ACL Powerx ABC final 2008 pastel colour.pdf

ABC -Reliability, Safety and Flexibility at Low Cost

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Our VisionTo be the Preferred Brand of Electr�c Cables �n the reg�on wh�lst

strengthen�ng the dom�nant pos�t�on �n Sr� Lanka.

Our Mission To expand our range of products and the services in the field of

electrification.

To be the most compet�t�ve �n chosen global markets and to ach�eve cont�nuous growth.

To create an env�ronment that w�ll �nculcate a feel�ng of ownersh�p �n our people and the�r fam�l�es.

To create a company that w�ll be �n the forefront of technology and w�n the adm�rat�on of our customers, suppl�ers,

shareholders and the commun�ty.


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ForewordWe bel�eve that th�s catalogue, wh�ch carr�es d�mens�ons, electr�cal propert�es and �nstallat�on data

on Power -X Aer�al Bundled Cables (ABC) accord�ng to the Nat�onal French standard NFC 33-209:1996 and Austral�an/New Zealand Standard AS/NZS 3560.1:2000 w�ll help many of our cl�ents �n the�r work.

We also take th�s opportun�ty to express our s�ncere grat�tude towards our cl�ents and well w�shers with whom we have built a mutually beneficial relationship.

ACL Cables PLC October 2008


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CONTENTS

1. About ACL Cables PLC 1

2. Some of the mach�nery used for the manufacture of Aer�al Bundled Cables 2

3. Certificates of Excellence 3

4. Awards of Excellence 4-6

5. Power-X Aer�al Bundled Cables 7

6. How does ABC fare better than convent�onal bare conductors ? 9

7. Construct�on of Power-X ABC 13

8. Cross-sect�onal draw�ng of Power -X ABC 14

9. Tables on Power-X ABC

NFC 33-209 15-29

AS/NZS 3560-1 30-35

10. L�ne d�agram of a typ�cal low voltage Power-X ABC l�ne 36

11. Diagrams of installed ABC fittings 37

12. Deta�ls of Drums used for ABC 38

13. Recommendat�ons for storage and transport of ABC 39

14. D�agrammat�c �nstruct�ons on handl�ng and storage of drums of ABC 40


1

ACL CABLES PLC

ACL Cables PLC �s the largest manufacturer of Cables �n Sr� Lanka hav�ng p�oneered the �ndustry �n the year 1962. Over the last 4 decades �t has grown and developed to be the major suppl�er of Bu�ld�ng w�res, XLPE or PVC �nsulated Armoured Power & Control Cables, Aer�al bundled cables etc. hold�ng 45% share of the Sr� Lankan Market. In the area of Duty Free projects ACL has ma�nta�ned a market share of 80%. ACL �s proud to have suppl�ed cables to 9 out of the 13 tallest bu�ld�ngs �n Colombo , Sr� Lanka.

ACL markets �ts range of XLPE �nsulated cables under the trade name Power-X. ACL acqu�red technology for the manufacture of ABC �n the year 1989 through a techn�cal co-operat�on agreement w�th NOKIA Cables of F�nland �n order to supply 800km of the product to Lanka Electr�c�ty Company on an As�an Development Bank funded tender. S�nce then ACL has upgraded �ts technology to surpass Nat�onal French Standard NFC 33-209 wh�ch �s cons�dered the most str�ngent Standard for ABC �n the world.

ACL �s proud to have surpassed NFC 33-209 s�nce only a few manufactures �n the South or South East As�an reg�on have reached the specifications of the standard.

COMPANY’S TECHNOLOGICAL DEVELOPMENT1962 - Company establ�shed w�th techn�cal

ass�stance from M�tsu� of Japan.

1978 - Introduct�on of w�re draw�ng fac�l�ty

1981 - Acqu�s�t�on of technology from Al�nd of Ind�a for draw�ng & process�ng of alum�n�um conductors to jo�ntly manufacture and supply 1400 metr�c tons of AAC – Fly Conductor for the Ceylon Electr�c�ty Board.

1985 - Manufacture of armoured power and control cables for the first time in Sri Lanka.

1989 - Acqu � s � t � on o f t echno logy to manufacture XLPE �nsulated Aer�al

Bundled Cables from NOKIA of F�nland to jo�ntly execute an order for 800km’s of that product on an ADB funded tender floated by the Lanka Electr�c�ty Company.

1993 - Acqu�s�t�on of technology from NOKIA of F�nland to draw and age alum�n�um alloy rods and the establ�shment of an ag�ng furnace.

1993 - Establ�shment of ACL Plast�cs PLC for the manufacture of our own PVC compound.

1998 - Successful upgrad�ng of XLPE Extrus�on Technology to Nat�onal French Strandard 33-209 and w�nn�ng a 500km order for Aer�al Bundled Cables from the Ceylon Electr�c�ty Board.

2003 - Introduct�on of Flex� range of Cables2005 - Introduct�on of F�re Rated Cables

2007 - Commences Alum�mum rod m�ll

CORPORATE HIGHLIGHTS

1962 - The company commenced operat�ons as a member of Assoc�ated Motorways Group (AMW) of Compan�es acqu�r�ng the name of Assoc�ated Cables L�m�ted.

1976 - Converts to a Publ�c L�m�ted L�ab�l�ty Company.

1978 - Moves out of AMW Group.1982 - Establ�shement of ACL’s own �sland-

w�de d�str�but�on network.1990 - Change of company name to ACL

Cables L�m�ted.1991 - Establ�shment of ACL Plast�cs

L�m�ted.1995 - Acqu�s�t�on of Ceylon Bulbs & Electr�cals

L�m�ted.1999 - Purchase of major shares of the

second largest cable manufacturer �n Sr� Lanka.


