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ICEA S-94-649-
STANDARD FORCONCENTRIC NEUTRAL CABLESRATED 5,000 - 46,000
VOLTS
Publication # ICEA S-94-649-2000
@ 2001 byINSULATED CABLE ENGINEERS A SSOCIATION, INC.
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ICEA S-94-649-2000
STANDARD FORCONCENTRIC NEUTRAL CABLES
RATED 5,000 - 46,000VOLTS
Standard #ICEA S-94-649-2OOO
Published 8 yINSULATED CABLE ENGINEERS ASSOCIATION, Inc.Pos t
Office Box 440South Yarmou th, Massachusetts 02 66 4, U.S.A.@ J an
u a r y 2001
Approved September 6, 2000 b yI N S U L A T E D C A B L E E N G
I N E E R S ASSOCIATION, IncApproved Ju l y 3, 2000 by
AEICApproved
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001 byINSULATED CABLE ENGINEERS ASSOCIATION, INC.
Contents may not be reproduced in any formwithout permission of
the Insulated Cable Engineers Association, Inc.All rights including
translation into other
languages, reserved under the Universal Copyright Convention,the
Berne Convention for the Protection of Literary and Artistic
Works,
and the International and Pan American Copyright
Conventions.
INSULATED CABLE ENGiNEERS ASSOCIATION, Inc.P.O. Box 440South
Yarmouth. Massachusetts 02664 USA
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ICEA S-94-649-2000 DATE: O7124100FOREWORD
This Standards Publication for Concentric Neutral Cables Rated 5
to 46 kV (ICEA S-94-649) wasdeveloped by the Insulated Cable
Engineers Association Inc. (ICEA).ICEA standards are adopted in the
public interest and are designed to eliminate
misunderstandingsbetween the manufacturer and the user and to
assist the user in selecting and obtaining the proper productfor
his particular need. Existence of an ICEA standard does not in any
respect preclude the manufacture oruse of products not conforming
to the standard. The user of this Standards Publication is
cautioned toobserve any health or safety regulations and rules
relative to the manufacture and use of cable made inconformity with
this Standard.Requests for interpretation of this Standard must be
submitted in writing to the Insulated CableEngineering Association,
Inc., P. O. Box 440, South Yarmouth, Massachusetts 02664. An
official written.interpretation will be provided. Suggestions for
improvements gained in the use of this Standard will bewelcomed by
the Association.The ICEA expresses thanks to the Association of
Edison Illuminating Companies for providing the basisfor some of
the material included herein through their participation in the
Utility Power Cable StandardsTechnical Advisory Committee
(UPCSTAC), and to the Institute of Electrical and Eiectronics
Engineers,
Insulated Conductors Committee, Discussion Group A-14 for
providing user input to this Standard.The members of the ICEA
working group contributing to the writing of this Standard
consisted of thefollowing:
F. Kuchta, ChairmanE. BartolucciP. CinquemaniL. HiivalaR.
SmithN. Ware
R. BristolD. FoxF. LaGaseB. VaughnB. Yu
J. CancelosiP.HallA . PackE. Walcott
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ICEA S-94-649-2000 DATE: 07/24/00TABLE OF CONTENTS
Part 1 GENERAL
..............................................................................................................................................
11.1 SCOPE
...................................................................................................................................................
11.2 GENERAL INFORMATION
..................................................................................................................
11.3 INFORMATIONTO BE SUPPLIED BY PURCHASER
.......................................................................
1Characteristicsof Systems on which Cable is to be Used
...................................................... 1Quantities
and Description of Cable
........................................................................................
21.4 DEFINITIONS AND SYMBOLS
............................................................................................................
2
1.3.11.3.2
Part 2
CONDUCTOR........................................................................................................................................
52.0
GENERAL..............................................................................................................................................
52 1 PHYSICAL AND ELECTRICAL PROPERTIES
..................................................................................
52.1.1 Copper Conductors
..................................................................................................................
52.1.2 Aluminum Conductors
..............................................................................................................
52.2 OPTIONAL SEALANT FOR STRANDED CONDUCTORS
................................................................
62.3 CONDUCTOR SIZE
UNITS...................................................................................................................
62.4 CONDUCTOR DC RESISTANCE PER UNIT
LENGTH......................................................................
6Direct Measurementof dc Resistance Per Unit Length
..........................................................
6Calculationof dc Resistance Per Unit Length
.........................................................................
62.5 'CONDUCTOR DIAMETER
...................................................................................................................
7
2.4.12.4.2
Part 3 CONDUCTOR SHIELD (STRESS CONTROL
LAYER)....................................................................
133.1
MATERIAL...........................................................................................................................................
133.2 EXTRUDED SHIELD
THICKNESS.....................................................................................................
13Reduced Extruded Shield Thickness
.....................................................................................
133.3 PROTRUSIONS AND IRREGULARITIES
.........................................................................................
133.4
VOIDS...................................................................................................................................................
143.5 PHYSICAL REQUIREMENTS
............................................................................................................
143.6 ELECTRICAL REQUIREMENTS
.......................................................................................................
14
3.2.1
3.6.13.6.2 Extruded Semiconducting Material
........................................................................................
14Extruded Nonconducting Material (For EPR Insulation
Only)............................................... 143.6.3
Semiconducting
Tape.............................................................................................................
143.7 WAFER BOIL TEST
............................................................................................................................
14
Part 4 INSULATION
.......................................................................................................................................
154.1
MATERIAL...........................................................................................................................................
154.2 INSULATION THICKNESS
.................................................................................................................
15Selectionof Proper Thickness
...............................................................................................
16For Three-phase Systems with 1O0 or 133 Percent Insulation Levei
..................... 164.2.14.2.1.14.2.1.24.2.1.34.2.1.4
For Deita Systems Where One Phase May Be Grounded For
PeriodsOver One
Hour..........................................................................................................
16For Single- and Two-Phase Systems with 100 Percent Insulation
Level ..........For Single- and Two-Phase Systems with 133 Percent
Insulation Level ............... 16Insulation or DISCHARGE-FREE
Cable Designs
Only........................................................ 16
Partial-Discharge Extinction Levei
...................................
.................................. 17
4.3 INSULATION REQUIREMENTS
........................................................................................................
164.3.1.1 Physical and Aging Requirements
...........................................................................
164.3.1.2 Electrical
Requirements............................................................................................
174.3.1.2.14.3.1.2.2 Voltage
Tests......................................................................................................
174.3.1 .2.3 Insulation Resistance
Test.................................................................................
184.3.1.2.4 Accelerated Water Absorption
.........................................................
................. 184.3.1.2.5 Capacity and Dissipation Factor
........................................................................
18
4.3.1
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ICEA S-94-49-2000 DATE: 07/24/004.3.1.3 Voids. Ambers. Gels.
Agglomerates and Contaminants as
Applicable...................19Crosslinked Polyethylene Insulation
(XLPE or TRXLPE) ................................. 19
Shrinkback - Crosslinked Polyethylene Insulation (XLPE or
TRXLPE) Only.......... 194.3.2.2 Electrical Requirements
...........................................................................................
21Discharge (Corona) Resistance
........................................................................
214.3.2.2.2 Voltage
Tests......................................................................................................
21Insulation Resistance
Test.................................................................................
21Accelerated Water
Absorption............................................................................
21Capacity and Dissipation
Factor........................................................................
22
4.3.1.3.14.3.1 3.2 Ethylene Propylene Rubber
(EPR)....................................................................
19Insulation For DISCHARGE-RESISTANTCable Designs Only
........................................... 20Physical and Aging
Requirements...........................................................................
20
4.3.1.44.3.2.14.3.2
4.3.2.2.14.3.2.2.34.3.2.2.44.3.2.2.54.3.2.3 Voids and
Contaminants...........................................................................................
22
Part 5 EXTRUDED INSULATION SHIELD
...................................................................................................
255.2 THICKNESS AND INDENT REQUIREMENTS
.................................................................................
255.1
MATERIAL...........................................................................................................................................
255.4 INSULATION SHIELD
REQUIREMENTS..........................................................................................
25
5.4.1.1
Removability..............................................................................................................
265.4.1.2
Voids..........................................................................................................................
265.4.1.3 Physical Requirements
............................................................................................
265.4.1.4 Electrical
Requirements............................................................................................
