UNDERGROUND CONSTRUCTION MANUAL MATERIAL DATA

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1 UNDERGROUND CONSTRUCTION MANUAL Back to MAIN INDEX Go to SECTION INDEX

2 CONSTRUCTION DESCRIPTION DWG CONSTRUCTION DESCRIPTION DWG LV cable details 5108 HV cable details 5109 Insect protected LV cable details 5110 Insect protected HV cable details kV equipment termination & connection data 5149/1 11kV equipment termination & connection data 5149/ kv equipment termination & connection data 5150 HV cable outdoor termination data 5151 HV cable joint data 515/1 HV cable joint data 515/ LV cable outdoor termination and joint data 5153 Copper crimp links 5147 Copper crimp lugs 5148 Aluminium crimp links 5154 Aluminium crimp lugs 5155 Bi-metal crimp lugs 5156 Adapters 591 Cable screen mechanical lugs 5376 B C.6.11 /6/11 INDEX D E L. Burton FILE: E

3 AND USE CABLE DETAIL CONDUCTOR SOLID / STRANDED DIA. OVERALL MINIMUM BENDING RADIUS (INTERNAL) DURING INSTALLED INSTALLATION SETTING MASS MAXIMUM PULLING TENSION 0.6/1kV Mains & Service Cables 40mm Al 4 Core Sector PVC 16mm Cu 4 Core PVC Stranded Stranded 55.1mm 3.0mm 660mm 140mm 440mm 90mm 3.8kg/m 0.79kg/m 4.8kN 4.5kN : On cable sheath or conductor. B C D E //03 T. Borg LV CABLE DETAILS FILE: E

4 CABLE DETAIL Cu SCREEN STRANDING DIA. OVERALL MINIMUM BENDING RADIUS (INTERNAL) MASS MAXIMUM PULLING SEMICOND. AVG /AREA DURING INSTALLED TENSION THICKNESS INSTALLATION SETTING 6.35/11kV 400mm Al Triplex TR-/MDPE /1.7mm 43.6mm 1410mm 940mm 90.8mm Per Core 7.74kg/m Note 0kN 0.9mm 60kN Note 3 & 4 1.7/kV 185mm Al Triplex /1.35mm 39.7mm 180mm 860mm 5.6kg/m 8kN 0.8mm TR- 68.7mm Note Note 3 & 4 LAT/PVC/MDPE 630mm Al 1 core /1.53mm 59.6mm 140mm 850mm 3.9kg/m 3kN 0.9mm TR- 95.6mm & 3 LAT/PVC/MDPE 630mm Al 1 core TR- LAT/PVC/MDPE Incorp. x 50/15mm + x 9/15sm /1.53mm 54.3mm 1360mm 810mm 3.9kg/m 5kN 0.8mm 95.6mm Per Core Per Core Cable Construction Notes: Triplex = 3 x 1C wound 3 in hand. : Each core. Note : For 3 cores. Note 3: For pulling sock. Note 4: Three core total. C D E F //03 C. Lindsay HV CABLE DETAILS FILE: F

5 CABLE DETAIL CONDUCTOR SOLID / DIA. OVERALL MINIMUM BENDING RADIUS (INTERNAL) MASS MAXIMUM PULLING AND USE STRANDED DURING INSTALLED TENSION INSTALLATION SETTING 0.6/1kV Mains & 40mm Al 4 Core Sector 4007 Stranded 59.1mm 1610mm 1070mm 4.1kg/m 4.8kN Service NYL/PVC Cables - Insect Protected 50mm Cu 4 Core NYL/PVC Stranded 36.0mm 100mm 680mm.4kg/m 14.0kN 16mm Cu 4 Core Stranded 5.0mm 690mm 460mm 1.03kg/m 4.5kN NYL/PVC : On cable sheath or conductor. B C D E //03 T. Borg INSECT PROTECTED LV CABLE DETAILS FILE: E