2

SOME OF THE MACHINERY uSED FOR THE MANuFACTuRE OF

Power - X ABC

7 Strand Aluminium Conductor is being stranded on Skip strander

Profile Projector being used to measure insulation thickness of ABC

A phase conductor is being extruded with XLPE

Aerial Bundled Cable is being assembled on Bow Cabler


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CERTIFICATES OF EXCELLENCE

ISO 14001:2006

ISO 9001:2000


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AwARDS OF EXCELLENCE

Industrial Excellence Award In Extra Large Manufacturing Category 2007 & 2008

Taiki Akimoto 5s Merit Award2007


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AwARDS OF EXCELLENCE

National Quality AwardLarge Manufacturing Category 2007

Highest Sri Lankan Award for Quality

National Productivity AwardLarge Manufacturing Sector2007

Highest Sri Lankan Award for Productivity


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Winner of World Class Award or the Highest Award of International Asia Pacific Quality Organization in 2008

Beating National Quality Award Winners of 46 Countries in the Asia Pacific region which included countries such as Japan, Australia, Mexico, Singapore, India, Korea Taiwan etc.

INTERNATIONAL AwARD OF EXCELLENCE


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A self - support�ng fully �nsulated cable system for d�str�but�on of power.

ABC �s a superbly rel�able, safe and econom�cal system for electr�c�ty d�str�but�on. It �s equally su�table for both c�t�es and rural areas. ABC completely outdates Bare Alum�n�um conductors, wh�ch are commonly used for electr�c�ty d�str�but�on �n As�a, M�ddle East, USA and �n certa�n countr�es of Europe.

History of ABCInsulated overhead cable systems have been

�n use s�nce early 1960’s �n Europe and North America. The first overhead system in Europe has had a separate catenary w�re. However, �n countr�es such as France and F�nland the catenary w�re was el�m�nated and the neutral conductor was modified to function as the messenger or the load bear�ng w�re.

In late 1960’s Sweden and Scand�nav�an countr�es developed a system �n wh�ch all the phase conductors and the neutral conductor are of the same construct�on and act together as messenger. Th�s �s called the Four Core System.

French systemThe French system, as specified by the EDF

has a 54.6 mm2 �nsulated neutral conductor, wh�ch

Technician inspecting an installed ABC line

act as a messenger. The neutral conductor �s made of Alum�n�um Alloy of h�gh tens�le strength to bear we�ght of the ent�re cable. The type of �nsulat�on �s Cross L�nked Polyethylene (XLPE). The three phase w�res and the neutral conductor w�th or w�thout street l�ght�ng w�res are bundled together.

The French system �s popular �n countr�es such as France, Italy, Spa�n, Belg�um and Sr� Lanka.

Four Core or German SystemHere, all four cores are of the same s�ze

and bear full we�ght and tens�on of the cable equally. The four cores are made of Alum�n�um and �nsulated w�th e�ther Polyethylene (PE) or XLPE. Th�s system �s popular �n Germany, Ireland, Austral�a , UK and Portugal.

Finnish AMKA SystemThe AMKA system cons�st of a bare or

�nsulated neutral made of Alum�n�um Alloy wh�ch �s called the messenger. Cable w�ll also have �nsulated phase conductors and may have one or two �nsulated street l�ght�ng conductors. The type of �nsulat�on can be PE or XLPE. Th�s system d�ffers from the French system �n that neutral �s 50 mm2 and not 54.6 mm2 . Furthermore, the French system always calls for XLPE �nsulated neutral

Power-X Aerial Bundled Cables (ABC)


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conductor. The AMKA system �s used �n F�nland, the M�ddle East, The Far East, South Amer�ca and Austral�a.

Experience of ACL with AB Cables, XLPE Extrusion and Technical Prowess

ACL has adopted XLPE as the preferred �nsulat�ng mater�al due to �ts super�or thermal current rat�ngs and abras�on res�stance. ACL can also prov�de cables w�th PE �nsulat�on for ABC conform�ng to any standard.

ACL CABLES have been �n the bus�ness of manufactur�ng ABC s�nce 1989, hav�ng secured technology from NOKIA CABLES of F�nland �n that year �n order to supply an order for 800km ABC to Lanka Electr�c�ty Company (Pvt) Ltd. (LECO) on As�an Development Bank funded tender wh�ch the two compan�es won through a Jo�nt Venture Agreement. W�th th�s technolog�cal agreement, ACL managed to secure technology for the extrus�on of Cross L�nked Polyethylene (XLPE), wh�ch paved the way for ACL to �ncorporate same �n other products as well.

Th�s �n�t�al transfer of technology was further strengthened �n the year 1993 by another techn�cal cooperat�on agreement, wh�ch enabled ACL to secure and establ�sh technology, mach�nery and a turnace to draw and age Alum�n�um Alloy Conductors.

The cables suppl�ed to LECO �n 1989 are st�ll funct�on�ng w�thout a compla�nt and that can be cons�dered ample proof of ACL’s determ�nat�on to do th�ngs r�ght even on �ncept�on.

Breakthrough technological development of ACL

S�nce Ceylon Electr�c�ty Board (CEB) was �ns�st�ng on Nat�onal French Standard NFC 33-209 for the supply of ABC, ACL cont�nued �ts �nternal Research and Development work and �n

1998 it surpassed the said standard to secure it first large order from the sa�d organ�zat�on for 500 km. th�s must be cons�dered a remarkable ach�evement for ACL s�nce only a handful of suppl�ers have ach�eved the NFC 33-209 �n the reg�on.