26Wafer Boil
Test..........................................................................................................
26Insulation Shield for DISCHARGE-RESISTANT Cable Designs Only
................................. 265.4.2.1
Removability..............................................................................................................
265.4.2.2 Physical Requirements
............................................................................................
275.4.2.3 Electrical
Requirements............................................................................................
27Wafer Boil
Test..........................................................................................................
27
5.3 PROTRUSIONS
...................................................................................................................................
255.4.1 Insulation Shield for DISCHARGE-FREE Cable Designs Only
............................................ 25
54.1.55.4.2
5.4.2.4Part 6 CONCENTRIC NEUTRAL CONDUCTOR
.........................................................................................
2828.1
MATERIAL...........................................................................................................................................6.2
CROSS-SECTIONAL AREA
...............................................................................................................
286.3 LAY LENGTH
......................................................................................................................................
286.4 CONCENTRIC WIRES
........................................................................................................................
286.4.1 Minimum Sizes
.......................................................................................................................
286.4.2 Contrahelical Wire
..................................................................................................................
28Diameter and
Area..................................................................................................................
28
6.6 OPTIONAL WATER BLOCKING COMPONENTS FOR METALLIC SHIELD
................................ 296.4.36.5 FLAT STRAPS
.......................................................................
T ............................................................
29
Part 7 JACI(ETS
.............................................................................................................................................31Low
and Linear Low Density Polyethylene, Black
(LDPWLLDPE)....................................... 317.1 MATERIAL
..........................................................................................................................................
31Medium Density Polyethylene, Black (MDPE)
......................................................................
32High Density Polyethylene, Black (HDPE)
............................................................................
33Semiconducting Jacket Type I
...............................................................................................
34Semiconducting Jacket Type I I
..............................................................................................
35Chlorinated Polyethylene (CPE)
............................................................................................
37Polypropylene, Black (PP)
.....................................................................................................
39
7.1.17.1.27.1.37.1.47.1.57.1.67.1.77.1.87.1.9
Polyvinyl Chloride (PVC)
............................................................................
r........................... 36Thermoplastic Elastomer
(TPE).............................................................................................
38
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ICEA S-94-649-2000 DATE: 071241007.2 JACKET TYPES
..................................................................................................................................
40
7.2.2 Overlaying Jacket
...................................................................................................................
4040.2.1 Extnided-To-Fill
Jacket...........................................................................................................7.3
JACKET IRREGULARITY
INSPECTION...........................................................................................
407.3.1 Non Conducting
Jackets.........................................................................................................
407.3.2 Semiconducting
Jackets.........................................................................................................
40P a d 8 CABLE ASSEMBLY AND IDENTIFICATION
...................................................................................
428.1 MULTIPLEX CABLE ASSEMBLIES
..................................................................................................
428.2 CABLE IDENTIFICATION
..................................................................................................................
428.2.1 Jacketed Cable
.......................................................................................................................
42Optional Cable Identification
....................................................................................
42
Optional Sequential Length
Marking......................................................................................
438.2.1.18.2.2 Unjacketed Cable
...................................................................................................................
438.2.3 Optional Center Strand Identification
.....................................................................................
438.2.4
Part 9 TESTING AND TEST
METHODS........................................................................................................
449.1 TESTING
..............................................................................................................................................
449.2 SAMPLING
FREQUENCY..................................................................................................................
449.3 CONDUCTOR TEST
METHODS........................................................................................................
449.3.1 Method for DC Resistance
Determination.............................................................................
449.3.2 Cross-Sectional Area Determination
.....................................................................................
449.3.3 Diameter Determination
.........................................................................................................
449.4 TEST SAMPLES AND SPECIMENS FOR PHYSICAL AND AGING
TESTS.................................. 449.4.1 General
...................................................................................................................................
449.4.2 Measurement of Thickness
....................................................................................................
449.4.2.1 Micrometer Measurements
......................................................................................
459.4.2.2Number of Test
Specimens....................................................................................................
45Size of Specimens
..................................................................................................................
45
Optical Measuring Device Measurements
...............................................................
45Preparation of Specimens of Insulation and
Jacket...............................................................
46Specimen for Aging Test
........................................................................................................
46Calculation of Area of Test
Specimens..................................................................................
46Unaged Test Procedures
.......................................................................................................
46
9.4.39.4.49.4.59.4.69.4.79.4.89.4.8.1 Test Temperature
.....................................................................................................
469.4.8.2 Type of Testing
Machine..........................................................................................
479.4.8.3 Tensile Strength Test
................................................................................................
479.4.8.4 Elongation Test
.........................................................................................................
479.4.9.1 Aging Test Specimens
.............................................................................................
479.4.9.2 Air Oven Test
............................................................................................................
489.4.9.3Hot Creep Test
.......................................................................................................................
48
9.4.9 Aging Tests
.............................................................................................................................
47Oil Immersion Test for Polyvinyl Chloride
Jacket..................................................... 48
Solvent Extraction
..................................................................................................................
48Wafer Boil Test for Conductor and Insulation Shields
...........................................................
48Insulation Shield Hot Creep
Properties....................................................................
489.4.13.1 Sample Preparation
..................................................................................................
499.4.1 3.2 Examination
...............................................................................................................
49
Protrusion, Irregularity and Void
Test.......................................................................
49Protrusion, Indentation and Irregularity Measurement Procedure
.......................... 49
9.4.1O9.4.1 19.4.129.4.13 Amber, Agglomerate, Gel, Contaminant,
Protrusion, Indent, Irregularity andVoid
Test.................................................................................................................................
49
9.4.12.1
9.4.1 3.39.4.13.4
Resampling for Amber, Agglomerate, Gel, Contaminant,
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y g
ICEA 5-94-649-2000 DATE:
07/24/00......................................4.14 Physical Tests
for Semiconducting Material Intended or Extrusion 50
9.4.14.1 Test Sample
50.............................................................................................................9.4.14.2
Test Specimens
........................................................................................................
509.4.14.3
Elongation.................................................................................................................
519.6 DIAMETER MEASUREMENT OF INSULATION AND INSULATION SHIELD
............................... 51
9.7.1 Heat Shock
.............................................................................................................................
51
9.4.15 Retests for Physical and Aging Properties and Thickness
................................................... 519.5
DIMENSIONAL MEASUREMENTS OF THE METALLIC SHIELD 519.7 TESTS FOR
JACKETS
......................................................................................................................
51
9.7.2 Heat Distortion
........................................................................................................................
529.7.3 Cold Bend
...............................................................................................................................
529.8 VOLUME RESISTWTTY
......................................................................................................................
52Insulation Shieid
.............................................................................................................
.......53SemiconductingJacket Radial Resistivity Test
.....................................................................
539.8.3.1 Sample Preparation
..................................................................................................
539.8.3.2 Test Equipment Setup
..............................................................................................
549.8.3.3 Calculation
................................................................................................................
55
SHRINKBACK TEST
PROCEDURE.............................................................................................
569.10.1 Sample Preparation
...............................................................................................................
569.10.3 Pass/Fail Criteria and Procedure
...........................................................................................
569.1 19.12 VOLTAGE
TESTS..........................................................................................................................
57
..................................................
9.8.19.8.29.8.3Conductor Shield (Stress Control)
.........................................................................................
52
9.9 ADHESION (Insulation Shield Removabili ty)
TEST.......................................................................
569.10.2 Test
Procedure.......................................................................................................................
56
RETESTS ON SAMPLES
..............................................................................................................
569.1 2.1 General
...................................................................................................................................
57
AC Voltage
Test......................................................................................................................
57PARTIAL-DISCHARGE TEST
PROCEDURE..............................................................................
57POLYMERIC STRESS CONTROL
LAYERS...............................................................................
57
9.10
9.1 2.29.139.14 METHOD FOR DETERMINING DIELECTRIC CONSTANT
ANDDIELECTRIC STRENGTH OF EXTRUDED NONCONDUCTING9.15 MOISTURE
CONTENT
..................................................................................................................
579.1 5.1 Moisture Under the Jacket
.....................................................................................................
579.1 5.2 Moisture in the Conductor
......................................................................................................
579.15.39.1 5.4 Water Expulsion Procedure
...................................................................................................
58Presenceof Water
Test..........................................................................................................
589.16 PRODUCTION TEST SAMPLING PLANS
...................................................................................
