UNDERGROUND CONSTRUCTION MANUAL Back to MAIN INDEX Go to SECTION INDEX
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 5111 11kV 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 6.1.05 C.6.11 /6/11 INDEX D 14.01.14 E 13.04.18 L. Burton FILE: 5 1 61 511 1 E
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 1634155 Stranded 163489 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 0.11.03 C 30.07.10 D 08.08.13 E 11.04.18 6//03 T. Borg LV CABLE DETAILS FILE: 5 61 5108 1 5108 E
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 433811 40/1.7mm 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 49934 48/1.35mm 39.7mm 180mm 860mm 5.6kg/m 8kN 0.8mm TR- 68.7mm Note Note 3 & 4 LAT/PVC/MDPE 630mm Al 1 core 4996 5/1.53mm 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 458354 5/1.53mm 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 4.3.11 D 0.11.1 E F 03.05.16 11.04.18 6//03 C. Lindsay HV CABLE DETAILS FILE: 5 61 5109 1 5109 F
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 410371 Stranded 36.0mm 100mm 680mm.4kg/m 14.0kN 16mm Cu 4 Core 40073 Stranded 5.0mm 690mm 460mm 1.03kg/m 4.5kN NYL/PVC : On cable sheath or conductor. B 0.11.03 C 30.07.10 D 19.06.13 E 11.04.18 6//03 T. Borg INSECT PROTECTED LV CABLE DETAILS FILE: 5 61 5110 1 5110 E
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 49967 40/0.85mm 9.9mm 190mm 970mm.3kg/m 5.3kN 0.8mm Insect TR-.7mm Note Note 3 & 4 Protected PVC/NJ/MDPE 185mm Al Triplex 49975 48/1.35mm 40.1mm 1730mm 1300mm 5.5kg/m 8kN 0.8mm TR- 68.7mm Note Note 3 & 4 PVC/NJ/MDPE 400mm Al Triplex 43389 40/1.7mm 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 45836 40/1.7mm 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 49918 40/1.7mm 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 49991 40/0.85mm 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 43655 3/1.35mm 41.5mm 110mm 750mm 1.3kg/m.5kN 0.8mm Insect TR- 3.9mm Note 3 Protected NJ/MDPE 300mm Al 1 core 44984 41/1.7mm 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 0.11.1 H 06.05.16 I 3.0.17 J 1.04.18 16/1/03 T.Borg INSECT PROTECTED HV CABLE DETAILS FILE: 5 61 5111 1 5111 J
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 3. 461556 461556 461598 461598 461614 Note 4 461614 35mm Al Triplex 185mm Al Triplex 400mm Al Triplex 4994 49967 49959 49975 433811 43389 1.7mm A/F 14.mm A/F Note 4 461614 Note 400mm Cu 1 core Insect Protected 49918 14.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. 4301 461564 461580 461580 35mm Al Triplex 185mm Al Triplex 4994 49967 49959 49975 1.7mm A/F 461580 40mm Cu Triplex Insect Protected 49983 14.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 185-400mm. Note 5: For use with 40mm Cu cable use II No. 015857 screen crimp lugs. Die Size Note: A/F = Across Flats dimension of hexagonal crimping dies. G 03.01.14 H 10.0.15 I 13.01.17 J 1.04.18 6//03 C.Lindsay 11kV EQUIPMENT TERMINATION AND CONNECTION DATA FILE: 5 61 5149 1 5149 1 J
