Raychem pyrotenax Alloy 825 Installation Manual
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Raychem pyrotenax Alloy 825 Installation Manual

Raychem pyrotenax Alloy 825 Installation Manual

Mi cable industrial
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MI Cable Industrial
Wiring Installation Manual

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Summary of Contents for Raychem pyrotenax Alloy 825

  • Page 1 For Alloy 825 Sheath Cables MI Cable Industrial Wiring Installation Manual...
  • Page 2 Important Safeguards nVent RAYCHEM Pyrotenax mineral insulated (MI) industrial wiring cables must be installed in accordance with the requirements of national and local codes and standards, the installation instructions in this manual, and the customer’s specification. Read these important safeguards and carefully follow the installation instructions.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS General Information ............1–2 1.1 Use of the Manual ............1 1.2 Safety Guidelines ............1 1.3 Approvals................2 1.4 Warranty .................2 Introduction ..............3–4 2.1 General ................3 2.2 Factory Terminated Cables ...........4 2.3 Field Terminated Cables ..........4 Storage and Handling ..........5–10 3.1 Storage ................5 3.2 Handling .................7 Pre-Installation ............11–14...
  • Page 4 iv | nVent.com...

  • Page 5: General Information

    1 GENERAL INFORMATION 1.1 Use of the Manual This manual covers storage and installation of PYROTENAX Alloy 825 Sheath MI industrial wiring cables. It is assumed that the cables have been correctly sized and the installation properly designed. Installers must be...

  • Page 6: Approvals

    1 GENERAL INFORMATION 1.3 Approvals MI industrial wiring cables are manufactured in accordance with international standards. • Factory terminated cables are: cCSAus Certified • Bulk cable is: cULus Listed and cCSAus Certified • Field installed termination kits for bulk cable are: cCSAus Certified Note: ATEX certified terminations also available.

  • Page 7: Introduction

    2 INTRODUCTION 2.1 General PYROTENAX MI industrial wiring cable is manufactured with nickel-clad copper or nickel conductors within a robust Alloy 825 sheath, embedded in highly compacted magnesium oxide insulation (Figure 1). This construction and the nature of the inorganic materials used provide MI cables with characteristics that surpass those of other cable types without the need for additional protection such as conduit.

  • Page 8: Factory Terminated Cables

    2 INTRODUCTION 2.2 Factory Terminated Cables Factory terminated cables can be connected as received to junction boxes and other equipment. The standard factory termination utilizes the epoxy sealing compound shown in Figure 22 on page 30. The cables are supplied with a metal identification tag showing the cable specifications and approvals.

  • Page 9: Storage And Handling

    3 STORAGE AND HANDLING The rugged construction of PYROTENAX MI industrial wiring cable makes it the perfect solution for all industrial applications, no matter how extreme. However, certain storage and handling guidelines should be followed to minimize the possibility of damage to the cable. 3.1 Storage To protect cables from physical damage and the environment, inspect the cables upon receipt and observe...
  • Page 10 3 STORAGE AND HANDLING Storage Measures • Store all cables indoors in a clean, dry location, if possible, and protect from moisture, construction equipment, falling objects, chemical spills, moving vehicles, and other hazards. • Store factory terminated cables in a manner that prevents damage to the sealing pot and flexible tails.

  • Page 11: Handling

    3 STORAGE AND HANDLING 3.2 Handling Moving Coils and Reels • Handle and install cables within suitable temperature limits (See Section 4.1, page 11). • Handle coils and reels utilizing equipment designed for that purpose. • Do not drop coils or reels from any height, particularly from trucks or other transporting equipment.
  • Page 12 3 STORAGE AND HANDLING Reels can be hoisted with a Do not lift by a single reel properly secured shaft extending flange. Cable or reel may be through both flanges. damaged. Cradle both reel flanges Never allow fork tines to touch between fork tines.
  • Page 13 3 STORAGE AND HANDLING • Roll reels to move them short distances and in the direction so that the cable does not unwind (Figure 4); this will tighten the cable windings, not loosen them. It is recommended that surfaces over which the reels are rolled be firm, level, and clear of debris that may damage the cable.

  • Page 14: Storage And Handling

    3 STORAGE AND HANDLING Reel Right Wrong Coil Right Wrong Figure 5: Unreeling / uncoiling cable 10 | nVent.com...

  • Page 15: Pre-Installation

    4 PRE-INSTALLATION Cable installations must be preplanned to ensure a successful installation. It is important to ensure that personnel are properly trained and qualified for the specific task they are performing. All applicable rules and regulations including federal, state / provincial, local, and municipal laws must be followed.

