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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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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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Licensed by Information Handling Services

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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y g

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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ICEA S-94-649-2000

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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ICEA S-94-649-2000 DATE: 07/24/00

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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DATE: 07124100ICEA S-94-649-2000

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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ICEA S-94-649-2000

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

ICEA S-94-649-2000

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