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. 461564 35mm Al Triplex 461564 461606 185mm Al Triplex 461606 4994 49967 49959 49975 1.7mm 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. 46157 35mm Al Triplex 46157 461580 185mm Al Triplex 461580 4994 49967 49959 49975 1.7mm 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. 435907 35mm Al Triplex Note 435915 185mm Al Triplex Note 3 4994 49967 49959 49975 1.7mm A/F Feeder Cables. Areva / Schneider Electric FBX Switchgear, Includes cable termination elbow, compression lugs c/w cable screen lugs, bolts, nuts and washers. 43593 400mm Al Triplex 43593 Note 4 433811 43389 14.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 185-300mm. Note 4: Conductor lug supplied in termination kit is bi-metal range taking 185-400mm. Die Size Note: A/F = Across Flats dimension of hexagonal crimping dies. Cable details are preliminary based on information from Midland Metals. E 10.0.15 F 14.04.16 G 13.01.17 H 1.04.18 C.Noel 4/11/05 A.Bletchly T.Borg 11kV EQUIPMENT TERMINATION AND CONNECTION DATA FILE: 5 61 5149 5149 H
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. 0104404 35mm Al Triplex 0104471 1090397 F & G / Ormazabal Switchgear Connection. 630A deadbreak bolted elbow connector assembly. PVC/NJ/HDPE Insect Protected 4301 185mm Al Triplex 49934 1.7mm A/F 0104490 LAT/HDPE 0104463 630mm Al 1 Core 0104469 14.mm A/F LAT/HDPE 015857 Feeder Cable. 0136053 35mm Al Triplex 0104471 1.mm A/F 1090397 Transformer Bushing Connection - Padmounted Substation. (no HV Switchgear). PVC/NJ/HDPE 00A deadbreak elbow connector assembly. Insect Protected 4043 185mm Al Triplex 49934 17.3mm A/F 1.7mm A/F 0104490 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 9.07.10 D 16.05.1 E 10.0.15 F 1.04.18 6//03 A.Bletchly T.Borg kv EQUIPMENT TERMINATION AND CONNECTION DATA FILE: 5 61 5150 1 5150 F
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. 4616 35mm Al Triplex 4616 461630 185mm Al Triplex 461630 4994 49967 49959 49975 1.7mm A/F 461648 400mm Al Triplex 461648 433811 43389 14.mm A/F 461648 400mm Cu 1 core Note + Insect Protected 49918 14.mm A/F 1.7/kV Outdoor termination. Includes cable termination, cable conductor bi-metal lugs, cable screen lug. 49884 35mm Al Triplex DBT Insect Protected 49991 010485 185mm Al Triplex 49934 1.7mm A/F 0104477 630mm Al 1 Core 4996 14.mm A/F 19.1/33kV Outdoor termination. 461655 50mm Al 1 Core 43655 Includes cable termination, cable conductor bi-metal lugs, cable screen lug. 461663 300mm Al 1 Core 44984 9.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 0.11.11 F 16.05.1 4/1/03 HV CABLE OUTDOOR TERMINATION DATA G 13.01.17 H 1.04.18 C.Lindsay FILE: 5 61 5151 1 5151 H
JOINT DETAIL CORRESPONDING CABLE LUG HEX. CRIMP DIE SIZE USE & DESCRIPTION DESCRIPTION CONDUCTOR SCREEN 6.35/11kV Underground Straight Joint. 451078 35mm Al Triplex 4994 Includes cable joint kit, cable conductor links, 451078 cable screen link. 49967 Note Note 5 461671 185mm Al Triplex 49959 1.7mm A/F 461671 49975 Note 461689 400mm Cu 1 core 49918 14.mm A/F Insect Protected Note 3 Note 7 461689 400mm Al Triplex 433811 14.mm A/F Note 4 Note 7 461689 As above + insect protection 43389 14.mm A/F Note 4 Note 7 1.7/kV Underground Straight Joint. 40419 Includes cable joint kit, cable conductor links, cable screen link. Note Note 5 35mm Al Triplex Insect Protection 49991 4040 185mm Al Triplex 49934 1.7mm A/F Note 6 4041 630mm 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 185-400mm 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 0.11.11 F G H 03.07.1 01.10.13 1.04.18 1/1/03 T.Borg HV CABLE JOINT DATA FILE: 5 61 515 1 515 1 H