59
Part 1O10.010.1QUALIFICATION TESTS
...............................................................................................................
62CORE MATERIAL QUALIFICATION TESTS
...............................................................................
62
Insulation Shield Qualification
................................................................................................
6310.1.5 Cyclic Aging
............................................................................................................................
6510.1.5.1 Cable
Length.............................................................................................................
66
10.1.5.3
Conduit......................................................................................................................
66Accelerated Water Treeing Test ( A m ) Procedure
............................................................
5610.1.6.1 General
.....................................................................................................................
6610.1.6.2 Sample Preparation
..................................................................................................
66
GENERAL
..............................................................................
?........................................................ 6210.1 1
Conductor Shield/lnsulation Qualification
..............................................................................
6210.1.210.1.3 High Voltage Time Test (HVTT)
rocedure...........................................................................
6510.1 4 Hot Impulse Test Procedure
..................................................................................................
65
10.15.210.1 25.4
Sample preparation
..................................................................................................
66Load Cycle
....................................................................................
:.......................... 5610.1 6
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ICEA S-94-649-2000 DATE: 07/24/0010.1.6.3 Aging Time
................................................................................................................
6610.1.6.4 Test Procedure
.........................................................................................................
6710.1.6.5 Water pH
...................................................................................................................
67
Qualification Test Physical
Measurements............................................................................
68THERMOMECHANICAL QUALIFICATION TEST - Optional
..................................................... 6810.2.1
Scope
......................................................................................................................................
6810.2.2 Procedure
...............................................................................................................................
6810.2.2.1 Fixture
.......................................................................................................................
6810.2.2.2 Load Cycling
.............................................................................................................
6810.2.2.3 Electrical Measurements
..........................................................................................
6910.2.2.4 Design Test
...............................................................................................................
69JACKET MATERIAL QUALIFICATION
TESTS...........................................................................
7010.3.1 Polyethylene
Jackets..............................................................................................................
7010.3.1.1 Environmental Stress Cracking
Test........................................................................
7010.3.1.1 1 Test Specimen
...................................................................................................
7110.3.1.1.2 Test Procedure
..................................................................................................
7110.3.1.2 Absorption Coefficient
Test.......................................................................................
7110.3.2 Semiconducting
Jackets.........................................................................................................
7110.3.2.1 Brittleness Test
.........................................................................................................
7110.3.3 Polyvinyl Chloride and Chlorinated Polyethylene Jackets
.................................................... 7110.3.3.1
Sunlight
Resistance..................................................................................................
7110.3.3.1.1 Test Samples
.....................................................................................................
7110.3.3.1.2 Test Procedure
..................................................................................................
71CV EXTRUSION QUALIFICATION TEST
....................................................................................
7110.4.1 Thermal Conditioning
.............................................................................................................
7210.4.2 Dissipation Factor Verification
...............................................................................................
7210.4.3 AC Withstand Verification
......................................................................................................
72OTHER QUALIFICATION
TESTS.................................................................................................
7210.5.1 Insulation
Resistance.............................................................................................................
7210.5.2 Accelerated Water Absorption Tests
.....................................................................................
7310.5.3 Resistance Stability Test
........................................................................................................
7310.5.4 Brittleness Test for SemiconductingShields
.........................................................................
73
...........................................................................O.1.7
Qualification Test Electncal Measurements 6810.1.810.2
Physical Measurements Before and After the
Therrnomechanical10.3
10.4
10.5
10.5.4.1 Test Samples
............................................................................................................
7310.5.4.2 Test Procedure
.........................................................................................................
7310.5.5 Dry Electrical Test for EPR Class 111 Insulation Only
.............................................................
7310.5.5.1 Test Samples
............................................................................................................
7310.5.5.2 Test Procedure
.........................................................................................................
7310.5.5.3 Electrical Measurements
..........................................................................................
7310.5.6 Discharge Resistance Test for EPR Class IV InsulationOnly
.............................................. 7310.5.6.1 Test
Specimens
........................................................................................................
7410.5.6.2 Test
Environment......................................................................................................
7410.5.6.3 Test Electrodes
........................................................................................................
74Dissipation Factor Characterization Test
...............................................................................
7410.5.7.1 Test Samples
............................................................................................................
7410.5.7.2 Thermal Conditioning
...............................................................................................
7410.5.7.3 Dissipation Factor Testing
........................................................................................
75
b .
10.5.7
Part 11
APPENDICES..............................................................................................
7 ................................. 76A l NEMA
PUBLICATIONS.........................................................................................................
76A2 ICEA PUBLICATIONS
...........................................................................................................
76APPENDIX A . NEMA, ICEA, IEEE, ASTM AND ANSI STANDARDS
.......................................... 76
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ICEA 5-94-649-2000 DATE: 07/24/00A3 IEEE STANDARDS
................................................................................................................
76A5 ANSI
STANDARDS................................................................................................................
78
PROCEDURE FOR DETERMINING DIAMETERSOF CABLE
............................ 80APPENDIX D
SHIELDING...............................................................................................................
85DEFINITIONOF SHIELDING
................................................................................................
85FUNCTIONS OF
SHIELDING................................................................................................
85USE OF INSULATION SHIELDING
......................................................................................
85GROUNDING OFTHE INSULATION
SHIELD.....................................................................
86D5 SHIELD
MATERIALS.............................................................................................................
86SPLICES AND TERMINATIONS
...........................................................................................
86HANDLING AND INSTALLATION
PARAMETERS............................................... 87E l
INSTALLATION TEMPERATURES
......................................................................................
87E2E3 DRUM DIAMEERS OF REELS
...........................................................................................
87E4 . MAXIMUM TENSION AND SIDEWALL BEARING
PRESSURES....................................... 87E5 TESTS DURING
AND AFTER
INSTALLATION...................................................................
87E 51 During Installation
.....................................................................................................
87E5.2 After Installation
........................................................................................................
873.3 InService
..................................................................................................................
87OPTIONAL FACTORY DC
TEST.......................................................
;................... 89REDUCED NEUTRAL
DESIGNS............................................................................
90ADDiTIONAL CONDUCTOR INFORMATION
....................................................... 94
A4 ASTM STANDARDS
..............................................................................................................
76EMERGENCY OVERLOADS
..................................................................................
79PPENDIX BAPPENDIX C
D1D2D3D4D6APPENDIX E
RECOMMENDED MINIMUM BENDING
RADIUS................................................................
87
APPENDIX FAPPENDIX GAPPENDIX HAPPENDIX I ETHYLENE ALKENE
COPOLYMER (EAM)
.......................................................... 97LIST
OF TABLES
Table 2-1Table 2-2Table 2-3Table 2-3 (Metric)Table 2 4Table 2-4
(Metric)Table 2-5Table 3-1Table 3-2Table 4-1Table 4-2Table 4-3Table
4-4Table 4-5Table 4-6Table 4-7Table 4-8Table 4-9Table 4-10Table
4-11
Weight Increment
Factors...........................................................................................
7Schedule for Establishing Maximum Direct Current ResistancePer
Unit Length of Completed Cable Conductors listed in Table 24
................... 7Nominal Direct Current Resistance n Ohms Per
1000 Feet at 25 OCof Solid and Concentric Lay Stranded
Conductor...................................................
8Nominal Direct Current Resistance n Milliohms Per Meter at 25 OCof
Solid and Concentric Lay Stranded Conductor
................................................... 9Nominal
Diameters for Copper and Aluminum Conductors
................................ 10Nominal Diameters for Copper and
Aluminum Conductors ................................ 11Factors for
Determining Nominal Resistanceof Stranded ConductorsPer 1000Feet at
25
OC..............................................................................................
12Extruded Conductor Shield Thickness
...................................................................
13Extruded Conductor Shield Requirements
............................................................
14Conductor Maximum Temperatures
........................................................................
15Insulat ion Physical Requirements Discharge-Free Designs
................................ 17Accelerated Water Absorption
Properties Discharge-Free Designs ................... 18Dielectric
Constant and Dissipation Factor Discharge-Free
Designs................. 18Shrinkback Test Requirements Cables
Having Sealed StrandConductors andlor a Tape 0ver.the Conductor
..................................................... 19Shrinkback
Test Requirements All Cables Not Covered by Table 4-5
................20Insulation Physical Requirements
Discharge-Resistant Designs ....................... 20Accelerated
Water Absorption Properties Discharge-Resistant Designs
..........21Dielectric Constant and Dissipation Factor
Discharge-Resistant Designs ........22BIL Values
......................................................................................................