The advantage of ach�ev�ng th�s standard and subsequent process �mprovements developed by ACL earned a first class image for ACL as a suppl�er of XLPE �nsulated ABC. In 2003 when one of the largest Corporates �n Ind�a was look�ng for a su�table partner for the �ntroduct�on ABC to New Delh�, ACL was recommended by an Ind�an agent. Th�s helped ACL to establ�sh contact w�th the largest Power d�str�but�ng company �n New Delh� and �ntroduce AB Cable know-how. Up to date ACL has suppl�ed more than US$ 14 m�ll�on worth of AB Cables to New Delh�, Ja�pur and Or�ssa.

ACL across the worldACL �n add�t�on to supply�ng the Ind�an

market has exported AB Cables to Bangladesh and Dom�n�can Republ�c prov�ng Techn�cal Super�or�ty and cons�stency �n Qual�ty. Nearly 25,000km of ABC manufactured s�nce 1989 and suppl�ed to lead�ng Author�t�es �n Sr� Lanka and abroad cont�nue to funct�on beaut�fully w�thout a s�ngle compla�nt Th�s speaks volumes about ACL be�ng the power house for AB Cables �n the South and South East As�a.

why Power-XThe technolog�cal �mprovements so ach�eved

by ACL contr�buted �mmensely to the upgrad�ng of qual�ty standards of both ABC and other XLPE �nsulated cables to world-class standards. ACL �n the year 1999 dec�ded to rename the ent�re range of XLPE �nsulated cables under the trade name of Power-X. Today, ACL market ABC and other XLPE �nsulated cables under the brand name Power-X to h�ghl�ght the Qual�ty Advantages our valued customers enjoy �n us�ng those cables.

Partly stripped ABC to show construction


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ABC acqu�re all � ts super�or�ty and character�st�c advantages over bare Conductors due to two factors ;

1. Ind�v�dual conductors are �nsulated,

2. They are bundled together.

Advantages of ABC

1. Super safe

S�nce the �nd�v�dual conductors and the fittings are insulated, accidental electrocution �s not poss�ble. Even �f a l�ne falls on to the ground cont�nu�ty of both the electr�c�ty supply and safety are ensured.

2. Super Reliability

Th�s �s the b�ggest advantage of ABC. Fully �nsulated ABC �s not subject to short-c�rcu�t�ng due to ra�nwater or way - leaf �nterference. Therefore, rel�able power supply �s ensured even dur�ng extreme weather cond�t�ons to the del�ght of both the consumers and Electr�c�ty D�str�but�ng Author�ty.

3. Eco- friendly

Bare conductors need clearance of vegetat�on at the t�me of �nstallat�on and for ma�ntenance. The clearance of vegetat�on e�ther dur�ng �nstallat�on o r ma �n tenance can be m�n�m�zed or totally el�m�nated w�th ABC. In fact ABC can be fixed onto a tree, wall or roof s�nce �t �s fully �nsulated. Clearance of way-leaf �s d�sl�ked by res�dents who l�ve along the route and lead to d�sputes w�th Author�ty. Th�s too can be avo�ded w�th ABC.

Installed very close to a house in a narrow lane

4. Aesthetically More Pleasing

Any bare system cons�sts of 4 – 5 conductors occupy�ng a larger space. In case of ABC, only one black overhead cable �s used. Th�s definitely appears more pleasing than bare conductors.

5. Low cost of maintenance

Due to reduced fa�lure rate and the el�m�nat�on of regular clearance of way-leaf, the crew requ�red for ma�ntenance and assoc�ated costs are less.

6. Possibility of live tapping

Fully insulated line taps can be fitted onto l�ve w�re w�thout �nterrupt�on of electr�c�ty. Th�s ensures h�gher revenue to Author�ty and customer del�ght.

How does ABC fare better than Conventional Bare Conductors?


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7. Pilferage is eliminated

One of the b�ggest compla�nts aga�nst Bare Conductors �s the ease of p�lferage of electr�c�ty. Fully �nsulated system of ABC prevents p�lferage of power ensur�ng h�gher revenue to Author�ty.

8. Higher revenue and least cost to Authority, Customer delight.

Ult�mate result of all the factors ment�oned above �s customer del�ght and h�gher revenue and increased profits to Authority.

9. Pole sharing

The same pole can be shared by the Electr�c�ty Author�ty and the Telecommun�cat�on Author�ty reduc�ng costs to both. M�n�m�ze d�srupt�on to aesthet�c appearance of the area.

In harmony with the vegetation and aesthetically more pleasing

10. Ease of Augmentation

The need to enhance the capac�ty of a part�cular d�str�but�on l�ne can be eas�ly met by str�ng�ng another l�ne of ABC below the ex�st�ng l�ne. No need to replace the earl�er l�ne.

11. ABC - install any where ability

ABC can be fixed on to any wall, roof, tree etc. s�nce �t �s comparat�vely l�ght and above all safe to touch. Th�s makes �t �deal for narrow lanes or areas where there �s th�ck vegetat�on. D�gg�ng of roads, wh�ch �s hated by everybody �s not requ�red.

12. Lessernumberoffittings

In the case of ABC lesser number of fittings are used s�nce all the cores are together. In the case of Alum�n�um bare conductors the number of fittings are at least four times hgher.Th�s enta�ls more labour and t�me for �nstallat�on of a bare conductor system.


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ABC totally merged with

vegetation

Two Aerial Bundled Cables running parallel to each other. Example of easy augmentation

13. Lower Impedence

In the case of ABC the total �mpedence of the cable �s lower than that of a bare conductor system of equ�valent s�ze. Th�s allows ABC to carry a h�gher current rat�ng.

14. Corrossion resistance

S�nce ABC �s a fully �nsulated system metal conductors are not exposed to elements of the nature.Therefore, ABC system �s �deal for coastal areas and generally lasts 5 to 10 years longer.


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as neat as could be

Biggest myth about ABC - it costs more (?)

