

To date there is no basis for correlation
between dc test results and cable life
expectancy.
PARTIAL LISTING OF EQUIPMENT SUPPLIERS

J. G. Biddle Company
Associated Research Inc.
Blue Bell PA 19422
Chicago IL 60648
Hipotronics
Von Corporation
Brewster NY 10519
Birmingham AL 35211
76
TESTING (CONT.)
MAXIMUM DC TEST VOLTAGES FOR SHIELDED
CABLES
NATIONAL ELECTRICAL MANUFACTURERS'ASSOCIATION
& IEEE STANDARD 400
EPR = NEMA WC-8, ICEA S-68-516
XLP = NEMA WC-7. ICEA S-66-524
PE = NEMA WC-5. ICEA S-61-402
ACCEPTANCE 133%
100%
Rated
(For Grounded I (For Ungrounded)
Circuit Voltage
Phase to Phase Conductor Size kV
Volts AWG-kcmil
2001-5000 8-1000 25
25 35
5001-8000 6-1000 35
55
8001-15000 2-1000 G) -
- 65 (D
1-looo (D
100 20
15001-25000 1-1000
25001-28000 80
1-1000 85
28001-35000 1/0-1000 100
(D Combined in S-61-402, S-68-516
Q Not in IEEE-400
Test to be made immediately after installation
IBICC; Cables does not make any recommendations

for maintenance testing.
ASSOCIATION OF EDISON ILLUMINATING

COMPANIES
The values listed are for ACCEPTANCE testing
before the cable is placed in regular service, a and are derived per AEIC CS5 & CS6-87, Section K.2: 'After installation and
high-voltage dc test may be made at 80 percent
in Table 131 & B2 applied for 15 consecutive minutes." of the test voltage specified
RatedkV
Voltage
Conductor Size Insulation Thickness
Phas -to-Phase AWG-kcmil Acceptance Test
Mils kV
5 B-1000
8 90 28
6-1000 115
15 2-1000 36
175 56
15 2-1000
25 220 64
1-2000 260
28 1-2000 80
280 84
35 1/0-2000
46 345 100
4/0-2000 445
69 500-2000 132
650 192
AEIC factory dc test voltages equal to 1.25
times the acceptance test values listed on
this sheet.
Two other testing values are given in AEIC
CS5 & CS6-87, Section K ''Tests During and
After Installation----
"K-1 - At any time during installation, a dc
voltage specified in Table B1 and B2 applied proof test may be made at a voltage not exceeding 75 percent of the test
for 5 consecutive minutes." (Thus take 1.25
x 0.75 x values listed on the
above table.)
-K-3 - After the cable has been completely
during the periodof guaranteeat 65 percent of installed and placed in service, a dc proof test may be made at any time
the test voltage specified in Table B 1 &B2 applied
(Thus take 1.25 x 0.65 x values listed on the for 5 consecutive minutes."
above table.)
77
HIGH VOLTAGE DC TEST REPORT
WARNING: TEST VOLTAGES ARE LETHAL
CAREFULLY REVIEW "TEST PROCEDURE"
OWNER _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
______________DATE TEST _ _ _ _ _ _
CUSTOMER _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
LENGTER MPCGR MOREL SIEALN3GEPASEPHAL R V3 MEGOHMty-
MEATHER
VOLMNTINTA
DC TEST
PE
TIME~~~~~~~~~~~P
APPIHEAD
'.R RTIN DUCT
DEINOR BYE0
3TERMINATDO PTHA
ETEMP
F
3INOR
0
IM
SAETY SETGOUNDED
PES 0
FR LERANE3 IIN
OUTDOOk 0OTOO
LOCKOLOD 3 MS
ETEEREU
OLO IP GRUNE 0 PSONLStTEQP0 0I
LBRRER
RESISTRSITNCATNCDEHG VLTG TS
UEARDED' F RHDUCIORMPOAY
VOLAG
TAGPPASLCLOED2
TIME MICROAMPS MICROAMPS MICROAMS MICROAMPS

