Low Voltage Aerial Bundled Cable Manual · 5.3.2 Pulling Equipment ... 7.3 Stringing Method ... Aerial Bundled Cable for Low Voltage Distribution 1.1 Summary The use of Low Voltage

CS10 # 2369224

Low Voltage Aerial Bundled Cable Manual

Prepared by Safety and Health

Corporate Services and Company Secretary

May 2014

Document Title: Low Voltage Aerial Bundled Cable Manual Issue Date: May 2014 CS10 # 2369224 © Horizon Power User to check printed document is correct

HORIZON POWER

DOCUMENT CONTROL

Document Owner (May also be the Process Owner)

Name: Mark Van Vuuren

Position: Field Practices Coordinator

Date: May 2014

Approved By * Name: Mark Van Vuuren

Position: Field Practices Coordinator

Date: May 2014

Authorisation **

Process Owner is hereby vested with authority and

responsibility to manage the process end to end.

Name: Lance Roberts

Position: Manager Safety and Health

Date: May 2014

Date Created/Last Updated May 2014

Review Frequency *** Every 3 years

Next Review Date *** May 2020

* Must be the Process Owner and is the person assigned authority and responsibility for managing the whole process, end-to-end, which may extend across more than one division and/or functions, in order to deliver agreed business results.

** This person will have the power to grant the process owner the authority and responsibility to manage the process from end to end.

*** Frequency period is dependent upon circumstances– maximum is 5 years from last issue, review, or revision whichever is the latest. If left blank, the default will be 1 year unless otherwise specified.

STAKEHOLDERS

The following positions must be consulted if an update or review is required:

NOTIFICATION LIST

The following positions must be notified of any authorised change:


HORIZON POWER

Important Notice to Users

This manual has been developed for use by Horizon Power employees’ and Service Providers engaged to perform Low Voltage Aerial Bundled Cable work on Horizon Power Electrical Networks.

It is issued by as a controlled document by Horizon Power to Horizon Power employees’ and Service Providers on the condition that it will only be used whilst undertaking Low Voltage Aerial Bundled Cable work on Horizon Power electricity distribution network.

Low Voltage Aerial Bundled Cable work will only be performed by individuals who are appropriately trained and qualified in accordance with accepted standards within Horizon Power. This Manual is not intended, and should not in any way be relied upon, as a substitute for such training.

Copyright 2014

Copyright is owned by Horizon Power.

Horizon Power (ACN 57 955 011 697).

All rights reserved. No part of this work may be reproduced or copied in any form or by any means (graphic, electronic, taping or information retrieval system) without the written permission of the copyright owner.

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Table of Contents

Section Page Number

1 INTRODUCTION .................................................................................................. 1-1

1.1 Summary ..................................................................................................................... 1-1 1.2 Overseas Usage .......................................................................................................... 1-1 1.3 Experience and Advantages ........................................................................................ 1-1 1.4 Cable Description ........................................................................................................ 1-2 1.5 Conductors .................................................................................................................. 1-2 1.6 Working Tensions ........................................................................................................ 1-2

2 CABLE IDENTIFICATION ................................................................................... 2-1

2.1 Core Identification ........................................................................................................ 2-1

3 POLE HARDWARE ............................................................................................. 3-1

3.1 Universal Bracket for Concrete/Wood Poles ................................................................ 3-1 3.2 Mounting Bracket for Universal Bracket on a Concrete Pole ........................................ 3-1 3.3 Clamps and Hanger ..................................................................................................... 3-2

4 STRINGING EQUIPMENT ................................................................................... 4-1

4.1 Pilot Rope .................................................................................................................... 4-1 4.2 Swivel .......................................................................................................................... 4-2 4.3 Cable Stockings ........................................................................................................... 4-2 4.4 Cumalong .................................................................................................................... 4-3 4.5 Dynamometer .............................................................................................................. 4-3 4.6 Pullifts (Crankers) ........................................................................................................ 4-4

5 STRINGING METHOD ......................................................................................... 5-1

5.1 Installation Method ....................................................................................................... 5-1 5.2 Manpower .................................................................................................................... 5-1 5.3 Tools and Equipment ................................................................................................... 5-1 5.3.1 Tools ............................................................................................................................ 5-1 5.3.2 Pulling Equipment ........................................................................................................ 5-2 5.3.3 Stringing Equipment .................................................................................................... 5-2 5.3.4 Intermediate and Termination Equipment .................................................................... 5-2 5.4 Position of Pulling Equipment ...................................................................................... 5-2 5.4.1 Self Loading Cable Recovery Trailer ............................................................................ 5-2 5.4.2 Winch .......................................................................................................................... 5-3 5.5 Positioning of Stringing Blocks ..................................................................................... 5-4 5.6 Installation of Pilot Rope .............................................................................................. 5-6 5.6.1 Stocking Attachment .................................................................................................... 5-6 5.7 Tensioning and Terminating Cable .............................................................................. 5-6 5.7.1 Using a Capstan Winch with Brake Drum Stand .......................................................... 5-7 5.7.2 Using a Hydraulic Winch with a Self Loading Cable Recovery Trailer .......................... 5-7 5.7.3 Forces ......................................................................................................................... 5-8

6 ELECTRICAL CONNECTIONS ........................................................................... 6-1

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6.1 Insulation Piercing Connectors (IPC’s) ........................................................................ 6-1 6.2 IPC Design .................................................................................................................. 6-1 6.3 Current Rating ............................................................................................................. 6-1 6.4 Service Disconnection ................................................................................................. 6-1 6.5 Tapping ....................................................................................................................... 6-1 6.6 Cable Separation ......................................................................................................... 6-1 6.7 Phase Balancing ......................................................................................................... 6-4 6.8 End Cap ...................................................................................................................... 6-4