:...........22Conductor Sites, Insulation Thicknesses and Test
Voltages .............................. 23
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ICEA S-94-649-2000 DATE: 07/24/00Table 4-1 1 (Metric)Table
5-1Table 5-2Table 5-3Table 6-1Table 6-2Table 6-3Table 7-1Table
7-2Table 7-3Table 7 4Table 7-5Table 7-6Table 7-7Table 7-8Table
7-9Table 7-1OTable 7-1 1Table 8-1Table 9-1Table 9-2Table 9-3Table 9
4Table 9-5Table 9-6Table 9-7Table 10-1Table 10-2Table 10-3Table
C-1Table C-2Table C-3Table C 4Table C-5Table iTable F-1Table
G-1Table G-2Table G-3Table G-4Table G-5Table G-6Table H-1Table
H-2Table H-3
Conductor Sizes. I ns utatm Thicknesses and Test Voltages
.............................. 23Insulation Shield Thickness Cables
Without Embedded Corrugated Wires...... 25Extruded Insulation
Shield Requirements Discharge-Free Designs...................
26Extruded Insulation Shield Requirements Discharge-Resistant
Designs..........27Concentric Neutral Wire
Size....................................................................................
29Full Neutral Concentric Copper Conductor
............................................................
29One-third Neutral Concentric Copper Conductor
.................................................. 30Low Density
and Linear Low Density Polyethylene. Black (LDPHLLDPE)
.......31Medium Density Polyethylene. Black (MDPE)
........................................................ 32High
Density Polyethylene, Black (HDPE)
..............................................................
33Polyvinyl Chloride (PVC)
...........................................................................................
36Polypropylene, Black
(PP).........................................................................................
39
Semiconducting Jacket Type I
.................................................................................
34Semiconducting Jacket Type
II................................................................................
35Chlorinated Polyethylene
(CPE)...............................................................................
37Thermoplastic Elastomer (TPE)
...............................................................................
38Extruded-To-Fill Jacket Thickness and Test
Voltage............................................ 41Overlaying
Jacket Thickness and Test Voltage
..................................................... 41Nominal
Insulation Thickness
..................................................................................
43Test Specimens for Physical and Aging
Tests.......................................................
45Insulation Shield Hot Creep Requirements
............................................................
49Bending Requirements for Heat Shock Test
..........................................................
52Summary of Product ion Tests and Sampling Frequency
Requirements........... 59Plan
E...........................................................................................................................
61Plan F
...........................................................................................................................
61Maximum Temperature Gradient for Thermal
Aging............................................. 69Generic
Grouping of Cable Components
...............................................................
70AC Withstand Voltage Requirements15-35 kV Rated
Cables.............................. 72Insulation Diameter
Calculation
...............................................................................
80Insulation Shield Adders
...........................................................................................
81Calculated Dimensions- Concentric Stranding
.................................................... 82Calculated
Dimensions- Compressed Stranding
................................................. 83Calculated
Dimensions-Compact Stranding
....................................................... 84DC Field
Test Voltages
..............................................................................................
88DC Test Voltages
........................................................................................................
89One-sixth Neutral Concentric Conductor for Copper Center
Conductor ...........90Oneeighth Neutral Concentric Conductor for
Copper Center Conductor .........90One-twelfth Neutral Concentric
Conductor for Copper Center Conductor ........91One-sixth Neutral
Concentric Conductoi or Aluminum Center Conductor ......91Oneeighth
Neutral Concentric Conductor for Aluminum Center Conductor
...92One-twelfth Neutral Concentric Conductor for Aluminum Center
Conductor ..92Concentric Stranded Class B Aluminum and Copper
Conductors ..................... 95Concentric Stranded Class C and
D Aluminum and Copper Conductors..........96
Bending Requirements for Cold Bend
Test............................................................
52
Solid Aluminum and Copper Conductors
..............................................................
94
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ICEA S-94-649-2000 DATE: 07/24/00Part IGENERAL
1.1SCOPEThis Standard applies to materials, constructions, and
testing of crosslinked polyethylene and ethylenepropylene rubber
insulated single conductor or multiplexed concentric neutral cables
rated 5 to 46 kV which
are used for the transmission and distnbution of electrical
energy.1.2 GENERAL INFORMATION
This publication is so arranged to allow selection from two
design concepts, one known as"DISCHARGE-FREE" and the other as
"DISCHARGE-RESISTANT, as well as allowing for selection ofthose
individual components (such as conductors, insulation type and
thickness, concentric neutral sizes,optional ackets, etc.) as
required for specific installation and service conditions.Parts 2
to 7 cover the major components of cables:Part 2 - ConuctorPart 3 -
Conductor ShieldPart 4 - InsulationPart 5 - Extruded Insulation
ShieldPart 6 - Concentric Neutral ConductorPart 7 - JacketsEach of
these parts designates the materials, material characteristics,
dimensions, and tests applicableto the particular component and, as
applicable, to the design concept.Part 8 covers the assembly and
identification of cables.Part 9 covers production test procedures
applicable to cable component materials and to completedPart 1O
covers qualification test procedures.Part 1I ontains appendices of
pertinent infomation.Units' n this Standard are expressed in the
English system. For information only, their approximate
cables.
metric equivalents are included.1.3 INFORMA TION 7 E SUPPLIED BY
PURCHASER
When requesting proposals from cable manufacturers, the
p;ospective purchaser should describe thecable desired by reference
to pertinent provisions of this Standard. To help avoid
misunderstandings andpossible misapplication of the cables, the
purchaser should also furnish the following information:1.3.1
a.b.d.e.f.9.
C.
Characterist ics o f Systems on which Cable is to be UsedLoad
current.Frequency - hertz.Normal operating voltage between phases
or phase to ground on single phase circuits.Number of phases and
conductors.Fault current and duration.Cable insulation
level.Minimum temperature at .which cable will be installed.
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ICEA S-94-6 49-20 00 DATE: 07124100h.1.2.3.1.2.
I
3.4 .5.6.
1.3.2a.b.C.d.e.f.9.h.i.j.k.
Description of installation.Inunderground ducts.Direct burial in
ground.Descriptions other than the foregoing.Installation
conditions.Ambient temperature.Number of loaded cables in duct bank
or conduit. If in conduit, give size and type of conduit(metallic
or nonmetallic), number of loaded conduits, enclosed or exposed,
and spacing betweenconduits.Load factor.Method of bonding anc
grounding of metallic neutral.Wet or dry location.Thermal
resistivity (rho) of soil, concrete and/or thermal
backfill.Quantities and Description of CableTotal number of feet,
including test lengths, and lengths if specific lengths are
required.Type of cable. Describe as single conductor,
three-conductor parallel, three-conductor triplexed,etc..Rated
circuit voltage, phase-to-phase.Type of conductor - copper or
aluminum, filled or unfilled stranded, solid.Size of conductors -
AWG or circular mils. If conditions require other than standard
stranding, acomplete description should be given.Type of
insulation.Thickness of insulation in mils.Size of neutral.Type of
jacket.Maximum allowable overall diameter in inches. When duct
space is not limited, it is desirable not torestrict the overall
diameter.Method of cable identification.
1.4DEFiNiTIONS AND SYMBOLSActive Length: Length of cable covered
by insulation shield and metallic shield.Agglomerate: A discernible
area of compound constituents in ethylene propylene basedinsulation
which is generally opaque and can be broken apart.Amber: A
localized area in crosslinked pplyethylene (XLPE or TRXLPE)
insulationwhich is dissimilar in color (ranging from bright yellow
to dark red) from thesurrounding insulation, which passes light and
is not always readily removablefrom the insulation matrix. This
does not include clouds, swirls or flow patternswhich are normally
associated with the extrusion process.AWG: American Wire GaugeBIL:
Basic Impulse Insulation Level.Bowtie Water Tree: A water tree
which originates within the insulation (usually at a contaminant
orother imperfection) and develops radially toward the insulation
shield and theconductor snield.