6 CABLE DETAIL Cu SCREEN STRANDING DIA. OVERALL MINIMUM BENDING RADIUS (INTERNAL) MASS MAXIMUM PULLING SEMICOND. AVG /AREA DURING INSTALLED TENSION THICKNESS INSTALLATION SETTING 6.35/11kV 35mm Al Triplex /0.85mm 9.9mm 190mm 970mm.3kg/m 5.3kN 0.8mm Insect TR-.7mm Note Note 3 & 4 Protected PVC/NJ/MDPE 185mm Al Triplex /1.35mm 40.1mm 1730mm 1300mm 5.5kg/m 8kN 0.8mm TR- 68.7mm Note Note 3 & 4 PVC/NJ/MDPE 400mm Al Triplex /1.7mm 47.3mm 040mm 1530mm 8.6kg/m 0kN 0.9mm TR- 90.8mm Per Core Note PVC/NJ/MDPE 98.1mm 60kN Triplex Envelope Note 3 & 4 400mm Al Triplex TR- PVC/NJ/MDPE Incorp. x 50/15mm + x 9/15sm /1.7mm 45.5mm 1960mm 1470mm 8.6kg/m 60kN 0.6mm 90.8mm Per Core Note 3 & 4 Per Core 98.1mm Triplex Envelope 400mm Cu 1 core /1.7mm 48.4mm 090mm 1570mm 5.kg/m 8kN 0.9mm TR- PVC/NJ/MDPE 90.8mm Note 1330mm Note 890mm Note 3 1.7/kV 35mm Al Triplex /0.85mm 34.5mm 1480mm 110mm.75kg/m 5.3kN 0.8mm Insect TR-.7mm Note Note 3 & 4 Protected PVC/NJ/MDPE 19/33kV 50mm Al 1 core /1.35mm 41.5mm 110mm 750mm 1.3kg/m.5kN 0.8mm Insect TR- 3.9mm Note 3 Protected NJ/MDPE 300mm Al 1 core /1.7mm 56.8mm 1580mm 1050mm 3.1kg/m 15kN 0.9mm TR- 93.1mm Note 3 LAT/NJ/MDPE Cable Construction Notes: Triplex = 3 x 1C wound 3 in hand. : For 1 core. Note 3: For pulling sock. Note : For 3 cores. Note 4: Three core total G H I J /1/03 T.Borg INSECT PROTECTED HV CABLE DETAILS FILE: J

7 TERMINATION & CONNECTION DETAIL CORRESPONDING CABLE LUG HEX. CRIMP DIE SIZE USE & DESCRIPTION DESCRIPTION CONDUCTOR SCREEN 6.35/11kV Feeder Cables. ABB SafeLink Switchgear. Includes cable termination, cable conductor bi-metal lugs (or Cu lugs for Cu cable) c/w bolts, nuts and washers, and cable screen lugs c/w bolts, nuts and washers. Refer Note Note mm Al Triplex 185mm Al Triplex 400mm Al Triplex mm A/F 14.mm A/F Note Note 400mm Cu 1 core Insect Protected mm A/F Feeder Cables. Transformer Bushing Connection - Padmounted Substation (no HV Switchgear). Includes cable termination, connection kit, cable screen lugs c/w bolts nuts and washers mm Al Triplex 185mm Al Triplex mm A/F mm Cu Triplex Insect Protected mm A/F Note 5 : Contains accessories to suit Double Brass Tape (insect protection). Note : Contains accessories to suit Nylon Jacket (insect protection) and Semiconductive oversheath. Note 3: Bushing insulation supplied with padmount. Note this is not suitable for 400mm Cu 1 core cable. Bushing insulation for 400mm Cu 1 core cable supplied with termination and connection kit. Bushing insulation for ABB SafeLink is NOT suitable for ABB SDAF. Note 4: Conductor lug supplied in termination kit is bi-metal range taking mm. Note 5: For use with 40mm Cu cable use II No screen crimp lugs. Die Size Note: A/F = Across Flats dimension of hexagonal crimping dies. G H I J //03 C.Lindsay 11kV EQUIPMENT TERMINATION AND CONNECTION DATA FILE: J

8 TERMINATION & CONNECTION DETAIL USE & DESCRIPTION CORRESPONDING CABLE DESCRIPTION LUG HEX. CRIMP DIE SIZE CONDUCTOR SCREEN 6.35/11kV Feeder Cables. ABB SD Series Switchgear. Includes cable termination, bushing insulation, cable conductor bi-metal lugs (or Cu lugs for Cu cable) c/w bolts nuts and washers, & cable screen lugs c/w bolts nuts and washers mm Al Triplex mm Al Triplex mm A/F Feeder Cables. Magnefix MD Series Switchgear, Includes cable termination, connection kit, cable screen lugs c/w bolts nuts and washers, & cable support clamps mm Al Triplex mm Al Triplex mm A/F 6.35/11kV Feeder Cables. Areva / Schneider Electric FBX Switchgear. Includes cable termination elbows, shear bolt connectors c/w cable screen lugs, bolts, nuts and washers mm Al Triplex Note mm Al Triplex Note mm A/F Feeder Cables. Areva / Schneider Electric FBX Switchgear, Includes cable termination elbow, compression lugs c/w cable screen lugs, bolts, nuts and washers mm Al Triplex Note mm A/F : Contains accessories to suit Double Brass Tape (insect protection). Note : Conductor lug supplied in termination kit is bi-metal range taking 5-95mm. Note 3: Conductor lug supplied in termination kit is bi-metal range taking mm. Note 4: Conductor lug supplied in termination kit is bi-metal range taking mm. Die Size Note: A/F = Across Flats dimension of hexagonal crimping dies. Cable details are preliminary based on information from Midland Metals. E F G H C.Noel 4/11/05 A.Bletchly T.Borg 11kV EQUIPMENT TERMINATION AND CONNECTION DATA FILE: H

