TENAGA NASIONAL General Manager (Assot Management Strategy & Design Standard) 114 Floor, Wisma TNB No. 19, dalan Timur 46200 Petaling Jaya Selangor Darul Ehsan ‘Tol: 03-79679000, Fax: 03-79572895 TECHNICAL SPECIFICATION, SPECIFICATION FOR PVC CABLE TRUNKING FOR USE IN LV FIVE-FOOT WAY SERVICE MAINS. Specification No. | KEJ05434:2003 _| Revision No. Prepared by Ir, Mohd Hafeez Bin Mohamed Senior Engineer (LV Overhead & Street Light) Asset Management Strategy & Design Standard Distribution Network, Distribution Division, TNB Approved by ‘NB, Distribution Division Technical Committee Dated 13 September 2017 Review Date 13 September 2017 | Remark Revise Standards Review Format UMAIZI HAMID) General Manager (Asset Management Strategy & Design Standard) Distribution Network Distribution Division, TNBTechnical Specification G Specification For PVC Cable Trunking For Use In Foot Way Service Mains TENAGA NASIONAL Specification No. KETOS&34-2005 Revision No. Page 1 of [Approved by | Distribution Division Technical Committee Dated 13 September 2017 10 SCOPE LL This specification covers the material, design, construction, performance and test requirements for Polyvinyl Chloride (PVC) cable trunking, which is intended to be used as an integral part of TNB five-footway service mains installation, 1.2 The PVC cable trunking shall be suitable for outdoor use in the Tropical Zone with high humidity of approximately 100%, heavy rainfall, ambient temperature of 28°C to 45°C, and an average of isoceraunic level of approximately 200 thunder-days per annum at a preferred operational altitude of up to 2,500 meters. 2.0 CONFORMITY WITH STANDARDS, 2a 22 Unless otherwise specified, this specification shall include, but is not limited to, the following standards or the latest version as reference and for compliance together with all current amendments for the design, construction, electrical characteristics, performance, and test requirements: i, IEC 61084-1 (2017) Cable trunking systems and cable ducting systems for electrical installations - Part 1: General requirements ii, IEC 61084-2-1 (2017) Cable trunking systems and cable ducting systems for electrical installations ~ Part 2-1 Particular requirements — Section 1: Cable trunking systems and cable ducting systems intended for mounting on walls or ceilings Other internationally recognized standards that are compatible to the abovementioned standards can be considered provided that an English version of such standards shall be submitted to TNB for further reference.Technical Specification G Specification For PVC Cable Trunking For Use In Five- Foot Way Service Mains TENAGA NASIONAL Specification No. | KEJ054342003 [Revision No. [Pese2of 14 ‘Approved by __| Distribution Division Technical Committee Dated 13 September 2017 3.0 FUNCTION 3a 3.2 33 34 The cable trunking system is introduced to provide an alternative to the current wooden backing method used to secure and install five-foot-way service cable mains, ‘The PVC cable trunking system is a semi-enclosed casing system comprising of a non-circular cross-section base tray with removable fastening clips, and a Junction Box base, assembled together to allow insulated cables to be laid in, and Junction Box to be mounted on. ‘The PVC trunking system is intended to be mounted directly on walls and shall provide adequate mechanical strength to hold and secure firmly the cables contained therein, and shall withstand the stresses likely to occur during transport, storage, installation and usage. When used as part of the TNB five-footway service mains, the PVC cable trunking shall be suitable to be used together with TNB approved PVC Aluminum insulated 7/2.10mm (7/.083”), 19/1.53mm (19/.064"), 7/1.12mm (7/,044”) service cables and junction boxes operating on a 3 phase, 4 wire 400 Volts, 50Hz, multiple neutral-earthed distribution system, 4.0 DESIGN AND CONSTRUCTION 4a For the intended purposes mentioned in paragraph 3.0 above, the cable ‘trunking system may consist of a base tray, fastening clips and junetion box base. The base tray, which will be surface mounted on the wall, will provide the base surface for the cables