MEGOHMS MEGOHMS MEGOHMS MEGOHMS KV
0 -GN KV
02 - GN j_ _ ___ _ _ _ _ __ KV
1 ~~~~~~~~~~KV
NEUT GN -30 SEC_____
2 MIN4
REMARKS 3MIN __ _ _ _ _ _ __ _ _ _ _ __f
7sMIN
6 MINI
B MIN
TOMIN
9tMIN
13MINI
___________ ~~~~~~~~~~~~12MIN
13 MIN
is MIN
SET CONTROL VOLTAGE TO ZERO REVERSE AMMETER

________________________________________________ ~ ~ ~ ~ ~ IKV A Ky A KEV A KV
-I MINI
'MAXIMUM TIME FOR SOME TESTS SEE CHARTS USE RUBBER GLOVES GROUND0 TESTED CABLE DISCONINECT TESTlEN
OPERATOR _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ W ITNESS _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
TEST
VOLTAGI AUTNORIZER
'70
NONDESTRUCTIVE TESTING
FAULT LOCATING
Time Domain Reflectorneter (TDR) units are portable commercially available devices which can be used
in the field to locate some types of conductor breaks or shorts Connected to the end of a cable the device
functions much like radar, sending out low voltage pulses which travel the length of the cable and echo
back when an open, short. or tap is encountered The device can usually locate faults within + 2". of the
cable length However. TDRs are only capable of locating breaks or shortshaving an impedance different
than that of a cable. for most cables. shorts having a resistance of less than a few ohms and opens having
a resistance greater than several hundred ohms Splices. taps etc sometimes distort the echo and can
mask the fault. Nevertheless, the method is nondestructive and is used successfully on faults having
characteristics within the capabilities of the method Note that the conductor may be in a low voltage or
medium voltage cable, shielded or nonshielded, it may even be the shield
AC TESTING
Several cable users are also including high voltage ac testing to determine RELATIVE CAPACITANCE (SIC)
and DISSIPATION FACTOR (insulation power factor) for cables being used in ac circuits HOWEVER. the test
voltage levels used and equipment are much different.
INSULATION TESTING
It the dc voltage applied during an insulation resistance (IR) test on power cables is relatively low, 0.6 to 2.5 kV,
the test is nondestructive. One such test instrument is the MEGGEWO which is a portable high-range resistance
ohmmeter.
These low voltage IR tests are particularly useful in detecting dead shorts and indicating grossly deterior-
ated insulation
The limitation for this low voltage IR test is its interpretation The significance of such testing on non-
shi Ided, nonmetallic-sheathed cable is very dependent upon the environment because the charac-
teristics of the return circuits are unknown.
Even though the test voltage is lower, the safety precautions stated in the Hipot Testing Procedure, and by
the test equipment manufacturer. must be observed
Again, low resistance readings may be caused by contaminated or moist cable ends, variable test voltage
because of too slow of cranking or variable input voltage to motor driven units, high humidity, etc Failure
to clean water based cable pulling lubricants from the cable test ends has caused erroneous rejection of
good cable.
TESTING
F Safety - Follow test equipment supplier's instructions. Stay clear of energized ends, operators must know
equipment. Be sure shields are grounded! Insulated conductors are capacitors.
r-1 Voltages - Check cable and termination manufacturer's guidelines.
E] Records - Keep detailed records and provide copy to owner.
79
VI. APPENDIX
A. CIRCUIT DESIGN CONSIDERATIONS

WHY CALCULATE
Mechanical damage, unless severe. is not usually detected until there is a path of moisture or carbon thru the
insulation. because the state of the art of field testing power cables is poor. Neither is it practical to measure
sidewall loading during cable pulling. Shields, especially of medium voltage cables, are likewise difficult to test for
mechanical damage.
USE CALCULATIONS TO ESTIMATE THE EXPECTED TQ4SIONS - TO INDICATE "NORMAL" OR "DIFFI-

CULT" CABLE PULLS.
1. CALCULATION PROCEDURE
Select raceway size considering fill, clearance, jam ratio and code requirements. Remember, NEC is minimal.
Select values for bending radii and coefficient of friction'.
Determine weight and weight correction factor.
For each raceway section, i.e. bend or straight

