1.

LOW VOLTAGE AERIAL BUNDLE CABLES (600/1000V)

This specification refersto aerial bundled cables (twisted cables) for rated voltage U 0/U equal
to 0.6/1 kV, with a cross-linked polyethylene (XLPE) insulating sheath and intended for
overhead low voltage lines.
1.1. NORMATIVE REFERENCES

- NFC 33-209: Insulated or protected cables for power systems - Bundle assembled
cores for overhead systems of rated voltage 0,6/1 kV
- IEC 60228: Conductors of Insulated Cables
- IEC 60502-1: Power Cables with Extruded Insulation and Their Accessories for Rated
Voltages from 1 kV (Um = 1,2 kV) up to 30 kV (Um = 36 kV) - Part 1: Cables
for Rated Voltages of 1 kV (Um = 1,2 kV) and 3 kV (Um = 3,6kV)
- IEC 60889: Hard-drawn aluminium wire for overhead line conductors.
- IEC 60811-100: Electric and optical fibre cables - Test methods for non-metallic
materials - Part 100: General
- IEC 60811-201: Electric and optical fibre cables - Test methods for non-metallic
materials - Part 201: General tests - Measurement of insulation thickness
- IEC 60811-202: Electric and optical fibre cables - Test methods for non-metallic
materials - Part 202: General tests - Measurement of thickness of non-metallic
sheath
- IEC 60811-203: Electric and optical fibre cables - Test methods for non-metallic
materials - Part 203: General tests - Measurement of overall dimensions
- IEC 60811-401: Electric and optical fibre cables - Test methods for non-metallic
materials - Part 401: Miscellaneous tests - Thermal ageing methods - Ageing in an
air oven
- IEC 60811-402: Electric and optical fibre cables - Test methods for non-metallic
materials - Part 402: Miscellaneous tests - Water absorption tests
- IEC 60811-403: Electric and optical fibre cables - Test methods for non-metallic
materials - Part 403: Miscellaneous tests - Ozone resistance test on cross-linked
compounds
- IEC 60811-404: Electric and optical fibre cables - Test methods for non-metallic
materials - Part 404: Miscellaneous tests - Mineral oil immersion tests for sheaths
- IEC 60811-412: Electric and optical fibre cables - Test methods for non-metallic
materials - Part 412: Miscellaneous tests - Thermal ageing methods - Ageing in an
air bomb
- IEC 60811-501: Electric and optical fibre cables - Test methods for non-metallic
materials - Part 501: Mechanical tests - Tests for determining the mechanical
properties of insulating and sheathing compounds
- IEC 60811-502: Electric and optical fibre cables - Test methods for non-metallic
materials - Part 502: Mechanical tests - Shrinkage test for insulations
- IEC 60811-503: Electric and optical fibre cables - Test methods for non-metallic
materials - Part 503: Mechanical tests - Shrinkage test for sheaths
 - IEC 60811-507: Electric and optical fibre cables - Test methods for non-metallic
materials - Part 507: Mechanical tests - Hot set test for cross-linked materials
- IEC 60811-606: Electric and optical fibre cables - Test methods for non-metallic
materials -Part 606: Physical tests - Methods for determining the density.
1.2. CABLE DESIGN

1.2.1. Conducting cores

The core of conductors has a circular stranded cross-section.

The wires of the support core neutral conductor are in aluminum-silicon-magnesium alloy.
Core of conductors other than neutral messenger is carried out in aluminum wires with purity
at least equal to that corresponding to 1350 code in conformity with IEC 60889 standard.
The presence of welding on the elementary wires of the stranded core is tolerated, but when
one considers the whole of the wires of the support neutral, two consecutive welding must be
distant at least 50 m.

1.2.2. Insulating sheath

The insulating sheath is an extruded sheath in black color reticulated polyethylene. It must be
possible to withdraw it easily.
In the case of neutral messenger, a paper-type separator can be applied to the core. For phase
conductors, the presence of a separator is optional, but when there is one separator, it must be
colored in the mass and must be the same on all the twisted cable cores.