to be laid in, Removable fastening. clips installed at intervals of 20 em (8 inches) along the base tray length may be used as a mean to firmly secure, hold and fasten the cables in the base tray. Removable junction box base plate is fastened onto the PVC base tray and will provide a base for mounting the Junction box onto the PVC cable ded for trunking system. A piece of junction box base plate shall be pro\ every 5.48 meter (18 feet) length of the base tray.Specification For PVC Cable Trunking For Use In Five- ‘Technical Specification & Foot Way Service Mains TENAGA NASIONAL Specification No. | KEIOS434:2003 Revision No. [Page 3of 14 ‘Approved by Distribution Division Technical Commitee Dated 13 September 2017 42 43 44 45 46 47 48 ‘The general design drawing of the cable trunking system and the junction box base are shown in Appendix A and B. ‘The means of fastening the cables in the base tray shall be designed so as to allow for easy installation, maintenance and replacement of the clips as a single unit without the use of any special tools. Fully covered plates shall not be used as a means of fastening as it is the intention of INB to keep the cables visible throughout. ‘The base tray, junction box base and clip shall be sized to accept the size, and number of cables appropriate to the rating and application of the distribution network system, and the insulation shall be appropriate to the cables rated voltage and temperatures of the cables. Bidders may propose alternative designs based on the conceptual design described in paragraph 4.1 - 4.4 and the functional requirements outlined paragraph 2.0 above. Relevant design drawings and documentation complete with the dimensions and descriptions shall be attached in the submission. The cable trunking system shall be manufactured and tested and complied fully with the relevant MS and IEC standards, and shall withstand a maximum operating temperature of 60°C 41/- 2°C, and evenly distributed load of 0.13 kg/em?, Al components with the exception of small fixing screws, that form part of the cable trunking system shall be made from heavy duty Poly Vinyl Cholride (PVC) material with weather, Ultra Violet (UV) and aged resistant, heat and non-flame propagating protection properties. ‘The manufacturer shall provide a report conducted by an independent and accredited laboratory to certify the UV and aged resistant properties of the material used.Specification For PVC Cable Trunking For Use In Five- = Foot Way Service Mains TENAGA NASIONAL ‘Specifieation No. [ KEI05434:2003 Revision No. Page 4of 14 ‘Approved by __| Distribution Division Technical Committee Dated 13 September 2017 4.9 The finished product shall be white in color. It shall not be coloured by painting or other superficial means. 4.10 The trunking system shall be free from sharp edges, burrs, flash or surface projections which could cause damage to insulated conductors or cables or inflict injury to installer or user, and shall be so designed that in normal use thei performance are reliable and without danger to persons or surroundings. 4.11 — The PVC trunking system shall have adequate mechanical strength and shall comply with at least the Class 4 (Impact 2 J) of Impact Test Values specified in Table 6 of IEC 61084-1 4.12 If screws or studs are used to secure the components of the trunking system, they shall not cause damage to cable insulation. The screws shall have isometric threads. Thread cutting screws shall not be used. 4.13 Screw fixing means shall be so designed to withstand the mechanical stress occurring during installation and normal use and shall comply with requirement of Clause 9 of IEC 61084-1 and other related amendments, if any. 5.0 SIZES ‘The trunking system shall be supplied complete with the junction box base, fastening clips and screws of appropriate dimensions and numbers. The cable trunking system sizes and dimensions shall be as follows:- No. Type Dimension Length (Width) mm x (Height) mm 1 2 Wire c/w 5 clips/meter 35mm x13 mm, 2 meters 2 | 3 wire chw 5 clips/meter 47mm x 13mm, 2 meters 3 | [Link] c/w 5 clips/meter 60mm x 13mm 2 meters 4 Junction box base plate 