1) compute the expected tension,
2) compare to limits - sidewall, attachment method/device, conductor.
When limit has been exceeded:

increase bending radii to reduce sidewall loading,
decrease fill,
reduce the number of bends,
check pulling opposite direction.
Even for new installations with optimum conditions, 0.4 seems to be the lower limit for coefficient of friction for cables in conduits.
80
I ~APPENDIX (CONT.)
2. CALCULATION INPUT
I ~~~Job - - _ _ _ _ _ _ _ _ _ _ Date _ -
C per NEC C noncode C parallel C cabled C multiconductor
U ~~~Cables Phase iit/d uctI type_______ kV _____ size
Neutral (Grounded) __________ ______ _______
I ~~~~Grounding - __ __
Duct C existing C new C design is 'locked'
size_ metal C rigid C IMC C EMT

plastic C PVC-40 C PVC-80 C PUD
I C tray
special
C~~~~~~~~~~~~
C fibre C transite
Make single line diagram. not necessarily to-scale, of raceway. Number sections of duct: with a section being a
straight portion or a curve. Offsets are two or more curves back-to-back
Describe bends: ending # . radius: angle: H/VUCD/VUCU/VDCDIVDCU & entrance angle
Describe bends ending z radius, angle, H/VUCD/VUCU/VDCD/VDCU & entrance angle
I ~ ~where H = Horizontal
le. VUCD =
V = Vertical U = Up D = Down
cable being pulled vertically up. with the concave side of the elbow down
I = Incline C = Concave
* ~~~~~~The
angle is the angle of deviation
NOTE The designer can do the most accurate take-oft from the dravwings
EXAMPLE *
iS 'I~~~~~~~~~~~~~~~~~~~~~~~~'
81~~~~~~~~
APPENDIX (CONT.)
3. PULL BOX SIZING

Over 600 V - Straight Pull See '96 NEC370-71 (a).I
L = 4 x Largest Cable Bending Multiplier.
EXAMPLE 5kV UniShieldI

L 3-350 (1.12")
3-4/0 (0.94")I
L = 48 x 1.1 2=54 inches, minimum
Over600 V -Angle Pull See '96 NEC370-71 (b).

L = 3 x Largest Cable Bending Multiplier + sum of other cables O.D.'s entering same side.I
VW
UniShield
3-500 (1.21" =I3
5k .1 3x09)+( .1
3-/ (09" L = 9 inches, minimum
3-4/0 3-500
600 V - for conduits of 3/4 inch and larger, or having #4 or larger conductors.
Straight Pull See '96 NEC370-28(a)(1)I
L = 8 x diameter of largest raceway
2"0 L 2"
L =8 x 3=24 inches, minimum
Angle Pull See '96 NEC370-28(a)(2).

L =3 x Largest Cable Bending Multiplier + sum of other cables O.D.'s entering same side.
2" ~
3" L (6 x3) +2 20 inches, minimum
L
82
I ~APPENDIX (CONT.)
4. DYNAMOMETER CORRECTION
(Load Cell)
Pulling Force (F) W =tare weight of idler pulley assembly
I ~~~S
=C + 0/2 cos (1/2) =T S.D R [ Io~/) -
(3 1 (3____________ _____
(degrees) 2 cos ((3/2) (degrees) 2 cos (13/2) (degrees) 2 cos (13/2)

0 0.500 120 1.00 150 1.93
30 0.518 125 1.08 155 2.31
45 0.541 130 1.18 160 2.88
60 0.577 135 1.31 165 3.83
90 0.707 140 1.46 170 5.74
100 0.778 145 1.66 175 11.5
105 0.821
110 0.872
115 0.931
~
Example ~1: ~ ~ ~ ~~=(4500) (0.577) -1 5 =2580 lb
I 60 ( ~~R = 4500 lb
= 15 lb
~~~~~~~~~~~~W
Example 2:12ic
4 12 +13.875/2=
5=~~~~~~~S 18.9 inch
13.875 inch: R=40lb cos ((3/2) 1. 1.-385, .1
W =15 lb 12
T 4500 -15 =2740 lb
2 (0.816)
I To Size Dynamometer:
~ -~~~R(T+W) [2 Cos ((3/2)]1
Example: estimated T = 1800 lb W = 15 lb 13=45'
R -(1 800 + 15) [2 cos (45/2) J - 3350 lbs
I ~
We would use a 5000 lb Dynamometer.
~~Urnitatlons
1. the forces of friction at the pulley must be negligible
I ~
2. "tare" w ight of idler assembly must be zeroed out
angle is constant and accurat ly known
~~3.
4. dynamometer is swinging free so its line bia. cts )3; but avoid drag on duct opening
APPENDIX (CONT.)I
5. SUSPENDING CABLE
I. Suspending By Clamping Around CableO I
for 600 V = see '96 NEC 300-19
for 600 + V - use the severest of either the cniteria of NEC 300-1 9, or 70 lb per clamp for single conductor-,
wrap single conductor cables with two half-lapped layers of jacketing tape under clamp.
0
11. Suspending by Conductor (Single Conductor)
Reference NEMA WC3; ICEA S-1 9-81, § 7.2.2.1
F ATW Where A = conductor area -sq inchI