Unl�ke Bare Conductors, ABC has a layer of �nsulat�on (PE or XLPE) on each conductor, wh�ch �ncreases the �n�t�al cost compared to a bare conductor system. Th�s type of compar�son �s grossly unprofessional and unfair. With ABC number of fittings and cost of installation is reduced. Furthermore, �mproved rel�ab�l�ty, wh�ch leads to customer sat�sfact�on, h�gher revenue and reduced cost to Author�ty, longer durab�l�ty of system makes ABC far more econom�cal than Bare Conductors. Stud�es done �n Sr� Lanka have shown that ABC system �s at least 15% less expens�ve than an equ�valent Bare Conductor System. Improved customer sat�sfact�on and safety have not been taken �nto the study s�nce they cannot be measured object�vely. Therefore, ABC system taken as a whole costs at least 25% less than an equ�valent bare conductor system.

In v�ew of the fact that ABC �s a super�or system compared to Bare Conductor System, the cont�nued use of the latter system is adopted and justified only where initial capital is a constraint.

ABC really Costs Less

than Bare Conductors

AND

What’s more, it is simply superior.


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THERE ARE TWO TYPES OF ABC CABLES ACCORDING TO NFC 33 -209: 1996

ABC ABC WITHOUT

MESSENGER CUM NEUTRAL CORE

ABC WITH MESSENGER CUM NEUTRAL CORE

Phase ConductorHard drawn Alum�n�um w�th a pur�ty of

des�gnat�on of 1350 as per NFC 31-122 �s �nsulated w�th black weather res�stant cross-l�nked polyethylene (XLPE) espec�ally developed for damp and ar�d trop�cal cl�mates and to w�thstand w�de d�fferences �n temperature.

Neutral MessengerThe messenger, wh�ch �s also the neutral

conductor, �s made of heat treated h�gh tens�le Alum�n�um Alloy and �s �nsulated w�th XLPE.

Street Lighting ConductorNormally 16mm2 or 25mm2 hard-drawn

Alum�n�um �nsulated w�th black weather res�stant XLPE. Th�s street l�ght�ng conductor w�ll be added to the bundled cable, only on the request made by customers.

Pilot CoresNormally 1.5mm2 unt�nned Copper

�nsulated w�th XLPE.

}Packing

All Aer�al Bundled Cables are suppl�ed �n non-returnable wooden drums su�table for out door storage. These drums can be treated us�ng su�table preservat�ves accord�ng to the specifications given by customers. Drum lengths and s�zes & des�gns of drums also can be arranged to su�t the customer needs.

Different types of Bundled CablesACL has the capab�l�ty to manufacture

and test ABC to IEC, NFC, BS & ASTM standards. Furthermore, ACL can manufacture ABC to any standard as requ�red by customer.

wHY XLPE?Cross L�nked Polyethylene cables are

durable, econom�cal, l�ght we�ght and the propert�es of the �nsulat�on offer cons�derable advantages over Polyethylene (PE) where current rat�ngs and short c�rcu�t rat�ngs are of the pr�mary �mportance.

The nom�nal conductor operat�ng temperature of XLPE �nsulated cable �s 900C where as that of PE �s only 700C. The cable has the advantage of s�mpl�c�ty �n construct�on, l�ghtness �n we�ght bes�des �ts excellent electr�cal, heat, mechan�cal and ant�-chem�cal corros�on propert�es.

XLPE cable w�thstands small bend�ng rad�us and allow�ng for easy handl�ng and �nstallat�on. Furthermore, the spl�c�ng and term�nat�ng methods for XLPE cables are very s�mple �n compar�son w�th those for other k�nds of cables.

CONSTRuCTION OF POwER – X ABC


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Aerial Bundled cables packed in drums at ACL yard being inspected before despatch

Cross Sectional Drawing of ABC 3x70+54.6+6+16 sq.mm (N-28)


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ABC wITHOuT MESSENGER NEuTRAL CORE

600 / 1000 V NFC 33 - 209 : 1996

2 or 4 x 16 mm2 Al/XLPE + K x 1.5 mm2 Cu/XLPE ABC

ITEM CODE uNITS N - 1 N - 2 N - 3 N - 4

Item Descr�pt�on mm2 2 x 16 2x16 + 2x1.5 4 x 16 4x16 + 2x1.5

Nom�nal Cross - Sect�onal Area Phase Conductors mm2 16 16 16 16 P�lot Core mm2 - 1.5 - 1.5

Number Of Strands Phase Conductors Nos. 7 7 7 P�lot Core No. - 1 - 1

Max�mum Res�stance Phase Conductors Ω/km 1.91 1.91 1.91 1.91 Of Conductor At 20 0 C P�lot Core Ω/km - 12.1 - 12.1

M�n�mum Break�ng Strength Phase Conductors daN 190 190 190 190

Nom�nal D�ameter Phase Conductors mm 4.8 4.8 4.8 4.8 Of Bare Conductors P�lot Core mm - 1.38 - 1.38

Nom�nal Th�ckness Phase Conductors mm 1.2 1.2 1.2 1.2 Of Insulat�ng Sheath P�lot Core mm - 1.2 - 1.2

Nom�nal Insulated Core D�ameter Phase Conductors mm 7.2 7.2 7.2 7.2 P�lot Core mm - 3.8 - 3.8

Current Carry�ng Capac�ty In a�r at 300C A 93 93 83 83 On facades A 83 83 75 75 In condu�tes �n walls A 72 72 63 63

Voltage Drop Phase Conductors V/A/km 3.98 3.98 3.44 3.44

Complete Cable

Approx�mate Overall D�ameter mm 15 16 18 19.5

Max�mum Lay P�tch cm 40 40 40 40

Lay D�rect�on R�ght R�ght R�ght R�ght

Max�mum Short C�rcu�t Rat�ng for 0.2 Sec kA 3.38 3.38 3.38 3.38 for 1.0 Sec kA 1.51 1.51 1.51 1.51 for 3.0 Sec kA 0.87 0.87 0.87 0.87