68mm(W) x 18mm (H) x 102 mm, 1.4mm(Thickness)Specification For PVC Cable Trunking For Use In Five- Technical Specification @ Foot Way Service Mains TENAGA NASIONAL Specification No. | KEJ0S434:2005, Revision No. Page 5 of 14 Approved by __| Distribution Division Technical Commitee Dated 13 September 2017 6.0 10 MARKING AND IDENTIFICATION ‘The markings shall comply in accordance with clause 7 of IEC 61084-1 and other related amendments, if any. In addition to this, the cable trunking shall be marked with the followings: i) Contract No. ii) Manufacture date iil) Delivery Month and Year iv) Warranty Period ¥)_ Supplier Name vi) Serial No/Batch No/Tracking No vii) Rated Current viii) TNB Acronym The marking shall be permanent at the product either using engrave/embossed/permanent ink/permanent sticker. Please refer to Guideline “Terma Serta Syarat Pengurusan dan Penguatkuasaan Jaminan Kualiti Produk Untuk Bahagian Pembahagian TNB” INSPECTION AND TESTING 7.1 General Requirements 7.1.1 Itis the responsibility of the manufacturer to ensure that the product is, inspected and tested at all stages of manufacturing in accordance to requirements as stipulated in this specification. 7.1.2 The approval or passing of any such tests and inspections shall not prejudice the right of TNB to reject the product if it does not comply with this specification when installed or if it does not giveSpecification For PVC Cable Trunking For Use In Five- Technical Specification Foot Way Service Mains TENAGA NASIONAL Specification No. ‘Approved by KEI0S43422005 Revision No [Page 6 of a Distribution Division Technical Committee Dated 13 September 2017 73 14 TAS complete satisfaction in service. This condition shall apply only if the causes of the abovementioned situations are due to any deficiency or wrong action on the part of the manufacturer towards the fulfillment of the requirements of this specification. The manufacturer shall allow the representative of TNB or its appointed Quality Agents access to all production facilities necessary for the manufacture of this product at all reasonable times, The manufacturer is responsible to maintain all Quality and Test records for a minimum period of five (5) years. TNB and/or its appointed agent reserved the right to inspect these records as and when deemed necessary. Not less than thirty working days, notice of all tests shall be given to TNB representative(s) in order that he or she may be present if he or she so desires. As many tests as in the opinion of the TNB representative(s) are possible shall be arranged together During such inspection, any corrective actions necessary shall be complied with within the scope of this specification. The tests shall be carried out in accordance to the standards as mentioned in Clause 2.0 above and any additional requirements as stated in this specification, Two (2) copies of all test certificates and reports shall be furnished to the TNB representative(s). All inspection and testing requirements please refer to Guideline “Terma Serta Syarat Pengurusan dan Penguatkuasaan Jaminan Kualiti Produk Untuk Bahagian Pembahagian TNB”Technical Specification eA) Specification For PVC Cable Trunking For Use In Five- = Foot Way Service Mains TENAGA NASIONAL ‘Specification No. | KEI05434:2003 Revision No. Page 7 oF 14 ‘Approved by __| Distribution Division Technical Committee Dated 13 September 2017 7.2 Type Test 7.2.1 The product shall have passed the type tests in accordance to standards 122 723 specified below and its other related amendments, if any.: ‘Marking Test (Clause 7 of IEC 61084-1) Dimensions Test (Clause 8 of IEC 61084-1) iii, Distortion test (Clause 10 of IEC 61084-1) iv, Impact Test (Clause 10.3 of IBC 61084-1) vy. Non-Flame Propagation Test (Clause 13 of IEC 61084-1) vi. Resistance to Heat Test (Clause 12.1 of IEC 61084-1) vii. Insulation Strength & Resistance Test (Clause 11.2 of IEC 61084-1) In the event that modifications to the design of the product are made which, in the opinion of TNB, will affect the performance of the product, the relevant type tests shall be repeated at the expense of the manufacturer, Type Tests shall be