Southwire 25464905 Operating instructions

Installation and Application Guide

for 600V Conductors

InstallatIon and applIcatIon GuIde For 600v conductors

Installation and Application Guide

for 600V Conductors

InstallatIon and applIcatIon GuIde For 600v conductors

This guide discusses recommended or “best” practices for installing 600 volt conductors in conduit.

The purpose of the guide is to identify those critical areas of design, pre-planning and cable pulling that

result in a successful installation. Within these areas are numerous commonly overlooked practices that

can result in a failed installation.

This guide is not intended to cover all aspects of cable installation, it is intended to provide guidelines

and information on the more commonly misapplied techniques and equipment. There are four primary

topics covered in this guide:











A NOTE FROM THE EDITOR…















a successful installation.









commercial and institutional installations.





Foreward

InstallatIon and applIcatIon GuIde For 600v conductors

1. PULL EVALUATION





b. Never assume that an installation is routine.

2. PROOFING CONDUIT



b. Never assume the conduit is clean.

3. CLEAN ENTRY AND EXIT FROM CONDUIT SYSTEM



exiting the conduit system.



4. CONDUCTOR LUBRICATION



inadequate conductor lubrication.



products provide uniform pre-lubrication assuring the



pull

products or



Best Practices

InstallatIon and applIcatIon GuIde For 600v conductors

SECTION 1. CABLE AND CONDUIT SELECTION

 ................................................................................ 7

 ..................................................................................................................... 7

 .......................................................................................................... 7

 ...................................................................................................... 

 ...................................................................................................................... 

 ........................................................................................................................... 

 ..................................................................................................................... 

 ................................................................ 

 ............................................................................................. 9

 ....................................................................................................................... 9

 .................................................................. 9

 .............................................................................................................. 

 ............................................................ 

 .................................................................. 

 .......................................................................................................... 

 ............................................................. 

 ........................................................ 

 ........................................................................................ 

 ................................................................................................................. 

 ................................................................................................... 

 ............................................................................................... 

 ........................................................................................................... 

 .............................................................................................. 

 ............................................................................................. 

 ............................................................................. 

 ................................................................................................ 

 ............................................................................... 

 .............................................................................................................. 

 ............................................................................................................................ 

SECTION 2. SETUP AND INSTALLATION

 ....................................................................................................... 

 ................................................................................................................ 

 .......................................................................................................................... 

Table of Contents

InstallatIon and applIcatIon GuIde For 600v conductors

 ..................................................................................... 

 ....................................................................................................................... 

 ................................................................................................... 

 ...................................................................................... 

 .................................................................... 

 ........................................................................................................ 

Reel Setup ...................................................................................................................... 

 ........................................................................................................................ 

 ...................................................................................................... 

 ..................................................................................................... 

 ................................................................................................................ 

 .......................................................................................................... 

............................................................................................ 

 ................................................................................................. 

 ....................................................................................... 

 ........................................................................................................ 

 .................................................................................................. 

 .................................................................................................... 

SECTION 3. DESIGN AND APPLICATION GUIDELINES

 .......................................................................................... 

 ........................................................................................................ 

 ......................................................................................................... 

 ................................................................................................................. 

 .................................................................................................. 

 .............................................................................................. 

SECTION 4. ANNEXES

 ........................................................... 

 .......................................................... 

 ........................................................................................ 

 ........................................................................................................ 

 ......................................................................................... 

PAGE 7

InstallatIon and applIcatIon GuIde For 600v conductors

INSTALLATION ASSESSMENT CHECKLIST



the application and environment. This checklist also provides steps to evaluate your selection.

Conductor Type: Select a conductor type based on your application and the conductor ratings

and listings.

Conduit Size:

ampacity.

Reel Size:



 Conduit Size:

codes and standards.

Conduit Layout:

compliance and

reasonable expectations of pull length.

 Maximum Tension:

pulling device limitations.

Jamming Probability:





Pulling Tension and Sidewall Pressure: 

for each segment.

Verify:

Redesign Pull:





c. Reduce number of bends

d. Reverse pull





CONDUCTOR TYPE







Further, conductors free



Copper Conductors – Traditionally copper conductors are a popular choice in conduit feeder













Section 1. Cable and Conduit Selection

PAGE 8

InstallatIon and applIcatIon GuIde For 600v conductors

Aluminum Conductors –













listed connectors.

CONDUCTOR SIZE





Ampacity –

for any derating factors such as more than three current carrying conductors in a conduit or high







Voltage Drop –







MAXIMUM REEL SIZES AND CONDUCTOR LENGTH







splice locations should be included in the conduit layout to limit the maximum cable length required.

PAGE 9

InstallatIon and applIcatIon GuIde For 600v conductors

CONDUIT SIZING AND FILL RATIO





.















N

 

  

 

Table 1





CONDUIT LAYOUT













CONDUCTOR SUPPORT IN VERTICAL RACEWAYS







.





Table 2





Number of Conductors







Percent Fill







Wire Size Aluminum Copper















100 ft

200 ft

180 ft

135 ft

120 ft

95 ft

85 ft

100 ft

80 ft

60 ft

50 ft

40 ft

35 ft

PAGE 10

InstallatIon and applIcatIon GuIde For 600v conductors

PULLING EVALUATION









small conductor installations.









damaged conductors.



