M�n�mum Bend�ng Rad�us mm 129.6 129.6 129.6 129.6

Approx�mate Cable We�ght kg/km 133.1 178.4 266.3 311.5

Nom�nal Drum Length m 1750 1500 1200 1000

S�ze of the Drum D - 2 D - 2 D - 2 D - 2

Drum We�ght kg 138 138 138 138

Gross We�ght of Cable + Drum kg 371 406 458 450

Table-01K represents the number of pilot cores, it may be zero 0 or 2


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600 / 1000 V NFC 33 - 209 : 1996





Number Of Strands Phase Conductors Nos. 7 7 7 7 P�lot Core No. - 1 - 1






Current Carry�ng Capac�ty In a�r at 300C A 122 122 111 111 On facades A 111 111 99 99 In condutes �n walls A 95 95 83 83


Complete Cable

Approx�mate Overall D�ameter mm 18 19.5 22 24








Drum We�ght kg 138 138 138 138

Gross We�ght of the Cable + Drum kg 382 386 422 409



17





Number Of Strands Phase Conductors Nos. 7 7 7 7 P�lot Core No. - 1 - 1






Current Carry�ng Capac�ty In a�r at 300C A 150 150 138 138 On facades A 134 134 123 123 In condutes �n walls A 116 116 107 107


Complete Cable

Approx�mate Overall D�ameter mm 21 23 26 28








Drum We�ght kg 145 145 145 145



600 / 1000 V NFC 33 - 209 : 1996



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2 x 50 mm2 Al/XLPE + K x 1.5 mm2 Cu/XLPE ABC

ITEM CODE uNITS N - 13 N - 14

Item Descr�pt�on mm2 2 x 50 2x50 + 2x1.5

Nom�nal Cross - Sect�onal Area Phase Conductors mm2 50 50 P�lot Core mm2 - 1.5

Number Of Strands Phase Conductors Nos. 7 7 P�lot Core No. - 1

Max�mum Res�stance Phase Conductors Ω/km 0.641 0.641 Of Conductor At 20 0 C P�lot Core Ω/km - 12.1

M�n�mum Break�ng Strength Phase Conductors daN 600 600

Nom�nal D�ameter Phase Conductors mm 8.1 8.1 Of Bare Conductors P�lot Core mm - 1.38

Nom�nal Th�ckness Phase Conductors mm 1.6 1.6 Of Insulat�ng Sheath P�lot Core mm - 1.2

Nom�nal Insulated Core D�ameter Phase Conductors mm 11.3 11.3 P�lot Core mm - 3.8

Current Carry�ng Capac�ty In a�r at 300C A 168 168 On facades A 149 149 In condutes �n walls A 130 130

Voltage Drop Phase Conductors V/A/km 1.27 1.27

Complete Cable

Approx�mate Overall D�ameter mm 23 25

Max�mum Lay P�tch cm 55 55

Lay D�rect�on R�ght R�ght

Max�mum Short C�rcu�t Rat�ng for 0.2 Sec kA 10.56 10.56 for 1.0 Sec kA 4.72 4.72 for 3.0 Sec kA 2.73 2.73

M�n�mum Bend�ng Rad�us mm 203.4 203.4

Approx�mate Cable We�ght kg/km 350.4 395.6

Nom�nal Drum Length m 1000 1000

S�ze of the Drum D - 3 D - 3

Drum We�ght kg 145 145

Gross We�ght of the Cable + Drum kg 495 541


600 / 1000 V NFC 33 - 209 : 1996



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3 x 25 mm2 Al / XLPE + N 54.6 mm2 + K x 16mm2 ABC


Item Descr�pt�on mm2 3x25 +54.6 3x25+54.6+1x16 3x25+54.6+2x16 3x25+54.6+3x16

Nom�nal Cross - Sect�onal Area Phase Conductors mm2 25 25 25 25 Neutral Messenger mm2 54.6 54.6 54.6 54.6 Street L�ght�ng Conductor mm2 - 16 16 16

Number Of Strands Phase Conductors Nos. 7 7 7 7 Neutral Messenger Nos. 7 7 7 7 Street L�ght�ng Conductor Nos. - 7 7 7

Max�mum Res�stance Phase Conductors Ω/km 1.2 1.2 1.2 1.2 Of Conductor At 20 0 C Neutral Messenger Ω/km 0.63 0.63 0.63 0.63 Street L�ght�ng Conductor Ω/km - 1.91 1.91 1.91

M�n�mum Break�ng Strength Phase Conductors daN 300 300 300 300 Neutral Messenger daN 1660 1660 1660 1660 Street L�ght�ng Conductor daN - 190 190 190

Nom�nal D�ameter Of Strands Neutral Messenger mm 3.15 3.15 3.15 3.15

Nom�nal D�ameter Phase Conductors mm 6.0 6.0 6.0 6.0 Of Bare Conductors Neutral Messenger mm 9.5 9.5 9.5 9.5 Street L�ght�ng Conductor mm - 4.8 4.8 4.8

Lay D�rect�on Neutral Messenger Left Left Left Left

Lay P�tch Neutral Messenger mm 190 190 190 190

Nom�nal Th�ckness Phase Conductors mm 1.4 1.4 1.4 1.4 Of Insulat�ng Sheath Neutral Messenger mm 1.6 1.6 1.6 1.6 Street L�ght�ng Conductor mm - 1.2 1.2 1.2

Nom�nal Insulated Core D�ameter Phase Conductors mm 8.8 8.8 8.8 8.8 Neutral Messenger mm 12.7 12.7 12.7 12.7 Street L�ght�ng Conductor mm - 7.2 7.2 7.2