conducted at any national or intemational independent laboratory accredited to ISOMEC 17025 by the National Accreditation Body who is the MRA/MLA signatory to ILAC, APLAC, EA, NACLA or IAAC. The tests to be conducted shall be within the scope of accreditation of the laboratory and shall cover the appropriate capacity limit for the specified tests. TNB shall reserve the rights to witness the conduet of the said tests if deemed necessary through its engineers or appointed representatives‘Technical Specification Y Specification For PVC Cable Trunking For Use In Five- Foot Way Service Mains TENAGA NASIONAL spe [ KEIO543 Revision No. Page 8 of 14 ‘Approved by __| Distribution Division Technical Committee Dated 13 September 2017 Note: a MRA —: Mutual Recognition Agreement b. MLA Multilateral Agreement c. ILAC : International Laboratory —_Acereditation Cooperation d. APLAC Asia Pacifie Laboratory Accreditation Cooperation e EA : European Cooperation for Accreditation NACLA : National Cooperation for Laboratory Accreditation g. IAAC — : _ Inter-American Accreditation Cooperation 73 Routine Tests 7.3.1 Routine tests shall be carried out by the manufacturer on all products in the finished state or, where appropriate, during the manufacturing processes in accordance to IEC standard or compatible standards and other related amendments, if any. 7.3.2. The routine test that shall be made on the products are:~ i, Check on markings (Clause 7 of IEC 61084-1) Physical and visual checks on dimension and construction, 7.4 Sampling Tests 7.4.1 The manufacturer shall carry out sampling tests on sample of products in the finished state. The sampling tests that shall be made on the products are: - Distortion test (Clause 10 of IEC 61084-1 and IEC 61084-2-1) Verification of material used for the batch production* 8a pf EN 2 FRING FOR SECMSpecification For PVC Cable Trunking For Use In Five- Speciation No. ‘Technical Specification & Foot Way Service Mains TENAGA NASIONAL [ KEI05434:2003 Revision No. Page 9 of 14 ‘Approved by ___| Distribution Division Technical Committee Dated 13 September 2017 Manufacturer shall furnish independent laboratory's report verifying the material used for the batch production, TNB reserves the right to sample a material batch for independent tests and verifications. 7.42 The manufacturer have to provide all necessary tools and testing equipments on their own initiative for the sampling test to be witnessed by TNB representatives. 7.8 Acceptance Tests 75.1 152 153 754 For each contract, a schedule for the implementation of acceptance testing shall be agreed between the manufacturer and TNBD in order that acceptance testing may be carried out on a regular basis. ‘The following documentation shall_be made available for inspection during acceptance testing: i, Routine Test report Sampling test Report Mill Certification or 1 st Report of material used for manufacturing ‘The acceptance tests to be carried out by the manufacturer and witnessed by a representative of TNBD shall consist of all the tests listed under routine tests and sampling tests. The check on the product shall be done periodically at the discretion of TNBD. If any sample fails in any of the tests, two further samples shall be taken from the same batch and submitted to the same tests in which the earlier sample failed. If both additional samples pass the tests, all the products in the same batch from which they were taken shall be regarded asSpecification For PVC Cable Trunking For Use In Five- Technical Specification Foot Way Service Mains TENAGA NASIONAL | Specification No. ‘KEIOS434:2003 Revision No. Page 10 of 14 [Approved by Distribution Division Technical Committee Dated 13 September 2017 8.0 16 1d complying with the requirements of this standard. If either of the addi regarded as failing to comply. 