Southwire 25464905 Operating instructions

25464905
Southwire
Brand
Southwire
Model
25464905
Type
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


.
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

d

2
N
 
 

Table 1

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
CONDUIT LAYOUT

®


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


CONDUCTOR SUPPORT IN VERTICAL RACEWAYS

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

.
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

Table 2

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
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
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.











m






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:
T
c




T
device

T
total

together in pounds
Table 3
Table 4
Maximum Allowable Conductor Stress
Metal



lb/cmil


0.006
Size (AWG)



7
6


























600

700


900









600,000

700,000


900,000


cmil Size (kcmil) cmil
PAGE 12
InstallatIon and applIcatIon GuIde For 600v conductors
Single Conductors:
T
c
pounds


T
c
pounds
T
c
pounds
Multiple Conductors (three or less conductors):
T
total
T
c
pounds


T
total
pounds
T
total
pounds
Multiple Conductors (more than three conductors):
T
total
T
c
pounds


T
c
pounds
T
c
pounds
T
total
pounds
T
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:
T
in
W pounds
 
Feeding Off Reel Vertically – 

conductor into the conduit:
T
in
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




d

Figure 2

WEIGHT CORRECTION FACTOR



Single Conductor:

Three Conductors (Triangular):

 


-

d


2
Three Conductors (Cradled):




d


2
Four Conductors or More (Complex):



Variable definitions for the following equations and examples:
T
in

T
out









PAGE 16
InstallatIon and applIcatIon GuIde For 600v conductors
Horizontal Straight Section:
T
out

in
Inclined and Vertical Straight Section:

T
out
cos
in
pounds

T
out
− cos
in
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):
T
out

in
e

SIDEWALL PRESSURE

surface area of the bend is smaller in small radius bends, that force is concentrated over a much smaller




T
R
For three single-conductor cables, cradled

T


For three single-conductor cables, triangular

T


 



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
6
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
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Southwire 25464905 Operating instructions

25464905
Southwire
Brand
Southwire
Model
25464905
Type
Operating instructions
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