Current Carry�ng Capac�ty Phase Conductors A 112 112 112 112 Street L�ght�ng Conductor A - 83 83 83


Complete Cable





M�n�mum Bend�ng Rad�us mm 229 229 229 229




Drum We�ght kg 225 225 225 225


ABC wITH MESSENGER NEuTRAL CORE

600 / 1000 V NFC 33 - 209 : 1996

Table-05K represents the number of cores for public lighting, it may be zero 0, 1, 2 or 3


20


600 / 1000 V NFC 33 - 209 : 1996

















Complete Cable









Drum We�ght kg 250 250 250 250



21


600 / 1000 V NFC 33 - 209 : 1996

















Complete Cable








S�ze of the Drum D - 15 D - 15 D - 15 D-15

Drum We�ght kg 215 215 215 215



22





Number Of Strands Phase Conductors Nos. #12 #12 #12 #12 Neutral Messenger Nos. 7 7 7 7 Street L�ght�ng Conductor Nos. - 7 7 7











Complete Cable

Approx�mate Overall D�ameter mm 37.5 37.5 37.5 37.5








Drum We�ght kg 215 215 215 215



600 / 1000 V NFC 33 - 209 : 1996

Table-08K represents the number of cores for public lighting, it may be zero 0, 1, 2 or 3 #- can be 19 strands based on customer request


23

3 x 70 mm2 Al / XLPE + N 54.6 mm2 + K x 25 mm2 ABC

ITEM CODE uNITS N - 31 N - 32 N - 33

Item Descr�pt�on mm2 3x70+54.6+1x25 3x70+54.6+2x25 3x70+54.6+3x25

Nom�nal Cross - Sect�onal Area Phase Conductors mm2 70 70 70 Neutral Messenger mm2 54.6 54.6 54.6 Street L�ght�ng Conductor mm2 25 25 25

Number Of Strands Phase Conductors Nos. #12 #12 #12 Neutral Messenger Nos. 7 7 7 Street L�ght�ng Conductor Nos. 7 7 7

Max�mum Res�stance Phase Conductors Ω/km 0.443 0.443 0.443 Of Conductor At 20 0 C Neutral Messenger Ω/km 0.63 0.63 0.63 Street L�ght�ng Conductor Ω/km 1.20 1.20 1.20

M�n�mum Break�ng Strength Phase Conductors daN 840 840 840 Neutral Messenger daN 1660 1660 1660 Street L�ght�ng Conductor daN 300 300 300

Nom�nal D�ameter Of Strands Neutral Messenger mm 3.15 3.15 3.15

Nom�nal D�ameter Phase Conductors mm 9.9 9.9 9.9 Of Bare Conductors Neutral Messenger mm 9.5 9.5 9.5 Street L�ght�ng Conductor mm 6.0 6.0 6.0

Lay D�rect�on Neutral Messenger Left Left Left

Lay P�tch Neutral Messenger mm 190 190 190

Nom�nal Th�ckness Phase Conductors mm 1.8 1.8 1.8 Of Insulat�ng Sheath Neutral Messenger mm 1.6 1.6 1.6 Street L�ght�ng Conductor mm 1.4 1.4 1.4

Nom�nal Insulated Core D�ameter Phase Conductors mm 13.5 13.5 13.5 Neutral Messenger mm 12.7 12.7 12.7 Street L�ght�ng Conductor mm 8.8 8.8 8.8

Current Carry�ng Capac�ty Phase Conductors A 213 213 213

Street L�ght�ng Conductor A 111 111 111

Voltage Drop Phase Conductors V/A/km 0.87 0.87 0.87

Complete Cable

Approx�mate Overall D�ameter mm 40 40 40

Max�mum Lay P�tch cm 100 100 100

Lay D�rect�on R�ght R�ght R�ght

Max�mum Short C�rcu�t Rat�ng for 0.2 Sec kA 14.79 14.79 14.79 for 1.0 Sec kA 6.61 6.61 6.61 for 3.0 Sec kA 3.82 3.82 3.82

M�n�mum Bend�ng Rad�us mm 243 243 243

Approx�mate Cable We�ght kg/km 1077.3 1178.9 1280.4

Nom�nal Drum Length m 600 600 600

S�ze of the Drum D - 15 D - 15 D - 15

Drum We�ght kg 215 215 215

Gross We�ght of the Cable + Drum kg 861 922 983


600 / 1000 V NFC 33 - 209 : 1996



24

3 x 70 mm2 Al / XLPE + N 70 mm2 + K x 16mm2 ABC


Item Descr�pt�on mm2 3x70 +N70 3x70+N70 +1x16 3x70+N70 +2x16 3x70+N70 +3x16

Nom�nal Cross - Sect�onal Area Phase Conductors mm2 70 70 70 70 Neutral Messenger mm2 70 70 70 70 Street L�ght�ng Conductor mm2 - 16 16 16

Number Of Strands Phase Conductors Nos. #12 #12 #12 #12 Neutral Messenger Nos. 7 7 7 7 Street L�ght�ng Conductor Nos. - 7 7 7