1al samples fails, the batch from which they were taken shall be Quality Control ‘The manufacturer shall set up and implement a good quality management system. This system shall be inspected / audited by TNB appointed Quality Audit Agent before the commencement of any new contract and subsequently at agreed regular interval to ascertain the proper implementation of the quality ‘management system. Corrective actions resulting from the audit shall be taken ina timely manner. Instruments And Calibration All measuring, recording and testing equipment to be used in assessing the quality of the products, sub components, assemblies or raw materials at all stages of manufacturing shall be calibrated using equipment calibrated by at recognized calibration laboratory approved by TNBD at the expense of the ‘manufacturer. Alternatively, if in-house calibrated equipment are used the measurements standards used shall be traceable to the Malaysian’ international standards of measures. Manufacturing of product shall not commence or shall be discontinued if the manufacturer defaults on this requirement, The manufacturer is responsible to maintain all calibration records for a minimum period of five ( 5 ) years. TNB and / or its appointed agents reserve the right to inspect these records as and when deem necessary SAFETY 81 Safety Information ‘The equipment must be accompanied by instructions and safety information in a language understood by the end-user. Such instructions‘Technical Specification Specification For PVC Cable Trunking For Use In Five- Foot Way Service Mains % TENAGA NASIONAL ‘Specification No. KEJ0S434:2003 [Revision No. Page I1 of 14 “Approved by Distribution Division Technical Committee Dated 13 September 2017 82 and safety information, as well as any labeling, must be clear, understandable and intelligible. Protection Against Third Party ‘The manufacturer shall take technical measures to ensure that general public persons and animals are adequately protected against the danger of physic: contact with the equipment. 9.0 TECHNICAL DATA injury or other harm which might be caused by direct or indirect All technical drawings and pertinent data of the design and construction of the products, in the format as shown in Appendix A attached shall be submitted for technical evaluation and test purposes.Specification For PVC Cable Trunking For Use In Five- ‘Technical Specification % Foot Way Service Mains TENAGA NASIONAL Specification No. | KEI0S434:2005 [ Revision No. Page (2 of 14 ‘Approved by __| Distribution Division Technical Committee Dated 13 September 2017 1 APPENDIX A TECHNICAL DATA. TION No | TECHNICAL REQUIREMENTS TECHNICAL DATA ‘Type No./ Trade Mark/ Manufacturer To be declare by manufacturer (Mandatory) 2 | Compliance to at least class 4 (Impact 2 J) Yes / No Classification of Impact Test value as per Clause 10.3 of IEC 61084-1 3 | Maximum Operating Temperature "c 4 | Non-flame propagation material Yes / No 5 | Ultra Violet protection material Yes / No 6 | Colour of Trunking 7 | Size of Base tray (Width) x (Height) x (Length) (mm) 8 _ | Size of Junction Box base plate (mm) (Width) x (Height) x (Length) x (Thickness) 9, | Size of fastening clip (W) x (H) x (L) (mm) 10 | Drawings of designs and construction Enclosed / Not Enclosed Type Test Certificate and Laboratory Report (tested and passed accordance to IEC 61084-1 shall be enclosed) Yes/No‘Technical Specification & Specification For PVC Cable Trunking For Use In Five- Foot Way Service Mains TENAGA NASIONAL Specification No. KEIOSAS43003 [Revision No. [Page 13 of 14 ‘Approved by Distribution Division Technical Committee Dated 13 September 2017 GENERAL CONCEPTUAL DESIGN DRAWING OF CABLE TRUNKING SYSTEN Fastening la suzes DIREnS TORE Gomme Gan Cn Tire] Stee + ann Be alee | Winn x Sen x ee clip want a | oaTechnical Specification Specification For PVC Cable Trunking For Use In Five- Foot Way Service Mains Specification No. [ KEI05434:2003 Revision No. Page 14 of 14 ‘Approved by jon Division Technical Committee Dated 13 September 2017 Appendix 8 GENERAL CONCEPTUAL DESIGN DRAWING OF JUNCTION BOX BASE rRouT ViEM SpE var REAR VIEW 7 - — 4| = e — 4 = a = 7 4 = Sasa, F aozanct) ' s1zes Hz) _ Tinensions ps (ome Gm (Lm d Vises | bane Length [02a Weight [van xe section of Junction Box gase Thiexness| 3.4mm Fastening clip van copies Junction Box Bai Front View Praguk: GENERAL DESTGN DEAUING GrOUNCTION BOX BASE [FaRTEna978705 No SERE® TWBD/KEJ/03/034 TENAGA NASTONAL, BERHAD