Maximum Allowable Tension on Pulling Devices –





Pulling Eye – 

Basket Grip –



Other Means –





PAGE 11

InstallatIon and applIcatIon GuIde For 600v conductors

Maximum Allowable Tension of Conductors – The metallic core of the conductor is generally the only



braids or armor not designed for the purpose in pulling tension calculations.

Variable deﬁnitions for the following equations and examples:



 

 

 

device



total



together in pounds

Table 3

Table 4

Maximum Allowable Conductor Stress

Metal







lb/cmil



0.006

Size (AWG)







































































600



700





900



















600,000



700,000





900,000





cmil Size (kcmil) cmil

PAGE 12

InstallatIon and applIcatIon GuIde For 600v conductors

Single Conductors:

pounds

 

 

pounds

pounds

Multiple Conductors (three or less conductors):

total

T

pounds

 

 

total

pounds

total

pounds

Multiple Conductors (more than three conductors):

total

T

pounds

 

 

pounds

pounds

total

pounds

total

pounds

CAUTION:

Pulling different conductor sizes at the same time is not recommended if the conductor size or other

characteristics are significantly different. If you must pull different size conductors, it must be done

with care. For example, if a run requires three 350 kcmil and three 8 AWG single conductors, it would

be preferable, though not necessarily ideal, to pull the three 350 kcmil single conductors and one 3

conductor 8 AWG cable at the same time. Pulling additional conductors into an existing conduit system

is generally not recommended. If this must be done, extreme caution must be taken. Of special concern

is the cutting action of the tensioned pulling rope.

PAGE 13

InstallatIon and applIcatIon GuIde For 600v conductors

CALCULATING PULLING TENSIONS



conduit pull. These calculations only provide an estimate to assist the user in determining the feasibility















pull

requires no pulling lubricant.

INCOMING TENSION







pulling tension.

Feeding Off Reel Horizontally –



the conductor from the reel:

W pounds

  

Feeding Off Reel Vertically – 



conductor into the conduit:

pounds

  

  









W.

PAGE 14

InstallatIon and applIcatIon GuIde For 600v conductors

COEFFICIENTS OF FRICTION











Table 5

pull

products

 



pull



stated above are appropriate.











lubrication of the conduit is recommended by lubricant manufacturers to achieve the best results.

CONDUCTOR CONFIGURATION





Figure 1













pull



















EMT PVC

Cable Outer Jacket or Insulation

Conduit Type

PAGE 15

InstallatIon and applIcatIon GuIde For 600v conductors

CONDUCTOR JAMMING







 







Figure 2



WEIGHT CORRECTION FACTOR







Single Conductor:



Three Conductors (Triangular):



 





-









Three Conductors (Cradled):

 

















Four Conductors or More (Complex):







Variable deﬁnitions for the following equations and examples:



out







 

 





 

 

PAGE 16

InstallatIon and applIcatIon GuIde For 600v conductors

Horizontal Straight Section:

out



Inclined and Vertical Straight Section:

 

out

cos

pounds

 

out

− cos

pounds

Approximation for Bends – 

the varying orientations and gravitational pulling directions are complicated. For this reason, it is

common practice to use an approximation for all bends.

Elbows and Bends (Approximation):

out



 e



SIDEWALL PRESSURE



surface area of the bend is smaller in small radius bends, that force is concentrated over a much smaller







 



For three single-conductor cables, cradled

 





For three single-conductor cables, triangular

 





 

 



 

PAGE 17

InstallatIon and applIcatIon GuIde For 600v conductors

Figure 3



Table 6

BEND RADIUS



of the conductor outside diameter. The general guidelines for conductor training bend radii are

given in Table 7.

Table 7













Cable Diameter

Inches







Bend Radius as a Multiplier

of the Cable OD





Cable Type









SP lbs/ft





PAGE 18

InstallatIon and applIcatIon GuIde For 600v conductors

INSTALLATION CHECKLIST

 Conduit Free of Debris: Was the conduit proofed using a mandrel to remove any debris and



Rollers and Sheaves Properly Installed:



Tugger Properly Setup: 





Reels Damage Free: 

Conductors Freely Payoff Reel:



Pull Rope Properly Attached:



 Conductor Lubrication: pull

, has the conductor been



Proper Terminations: 



CONDUIT PROOFING



the pull impossible to accomplish. Further, debris in conduit is often a contributing factor in damaged

conductors.

Prooﬁng – 













is clear of potentially damaging debris.

INSTALLING ROLLERS AND SHEAVES







Section 2. Setup and Installation

PAGE 19

InstallatIon and applIcatIon GuIde For 600v conductors

Placement – 

assemblies that are required based on the conductor minimum bend radius and support needed.













Pulley sizes and count – Wherever pulleys and sheaves are required, it is important to account





that point in the pull.









Sheave wheel sizes and types – When pulling conductors around sheaves, large sheave













NOTE: Never use a three-sheave assembly on a 90-degree bend to pull conductors.

Table 8

Bending Angle (degrees)











Number of Sheaves











Southwire 25464905 Operating instructions

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