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ICEA S-94-649-2000Cable Core:
Cable CoreExtruder Run:
- -CertifiedTest Report:
Contaminant:Dielectric Constant:Discharge-FreeCable
Design:Discharge-ResistantCable Design:Dissipation Factor:
EPR InsulatingCompound:Filled CrosslinkedPolyethylene
Insulation:Gel:
High DielectricConstant Compound:Jacket Extruder Run:
kcmil:Lot (Cable):Lot (Material):Master Length:
DATE: O7124100The portion of a cable which includes the
conductor, the conductor shield, theinsulation and the insulation
shield.A continuous run of cable core with one conductor size, one
conductor shieldcompound, one insulation compound and thickness,
and one insulation shieldcompound.A report containing the results
of production tests or qualification tests whichdeclares that the
cable shipped to a customer meets the applicablerequirementsof this
Standard.Any solid or liquid material which is not an intended
ingredient.Specific Inductive CapacityA cable designed to eliminate
electrical discharge in the insulationat n onal operating voltage.A
cable design capable of withstanding electrical discharge.
The cotangent of the dielectric phase angle of a dielectric
material or thetangent of the dielectric loss angle. it is often
called tan 6.A mixture of ethylene propylene base resin and
selected ingredients.XLPE nsulation containing 10 percent or moreof
mineral fillers by weight.
A discernible region of compound constituents in ethylene
propylene basedinsulation which is gelatinous, not readily
removable from the insulation, andgenerally translucent.An extruded
compound used for the conductor shield which has a
dielectricconstant typically between8 and 200.A cable with a jacket
which was applied in one continuous run with one jacketcompound and
one jacket thickness.thousands of circular mils (formerly MCM)
b
The quantity of cable requiring one test.A quantity of material
used in cable construction which is produced at the samelocation
under the same manufacturing conditions during the same time
period.A continuous length of cable collected on a reel at the end
of an extrusion line.
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ICEA S-94-649-2000Maximum ConductorTemperatures:
NormalOperating:EmergencyOverload:
ShcrtCircuit:Partial DischargeLevelpc:Room
Temperature(RT):Shipping Length:
Shipping Reel:Translucent:
Tree RetardantXLPE Insulation:
Unfilled CrosslinkedPolyethylene:V:VVented Water Tree:Void:
Water Tree:
XLPE insulation:
DATE: 7124100
The highest conductor temperature permissible for any pari of
the cableline under normal operating current load.The highest
conductor temperature permissible for any part of the cable
lineduring emergency overload of specified time, magnitude, and
frequency ofapplication.The hignest cenductor temperature
permissible for any part of he cable lineduring a circuit fault of
specified time and magnitude.The maximum continuous or repetitious
apparent charge transfer, measuredin picocoulombs, occurring at the
test voltage.picocoulombs25 OCf 5 OCair temperature.A completed
length of cable which has passed all test requirements. It may
ormay not be cut into shorter lengths before it is supplied to the
end usecustomer.A completed reel of cable shipped to the end use
customer.A localized area in crosslinked polyethylene (XLPE or
TRXLPE) insulationdissimilar to the surrounding insulation which
passes light and is not readilyremovable from the insulation
matrix. There are no requirements fortranslucents in this
standard.A tree retardant crosslinked polyethylene (TRXLPE)
insulation compoundcontaining an additive, a polymer modification
or filler that retards thedevelopment and growth of water trees in
the insulation compound.XLPE insulation containing less than 10
percent mineral filler by weight.phase-to-phase
voltagephase-to-ground voltageA water tree which originates at the
conductor shield or insulation shieldAny cavity in a compound,
either within or at the interface with another
extrudedlayer.Microchannels in the insulation whicn develop in the
presence of moisture,voltage stress and some type of catalyst such
as a contaminant, a protrusion,space charge or ion(s).A crosslinked
polyethylene insulation.
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ICEA S-94-649-2000 DATE: 07124100Part 2CONDUCTOR
2.0 GENERALConductors shall meet the requirementsof the
appropriate ASTM standards referenced in this Standardexcept that
resistance will determine cross-sectional area as noted in 2.4 and
diameters will be inaccordance with 2.5.Requirements of a
referenced ASTM standard shall be determined in accordance with the
procedure orThe following technical information on typical
conductors may be found in Appendix H:method designated in the
referenced ASTM standard unless otherwise specified in this
Standard.
a. Approximate diameters of individual wires in stranded
conductors.b. Approximate conductor weights.2.1 PHYSICAL A
ND,ELECTRICA L PROPERTIES
The conductors used in the cable snall be copper in accordance
with 2.1.1or aluminum in accordancewith 2.1 -2, s applicable,
except as noted in 2.0.Conductors shall be solid or stranded. The
outer layer of astranded copper conductor may be coated to obtain
free stripping of the adjacent polymeric layer. Thereshall be no
moisture in stranded conductors in accordance with 9.15.2.1.1
Copper Conductors
1.2.3.4.5.6.7.8.9.
ASTM B 3 for soft or annealed uncoated copper.ASTM B 5 for
electrical grade copper.ASTM B 8 for Class A, B,C.or D stranded
copper conductors.ASTM B 33 for soft or annealed tin-coated copper
wire.ASTM B 496 or compact-round stranded copper conductors.ASTM B
784 or modified concentric lay stranded copper conductor.ASTM B 785
or compact round modified concentric lay stranded copper
conductor.ASTM B 787 or 19wire combination unilay-strandedcopper
conductors.ASTM B 835 or compact round stranded copper conductors
using single input wire constructions.
2.1.2 Aluminum Conductors12.3.4.5.6.7.8.9.
ASTM B 230 or electrical grade aluminum 1350-H19.ASTM B 231 for
Class A, B,C, or D stranded aluminum 1350 conductors.ASTM B 233 or
electrical grade aluminum 1350 drawing stock.ASTM B 400 or
compact-round stranded aluminum i 50 conductors.ASTM B 609 or
electrical grade aluminum 1350 annealed and intemediate
tempers.ASTM i 786 for 19wire combination unilay-stranded aluminurn
1350 conductors.ASTM B 800 for 8000 series aluminum alloy annealed
and intermediate tempers.ASTM 6 01 for 8000 series aluminumalloy
wires, cornpact- round, compressed and concentric-layClass A, B,C
and D stranded conductors.ASTM B 836 or compact round stranded
aluminum conductors using single input wireconstructions.
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ICEA S-94-649-2000 DATE: 71241002.2 OPTIONAL SEALA NT FOR
STRANDED CONDUCTORS
With the approval of the purchaser, a sealant designed as an
impediment to longitudinal waterpenetration may be incorporated in
the inierstices of the stranded conductor. Compatibility with
theconductor shield shall be determined in accordance with ICEA
Publication T-32-645. Longitudinal waterpenetration resistance
shall be determined in accordance with ICEA Publication T-31-610
and shall meet aminimum requirement of 5 psig.2.3 CONDUCTOR SIZE
UNITS
Conductor size shall be expressea by cross-sectional area in
thousand circular mils (kcmil). The AWGequivalents for small sizes
shall be found in Table 2-4. The metric equivalents for all sizes
are found inTable 2 4 Metric).2.4CONDUCTOR DC RESISTANCE PER UNIT
LENGTH
The dc resistance per unit length of each conductor in a
production or shipping length of completedcable shall not exceed
the value determined from the schedule of maximum dc resistances
specified in Table2-2 when using the appropriate nominal value
specified in Table 2-3. The dc resistance shall be determinedin
accordance with 2.4.1 or 2.4.2.Where the outer layer of a stranded
copper conductor is coated, the direct current resistance of
theresulting conductor shall not exceed the value specified for an
uncoated conductorof the same size.When a sample is taken from a
multiple conductor cable, the resistance shall comply with
theappropriate maximum resistance value specified for a single
conductor cable.2.4.1 Direct Measurementof dc Resistance Per Unit
Length
The dc resistance per unit length shall be determined by dc
resistance measurements made inaccordance with 9.3.1 to an accuracy
of 2 percent or better. If measurements are made at a
temperatureother than 25 OC, the measured value shall be converted
to resistance at 25 OC by using either of thefollowing:1. The
appropriate multiplying actor obtained from ICEA T-27-58UNEMA
WC-53.2. A multiplying factor calculated using the applicable
formula in ICEA T-27-5811NEMA WC-53.If verification is required for
the direct-current resistance measurement made on an entire length
ofcompleted cable, a sample at least 1 foot (0.3 m) long shall be
cut from that reel length, and the direct-current resistance of
each conductor shall be measured using a Kelvin-type bridge or a
potentiometer.