7 IMPORTANT POINTS .......................................................................................... 7-1

7.1 Cable Description and Identification ............................................................................ 7-1 7.2 Stringing Equipment .................................................................................................... 7-1 7.3 Stringing Method ......................................................................................................... 7-1 7.4 Electrical Connections ................................................................................................. 7-2

8 TREE CLEARANCE FOR AERIAL BUNDLED CABLE ...................................... 8-1

8.1 Clearance Zone ........................................................................................................... 8-1 8.2 Inspection Zone ........................................................................................................... 8-1 8.3 Assessing How Much Needs to be Pruned within the Clearance Zone ........................ 8-1 8.3.1 Basic Clearance .......................................................................................................... 8-1 8.3.2 Tree Growth and Regrowth ......................................................................................... 8-1 8.3.3 Overhanging Branches ................................................................................................ 8-1

9 TECHNICAL DATA .............................................................................................. 9-1

9.1 Minimum Spacing between Circuits for Under crossings ............................................. 9-3 9.2 Baulk Installation Details ........................................................................................... 9-12

10 CABLE JOINTING .......................................................................................... 10-1

10.1 Joint Layout ............................................................................................................... 10-1 10.2 Joint Preparation ....................................................................................................... 10-1

11 CABLE REPAIRS ........................................................................................... 11-1

11.1 Cable Repair Kit ........................................................................................................ 11-1 11.2 Cable Repair Instructions .......................................................................................... 11-1

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List of Figures

Figure 1 – Cable Identification ....................................................................................... 2-1

Figure 2 – Universal Bracket ......................................................................................... 3-1

Figure 3 – Hooked Bracket ............................................................................................ 3-1

Figure 4 – Termination Clamp ....................................................................................... 3-2

Figure 5 – Suspension Clamp ....................................................................................... 3-2

Figure 6 – Angle Yoke ................................................................................................... 3-2

Figure 7 – Stringing Equipment ..................................................................................... 4-1

Figure 8 – Swivel ........................................................................................................... 4-2

Figure 9 – Single Eye Stocking used in LV ABC Stringing ............................................. 4-2

Figure 10 – Cumalong ................................................................................................... 4-3

Figure 11 – Dynamometer ............................................................................................. 4-3

Figure 12 – Web strap ratchet hoist ............................................................................... 4-4

Figure 13 – Self Loading Cable Recovery Trailer .......................................................... 5-3

Figure 14 – Winch working position ............................................................................... 5-3

Figure 15 – Position of Stringing Blocks ........................................................................ 5-4

Figure 16 – Angle of Deviation 26-50° ........................................................................... 5-5

Figure 17 – Stocking Attachment for Pilot Rope ............................................................ 5-6

Figure 18 – Components of IPC before and after clamping ........................................... 6-2

Figure 19 – Clamp (A) ................................................................................................... 6-2

Figure 20 – Clamp (B) ................................................................................................... 6-3

Figure 21 – Clamp (C) ................................................................................................... 6-3

Figure 22 – End Cap ..................................................................................................... 6-5

Figure 23 – Tree Clearance for ABC ............................................................................. 8-2

Figure 24 – Ground Clearance for ABC ......................................................................... 9-2

Figure 25 – Min Spacing between Circuits for Undercrossings ...................................... 9-3

Figure 26 – Min Vertical In-span Separation C .............................................................. 9-4

Figure 27 – Pole Footing with Bolted Baulk ................................................................. 9-12

Figure 28 – Joint Layout .............................................................................................. 10-1

Figure 29 – Joint Preparation ...................................................................................... 10-1

Figure 30 –Cable Repairs - 1....................................................................................... 11-1







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List of Tables

Table 1 – Universal Bracket details ................................................................................3-1

Table 2 – Hooked Bracket details ..................................................................................3-2

Table 3 – Clamps and Hanger details ............................................................................3-2

Table 4 – Stringing Equipment details ............................................................................4-1

Table 5 – Pilot Rope details ...........................................................................................4-2

Table 6 – Swivel details .................................................................................................4-2

Table 7 – Cable Stocking details ....................................................................................4-3

Table 8 – Cumalong details ...........................................................................................4-3

Table 9 – Dynamometer details .....................................................................................4-4

Table 10 – Pullifts details ...............................................................................................4-4

Table 11 – Stringing block details ..................................................................................5-4

Table 12 – Angle of Deviation 26-50° details..................................................................5-5

Table 13 – Forces ..........................................................................................................5-8

Table 14 – IPC clamps (A) detailed ................................................................................6-2

Table 15 – IPC clamps (B) detailed ................................................................................6-3

Table 16 – IPC clamps (C) detailed................................................................................6-4

Table 17 – End Cap details ............................................................................................6-5

Table 18 – Min Spacing between Circuits for Under Crossings ......................................9-3

Table 19 – Minimum Vertical In-span Separation C .......................................................9-4

Table 20 – Joining Sleeve details ................................................................................. 10-2

Table 21 – Minor Repair Kit details .............................................................................. 11-4

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1 INTRODUCTION

Aerial Bundled Cable for Low Voltage Distribution

1.1 Summary

The use of Low Voltage Aerial Bundled Cable (LV ABC) is expected to dramatically increase in Australia. Compared with conventional bare conductor overhead systems, overseas experience show that LV ABC promises to be cheaper, safer, more reliable, require less tree clearing and pruning and so be more aesthetic, be less labour intensive, require less maintenance and eliminate bushfires being initiated by conductor clashing.

1.2 Overseas Usage

LV ABC is used on every continent and in a total of approximately 80 countries.