9 TERMINATION & CONNECTION DETAIL CORRESPONDING CABLE CONDUCTOR LUG SCREEN LUG USE & DESCRIPTION DESCRIPTION HEX CRIMP DIE SIZE HEX CRIMP DIE SIZE 1.7/kV Feeder Cable mm Al Triplex F & G / Ormazabal Switchgear Connection. 630A deadbreak bolted elbow connector assembly. PVC/NJ/HDPE Insect Protected mm Al Triplex mm A/F LAT/HDPE mm Al 1 Core mm A/F LAT/HDPE Feeder Cable mm Al Triplex mm A/F Transformer Bushing Connection - Padmounted Substation. (no HV Switchgear). PVC/NJ/HDPE 00A deadbreak elbow connector assembly. Insect Protected mm Al Triplex mm A/F 1.7mm A/F LAT/HDPE Note : Remove outer layer of conductor strands to insert conductor in elbow cable connector. Do not score or damage remaining strands. Note : Conductor lug to fit 95mm. Die Size Note: A/F = Across Flats dimension of hexagonal crimping dies. Cable details are preliminary based on information from Midland Metals. C.Noel C D E F //03 A.Bletchly T.Borg kv EQUIPMENT TERMINATION AND CONNECTION DATA FILE: F

10 TERMINATION / CONNECTION DETAIL CORRESPONDING CABLE LUG HEX. CRIMP DIE SIZE USE & DESCRIPTION DESCRIPTION CONDUCTOR SCREEN 6.35/11kV Outdoor termination. Includes cable termination, cable conductor bi-metal lugs (or Cu lugs for Cu cable), cable screen lugs mm Al Triplex mm Al Triplex mm A/F mm Al Triplex mm A/F mm Cu 1 core Note + Insect Protected mm A/F 1.7/kV Outdoor termination. Includes cable termination, cable conductor bi-metal lugs, cable screen lug mm Al Triplex DBT Insect Protected mm Al Triplex mm A/F mm Al 1 Core mm A/F 19.1/33kV Outdoor termination mm Al 1 Core Includes cable termination, cable conductor bi-metal lugs, cable screen lug mm Al 1 Core mm A/F 16.5mm A/F : Contains accessories to suit Double Brass Tape (insect protection). Note : Contains accessories to suit Nylon Jacket (insect protection) and semiconductive oversheath. Die Size Note: A/F = Across Flats dimension of hexagonal crimping dies. E F /1/03 HV CABLE OUTDOOR TERMINATION DATA G H C.Lindsay FILE: H

11 JOINT DETAIL CORRESPONDING CABLE LUG HEX. CRIMP DIE SIZE USE & DESCRIPTION DESCRIPTION CONDUCTOR SCREEN 6.35/11kV Underground Straight Joint mm Al Triplex 4994 Includes cable joint kit, cable conductor links, cable screen link Note Note mm Al Triplex mm A/F Note mm Cu 1 core mm A/F Insect Protected Note 3 Note mm Al Triplex mm A/F Note 4 Note As above + insect protection mm A/F Note 4 Note 7 1.7/kV Underground Straight Joint Includes cable joint kit, cable conductor links, cable screen link. Note Note 5 35mm Al Triplex Insect Protection mm Al Triplex mm A/F Note mm Al 1 Core 4996 Mech Conn 14.mm A/F : Contains accessories to provide Insect Protection to completed joint. Note 6: Conductor link supplied in joint kit is bi-metal range taking 95-40mm. Note : Contains accessories to suit Double Brass Tape (insect protection). Note 7: Conductor link supplied in joint kit is bi-metal range taking mm Note 3: Contains accessories to suit Nylon Jacket (insect protection). Die Size Note: A/F = Across Flats dimension Note 4: Suitable to transition from 185mm Cu or 40mm Cu to 400mm Al. of hexagonal crimping dies. Note 5: Conductor link supplied in joint kit is bi-metal range taking 5-95mm. E F G H /1/03 T.Borg HV CABLE JOINT DATA FILE: H

12 JOINT DETAIL CORRESPONDING CABLE LUG HEX. CRIMP DIE SIZE USE & DESCRIPTION DESCRIPTION CONDUCTOR SCREEN 19.1/33kV Underground Straight Joint mm Al 1 Core Includes cable joint kit, cable conductor links, & 3 Insect Protected cable screen link mm Al 1 Core 44984, & 4 Insect Protected 9.mm A/F 16.5mm A/F : Contains accessories to provide Insect Protection to completed joint. Note : Contains accessories to suit Nylon Jacket (insect protection). Note 3: Conductor link supplied in joint kit is bi-metal range taking 5-95mm. Note 4: Conductor link supplied in joint kit is bi-metal range taking mm. B C /1/03 HV CABLE JOINT DATA C.Lindsay FILE: C