2.4.2b
Calculation of dc Resistance Per Unit LengthThe dc resistance
per unit length at 25 OC shall be calculated using the following
formula:
R = K p/AWhere:R = Conductor resistance in n/lO00 t.K = Weight
increment factor, as given in Table 2'1.p = Volume resistivity in
a.cmil/ft., determined in accordance with ASTM B 193 using round
wiresA = Cross-sectional area of conductor in kcmil, determined n
accordance with 9y3.2.
When the volume resistivity is expressed in nanoohm meter (nom)
and area is expressed in squaremillimeters (mm2) he resistance is
expressed in milliohm per meter (mnlm).
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ICEA S-94-649-2000
Conductor T ypelSizeSolidAll Sizes
Concentric-lay Strand, Class A, B, C and>2000 - 3000 kcmil
(MO13 1520 mm2)
Combination Unilay StrandAll SizesConcentric-lay Strand 8000
Series AluminumAil Sizes
8 AWG - 2000 kcmil (8.37 - 1013mm )
DATE: 07/24/00
Weight Factor K)1
1 o21.O31 o21 o2
2.5 CONDUCTOR DIAMETER
Cable Type
The conductor diameter shall be measured in accordance with
9.3.3.The diameter shall not differ fromthe nominal values shown in
Table 2-4 by more than i 2 percent.
Maximum d c Resistan ce
Table 2-1Weig ht Increment Factors'
Single Conductor Cables andFlat Parallel Cables
Table 2-3aValue Plus 2%(R max = R x 1.02)
Table 2-2S c h e d u l e for Establishing Maximum Direct Current
Res ista ncePer Unit Length of Completed Cable Cond uctors listed
in Table 2 4
Twisted Assemblies ofSingle Conductor Cables Tabie 2-3" Value
Plus 2% Plus An Additional 2% - ForOne Layer of ConductorsR rnax =
R x 1.O2 1.02)a For conductor strandings or sizes not listed in
Tables 2-3, the norninql direct current res istan ce pe r unit
length of acompleted singie conductor cable shail be calculated
from the factors given in Table 2-5 using the
followingformula:I
R =- 10-jWhere: R = Conductor resist ance in N1O00 t.f = Factor
from Table 2-5A = Cross-sectional area of conductor in kcmil
See 9.3.2 or cross-sectional area determination
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ICEA S-94-649-2000
0.5080.4030.3190.253
DATE: 07/24/00
0.5220.4140.3290.261
Table 2-3Nominal Direct Current Resistance in Ohms Per 1000 Feet
at 25 OC
...............
of Solid and (Solid
.............................................
............................................................
...............
...
............
ConductorSueAWG or kanil
ConcentricLay Stranded'Aluminurn Aluminum
Uncoated CoatedClass B.C.D ~~~~
Class0.6780.5380.4270.3380.269
Class Dlass 8,C.D0.6520.5190.41 10.3250.258
Class C0.6780.5380.4270.3390.269
1.O50.8330.6610.5240.415
1 O70.8510.6750.5340.424
O. 6800.5380.4270.3390.2693211OZO
0.3290.2610.2070.1640.130
0.2010.159O. 1260.1000.0794
0.2070.1640.1300.1020.0813
0.3340.2660.21 10.1680.133
0.2050.1 620.1290.1020.0810
0.21 30.1690.1340.1060.0842
0.2130.1690.1340.1060.0842
0.2130.1690.1340.1060.08420.06690.05300.04480.03740.0320
310410250300350
0.1030.08190.06940.04950.0578
0.06300.0500.........0.06450.051 1.........
0.1050.08360.07070.05900.0505
0.06420.05100.04310.03600.0308
0.06670.05240.04480.03740.0320
0.06690.05300.04480.03740.0320400450500550600
0.04330.03850.03471.....
0.04420.03930.03540.03210.0295
0.02690.02400.02160.01960.0180
0.02770.02460.02220.02040.0187
0.02800.02490.02240.02040.0187
0.02800.02490.02240.02040.0187650700750800900
...............
0.02720.02530.02360.02210.0196
0.01660.01540.01440.01 350.0120
0.01710.01590.01480.01390.0123
0.01720.01600.01490.01400.0126
0.01730.01600.01500.01400.012610001100120012501300
...............0.01770.01 610.01470.01410.0136
0.01 110.01010.009250.008880.00854
0.01 110.01020.009340.008970.00861
0.01120.01020.009340.008970.00862
0.01080.009810.008990.008630.00830a007710.0071
90.006740.006340.0061 6
...............
0.01 260.01 180.01 110.01 040.0101
0.007930.007400.006940.006530.00634
0.007930.007400.007000.006590.00640
0.008010.007470.007000.006590.00640
1400150016001700175018001900200025003000
...
............0.009820.009310.008850.007150.00596
0.005990.005680.005390.004360.00363
0.006160.005840.005550.004480.00374
0.006160.005840.00555......
~
0.006220.005890.00560......
Concentric ay stranaed indudes compressed and compact
mnductors.
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DATE: 07/24/00ICEA S-94-649-2000Table 2-3 Metric)Nominal Direct
Current Resis tanc e in Milliohms Per Meter at 25 C:entric Lav
Stranded Conductor
Concentric Lay Sbandw'of Solid and Ca
%idAluminumondu dor Size AJuminurn
~ Kcmil
4
110ZO
Coated Uncoated coatedUnmated Class B,C,D ~Class
B2.221.761.401.110.882
Class Dlass B.C.0 Class C2.221.761.401.110.882
~~
2.161.711.361 O80.856
3.512.792.211.751.39
2.141.701.351O70.846
2.231.761.401.110.882
3.442.732.171.721.36
2.101.671.321 O50.830
8.3710.613.316.821.126.733.642.453.567.4
~~ ~
0.6990.5540.4400.3480.276
0.6990.5540.4400.7480.276
0.6590.5220.4130.3280.260
0.679O. 5380.4260.3350.267
1.100.8720.6920.5510.436
0.6720.5310.4230.3350.266
0.6990.5540.4400.3480.276
1O80.8560.6790.5380.426~
0.3440.2740.2320.1940.166
0.21 10.1670.1410.1180.101
0.2190.1720.147O. 1230.105
0.2190.1740.1470.123O. 105
0.219O. 1740.1470.1230.105
0.3380.2690.2280.1900.162
0.2070.164.........0.2120.168.........
85.0107127152177203228253279304
310410250300350400450500550600650700750800900
1O0011001200125013001400150016001700175018001900200025003000
...............0.1450.1290.1160.1050.0968
0.08820.07870.07080.06430.0590
0.09090.08070.07280.06690.0613
0.09180.08170.07350.06690.0613
0.09180.08170.07350.06690.0613
O. 1420.1260.114.....................
~~
0.05640.05250.04890.04590.041 3
~~
0.05670.05250.04920.04590.041 3
............
...
...............
0.08920.08300.07740.0725O.OE43
0.05440.05050.04720.04430.0394
0.01610.05220.04850.04560.0403
329355380405456507557608633659709760811861887
...............
..............................
~
0.03540.03220.02950.02830.0272
0.03640.03310.03030.02910.0280
0.03640.03350.03060.02940.0282
0.03670.03350.03060.02940.0283
...............0.05810.05280.04820.04620.0446
...............
...............
0.04130.03870.03640.03410.0331
0.03530.02360.02210.02080.0202
0.02600.02430.02280.02140.0208
0.02630.02450.02300.02160.0210
..
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ICEA 5-94-649-2000 DATE: O7124100Table 2 4Nominai Diameters for
Copper and Aluminum Conductors
I
Nominal Diameters (Inaies)Concentric Lay Stranded
UnilayCompreskcmil CombinationUnilayO.
1430.1600.1790.2020.226
AWG87654321110ZO30410
Solid0.12850.14430.16200.18190.20430.22940.25760.28930.32490.36480.40960.46000.50000.54770.5916
Cornpact' Compressed Class B Class C Class
D16.5120.8226.2433.0941.74
0.1460.1649.1840.2060.232
0.1480.1660.1860.2080.234
0.1340.1690.213
...