In France, Electricite’ de France (EDF) first used a form of LV ABC in the mid-1950’s. From 1966 EDF have used aluminium conductor and from 1977 XLPE insulation has been used. In France, approximately 142,000 km of LB ABC is erected, and each year EDF remove 7000 km of bare conductor and replace it with LV ABC. In 1984, Bundled Cable, used on the facades of buildings and strung between poles, comprised 27% of France’s Low Voltage aerial network.

In Scandinavia LV ABC has been used since 1960’s and approximately 150,000 km has been installed in Finland and in 1984 it comprised 75% of Finland’s Low Voltage aerial network. In Sweden LV ABC has been used since the mid-1960’s and approximately 60,000 km was in service in 1984 when it comprised 40% of Sweden’s Low Voltage aerial network.

In Ireland, approximately 6,000 km has been installed since 1980.

In Britain, a very small quantity of cable has been used, mainly in the East Midlands Electricity Board for under eaves wiring.

1.3 Experience and Advantages

The extensive experience overseas indicates the following advantages:

Reduced cost for new work. Savings of at least 10% have been achieved in authorities that have adopted LV ABC in significant quantity.

Significantly improved safety for linespersons, particularly when working on live conductors.

Significant reduction in the amount of tree clearing and pruning necessary. This reduces tree pruning costs and because the appearance of lines is improved, electricity authorities get fewer objections from customers. In the SECV, the area of clearance space required around LV ABC is approximately 10% of the area of the clearance space required around bare LV Conductors. In France, where LV ABC has been used tree cutting has been reduced by a third.

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Bushfires cannot be initiated from clashing conductors.

Reduced maintenance. In France, line inspection has been halved; de-energising of the network for work in proximity has been practically eliminated; phase-to-earth faults eradicated (incidents due to wind represent 40% of outages with bare conductors); repair of suspension points eradicated and lightning damage considerably reduced.

Less construction resources required due to quicker and easier erection.

Reduced clearances. Overseas authorities have reduced minimum ground clearances and the clearance between LV ABC and buildings.

Improved reliability in comparison with both bare conductor overhead systems and underground systems. Insulated conductors prevent accidental contact and supply can be maintained temporarily in the event of a suspension system collapse.

1.4 Cable Description

The cable consists of four cores, each comprising a cross linked polyethylene (XLPE) insulated aluminium conductor, twisted together to form a bundle. Electrical connections are made by the use of insulation piercing connectors and the cable is supported at intermediate poles and strain poles with easy to install mechanical fittings. The electrical and mechanical characteristics of the cable are similar to existing bare conductors.

1.5 Conductors

The conductors used for all the cores are of stranded hard drawn aluminium which are partially compacted, these may be sized 25, 35, 50, 70, 95 or 150 mm2.

1.6 Working Tensions

A bundle consisting of four laid-up conductors gives ABC a very high ultimate tensile strength (UTS), for example on the basis of 170 N/mm2 a 4 x 95 mm2 bundle has a UTS of 65 kN. Although, in theory, it would be possible to use this high UTS to design for reduced sages and/or longer spans, this is not necessarily economic or desirable for the following reasons:

1. Adoption of high tensions automatically increases the loading at angle and terminal poles and their associated stays, thus increasing their size. This is particularly relevant to LV distribution systems in the UK which incorporate a high percentage of angle and terminal poles and where, because of wayleave difficulties and the need to make service connections, spans greater than 60 m are not usual.

2. In order to fit connectors to the tensioned conductors it is necessary to open up the bundle. This clearly becomes more difficult as the tension increases and hence a lower tension is desirable. Similarly, during the installation of lines, erection at high tensions is more difficult and to some extent less safe.

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2 CABLE IDENTIFICATION

Figure 1 – Cable Identification

2.1 Core Identification

Conductors must be readily identifiable, particularly in poor light, and there is a special need to distinguish between the phase and neutral conductors.

The phase conductors are identified by prominent longitudinal ribs on the core insulation, one, two or three ribs to distinguish between the three phases.

The neutral has a minimum of sixteen low profile, longitudinal ribs equally spaced around the circumference of the core, these serving to ensure that the neutral can be identified at all times by sight and touch irrespective of the position of the neutral in the lay of the bundle.

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3 POLE HARDWARE

3.1 Universal Bracket for Concrete/Wood Poles

Figure 2 – Universal Bracket

Stock No. Application Safe Working Load (kg)

CB 3020 LV ABC 1.8 kN

Table 1 – Universal Bracket details

3.2 Mounting Bracket for Universal Bracket on a Concrete Pole

Figure 3 – Hooked Bracket

Stock No. Application Safe Working Load (kg)

CB 0287 Attachment of universal bracket to concrete pole

1.8 kN

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Table 2 – Hooked Bracket details

3.3 Clamps and Hanger

Figure 4 – Termination Clamp

Figure 5 – Suspension Clamp

Figure 6 – Angle Yoke

Stock No. Application Safe Working Load (kg) SWL (kN)

CC 0100 Termination Clamp 95 mm2 LV ABC 15 kN

CC 0101 Suspension Clamp 95 mm2 LV ABC 22kN

CC 0090 Angle Yoke 95 mm2 LV ABC 12kN

Table 3 – Clamps and Hanger details

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4 STRINGING EQUIPMENT

Figure 7 – Stringing Equipment

Stock No. Description Application SWL (Kg)

CB 3020 Universal Bracket 4 x 95 mm2 LV ABC

4 x 150 mm2 LV ABC 1.8 kN

CB 3023 Single Stringing

Block Adaptor

4 x 150 mm2 LV ABC

4 x 150 mm2 LV ABC 3 kN

Table 4 – Stringing Equipment details

4.1 Pilot Rope

Multi-filament polyester pulling ropes are available for use, details are shown in Table 5 below. The rope is used to pull the cable from its drum into its final position.