LW ~~T
= conductor tensile strength-lb/in
2
W = cable weight - pound/foot

L = length -feetI
F = minimum safety factor = 7. unless otherwise
required by appropriate authorityI
Example:
Suspended 470 ft of 15 kV cable having three 4/0 AWG soft-drawn copper conductors, 1080 lb/MF *
weight, each supported at top, with full tension terminal:
F = ((211 600) (ir/4) /1 000 000 1 24 000 =- 79 =OKI
1(1080) (47 0/1000)1
OWhen the suspended cable is laid over an elbow at the top, check sidewall loading.I
84~~~~~~~
APPENDIX (CONT.)
6. DIAMETER OVERALL OF MULTI-CONDUCTOR ASSEMBLIES
DOA = d ia meter of 1/C - f actor f rom chart:
Number of Conductors Factor

1 1.000
2 2.000
3 2.155
4 2.414
5 2.700
6 3.000
7 3.000
8 3.310
9 3.610
Diameter of Largest Possible Conductor in Outer Interstices of Cables
(Keeping within a circumscribing circle.)

Diameter of interstice Diameter of main conductor x
factor from chart
Number of Main Conductors Factor

2-Flat 0.250
2-Round 0.667
3-Triangle 0.483
4-Round 0.414
5-Round 0.377
6-Round 0.354
85
APPENDIX (CONT.)
B. PURGING WATER FROM STRAND OR SHIELD
NOTE: Shielding systems, such as UniShield, having the metal shield components embedded within a polymer do
not collect water droplets in the shield system.
CABLES ON REELS: Position the inside end to its lowest possible elevation. Unlash the cable ends.
ALL CABLES: Purge the shield separately from the insulated strands; otherwise the gas will only flow thru the
path offering the least resistance.
CABLES NOT INSTALLED: Remove end seals. At the cable end having the highest elevation apply two layers of
half-lapped HV insulating tape to act as a sealing cushion. Interconnect the cable ends to the dry gas supply
using hoses, valves, pipefittings, and flow regulators as necessary.
Attach a one gallon plastic bag to the exhaust end of the cable. Secure the bag with tape or clamps. Make a small
vent hole by clipping one bag corner.
As shown in the sketch, several cables may be manifolded to the gas supply. Dry nitrogen is available from a
welding gas supplier. Apply 15-25 psig. Maintain pressure for at least eight hours after all indications of moisture
have stopped.
Water vapor may be readily detected by sprinkling in the plastic bag, one tablespoon of Anhydrous Cupric Sulfate
which turns blue instead of 'off' white. The Sulfate is available from scientific laboratory supply houses.
INSTALLED CABLES: Of course, the splices and terminations can be removed and the cable purged as related
earlier.
To remove water from the strand, the cable can be lightly loaded to drive the vapor out one end of the cable,
providing the cable's termination design has an open strand. Or a termination can be removed and low voltage
and low current applied to drive out water.
A shield system may be purged by attaching a truck air valve (having stem removed) over 112 inch holes cut into
the jacket at both ends of the cable section. Then gas applied and checked as before, except to 15 psig
maximum. Do not try to purge across or thru splices!
0C
APPENDIX (CONT.)
PURGING WATER FROM STRAND OR SHIELD
REDUCING SUPPLY
HOSE COUPLING 12" HOSE
1/C CABLE
'THREADED HOSE 'CLAMP
CLAMPS NIPPLE ADAPTOR
PRESSURE
--- ,REGULATOR
CRY
NITROGEN
3/C CABLE
87
APPENDIX (CONT.)I
CONSTANTS
e=2.718 10, = 100I