...0.1410.1580.1780.2000.225
0.1480.1660.1860.2080.235
...............52.6266.3683.69105.6133.1
0.2380.2680.2990.3360.376
0.2520.2830.3220.3620.406
0.2600.2920.3320.3730.419
0.2630.2960.3330.3740.420
0.2640.2970.3330.3740.420
0.2540.2860.3210.3600.404
......0.3130.3520.395167.8211.6250300350
0.4230.4750.5200.5700.616
0.4560.5120.5580.61 10.661
0.4700.5280.5750.6300.681
~~
0.4710.5290.5760.6310.681
0.4720.5300.5760.6310.682
0.4540.5100.5540.6070.656
0.4430.4980.5420.5940.641
400450500550600
0.63250.67080.7071......
0.6590.7000.7360.7750.813
0.7060.7490.7890.8290.866
0.7280.7720.8130.8550.893
0.7290.7730.8140.8550.893
0.7290.7730.8150.8550.893
0.7010.7440.784......
0.6850.7270.7660.8040.840
650700750800900
0.8450.8770.9080.9380.999
0.9010.9350.9681 o001.061
0.9290.9640.9981O311 o94
0.9300.9650.9991 O321 O93
0.9300.9650.9981 O321 O95
............
...
0.8740.9070.9390.9691 O28
............
..................
...............
1O001100120012501300
1 O60............
1.1171.1731.2251.2511.276
1.1521.2091.2631.2891.315
1.1531.2101.2641.2901.316
1.1531.211i 2641.2901.316
...............1 o841.1371.1871.2121.236
14001500160017001750
...............
1.3231.3701.4151.4591.480
1.3641.4121.4591.5041.526
1.3651.4131.4601.5041.527
1.3651.4131.4601 5041.527
.........1.....
1.2821.3271.3711.4131.43418001900200025003000
......
.........1.5021.5421.5831.7691.938
1.5481.5901.6321.8241.998
1.5481.5901.6321.8241.999
1.5491.5911.6321.8241.999
......
.........
1.4541.4941.533......
......
.........Diameters shown are for compact round, compact modified
concentric and compact single input wire.
** Diameters shown are for concentric round and modified
concentric.
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Concentric Lay StrandedCompresed Class B- Class C Class D
3.71 3.76 3.764.01 4.17 4.22 4.224.52 4.67 4.72 4.725.08 523
5.28 5.315.72 . 5.89 5.94 5.976.40 6.60 6.68 6.717.19 7.42 7.52
7.548.18 8.43 8.46 8.469.19 9.47 9.50 9.5010.3 10.6 10.7 10.7
3.58
DATE: 07/24100
Combination UnilayUniiay Compressed3.63 ...4.06 ...4.55 ...5.1 3
...5.74 ...6.45 ...7.26 ...8.15 7.959.14 8.9410.3 10.0
Conductor
Kari i l
11.6 11.9 12.0 12.0 ...13.0 13.4 13.4 13.5 ...14.2 14.6 14.6
14.6 ...15.5 16.0 16.0 16.0 ...16.8 17.3 17.3 17.3 ...17.9 18.5
18.5 18.5 ...19.0 19.6 19.6 19.6 ...20.0 20.7 20.7 20.7 ...21.1
21.7 21.7 21.7 ...22.0 22.7 22.7 22.7 ...22.9 23.6 23.6 23.6
...23.7 24.5 24.5 24.5 ...24.6 25.3 25.4 25.3 ...25.4 26.2 26.2
26.2 ...26.9 27.8 27.8 27.8 ...28.4 29.3 29.3 29.3 ...29.8 30.7
30.7 30.8 ...31.1 32.1 32.1 32.1 ...31.8 32.7 32.8 32.8 ...32.4
33.4 33.4 33.4 ...33.6 34.6 34.7 34.7 ... .34.8 35.9 35.9 35.9
...35.9 37.1 37.1 37.1 ...37.1 38.2 38.2 38.2 ...37.6 38.8 38.8
38.8 ...38.2 39.3 39.3 39.3 ...39.2 40.4 40.4 40.4 ...40.2 41.5
41.5 41.5 ...44.9 46.3 46.3 46.3 ...49.2 50.7 50.8 50.8 ...
13.316.821.126.733.6t 42.4
110 53.5ZO 67.4
11.312.613.815.116.317.418.519.520.421.322.223.023.924.626.127.528.930.130.831.432.633.734.835.936.436.937.938.9......
300350
650700750800900
329355380405456
...........................,.................
Table 2 4 Metric)Nominal Diameters for Copper and Aluminum
ConductorsNominalDiameten (mm)
I
21.522.323.123.825.426.9...........................
Solid Compact.
4.1 4.294.62 ...5.19 5.41
17001750
5.83 6.056.54 6.817.35 7.598.25 8.539.27 9.5510.4 10.711.7
12.1e3 13.213.9 14.515.0 15.616.1 16.717.0 17.818.0 18.7... 19.7...
20.7
861887
18001900200025003000
912963i01312661520
.........
......
.........
......Diameters snown are for compact round, compact modified
concenuic and compact single input wire.
** Diameters shown are for wncentnc round and modified
concenuic.
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conductor SizeAluminum Uncoated
copper
Table 2-5'Factorst for Determinina Nominal Resistanceo f
Stranded Conductors Per 1000 Feet at 25 OCDiameter of Individual
Coated Copper Wires in inchesfor Stranded Conductorsll Sizes
0.460 Under 0.290 Under 0.103to 0.290, to 0.103, to
0.0201,inclusive Inclusive inclusive
Under 0.0201to 0.0111,Inclusive
11456
11568
Concentric Stranded(8.37 - 1013 mm2)8 AWG - 2000 kcmil
Under 0.0to 0.001Inclus
1158
1169
17692 10786I I> 2000 - 3000 k a i i i l I 17865 I 10892 I
11153 I 11211 1 11327(MO13 - 1520 mm')
11045 11102 11217
Conductivity utilizedfor above fadors,Percent
The factors given in Table 2-5 snaii be b a d n the following:A.
Resistivity1.A volume resistivity of 10.575 n.anillft (100%
conductivity)at 25 OC for uncoated (bare) copper.2. A 25OC olume
resistivity converted from the 20 OC alues specified inASTM B 33
for tin coated copper.3. A volume resistivity of 17.345 r;.cmil/ft
(61.0% conductivity)at 25 OC for aluminum.B. increase in Resistance
Due to Stranding1. The value of K weight ncrement factor) given
inTable 2-1.
94.16 I 93.15
t See Table 2-2 for Useof Factors.