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Stock No. Description Application SWL (kN)

Non stock Purchase Requisition Required

14 mm Polyester

14 mm Polyester

4 x 95 mm2 LV ABC

4 x 150 mm2 LV ABC

27.4 kN

27.4 kN

Table 5 – Pilot Rope details

4.2 Swivel

The swivel must be used as a link between the pulling rope and the conductor stocking. Apart from providing this link the swivel relieves torsion (twisting) stress that usually exists between the pulling rope and conductor bundle.

Figure 8 – Swivel

Stock No. Application SWL (kN)

CZ 0389 4 x 95 mm2 LV ABC


Table 6 – Swivel details

4.3 Cable Stockings

A synthetic stocking is available for use with the ABC. Details of cable stocking available are shown in Table 7 below.

Figure 9 – Single Eye Stocking used in LV ABC Stringing


CC 0073 4 x 95 mm2 LV ABC 10 kN

CC 0078 4 x 150 mm2 LV ABC 25 kN

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Table 7 – Cable Stocking details

4.4 Cumalong

Figure 10 – Cumalong


CC 0071 4 x 95 mm2 LV ABC


Table 8 – Cumalong details

4.5 Dynamometer

Installed between Pull-lift and Chain or sling the dynamometer measures the working load tension applied to the cable.

Figure 11 – Dynamometer



LV ABC 10 kN (1000 kg)

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Table 9 – Dynamometer details

4.6 Pullifts (Canker’s)

Different types of ratchet chain lever or web strap hoists are available for pulling ABC to designated load tension. (Figure 12 shows a web strap ratchet hoist).

Figure 12 – Web strap ratchet hoist



LV ABC 10 kN (1000 kg)

Table 10 – Pull-lift details

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5 STRINGING METHOD

5.1 Installation Method

ABC shall be installed using the ‘slack tension’ method. This method is used to safeguard the cable against damage, such as abrasion, by maintaining round or other obstruction clearances during stringing.

The only exception to using the ‘slack tension’ method occurs when there is sufficient manpower to ensure that the cable is not dragging along the ground or damaged by sharp objects.

5.2 Manpower

The minimum number of Linespersons required to string and tension ABC for a new construction is three. When replacing existing aerial conductors with ABC (retro-fit), the minimum number of linespersons required is four.

The Linesperson in Charge shall:

1. Brief the gang on the proposed job.

2. Allocate specific duties to each member of the gang.

3. Nominate or act as an observer who shall observe the work at all times to ensure that it is carried out in a safe manner.

5.3 Tools and Equipment

5.3.1 Tools

95 ABC Stripper (Stock # NT 0443)

150 ABC Stripper (Stock # NT 0444)

ABC Spanner (Stock # NT 0310)

ABC Cable Cutters (Stock # NT 0065)

Pull lifts (Canker’s)

Dynamometer

Cumalong

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5.3.2 Pulling Equipment

Self-loading Cable Recovery Trailer

Winch and Pilot Rope

Stocking and Swivel

Hand Held Transceivers

5.3.3 Stringing Equipment

Stringing blocks

Single Stringing Block Adapter

Double Stringing Block Adapter

5.3.4 Intermediate and Termination Equipment

Chain, Nylon Fibre Sling

Strain Clamps

Suspension Clamps

Angle Yoke

Universal Bracket

5.4 Position of Pulling Equipment

5.4.1 Self-Loading Cable Recovery Trailer

The drum shall be loaded such that the cable is fed from the bottom of the drum. When positioning the brake Drum Stand, make sure that:

The distance from the pole should not be less than the height of the pole.

It is positioned to one side of the poles alignment, so that the ABC does not rub against the pole.

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Figure 13 – Self Loading Cable Recovery Trailer

5.4.2 Winch

Locate the winch in a suitable working position.

The winch should be placed beyond the final pole position at a distance not less than the height of the pole and offset from the poles alignment.

Figure 14 – Winch working position

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5.5 Positioning of Stringing Blocks

The following guidelines are to be used when using the Stringing Blocks for in-line situations and angles encountered between 0 and 50°.

Figure 15 – Position of Stringing Blocks


CB 3023 Single Stringing

Block Adaptor

LV ABC Stringing

0-25° 3 kN

Table 11 – Stringing block details

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Figure 16 – Angle of Deviation 26-50°

Note I: The use of two stringing blocks allows easy adaption of the suspension claps.

Note II: The 12 mm holes in the base of the stringing blocks allows the adaption of a 10 m rod of adjustable length to spread the stringing blocks apart during stringing and clamping.

When an angle of more than 50° is encountered, the pole construction must change to a double termination, where two eyebolts and two strain clamps are to be used.


CB 3024 Double Stringing

Block Adaptor

LV ABC Stringing

26-50° 3 kN

Table 12 – Angle of Deviation 26-50° details

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5.6 Installation of Pilot Rope

After each pole has been dressed with the appropriate mounting hardware, attach the stringing blocks. Ensure that the pilot rope passes over/under any obstructions, existing conductors etc. in the positions which the ABC must occupy.

5.6.1 Stocking Attachment

When attaching the pilot rope to the nylon stocking, ensure that the swivel is located between both as sign in Figure 17 below.

Figure 17 – Stocking Attachment for Pilot Rope

Note:

1. Cable ends should be staggered at approximately 25 mm intervals before attachment of stocking.

2. Do not apply electrical or other insulation tape to the ABC underneath the stocking.

3. Apply approximately 25 mm of insulation tape over the stocking about 25 mm from the end.

4. Using 12.70 mm (½”) Band-it, clamp the stocking over the insulation tape, and then completely cover the Band-it with insulation tape.

5. Ensure there is a smooth transition from pilot rope to cable to prevent jamming when passing through stringing blocks.