1.2.3. Conductors assembly

Conductors shall be bundled assembly, according to the provisions hereafter:

Twisted cables with neutral messenger (support core neutral)

a. 1 x 35 mm² +1 x 54,6 mm²
b. 3 x 35 mm² +1 x 54,6 mm²
c. 3 x 50 mm² +1 x 54,6 mm²
d. 3x 70mm2 + 1 x 54.6mm2

1.3. SPECIFICATIONS

1.3.1. Characteristics of the conducting cores

The aluminum wires used for manufacturing of phase conductor cores of ABC cables without
neutral messenger shall present before wiring, a tensile strength at least equal to 120 MPa.
 The aluminum alloy wires used for conducting cores manufacturing of the support core
neutral must present before wiring, the following characteristics:
a. Nominal diameter of wires: 3.15 mm for the 54,6 mm² for the neutral messenger
b. Linear expansion rate: 23.10-6 per degree Celsius
c. Modulus of elasticity: 62.000 MPa

The conducting cores shall meet the characteristics indicated below.

a) Geometrical characteristics: Minimum thickness in a point

b) Mechanical characteristics
In the delivery condition:
i. Minimum Resistance to tensile tension: 14.5 Mpa
ii. Minimum linear extension at the break: 200%
After ageing in air oven:
i. Maximum Variation of the tensile strength: ± 25%
ii. Maximum variation of linear extension at the break: ± 25%

c) Physicochemical (hot linear extension)

i. Maximum linear extension under load: 100%.
ii. Maximum permanent linear extension after cooling: 15%

1.3.2. Characteristics of twisted cables

Assembly step
The conductors must be twisted on the right-hand direction with step limits
fixed in the following table:

Self-supported twisted cable Twisted cable with neutral messenger

Cross-Section Maximum step Cross-Section of Maximum step

phase
of conductors (cm) (cm)
Conductors
(mm²)
(mm)

10 (*) 35 85
16 40 50 90
 25 45 70 100
(*) To be specified by the supplier.

Technical Data Sheets

i. ABC 3x35+1x54.6mm2 Cable

No Description Unit Required by EDCL Offered by Bidder

IEC 60502, IEC 61089,
1 Standard
IEC 60228, IEC 60889
2 Manufacture (*)
3 Country of origin (*)
4 Voltage kV 0.6/1 kV
Conductor of phase
5 Material Aluminium
6 Section mm² 35 mm²
7 Class (IEC 60228) 2
8 Diameter mm 6.8 to 7.3mm
9 Resistance of CC at 20°C Ohm/km ≤ 0.868 Ohm/km
10 Insulation type XLPE
11 Thickness mm 1.6 mm
Diameter over insulation mm
12 10.0 ≤ Ø ≤ 10.9
(mm)
Neutral messenger
Aluminium-silicon
13 Material
magnesium alloy
14 Section mm² 54.6
15 Class(IEC 60228) 2
15 Diameter mm 9.2 to 9.6
17 Resistance of CC at 20°C Ohm/km ≤ 0.63
18 Insulation type XLPE
19 Thickness mm 1.6
20 Breaking load daN ≥ 1660
Twisted cable
 Nominal current (IEC
21 ≥ 135 A
60287)
22 Weight kg/km 508
23 Phase Conductor marking Numerical

ii. ABC 3x50+1x54.6mm2 Cable

Sn Description EDCL Requirement Supplier indication

1 IEC 60502, IEC
Standard 61089, IEC 60228,
IEC 60889
2 Manufacture (*)
3 Country of origin (*)
4 Voltage kV 0.6/1
Conductor of phase
5 material Aluminium
6 section mm² 50
7 class (IEC 60228) 2
8 Diameter mm 7.9 to 8.4
9 resistance of CC atOhm/km ≤ 0.641
20°C
10 insulation type XLPE
11 Thickness mm 1.6
12 Diameter over 11.1 ≤ ᶲ ≤ 12.2
insulation
Neutral messenger
13 material Aluminium-silicon-
magnesium alloy
14 section mm² 54.6
15 class (IEC 60228) 2
16 Diameter mm 9.2 to 9.6
17 resistance of CC atOhm/km ≤ 0.63
20°C
18 insulation type XLPE
19 Thickness mm 1.6
20 Breaking load daN ≥ 1660
Twisted cable
21 Nominal current (IECA ≥ 168
60287)
22 Weight kg/km (*)
23 Diameter mm (*)
24 Phase Conductor marking numerical