13 TERMINATION / CONNECTION DETAIL USE & DESCRIPTION CORRESPONDING CABLE DESCRIPTION LUG OR LINK CRIMP DIE SIZE 0.6/1kV Outdoor Termination mm Al 4 Core mm A/F Includes cable termination, bi-metal lugs, lug seals mm 4 core + insect protection mm A/F Outdoor Termination. Includes cable termination, Cu links mm Cu 4 Core mm A/F JOINT DETAIL USE & DESCRIPTION CORRESPONDING CABLE DESCRIPTION LINK CRIMP DIE SIZE 0.6/1kV Underground Straight Joint mm Al 4 Core mm A/F Includes cable joint kit, links mm Cu 4 core mm A/F + insect protection mm Cu 4 Core mm A/F : Contains accessories to provide Insect Protection to completed joint. Die Size Note: A/F = Across Flats dimension of hexagonal crimping dies. B C HARD COPY UNCONTROLLED 5//03 T. Borg LV CABLE OUTDOOR TERMINATION AND JOINT DATA FILE: C

14 COPPER CRIMP LINKS CABLE AREASUPPLIER DESCRIPTION 10mm CK10 CATALOGUE NUMBER H1454 CAS 10 HEX CRIMP DIE SIZE 5.7mm A/F I. I. No mm CK16 H1455 CAS mm A/F mm CK5 H1458 CAS mm CK35 H1488 CAS 35 9.mm A/F mm CK50 H1460 CAS mm A/F mm CK70 H1461 CAS mm A/F mm CK95 H146 CAS mm A/F mm CK10 H149 CAS mm A/F mm CK150 H1493 CAS mm A/F NOTES 1. The screen of some HV cables require non standard die size. Refer drawing Links and die sizes listed are for standard Cu cables 185mm 40mm 400mm CK185 CK40 CK400 H1494 CAS 185 H1495 CAS 40 H1470 CAS mm A/F 3.1mm A/F 8.1mm A/F Note and unsuitable for flexible cables. 3. Links listed are not Barrier Links. 4. A/F = Across flats dimension of hexagonal crimping dies. 5. Crimping tool requirement: - tonne minimum. - 3 tonne minimum. B.1.05 C HARD COPY UNCONTROLLED 15/1/03 T. Borg STANDARD COPPER CRIMP LINKS FILE: C

18 BI-METAL CRIMP LUGS CABLE AREA 35mm SUPPLIER DESCRIPTION BG35/M1 CATALOGUE NUMBER H15310 BL 35-1 HEX CRIMP DIE SIZE 9.0mm A/F I. I. No mm BG50/M1 H15313 BL mm A/F mm BG70/M1 H15316 BL mm A/F mm BG95/M1 H15319 BL mm A/F mm BG10/M1 H1531 BL mm A/F mm BG150/M1 H1534 BL mm A/F Use Alvan grease I.I. No mm 40mm BG185/M1 H1537 BL H15330 BL40-1.0mm A/F 8.4mm A/F mm BG300/M1 H15333 BL mm A/F mm BG630/M16 H15336 BL mm A/F BI-METAL CRIMP LUGS SECTOR CABLE 1 3 Nest and Indent crimp lug shown Note: lugs only are suitable for connection to 11kV ABB SD series switchgear. CABLE AREA 10mm 4C Solid Conductor 40mm 4C Stranded Cond. 300mm 4C Stranded Cond. SUPPLIER DESCRIPTION BGI10/M1 BG4HR40/M1 CATALOGUE H15661 NUMBER BLS10/4-1 H15366 BL 40-1 H15333 Note: A/F = Across flats dimension of hexagonal crimping dies. CRIMP DETAIL 14 Nest 16 Indent 8.4mm A/F 8.4mm A/F I. I. No B HARD COPY UNCONTROLLED 6//03 C.Lindsay STANDARD BI-METAL CRIMP LUGS FILE: B

19 ADAPTERS DESCRIPTION USED WITH Tyco EXRM 1366 ABB SafeLink 1mm termination 16mm thread to 1mm lug to 16mm schneider bushing Schneider AO48085 ABB SDAF 1mm termination 16mm thread to 1mm thread to 16mm Schneider bushing RMU FUSE CAPS DESCRIPTION USED WITH 4517 Cover, fuse housing (1 ph) Schneider FBX RMU 4541 Cover, fuse housing (1 ph) ABB Safelink1 & ABB Safelink RMU B C HARD COPY UNCONTROLLED 05/07/13 T. Borg ADAPTERS FILE: C

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