6. Check the integrity of stocking and that the swivel is free to rotate.

5.7 Tensioning and Terminating Cable

As the cable is not to be allowed to drop onto or drag along the ground or over any obstacle, it must be pulled through using the ‘slack tension’ method. This means the braking mechanism on the brake drum should be adjusted to maintain required clearances.

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5.7.1 Using a Capstan Winch with Brake Drum Stand

After the end of the ABC on the drum has been checked to be secure, make three and a half turns on the capstan, engage the capstan, then take the slack up to the pilot rope gradually adjusting the brake on the brake drum to maintain clearances.

The observer shall monitor the progress of the stocking/swivel joint through each stringing pulley. The cable/brake drum operator shall observe the cable on the drum, but must inform the winch operator by transceiver to stop when only four turns remain on the cable drum.

When the cable is approximately four metres from the final termination pole, apply more brake tension to the brake drum to take up excess cable sag. Ensure excessive tension is not applied to cable drum brake. Continue to pull cable through the stringing pulleys until the required amount of cable has passed through the final stringing pulley.

Terminate the cable at the winch end first with the pull lift and cumalong to remove the tension from the winch. Using the pull lift, cumalong, chain and dynamometer, tension the ABC at the brake drum end according to the correct tension charts and terminate using the strain clamp. Make sure that, when the ABC is served at the termination pole, the remainder is LOWERED to the ground.

5.7.2 Using a Hydraulic Winch with a Self-Loading Cable Recovery Trailer

After the end of the ABC on the drum has been checked to be secure, engage the winch, and then take the slack up in the pilot rope gradually adjusting the brake on the brake drum to maintain clearances.

The observer shall monitor the progress of the stocking/swivel joint through each stringing pulley. The cable/brake drum operator shall observe the cable on the drum, but must inform the winch operator by transceiver to stop when only four turns remain on the cable drum.

After the required amount of cable has passed through the last stringing block on the termination pole, the winching ceases.

Terminate the cable at the winch end first with the pull lift and cumalong to remove the tension from the winch. Take up the excess slack by rewinding the ABC back on the self-loading trainer. Using the pull lift, cumalong, chain and dynamometer, tension the ABC according to the correct tension charts and terminate using the strain clamp. Make sure that, when the ABC is severed at the termination pole, the remainder is LOWERED to the ground.

Note: The cable should be secured to the suspension clamps in descending order of line angle deviation. That is, poles with the largest angle of deviation should be clamped in first.

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5.7.3 Forces

Pounds (lbf) Kilograms (kgf) Newtons (N) Kilo Newtons (kN)

0 0 0 0

100 45.9 450 .45

200 90.7 890 .89

225 101.9 1000 1.00

250 113.1 1110 1.11

275 124.4 1220 1.22

300 135.6 1330 1.33

325 147.8 1450 1.45

350 159.0 1560 1.56

375 170.2 1670 1.67

400 181.4 1780 1.78

425 192.6 1890 1.89

450 203.9 2000 2.00

475 215.1 2110 2.11

500 227.3 2230 2.23

525 238.5 2340 2.34

550 249.7 2450 2.45

575 261.0 2560 2.56

600 272.2 2670 2.67

625 283.4 2780 2.78

650 294.6 2890 2.89

675 305.8 3000 3.00

700 317.0 3110 3.11

725 329.3 3230 3.23

750 340.5 3340 3.34

775 351.7 3450 3.45

800 362.9 3560 3.56

825 374.1 3670 3.67

850 385.3 3780 3.78

875 396.5 3890 3.89

900 407.7 4000 4.00

925 420.0 4120 4.12

950 431.2 4230 4.23

976 442.4 4340 4.34

1000 453.6 4450 4.45

1025 464.8 4560 4.56

1050 476.1 4670 4.67

1075 487.3 4780 4.78

1100 498.5 4890 4.89

1125 509.7 5000 5.00

1150 521.9 5120 5.12

1175 533.1 5230 5.23

1200 544.3 5340 5.34

1300 590.2 5790 5.79

1400 635.1 6230 6.23

1500 680.9 6680 6.68

1600 725.8 7120 7.12

1700 771.7 7570 7.57

1800 815.5 8000 8.00

Table 13 – Forces

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6 ELECTRICAL CONNECTIONS

6.1 Insulation Piercing Connectors (IPC’s)

Insulation Piercing Connectors are required for all electrical connections to the main Aerial Bundled Cable. Cable ties should be used, and applied to secure the tapping conductors to the conductor being tapped. The application of the electrical connection to the ABC shall not impair the environmental protection afforded by the insulation.

The IPC’s provide a simultaneous connection between insulated cores either main conductor to main conductor, or main conductor to service cable.

Note: IPC’s are NOT designed to make or break a load

6.2 IPC Design

No insulation is to be stripped from the main conductor or service cores. The design of the IPC is such that connection is make by piercing teeth being forced into the main conductor/s or service cables when tension is applied to the insulated shear head bolt.

Once the insulated bolt head has sheared off, remove the remainder of the shear head so that moisture will not be trapped around the bolt head.

6.3 Current Rating

Insulation Piercing Connectors are rated at the current carrying capacity of the largest nominal size of conductor that is allowable for a particular connector, plus 20%.

6.4 Service Disconnection

Where a service or main conductor is to be disconnected from a main cable the IPC must not be removed because of the risk of moisture penetrating the cable. Instead, approximately 100 mm of the disconnected cable should be left in the IPC, bent downwards to avoid moisture entering the IPC, and then sealed correctly.

6.5 Tapping

When tapping either main cable to main cable or services to main cable, it very important that the neutral insulation piercing connector is positioned furthest away from the pole. The reason for this is that if the service cable or ABC was to break away, the neutral would be the last to pull apart.