iii. ABC 3x70+1x54.6mm2 Cable

Sn Description Unit EDCL Requirement Supplier indication

1 Standard (*) IEC 60502, IEC
61089, IEC 60228, IEC
60889
2 Manufacture (*)

3 Country of origin (*)

4 Voltage kV 0.6/1
Conductor of phase
5 Material Aluminium
6 Section mm² 70
7 Class (IEC 60228) 2
8 Diameter mm 10.0 to 10.2
9 resistance of CC at 20°C Ohm/km ≤ 0.443
10 insulation type XLPE
11 Thickness mm 1.8
12 Diameter over insulation (mm) 13.3 ≤ ᶲ ≤ 14.2
Neutral messenger
13 Material aluminium-silicon-
magnesium alloy
14 Section mm² 54.6
15 class (IEC 60228) 2
 16 Diameter mm 9.2 to 9.6
17 resistance of CC at 20°C Ohm/km ≤ 0.63
18 insulation type XLPE
19 Thickness mm 1.6
20 Breaking Load daN ≥ 1660
Twisted cable
21 Nominal current (IEC 60287) ≥ 213 A
22 Weight (kg/km) (*)
23 Diameter (mm) (*)
24 Phase Conductor marking numerical

1.3.3. TESTS

Copies of previous Type Test and Routine Test Reports issued by the National Testing/
Standards Authority of the country of manufacture (IEC 17025 accredited laboratory) shall be
submitted with the offer for evaluation (all in English Language). A copy of the accreditation
certificate for the laboratory shall also be submitted. Any translations of certificates and test
reports into English shall be certified by the Testing Authority.

Powerfrequency withstand voltage: The checking is carried out after an immersion of 24

hours in water with (20 ± 5) °Con a sample of twisted cable of at least 20 m length with
emergent ends of approximately 15 cm.

The testing voltage of 10 kV, almost sinusoidal, is applied during 30 minutes. The testing
voltage is applied between each conducting core of the twisted cable and water and it is
brought to the above mentioned value as quickly as correct reading of the measuring devices
allows it. During the application of the voltage, the sheath should not be perforated (not
punctured).

Lightning impulse withstand: The conductors shall be designed to be able to support,

without perforation, a normal 1,2/50 is lightning impulse voltage having a peak value equal to
20 kV. The test is carried out on some approximately 3 m length samples, immersed in water
with ambient temperature and ends exceed approximately 15 cm the level of water. The
voltage is applied between the cores and water. Positive polarity voltage is applied five times
then negative polarity five times. The voltage wave of the last impulse of each of both series
is then recorded. During the application of the voltage, not any perforation of the insulating
sheathshould occur.
1.3.3.1. Type tests

Characteristics of cores: Checking of the mechanical resistance of the conducting cores

Characteristics of the insulating sheath: Checking of the resistance of the insulating
sheath to the bad weather.

1.3.3.2. Characteristics of the finished cable:

i. Insulation resistance
ii. Adherence of the neutral sheath
iii. Power frequency withstand
iv. Lightning impulse withstand
v. Withstand of the neutral under thermal and mechanical stresses
vi. Aptitude to piercing of the insulating sheaths

Suppliers shall include in their bid offers type test certificates, issued by an approved,
reputable, independent testing laboratory.

1.3.3.3. Acceptance tests:

Acceptance tests will be done in factory and all expenses will be borne by the Employer. Tests
will be sanctioned by statement signed by the testing attendees.

Acceptance tests shall be carried out on 10% of drums proposed for the conductor order for
each cross-sectional area.