JOINT DETAIL CORRESPONDING CABLE LUG HEX. CRIMP DIE SIZE USE & DESCRIPTION DESCRIPTION CONDUCTOR SCREEN 19.1/33kV Underground Straight Joint. 434074 50mm Al 1 Core 43655 Includes cable joint kit, cable conductor links, & 3 Insect Protected cable screen link. 43408 300mm 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 10-300mm. B 06.01.14 C 1.04.18 1/1/03 HV CABLE JOINT DATA C.Lindsay FILE: 5 61 515 515 C
TERMINATION / CONNECTION DETAIL USE & DESCRIPTION CORRESPONDING CABLE DESCRIPTION LUG OR LINK CRIMP DIE SIZE 0.6/1kV Outdoor Termination. 010493 40mm Al 4 Core 1634155 8.4mm A/F Includes cable termination, bi-metal lugs, lug seals. 4007 43413 50mm 4 core + insect protection 410371 10.4mm A/F Outdoor Termination. Includes cable termination, Cu links. 406991 16mm Cu 4 Core 163489 40073 6.3mm A/F JOINT DETAIL USE & DESCRIPTION CORRESPONDING CABLE DESCRIPTION LINK CRIMP DIE SIZE 0.6/1kV Underground Straight Joint. 010466 40mm Al 4 Core 1634155 8.4mm A/F Includes cable joint kit, links. 010466 4007 434066 50mm Cu 4 core 410371 10.4mm A/F + insect protection 0104307 16mm Cu 4 Core 163489 6.3mm A/F 0104307 40073 : Contains accessories to provide Insect Protection to completed joint. Die Size Note: A/F = Across Flats dimension of hexagonal crimping dies. B 18.3.11 C 13.01.17 HARD COPY UNCONTROLLED 5//03 T. Borg LV CABLE OUTDOOR TERMINATION AND JOINT DATA FILE: 5 61 5153 1 5153 C
COPPER CRIMP LINKS CABLE AREASUPPLIER DESCRIPTION 10mm CK10 CATALOGUE NUMBER H1454 CAS 10 HEX CRIMP DIE SIZE 5.7mm A/F I. I. No. 406150 16mm CK16 H1455 CAS 16 6.3mm A/F 0158076 5mm CK5 H1458 CAS 5 0157738 35mm CK35 H1488 CAS 35 9.mm A/F 0157746 50mm CK50 H1460 CAS 50 10.4mm A/F 406151 70mm CK70 H1461 CAS 70 11.5mm A/F 0157754 95mm CK95 H146 CAS 95 14.mm A/F 015776 10mm CK10 H149 CAS 10 16.5mm A/F 0157789 150mm CK150 H1493 CAS 150 18.3mm A/F 40395 NOTES 1. The screen of some HV cables require non standard die size. Refer drawing 515.. Links and die sizes listed are for standard Cu cables 185mm 40mm 400mm CK185 CK40 CK400 H1494 CAS 185 H1495 CAS 40 H1470 CAS 400 0.0mm A/F 3.1mm A/F 8.1mm A/F Note 5 0104160 403954 0105045 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 9.11.16 HARD COPY UNCONTROLLED 15/1/03 T. Borg STANDARD COPPER CRIMP LINKS FILE: 5 61 5147 1 5147 C
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. 0158641 50mm BG50/M1 H15313 BL 50-1 13.mm A/F 401004 70mm BG70/M1 H15316 BL 70-1 13.mm A/F 403964 95mm BG95/M1 H15319 BL 95-1 17.3mm A/F 406797 10mm BG10/M1 H1531 BL 10-1 17.3mm A/F 403973 150mm BG150/M1 H1534 BL 150-1.0mm A/F 403967 Use Alvan grease I.I. No. 0343764 185mm 40mm BG185/M1 H1537 BL 185-1 H15330 BL40-1.0mm A/F 8.4mm A/F 401041 406400 300mm BG300/M1 H15333 BL 300-1 8.4mm A/F 403953 630mm BG630/M16 H15336 BL 630-16 43.mm A/F 0104476 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. 406397 406398 403953 B 18.3.11 HARD COPY UNCONTROLLED 6//03 C.Lindsay STANDARD BI-METAL CRIMP LUGS FILE: 5 61 5156 1 5156 B
ADAPTERS DESCRIPTION USED WITH 444040 Tyco EXRM 1366 ABB SafeLink 1mm termination 16mm thread to 1mm lug to 16mm schneider bushing 45814 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 05.01.15 C 03.08.15 HARD COPY UNCONTROLLED 05/07/13 T. Borg ADAPTERS FILE: 5 61 591 1 591 C