6.6 Cable Separation

A cable separation tool facilitates the adaption of IPC’s, and can easily be used to separate conductors. By no means must any substitute be used, i.e. screwdriver, spanner etc. Check that the bold ends of the IPC’s are not touching the other cores of the ABC when the separating tools are removed.

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Figure 18 – Components of IPC before and after clamping

Figure 18 shows the components of the IPC before and after clamping. Although the IPC has a neoprene seal around each set of clamping teeth to prevent water from penetrating the joint, it must not be clamped in a vertical position.

Care must be taken to ensure the correct IPC is used for each installation. The IPC’s before are suited to four different applications and must not be used otherwise.

(A) Double bolt clamp to be used on ABC to ABC, or ABC to XLPE or PVC covered aluminium or copper mains. The range of conductor size for both sides of the IPC is 35-95 mm2 (CC 0080) and 50-185 mm2 / 50-150 mm2 (CC 0081). This clamp is not to be used on bare conductors.

Figure 19 – Clamp (A)

Stock No. Description Application

CC 0080 Double Bolt Insulation

Piercing Connector 35-95 mm2 / 35-95 mm2


Piercing Connector 50-185 mm2 / 50-150 mm2

Table 14 – IPC clamps (A) detailed

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(B) Single bolt clamp suitable for use on 95 mm2 ABC to 6-35 mm2 aluminium/copper service cables. This clamp is not to be used on bare conductors.

Figure 20 – Clamp (B)


CC 0082 Single Bolt Insulation Piercing Connector

95 mm2 / 6-35 mm2


Piercing Connector 150 mm2 / 6-35 mm2

Table 15 – IPC clamps (B) detailed

(C) Double bolt clamp suitable for use on 95 mm2 ABC to 50-150 mm2 bare aluminium conductor and 150 mm2 ABC to 50-150 mm2 bare aluminium conductor.

Figure 21 – Clamp (C)

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Table 16 – IPC clamps (C) detailed

6.7 Phase Balancing

Method to be used to ensure correct phase balancing for single phase connections.

Step 1. Add the numbers in the house number.

Step 2. Divide this number by three, and if:

(a) It is divisible without a remainder, it is connected to the red phase.

(b) With a remainder of 1, it is connected to the white phase.

(c) With a remainder of 2, it is connected to the blue phase.

Example:

House numbers: 56 = blue phase 57 = red phase 58 = white phase

Note: If a house number 1 or 2 are found, treat these numbers as remainders

That is: house number 1 = white phase house number 2 = blue phase

In the case of a duplex, with separate services and sharing the same house number, connect one half of the duplex to a different phase.

That is: house number 35a and 35b 35a = blue phase 35b = red or white phase

6.8 End Cap

The other type of End Cap which is available does not permanently adhere to the ends of the cores of the ABC as does the Live End Seal Cap. The End Cap is smaller and does not require a mastic strip for the End Cap to adhere to, but is simply pushed onto the end of the core.

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When completely pressed onto the cores, the End Cap provides a permanent watertight seal because of the circular ribs inside the cap. The End Cap, if used as a temporary seal, can easily be removed and re-used again.

Figure 22 – End Cap


CJ 0063 End Cap 95 mm2

CJ 0062 End Cap 150 mm2

Table 17 – End Cap details

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7 IMPORTANT POINTS

7.1 Cable Description and Identification

Each phase of the bundle is embossed with a number i.e. 1 Red, 2 White, 3 Blue, as well as having the same corresponding number of prominent longitudinal ribs on the core insulation.

The neutral is fully ribbed around the circumference of the core insulation.

7.2 Stringing Equipment

Make sure that sufficient stringing equipment is available before attempting to string ABC.

Do not use any substitute stringing equipment other than that equipment which is mentioned in this booklet.

7.3 Stringing Method

The minimum number of linespersons required to string and tension ABC for a new construction is three.

The minimum number of linespersons required to string and tension ABC for a retro-fit or aerial changeover is four.

When positioning the Brake Drum Stand and the Winch, be sure that their distances from the poles are not less than the height of the pole.

The Brake Drum Stand and the Winch should be positioned to one side of the poles alignment to avoid abrasion of the cable against the pole.

When an angle greater than 25° and less than 50° is encountered, an Angle Yoke is to be used with two suspension clamps.

Do not leave suspension clamps and cable hangers attached to the hook on the universal bracket when pulling out the cable.

Ensure that the stringing block adaptors are correctly attached to the universal bracket.

Any angle over 50° is to be double terminated.

It is extremely important for the universal bracket on an angle pole to split (halve) the angle, this determines the position of the Stringing block(s) for the correct clamping in procedure.

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If the overall conductoring distance of 95 mm2 ABC is in excess of a full drum (400 metres), then the person responsible at the brake drum must ensure that no less than four complete turns (10 metres) remain on the drum whilst paying out under tension.

Ensure pilot rope passes over under any obstructions when installing into stringing blocks.

Staggering the ends of the cable 25 mm (approx.) before attaching the cable stocking.

Ensure that the stocking has a band of insulation tape at its end, clamped with Band-it then covered with insulation tape.

Ensure that the swivel is attached to the stocking to avoid unnecessary twisting of the pilot rope.

Do not over tension the cable, refer to the appropriate sag and tension charts.

The cable should be clamped, after being tensioned and terminated in descending order of line deviation.

Observe cable phasing orientation if more than one drum of cable will be used.

Check inside of the ABC drum for nails protruding, splinters of wood, etc. prior to paying out.

If using the Self Loading Cable Recover Trailer, make sure the cable is payed out from the bottom of the drum

Make sure that the Stringing blocks on each termination pole during a retro-fit are suspended with slings so that there is no chance of the block becoming alive during stringing.