Complete Cable









Drum We�ght kg 215 215 215 215



600 / 1000 V NFC 33 - 209 : 1996



25
















Complete Cable









Drum We�ght kg 225 225 225 225



600 / 1000 V NFC 33 - 209 : 1996



26
















Complete Cable









Drum We�ght kg 225 225 225 225



600 / 1000 V NFC 33 - 209 : 1996



27
















Complete Cable


Max�mum / m�n�mum Lay P�tch cm 115 / 130 115 / 130 115 / 130 115 / 130







Drum We�ght kg 225 225 225 225



600 / 1000 V NFC 33 - 209 : 1996



28



Item Descr�pt�on mm2 3x120 +N95 3x120+N95 +1x16 3x120+95 +2x16 3x120+N95 +3x16













Complete Cable









Drum We�ght kg 225 225 225 225



600 / 1000 V NFC 33 - 209 : 1996



29


ITEM CODE uNITS N -54 N -55 N -56 N -57














Complete Cable


Max�mum / m�n�mum Lay P�tch cm 115 / 130 115 / 130 115 / 130 115 / 130







Drum We�ght kg 225 225 225 225



600 / 1000 V NFC 33 - 209 : 1996



30

AERIAL BuNDLED CABLE wITH ALuMINIuM CONDuCTORS

600 / 1000 V AS/NZS 3560.1:2000

Table-16

2 or 4 Core Al/XLPE ABC

ITEM CODE uNITS AS - 1 AS - 2

Item Descr�pt�on mm2 2 x 16 4 x 16

Nom�nal Cross - Sect�onal Area mm2 16 16

Number Of Strands Nos. 7 7

Max�mum Res�stance Of Conductor At 20 0 C Ω/km 1.91 1.91

M�n�mum Break�ng Strength kN 2.2 2.2

Nom�nal D�ameter Of Bare Conductors mm 4.7 4.7

Nom�nal Th�ckness Of Insulat�ng Sheath mm 1.3 1.3

Nom�nal Insulated Core D�ameter mm 7.9 7.9

Current Carry�ng Capac�ty For typ�cal Austral�an Installat�on cond�t�ons A 78 74

For typ�cal New Zealand Installat�on cond�t�ons A 87 83

Complete Cable

Approx�mate Overall D�ameter mm 15.8 19.1

Max�mum Lay Length mm 443 535

Lay D�rect�on Left Left

for 0.2 Sec kA 3.38 3.38

Max�mum Short C�rcu�t Rat�ng for 1.0 Sec kA 1.51 1.51

for 3.0 Sec kA 0.87 0.87

M�n�mum Bend�ng Rad�us mm 95 115

Approx�mate Cable We�ght kg/m 0.14 0.28




Gross We�ght of Cable + Drum kg 418 425


31


600 / 1000 V AS/NZS 3560.1:2000

Table-17

2,3 or 4 Core Al/XLPE ABC

ITEM CODE uNITS AS - 3 AS - 4 AS - 5

Item Descr�pt�on mm2 2 x 25 3 x 25 4 x 25

Nom�nal Cross - Sect�onal Area mm2 25 25 25

Number Of Strands Nos. 7 7 7

Max�mum Res�stance Of Conductor At 20 0 C Ω/km 1.20 1.20 1.20

M�n�mum Break�ng Strength kN 3.5 3.5 3.5

Nom�nal D�ameter Of Bare Conductors mm 6 6 6

Nom�nal Th�ckness Of Insulat�ng Sheath mm 1.3 1.3 1.3

Nom�nal Insulated Core D�ameter mm 9.2 9.2 9.2

Current Carry�ng Capac�ty

For typ�cal Austral�an Installat�on cond�t�ons

A 105 97 97

For typ�cal New Zealand Installat�on cond�t�ons

A 118 109 109

Complete Cable

Approx�mate Overall D�ameter mm 18.4 19.8 22.2

Max�mum Lay Length mm 516 555 622

Lay D�rect�on Left Left Left

for 0.2 Sec kA 5.28 5.28 5.28

Max�mum Short C�rcu�t Rat�ng for 1.0 Sec kA 2.36 2.36 2.36

for 3.0 Sec kA 1.36 1.36 1.36


Approx�mate Cable We�ght kg/m 0.2 0.3 0.4


S�ze of the Drum D - 3 D-45 D - 25


Gross We�ght of Cable + Drum kg 545 808 562


32


600 / 1000 V AS/NZS 3560.1:2000

Table-18








Nom�nal D�ameter Of Bare Conductors mm 7 7 7





A 125 120 120


A 140 134 134

Complete Cable


Max�mum Lay Length mm 3.31 3.31 3.31

Lay D�rect�on 1.91 1.91 1.91

for 0.2 Sec kA 7.39 7.39 7.39


for 3.0 Sec kA 1.91 1.91 1.91




S�ze of the Drum D - 3 D - 25 D-45




33


600 / 1000 V AS/NZS 3560.1:2000

Table-19






Max�mum Res�stance Of Conductor At 20 0 C W/km 0.641 0.641 0.641

M�n�mum Break�ng Strength kN 7 7 7

Nom�nal D�ameter Of Bare Conductors mm 8.2 8.2 8.2





A 150 140 140


A 168 157 157

Complete Cable




for 0.2 Sec kA 10.56 10.56 10.56


for 3.0 Sec kA 2.73 2.73 2.73




S�ze of the Drum D - 2 D-45 D-45




34


600 / 1000 V AS/NZS 3560.1:2000

Table-20

2 or 4 Core Al/XLPE ABC




Number of Strands Nos. 19 19 19



Nom�nal D�ameter of Bare Conductors mm 9.9 11.6 11.6

Nom�nal Th�ckness of Insulat�ng Sheath mm 1.5 1.7 1.7




A 175 230 215


A 196 258 241

Complete Cable




for 0.2 Sec kA 14.79 20.07 20.07


for 3.0 Sec kA 3.82 5.18 5.18




S�ze of the Drum D-45 D - 25 D-45




35


600 / 1000 V AS/NZS 3560.1:2000

Table-21

4 Core Al/XLPE ABC

ITEM CODE uNITS AS - 15 AS - 16

Item Descr�pt�on mm2 4 x 120 4 x 150

Nom�nal Cross - Sect�onal Area mm2 120 150

Number Of Strands Nos. 19 19

Max�mum Res�stance Of Conductor At 20 0 C W/km 0.253 0.206

M�n�mum Break�ng Strength kN 16.8 21.0

Nom�nal D�ameter Of Bare Conductors mm 13.2 14.5

Nom�nal Th�ckness Of Insulat�ng Sheath mm 1.7 1.7