.T= 1.414 106 = 1000 000 1021 =i /ioo=o0.0
Vr 1.732 sinh x =(W-e-'e) /2 - -/000.1
7r/4 0.7854 cosh x =(ex+e-E)/2 Io-,, 1/1 000 000 = 0.000 001I
SYMBOLSI
Cl =clearance
cmil = circular mu l area of circle having diameter of 0.001 inch
d =overall diameter of a single conductor cable
0 =inside diameter of racewayI
DOA = diameter overall
= coefficient of fri ction
Y. =sumnmation
kip =lOO00lb
L = length of duct run, ftI
Lm = maximum length, ft
kcmil = thousands of circular milsI

MFT = thousands of feet
mm = millimeterI
n = number of conductors
m = sidewall load limit, lb/ftI
P = sidewall load, calculated, lb/ft
R = radius of bend, ft
T1 = pulling tension at point ' 1.
Tm = maximum tension, lb
W =cable weight, lb/ft

w =weight correction factor
6) = angle of deviation= radians= degree x 7r /180I
1/C =one conductor
3/C ==three conductorI
> g~reater than (the large part of arrow to biggest)

<= less than or equalI
< less than
>= greater than or equalI
88
APPENDIX (CONT.)
CABLE INSTALLATION DATA
By: DATE-
USER: Name
Cable Installation Address
INSTALLER: Company
Site Supervisor
DESIGNER: Company
Individual
PURCHASER: Company - -- Order Mfgr Order
Phase Cable Type Voltage -- -size -/buct - Reel
Grounded (Neutral) Cable Type Voltage---Size ::/!Duct -- Reel
Grounding Cable Type- . .---- -- Size -/Duct - Reel
WHEN: Manufactured efivered . .- Installed -- Energized
ENVIRONMENT: 0 wet 0 air 0 raceway . 0 indoor 0 hazardous
0 dry 0 underground 0 no raceway 0 outdoor 0 ambient temp.
RACEWAY: Type . .- Material Inside Dimensions
CABLE END: 1 -Termination 0 indoor 0 outdoor gn lead size
mfgr &type
Lightning or Surge Arrestor - feet of wire from arrestor to cable end
mfgr &type..
2: Termination 0 indoor C outdoor gn lead size-
mfgr &type-
Lightning or Surge Arrestor - feet of wire from arrestor to cable end
mfgr &type
SPLICE: 1. 0 straight 0 Y 03 T 0 transition, mfgr &type gn lead size
2. 0 straight 0 Y 0 T 0 transition, mfgr &type gn lead size
INSTALLATION: pulling rope - material - -size- 0 eyes

• basket grip
puller - type 0 serving
lubricant - mfgr & type how many grips
• cabled 0 parallel
dynamometer - mfgr - -. .range-- type
TESTING: (attach data sheet): when &who ins. resistance volt - time
cleaning solvent (brand &type)- .-. .dc hi voltage- volt . .time
corona suppression (lugs, etc)- ac hi voltage- volt . .time
SKETCH: (Put on back or separate sheet] - Include all bends such as offsets, and vertical sections as shown in Pulling Calculation
Input, page 46. Indicate where reels were set-up, size of boxes or manholes, location of splices or taps.
CIRCUIT: Identity I ength (source to load)