Hand held transceivers must always be used during stringing operations. (Three is the minimum required.)

7.4 Electrical Connections

Make sure that the correct IPC is used.

Ensure that the correct size of cable is positioned in the appropriate side of the IPC.

Do not allow an IPC to make or break a load.

Do not remove any insulation from cables when a connection is made using an IPC.

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If using a double insulated cable, the outside sheath of the cable must be removed prior to attaching an IPC.

Do not exceed the recommended maximum bending radius of ABC.

i.e. 95 mm2 single Core – 95 mm radius 150 mm2 Single Core – 115 mm radius

95 mm2 Bundle – 345 mm radius 150 mm2 Bundle – 410 mm radius

Ensure correct size of ratchet or ring spanner is used to tighten IPC’s.

Do not exert a bending force on the shear head of the IPC.

Remove shear head from IPC when correct tension is attained.

Do not remove an IPC from the ABC once it has been installed.

Do not install an IPC on a vertical core or in a vertical position.

Use the recommended end caps on ABC cores at termination points to stop the ingress of moisture into the cable.

Allow approximately 80 mm between IPC’s on installation.

Make sure that service cables and tops to the main bundle have drip loops to prevent water entering the IPC.

Ensure that DIN fuses are positioned in the Ensto fuse tray correctly.

Do not allow the bottom bolt of the Ensto bracket to come into contact with the fuse tray when closing.

Ensure that the drip loops in the line and load side of the Ensto do not interfere with the removal/replacement and closing of the fuse tray.

Make sure the neutral connection on the Ensto and Pfisterer are against the pole,

There is no necessity to stagger compression joints at a double termination pole. (Separate cores only)

When operating the Ensto, ensure that the fuse tray is fully closed.

Ensure tee of cable cores are shaped prior to connecting to the main cable.

If more than one single phase connection is made in a circuit breaker box, ensure that the house numbers are connected with the lowest house number from the left hand side when viewing from the front of the box.

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8 TREE CLEARANCE FOR AERIAL BUNDLED CABLE

Aerial Bundled Cable (ABC) avoids many of the risks associated with bare conductors provided the insulation remains intact. Insulation may be damaged by constantly rubbing or hitting from objects such as tree branches and buildings.

8.1 Clearance Zone

The clearance zone is a 1 m radius around the low voltage ABC.

8.2 Inspection Zone

The Inspection zone requires any unsound tree timber, inside a 45° angle from both sides of the base of a pole, to be removed.

8.3 Assessing How Much Needs to be pruned within the Clearance Zone

8.3.1 Basic Clearance

To minimise the risk of abrasion it will be necessary to remove any branches from within one metre of the cable that could damage the insulation through tree movement or growth within the pruning interval.

8.3.2 Tree Growth and Regrowth

Adequate allowance must be made for tree growth or regrowth within the pruning intervals. Light leafy regrowth, such as that produced by Eucalyptus trees within one year of cutting, can be left in contact with the ABC. However, it must be cleared before it becomes firm enough to cause abrasion.

Consideration should be given to training the growth past and around the cable, by removing only those branches likely to rub against the cable, back to the junction with another branch or the trunk.

8.3.3 Overhanging Branches

Branches are permitted to overhang ABC provided that clearances specified are maintained. Obviously unsound branches within the inspection zone should receive attention.

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Figure 23 – Tree Clearance for ABC

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9 TECHNICAL DATA

FACADE MOUNTING OF LV ABC

Façade Application

The mounting of LV ABC on the facades of commercial buildings or terraced houses can be an obvious benefit in areas of particular architectural or historic significance.

Facade mounted LV ABC is particularly suited for streets with buildings located in-line with each other, and separated occasionally by narrow laneways. Mounted on both sides of the street, this method removes the need for a pole line, service poles and service cables strung across the street which can at times be rather obtrusive.

Facade mounting of LV ABC may also be an economically attractive option to local councils looking into the undergrounding of existing bare overhead mains to "beautify" or to "improve the look of' prominent streetscapes or shopping precincts.

In most installations, it is likely that the facade mounted LV ABC would be hardly noticeable from the street and could be even less detectable if it is painted over (e.g. when the facade itself is repainted).

Advantages of Façade Mounting

The advantages of facade mounted LV ABC includes:

a) Enhanced appearance of the streetscape; b) Virtually no disruption during construction; and c) More reliable electricity supply to property and perceived better value by removal of aerial

services which are prone to being hit by tall vehicles.

Factors to be considered when Facade Mounting

The following notes should be useful when considering façade mounting:

a) Both 95 mm2 and 150 mm2 LV ABC are suitable for facade mounting.

b) Non-tensioned construction is to be used in most installations.

c) Strain clamps should be used to terminate the cable for all runs over 10 m. In-line strains are to be used so that no run between strain clamps is more than 60 m. Intermediate wall supports should be spaced at every 500 mm to 700 mm intervals.

d) Tensioned construction is seldom used but is applicable where the façade cable crosses over laneways or other similar situations. An everyday tension of 1.4 kN is recommended for 4 x 95 mm2. Tensions for other sizes should be chosen to give an equivalent sag to this.

e) Window openings shall be avoided.

f) Paralleling of the LV ABC to supply large commercial customers is possible with some facade fittings.

g) Steel street lighting columns shall be supplied via underground cable.

h) Consumers' mains are not to be altered. This could cause deteriorated cable insulation to fail, requiring expensive replacement.