Nom�nal Insulated Core D�ameter mm 17.5 18.9



A 250 280


A 280 314

Complete Cable

Approx�mate Overall D�ameter mm 42.2 45.6

Max�mum Lay Length mm 1182 1277

Lay D�rect�on Left Left

for 0.2 Sec kA 25.35 31.69

Max�mum Short C�rcu�t Rat�ng for 1.0 Sec kA 11.34 14.17

for 3.0 Sec kA 6.55 8.18

M�n�mum Bend�ng Rad�us mm 380 410

Approx�mate Cable We�ght kg/m 1.66 2.02




Gross We�ght of Cable + Drum kg 1038 1428


36

7

7. D

EAD

EN

D (T

ERM

INA

L) P

OLE

6. L

ARG

E A

NG

LE A

SSEM

BLY

5. T

HRE

E PH

ASE

S

ERVI

CE

CO

NN

ECTI

ON

4. T

EE O

FF P

OLE

3. S

ING

LE P

HA

SE

S

ERVI

CE

CO

NN

ECTI

ON

1. T

RAN

SFO

RMER

2. I

NTE

RMED

IATE

PO

LE

S

MA

LL A

NG

LE A

SSEM

BLY

LV A

BC (B

RAN

CH

LIN

E)

HO

USE

13

2

FAC

TORY

46

5

LV A

BC (M

AIN

LIN

E)

ROA

D

POLE

ROAD

ROAD

Lin

e D

iag

ram

of

a T

ypic

al Lo

w V

olt

ag

e X

LPE

Insu

late

d A

eri

al

Bu

nd

led

Ca

ble

Dis

trib

uti

on

Lin

e


37

DIAGRAMS OF INSTALLED ABC FITTINGS


38

DETAILS OF DRuMS uSED FOR ABC

DRuM NO DRuM SIZES IN DRuM SIZES IN inches mm

(F X B X T) (F X B X T)

D2 44 X 20 X 22 1118 X 508 X 559

D3 44 X 20 X 36 1118 X 508 X 914

D25 54 X 20 X 23 1372 X 508 X 584

D45 56 X 22 X 36 1422 X 559 X 914

D5 56 X 28 X 36 1422 X 711 X 914

D15 56 X 24 X 36 1422 X 609.6 X 914

D16 60 X 28 X 36 1524 X 711.2 X 914

F - Flange D�ameter

B - Barrel D�ameter

T - Inner Traverse

t - Th�ckness of Flange

h - Sp�ndle Hole D�ameter

Note : t =76.2 mm h = 95mm for all above drums

F

T

h

t

B


39

❏ Cables shall be protected from all damage dur�ng storage and transport.

❏ The drums shall be transported upr�ght �n all cases (w�th the�r ax�s hor�zontal). Any movement of drums shall be prevented dur�ng transport.

❏ Load�ng and unload�ng shall be carr�ed out w�th appropr�ate equ�pment, wh�ch cannot damage the cables and drums.

❏ Full drums shall be rolled only over short d�stances and on sol�d flat ground, and only �n the d�rect�on �nd�cated on the drums. Cable ends shall be fixed securely.

RECOMMENDATIONS FOR LAYING AND INSTALLATION OF ABC

❏ Cables shall be la�d and used �n such a way that the�r propert�es are not �mpa�red. In th�s context, the follow�ng po�nts shall be cons�dered.

a) Operat�ng cond�t�ons, such as concentrat�on of �nsulated cables, the effect of external heat sources, solar rad�at�on, etc.;

b) The method of lay�ng;

c) Adverse external factors;

d) potent�al attack by fauna and flora.

❏ When cables are la�d hor�zontally w�thout be�ng tens�oned, for example on walls or ce�l�ngs, the d�stance between brackets shall be approx�mately 0.6 m (1m �f the cables are �nstalled vert�cally). When cables are �nstalled under tens�on on poles for example, appropr�ate clamps shall be used.

MINIMuM BENDING RADIuS❏ Dur�ng �nstallat�on, the bend�ng

rad�us measured on the �nner generatr�x of the complete cable shall be not less than 18 D (wh�ch are g�ven �n tables relevant to each s�ze of cable), where D �s the d�ameter of the largest core.

❏ In the case of lay�ng w�th controlled bend�ng, �n other words bend�ng over a form at a temperature greater than or equal to 15oC, the above bend�ng rad�us may be halved.

RECOMMENDATIONS FOR STORAGE AND TRANSPORT OF ABC


40

Diagrammatic instructions on handling and storage of drums of ABC

Keep the drum upr�ght, us�ng wedges or other appropr�ate dev�ces �n the heels of the flanges

Drums may be stacked flange on flange, provided that they are lagged. The lower layer of drums shall be wedged throughout.

Never lay the drums on the�r flanges.

TRANSPORT

Roll the drum �n the d�rect�on of w�nd�ng of the turns

Drums may be bandled w�th cranes or fork-l�ft trucks

Unreel�ng

Unreel l�ke th�s Co�ls may be unwound l�ke th�s, accord�ng to the manufacturer’s

�nstruct�ons

Never unreel �n th�s way

Recommended method Not recommended

Re-w�nd�ng


41


42

N.B. Wh�lst every care �s taken to ensure that the �nformat�on conta�ned �n the publ�cat�on �s correct, no legal respons�b�l�ty can be accepted by ACL for any �naccuracy. ACL reserves the r�ght to alter or mod�fy the �nformat�on conta�ned here�n at any t�me �n the l�ght of techn�cal or other developments

ACL Powerx ABC final 2008 pastel colour.pdf

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Transcript of ACL Powerx ABC final 2008 pastel colour.pdf