Source: Vol t -Hz kVA Ogr C] A 0 1 phase
0 ungr 0 Y 0 3 phase
Fault AMPS
Overcurrent Protection: 0 circuit breaker type
o clearing time (sec) 4) gn
Loads- load factor-- - power factor
type. motor- type, size, how started
transformers. capacitors, furnaces, lighting fixtures- size. type, connection
all: gn/ungn . wy. 1 /34i,. amps: running, full load
I
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11
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General Cable
V~~~ 4brive
Tesseneer
~ ~ ~ ~ I
107
HighandHeihtsK
Phone:(888)
93-335
Fax:
572-844(859
www~geeralcal
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enera a e

(tO/90) (ri) 90906-OH

1600 West Main Street

9. Inclined Pull ...................................... 48

Th data and recommendationsthat follow are based on information currently availableand

* The cable selected is proper for your application

How to Handle Cable Reels

Never allow forks to touch cable

Always load with flanges on edge Never drop reels.

Prevent impact damage by:

• Aligning reels flange to flange

Review local, state and national codes relating to cable installation

Consult local inspection authority

Check for shipping damage before accepting shipment

Confirm tlat the cable specified was received

Reseal cable ends

Remove nails and staples from reel flanges

Calculate and observe recommended bending radii

Use swivels and avoid overruns when unreeling

Provide firm support for reels

Protect cable from mechanical damage and from liquid spills

Check cable end seals periodically

Advise all splicers, installers and handlers of all special instructions

There are five main considerations in any cable installation:

CP/EP - 1/C - 31 OF FREP, PE, XLPIE - 1 /C - 58OF

CIP = Chlorosulfonated Polyethylene (HypalonO), CPE = Chlorinated Polyethylene,

M portable electric generator M shackles/clevis

short ropes for temp tie-offs M 50 ft measuring tape

The following diagrams illustrate various cable feed-in setups.

PPLY LUBE HERE

Setup for overhead. into tray

Single Sheaves may be used only for GUIDING cables.

For pulling around bends, use conveyor sheave assemblies of

BICC CABLES APPROVAL LIST

Name of Lubricant Manufacturer

POLYWATERQD A, G, & J American Polywater Corporation

POLYWATERQD Plus Silicone, American Polywater Corporation

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

DYNA-BLUEO Cable Lubricant American Polywater Corporation

Wirepull Mac Products, Kearney, NJ

Cable lubricants should be currently I.I.L. listed.

Lr) Lr) Lr) C.) Lc) Lr) M

0 4 Lo0 -'tr Cj CD Ln CY) C) CD u) 00 >

(7)M MC) Lc) vCO (o WN M

uj ao C\j q c\j N C\i

SWEEP ELBOW RADIUS

ELBOW CENTERLINE RADIUS OnChes)

1 0.44 0.96 1.21 1.46 1.96 2.46 2.96 3.46 3.96 1

4 1.17 1.83 2.33 2.83 3.33 3.83 4

6 2.25 2.75 3.25 3.75 6

EXAMPLE: Find inside radius of 15 inch sweep elbow for 2-C.

z Lr) C14 00 Lr) 0co0C,4 c

c\j 0 Co Co 1* c'J C) 0 C)0 CD

IE 7, - - - CD CD C\J - - C\J V) "T N V) V) 1-:r LO CD r -

.TcMCo coco',t N-0 000 000 C>00 ac

0 I-T CY) I-T M

0 r- 0) - COLO CD CO '-T a) M OD-* LO C\J CO CIJ 0 C\J C\J N

(0,14rcM -00 000 000 0

(Dl.T0j -C)o oco 000 0

CO (D'.0, N 0 a 0 O a 0 0 0 0 00(0,q cq-O 000 000 ao

0 C.) N 19t 'M 'cr "tr CY CD ; Lf) 6 Zn

z a) c.0 cD T -T cl) cm cm -T -T -r v cDcoco Vqm N-- CM.0, IT -T CT

N-0 000 000 0 C\A-a 000 000 0