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Figure 24 – Ground Clearance for ABC Complies with code of practice for overhead line construction

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9.1 Minimum Spacing between Circuits for under crossings

Figure 25 – Min Spacing between Circuits for Under crossings

Lower Circuit Voltage in kV

Upper Circuit Voltage in kV

Attached to Common Structure at Point of

Undercrossing A (mm)

Not attached to Common Structure at Point of

Undercrossing B (mm)

LV ABC LV 380 600

LV ABC LV to 11 1200 1200

LV ABC 11 to 33 1200 1200

LV ABC 33 to 66 1800 1800

LV ABC 132 2400 2400

Table 18 – Min Spacing between Circuits for Under Crossings

1. The spacing shall be maintained with no wind and the upper circuit at the temperature specified below:

LV minimum design temperature normally 50°C;

Up to 33 kV maximum design temperature normally 65°C; or

Up to 132 kV maximum design temperature normally 85°C.

2. Lower circuit at 15°.

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Figure 26 – Min Vertical In-span Separation C

Lower Circuit Voltage in kV

Upper Circuit Voltage in kV

Minimum Vertical In-span Separation C (mm)

LV ABC LV 600

LV ABC LV to 11 1200

LV ABC 11 to 33 1200

LV ABC 33 to 66 1800

LV ABC 132 2400

Table 19 – Minimum Vertical In-span Separation C

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9.2 Baulk Installation Details

Figure 27 – Pole Footing with Bolted Baulk

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10 CABLE JOINTING

10.1 Joint Layout

Figure 28 – Joint Layout

Ensure phase and neutral are correctly matched and orientated.

Each core must be cut accurately to ensure correct balance of tensions.

Note: It is extremely important that, on completion, all four cores will have exactly the same tension at each compression sleeve.

10.2 Joint Preparation

Figure 29 – Joint Preparation



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1. Mark cable end with tape at half sleeve length.

2. Strip insulation as shown on drawing.

3. Insert cable into sleeve ensuring tape mark is within 1-2 mm of full penetration.

4. Crimp with appropriate die, in sequence starting at number 1.

5. Do not overlap the crimps.


CJ 0491 Full Tension Sleeve 95 mm2 / 95 mm2

CJ 0490 Full Tension Sleeve 150 mm2 / 150 mm2

Table 20 – Joining Sleeve details



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11 CABLE REPAIRS

11.1 Cable Repair Kit

Application – the kit is to be used on 95 mm2 and 150 mm2 cables:

1. Minor cable insulation damage.

2. Where an IPC has to be removed due to mains cable damage.

3. Where an IPC has been removed by mistake.

Contents:

1 off – Sigmaform SGR54 -14 x 250 mm Shrinkaround™ Sleeve.

1 off – Heatproof paper 400 x 220 x 1.6 mm.

1 off – Aluminium oxide abrasive strip 300 x 25 mm.

1 off – TCE cleaning pad.

1 off – Instruction sheet.

11.2 Cable Repair Instructions

Figure 30 –Cable Repairs – 1

Step 1

Separate the damaged cable using the Cable Separation Tool. (The wedge will not provide adequate separation)

Abrade the cable jacket to be covered CIRCUMFERENTIALLY, with either the abrasive strip, a file or a carding brush.

Roll the Shrinkaround™ Sleeve tightly to give it a circular shape.



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Note: Emery paper must not be used as it deposits a conductive material on the cable.

Figure 31 –Cable Repairs - 2

Step 2

Place the Shrinkaround™ Sleeve around and on the cable so that the sealant side of sleeve is next to the cable and the contact adhesive of the lower flap is facing up.

Remove the protective release paper from both flaps of the Shrinkaround™ Sleeve. This will expose the surfaces of the contact adhesive.


SIGMAFORM ‘SGR’ Series Shrinkaround™ Sleeve is a heat shrinkable polyolefin, split sleeve. The Shrinkaround™ Sleeve is ‘bonded’ together with contact adhesive to form a circular tubing over damaged cable sheaths and is especially designed for use on all cable insulations.

Shrinkaround™ Sleeve provide complete waterproofing, insulation, abrasion and corrosion resistance under the adverse environmental conditions. Shrinkaround™ Sleeve have excellent electrical properties as well as being highly resistant to moisture, fungus and weathering.



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Note: Allow 50 mm per end overlap beyond the damaged area.


Step 3

Align the centre of the top flap over the centre of the lower flap, so that the edge of the top flap is at the white line of the lower flap.

PRESS DOWN FIRMLY on the centre of the flaps to mate the adhesive surfaces.

Note: Once the surfaces contact each other, DO NOT try to pull apart or re-align.

Centre the sleeve over the damaged area allowing 50 mm per end overflap. Place the flap on top of the cable.

Run the hot torch nozzle over the full length over the flap to ensure a good bond between the flaps.


Step 4

Place a length of heat-proof paper between the core t be repaired and the other cores. The cable separation tool can be used to hold the paper in place.

Ensure that only the wrap around sleeve is exposed to the flame.



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Heat the centre area until it shrinks over the cable and the blue spots turn black. Then heat the flap until the ‘Sigmaform’ letters become shallow and flatten out.


Step 5

Work towards one end, applying heat uniformly and smoothly until all blue spots turn black. Then apply more heat to the flap area so the ‘Sigmaform’ letters become shallow and flatten out. Make sure the Mastic is flowing around the end.

Repeat the same procedure on the unshrunk half.

Note: Ensure that the protective heat-proof paper is in place.


Step 6

Leave completed repair to cool.

Remove Cable Separation Tool and the heat proof paper, and return cable to original position.


CZ 0600 Minor Repair Kit For damage of no more than 100 mm of insulation on 95 mm2 / 150 mm2

ABC cable.

Table 21 – Minor Repair Kit details



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Low Voltage Aerial Bundled Cable Manual · 5.3.2 Pulling Equipment ... 7.3 Stringing Method ... Aerial Bundled Cable for Low Voltage Distribution 1.1 Summary The use of Low Voltage

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