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16 0.4112 - 550(107 - 279)i
Part 3CONDUCTOR SHIELD (STRESS CONTROL LA YER)3.1 MATERIAL
Th e conductor shall b e c overed with a n extmded thermosetting
conductor shield material. The extrudedmaterial shall b e either
semiconducting or nonconducting for ethy lene propylene rubbe r EP
R) typeinsulation and semiconducting only for crosslinked
polyethylene XLPE or TRXLPE) type insulation. Theextruded shield
shall be compatible with all cable component materials with which
it is in contact. Theallowable operating temperatures of the
conductor shield shall be equal to or greater than those of
theinsulation. T he conductor shield shall be easily removable from
the conductor and the outer surfa ce of theextruded shield shall b
e firmly bon ded to th e overlying insulation.A semiconducting tape
may be used between the conductor and the extruded shield. The
tape, ifutilized, shall not be considered as part of the extruded
shield thickness.3.2 EXTRUDED SHIEL D THICKNESS
(See9.4.2). Th e extruded conductor shield thickne sses shall b
e as follows:Table 3-1Extruded Conductor Shield Thickness
~~
Extruded Shield Thickness
mils
Conductor Size,AWG or kcmil(mm2)A (8.37 - 107) I l 2 I Il-
410
0.61001 and larger507 and larger)3.2.1 Reduced Extruded Shield
Thickness
For compact round and solid conductors which have a diameter
eccentricity less than or equal to 2 mils(0.051 mm) measured before
the extruded shield is applied, the extruded shieid thickness may b
e 50 percentof Table 3-1 values with prior agreement between the
manufacturer and the purchaser. Protrusions andirregularities into
t h e conductor shield shall not exceed 50% of t h e required
minimum point shield thickness.All other requirements remain unch
ange d. Diameter eccentricity is defined as the maximum diameter
minusthe minimum d iameter of a given cross section.3.3 PROTRUSIONS
AND IRREGULARITIES
(See 9.4.13). T he co ntact surface between the extruded
conductor shield and :he insulation shall be
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ICEA S-94-649-2000 DATE: 07/24/00cylindrical and free from
protrusions and irregularities that extend more than 5 mils (0.127
mm) into theinsulation and 7 mils (0.18 mm) into the extruded
conductor shield.3.4VOIDS
(See 9.4.13). The extruded conductor shield and insulation
interface shall be free of any voids largerthan 3 mils (0.076
mm).3.5 PHYSICAL REQUIREMENTS
The crosslinked material intended for extrusion as a conductor
shield shall meet the followingrequirements: Table 3-2Extruded
Conductor Shield Requirements
Physical Requirements 1 ExtrudedConductor ShieldElongation ater
air oven test for 168 hoursat 121OC 1 OC for insulations rated
90OC) rat 136OC l OC for insulations rated 105 OC),minimum
Dercent
1O0
Brittleness temperature not warmer than, OC I -253.6 ELECTRICAL
REQUIREMENTS3.6.1 Extruded Semiconducting Material
(See 9.8.1). The volume resistivity of the extruded
semiconducting conductor shield shall not exceed1O00 ohmmeter at
the maximum normal operating temperature and emergency operating
temperature.3.6.2 Extruded Nonconducting Material (For EPR
Insulation Only)
The extruded nonconducting conductor shield shall withstand a
2.0 kV dc spark test, for test frequencysee Table 9-5, and meet the
following requirements at room temperature, at the maximum normal
operatingtemperature, and emergency operating
temperature:Dielectric Constant, range 8 - 20060 Hz ac voltage
withstandstress, volts per mil, minimum- Lielectric constant
3.6.3 Semiconduct ing TapeIf a semiconducting tape is used over
the conductor, the maximum dc resistance of the tape at
roomtemperature shall be 10,000 ohms per unit square when
determined in accordance withASTM D 4496.
3.7 WAFER BOIL TEST(See 9.4.12). The extruded conductor shield
shall be effectively crosslinked.
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K E A S-94-649-2000
XLPE, TRXLPE, andEPR Classes I, I & IV
DATE: 07/24/00
90OC 130OC 250OC
Par i 4INSULATION
EPR Class III 1 105C I 140 O C
4.1 MATERIAL
250 C
The insulation shall be one of the following materials meeting
the dimensional, electrical, and physicalrequirements specified in
this section:.Filled or unfilled crosslinked polyethylene
(XLPE).Filled or unfilled tree retardant crosslinked polyethylene
(TRXLPE)Ethylene propylene rubber (EPR)A filled crosslinked
polyethylene or filled tree retardant crosslinked poiyethylene
insulation (XLPE orTRXLPE), meeting the requirements of this
specification,is one that contains 10percent or more of
mineralfillers by weignt. A tree retardant crosslinked polyethylene
insulation is a compound containing the following:an additive, a
polymer modification, or filler that retards the development and
growth of water trees in thecompound. These XLPE and TRXLPE
insulations are intended for use only in cables of the
"DISCHARGE-FREE design concept. (See 4.3.1)Ethylene propylene
rubber insulation has four classifications:
I I I & I I I are for use only in cables of
the"D1SCHARGE-FREE" design (See 4.3.1);IV is for use only in cables
of the "DISCHARGE-RESISTANT' design (See 4.3.2).All of the
insulations are suitable for use on cables in wet or dry locations
at voltages between 5 and 46kV between phases at the 100 and 133
percent insulation level. The conductor temperature shall not
exceedthe following:
Table 4-1Conductor Maximum Temperatures
Normal Emergency 1 Short Circuitinsulation Materialt Operation
Overload* i'See Appendix B."Lower temperatures for normal operation
may be required because of the type of material used in the cable
joints. terminationsand separable connectors or because of cable
environment wnditions. Cable users should be aware that all of the
jacketsdescnbed in Pari 7 are not necessarily suitable for cables
having this maximum temperature rating. Consult cable manufacturer
forfurther information."'Condudor fault airrent shall be determined
in accordance with I C s P-32-382.to ther insulation materials
composed of Ethylene and Alkene units, which are designated as EAM,
may be available and can meetthe same physical and electrical
requirements as the insulation materiais descnoed in this standard.
See Appendix I and/or contadthe manufacturer or further
information.
4.2 INSULATION THICKNESS -The insulation thicknesses given in
Table 4-11 are based on the rated circuit voltage,
phase-to-phase,and on the cable insulation level.
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ICEA S-94-649-2000 DATE: O7124100The minimum thickness and
maximum thickness of the insulation shall be as specified in Table
4-11For identification, nominal thicknesses are shown in Table
8-1.(see9.4.2 for method of measurement).
4.2.1 Selection o f Proper ThicknessThe thickness of insulation
for various systems shall be determined as follows:
4.2.1.1 For Three-phase Systems with 100 or 133 Percent
Insulation LevelUse the thickness values given in the respective
columns of Table 4-1 1.
4.2.1.2 For Delta Systems Where One Phase May Be Grounded For
Periods Over One HourSee 173 percent level in note c following
Table 4-1 1
4.2.1.3 For Single- and Two-Phase Systems with 100 Percent
Insulation LevelMultiply the voltage to ground by 1.73 and use the
resulting voltage value or next higher rating to select
the corresponding insulation thickness in the 1O0 percent
insuiation evel column of Table 4-11.4.2.1.4 For Single- and
Two-Phase Systems with 133 Percent Insulation Levei
Multiply the voltage to ground by 1.73 and use the resulting
voltage value or next higher rating to selectthe corresponding
insulation thickness in the 133 percent insulation evel column of
Table 4-1 .4.3 INSULATION REQUIREMENTS
Insulations used in DISCHARGE-FREEcable designs are described n
4.3.1.Insulations used in DISCHARGE-RESISTANTcable designs are
described in 4.3.2.4.3.1 Insulation for DISCHARGE-FREE Cable
Designs Only4.3.1.1 Physical and Aging Requirements
When tested in accordance with Part 9, the insulation shall meet
the following requirements:
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I
Physical Requirements
DATE: 07/24/00
Insulation TypeXLPE and TRXLPE EPR ClassUnfilled Filled I II
Tensile Strength, Minimumpsi 1800 700 1200( M W (12.5) (4.8)
(8.2) 700(4.8)
*For XLPE and TRXLPE insulations if this value is exceeded, the
Solvent Extraction Test may beperformed and will serve as a referee
method to determine compliance (a maximum of 30 percentweight loss
after 20 hour drying time).
Elongation at Rupture, 250Minimum Percent
4.3.1.2 Electrical Requirements4.3.1.2.1 Partial-Discharge
Extinction Level 6
250
(See 9.13). Each shipping length of completed cable shall be
subjected to a partial discharge test. Thepartial discharge shall
not exceed 5 picocoulombs at the ac test voltage given in Table 4-1
1.
Aging Temperature, OC 121 121of Unaged ValuePercentage of Unaged
Value
Tensile Strength, Minimum Percentage 75 75 80Elongation, Minimum
75 1 75 80
4.3.1.2.2 Voltage Tests
1367575
(See 9.12). Each shipping length of completed cable shall
withstand, without failure, the ac test voltagesgiven in Table 4-1
1. The test voltage shall be based on the rated voltage of the
cable and the size of theconductor.Factory dc testing is not
required by this specification. However, a dc test may beperformed
with prioragreement between the manufacturer and the purchaser.
Suggested dc test voltages are listed in AppendixF. For purposes of
this Standard, the BIL shall be in accordance with Table 4-10. The
minimum impulse
Elongation, Maximum Percent 175
17
1O0 50Set, Maximum Percent 1 1 0 1 5 5
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ICEA S-94-649-2000 DATE: 07/24/00withstand value for all
discharge-free cable designs shall be 800 Vlmil (31.5 kV/mm) except
for XLPE ofTRXLPE insulated cable designs rated for 15 kV where the
minimum impulse withstand value shall be 1200V/mil (47.2
kV/mm).4.3.1.2.3 Insulation Resistance Test
(See 10.5.1). Each insulated conductor in the completed cable
sh