1.3.3.4. Characteristic of the cores:

i. Constitution
ii. Dimensions
iii. Linear Resistance
iv. Stranding step

1.3.3.5. Characteristics of the insulating sheath:

i. Dimensions
ii. Mechanical Characteristics
iii. Hot linear extension
iv. Hot Retraction

1.3.3.6. Characteristics of finished cable:

 i. Constitution
ii. Identification of conductor phases
iii. Marking
iv. Assembly step
v. Capillarity
vi. Adherence of the neutral sheath

1.3.4. MARKING OF TWISTED CABLE CONDUCTORS

The characters must have a minimum height of 5 mm and a minimum width of 2 mm

(for the figure “1”, the minimal width is 1 mm):

i. Rated voltage (0.6/1kV)

ii. Cable reference and size (e.g. XXX 4mm², etc.)
iii. Manufacture’s name
iv. Owner’s name (EDCL LTD -RUEP, RWANDA)
v. Sequential length marking at every meter interval starting from 000

1.3.4.1. Twisted cable without neutral messenger (self-supporting cable)

The inscriptions printed in hollow or relief or with ink are the following:
i. phase conductor: figures “1”,”2” or “3” separated by maximum 50 mm in the case of
marking with ink and maximum 200 mm in the case of a marking in hollow or relief.
The figures are placed longitudinally and head-to-tail
ii. neutral conductor: reference standard and the name of the manufacture plant with a
maximum 250 mm spacing, placed longitudinally and head-to-tail, the index of this
specification and the possible trademarks.

1.3.4.2. Twisted cable with neutral messenger

The inscriptions are the following:

1.3.4.2.1. Printed in hollow or relief:

i. Phase conductor: figures 1,2 or 3 separated by maximum 200 mm and longitudinally
placed and head-to-tail;
ii. Neutral conductor: reference UTE of the manufacturing plant separated by maximum
250 mm placed longitudinally and head-digs.
 1.3.4.2.2. Printed in hollow or relief or with ink:
Neutral messenger: the index of the standard of reference separated by maximum 500 mm as
well as the possible trademarks;

1.3.4.2.3. Marking on drum and name plate

Each drum shall bear an indelible distinguish number on the outside of the flange and
particulars of the cable are as follows.
Also the drum of conductor shall be provided with a name plate that shall be
Weather proof material (Aluminum material), fitted in a visible position of outside of the
flange and indelibly marked showing the appropriate items indicated as follow:

i. Owner’s name (EDCL)

ii. Cable name, type and size
iii. Length of cable
iv. Net & Gross weight
v. Manufacture’s name
vi. Date of manufacturing
vii. Direction of rotation of the reel by arrow
viii. Work order No.
ix. Destination
x. Each cable oversheath shall be sequentially marked at one(1) metre intervals from zero
up to the specified drum length, so as to indicate the amount of cable remaining on the
drum.

1.3.5. PACKING AND DELIVERY

The supplier shall provide packing of the cable as is required to prevent their Damage or
deterioration during transportation to their final destination and long period of storage. The
packing shall be sufficient to withstand, without limitation, rough handling, and exposure to
extreme temperatures, salt and precipitation during transportation and open storage.

The length of the delivered cable shall be compatible with the capacity of the drum:

i. Cable shall be shipped from the factory to the specified site or EDCL LTD’s
warehouse.
 ii. No drum shall contain more than one length of cable and drum size and weight of
cable shall be considered by the supplier, considering the distance of transportation
and the absence of heavy handling facilities.
iii. Both end of conductor shall be sealed to prevent the ingress of moisture into the
conductor.
iv. Both ends of cable shall be fitted with temporary binders to prevent the cores from
separating.
v. Each shipment shall include a detailed packing list identifying the cable.
vi. The drums shall be made of stout wood to protect the cable from damage. The lagging
batten of the cable drum shall be secured at least with two nails of each end in addition
to steel bonding straps.
vii. The conductor shall be tightly wrapped on the conductor drum and no turn shall be left
loose.