  • Page 16: Factory Terminated Cables

    4 PRE-INSTALLATION 4.3 Factory Terminated Cables Prior to installation of long runs of cable, attach a short length of PVC conduit to the factory terminated ends to provide protection for the sealing pot and flexible tails (Figure 6). Use 1 in (25 mm) minimum PVC pipe, or larger if a 1 in or 1-1/4 in (25 mm or 32 mm) gland connector is supplied.

  • Page 17: Set-Up

    4 PRE-INSTALLATION 4.5 Set-Up Examine cable trays, trapeze support systems, and other support systems for acceptability prior to pulling activities. Install permanent supports properly to ensure the rigidity of the cable tray, trapeze, or other support system so that neither the support system nor the cable will be subjected to damage during the pulling process.
  • Page 18 4 PRE-INSTALLATION Sheave Roller Right Wrong Figure 7: Reel set-up Station experienced cable pulling observers along the route, in contact (visually, by radio, or by phone) with the other members of the crew. 14 | nVent.com...

  • Page 19: Installation

    5 INSTALLATION Following these installation instructions will consistently produce satisfactory MI cable installations. Further information on proper installation techniques may be obtained by contacting nVent Technical Support, see Section 1.1. 5.1 General Installation Guidelines • When subject to potentially damaging abuse, protect the cable with a metal guard such as angle iron or steel channel.
  • Page 20 5 INSTALLATION Deadblow hammer Wooden blocks Figure 8: Straightening and dressing MI cable Bending Radius The minimum bending radius for permanent training of PYROTENAX MI cable is shown in Table 1, although it is recommended that bends are kept as large as possible. Where smaller bends are necessary, a conduit bending tool (Figure 9) may be utilized, but care must be taken not to bend the cables to less than the minimum bending radius.
  • Page 21 5 INSTALLATION MI cable Conduit bending tool Figure 9: Use conduit bending tool for smaller bends The relationship between cable diameter and minimum bending radius is shown in Figure 10. When small bends are necessary, do not try to make the entire bend in one operation.
  • Page 22 5 INSTALLATION Pulling the Cable into Position For ease of installation, it is recommended that the cables be completely uncoiled, or removed from the reel, and laid out in a straight run with the end to be pulled closest to the entry point into the support system (cable tray, trapeze, etc.).
  • Page 23 5 INSTALLATION Single Conductor Cable Cables may be run in triplex or quadruplex (includes a neutral), or alternatively, side-by-side configuration. The triplex / quadruplex configuration is recommended for best sheath current cancellation. When single conductor cables enter a ferrous metal enclosure, precautions must be taken to prevent heating by induction.
  • Page 24 5 INSTALLATION the Rapid Rise Fire Tests of Protection Materials for Structural Steel. The support system component material should be selected based on the environment in which it is installed, as it may have to withstand the high temperatures possible in a hydrocarbon flash fire and / or the harmful effects of corrosive areas.
  • Page 25 5 INSTALLATION Allow extra cable to form several service loops along the cable run, if possible. Band together the cable forming the loops using stainless steel adjustable gear clamps or tie wire. Keep the diameter of the loops as large as practically possible.
  • Page 26 5 INSTALLATION Steel or stainless steel cable tray securely anchored to I-beam support Support spacing per NEC/CEC, other national electrical codes and standards or customer specification Service loop (one or more loops of cable) Ground conductor MI cable secured to rungs of tray every 2 ft (610 mm)

  • Page 27: Connection To Junction Boxes And Other Equipment

    5 INSTALLATION Once the cables have been pulled into position, secure cables to the channel with steel or stainless steel single bolt pipe clamps sized to correspond with the outside diameter of the cable or cable bundle. This ensures a neat installation, prevents movement of the cables, and is particularly important in the case of vertical runs of cable as it prevents the top section of cable from supporting the...
  • Page 28 5 INSTALLATION Connect the MI cable to junction boxes, motors, or other equipment suitable for the area classification (hazardous or nonhazardous) and environmental conditions (corrosive, wet, etc.) expected. Metal junction boxes are recommended because the cable sheath can be bonded to ground, through the gland connector, to the junction box.
  • Page 29 5 INSTALLATION Metal junction box Ground screw Pot – extend Threaded hub above bottom of junction box Gland connector MI cable Figure 15: Connection to metal junction box Nonmetallic Ground screw junction box Pot – extend Threaded above bottom ground bushing of junction box Gland connector...

  • Page 30: Installation In Hazardous Areas

    5 INSTALLATION In outdoor locations, form a large “U” shaped drip loop (Figure 17) or a large drip / expansion loop (Figure 18) at the points of entry into junction boxes and other equipment. This prevents moisture, which may track along the cable sheath and collect around the entry point, from entering the junction box through the hub.
  • Page 31 5 INSTALLATION Gland connector MI cable Large expansion Explosion-proof loop 5 engaged motor threads Figure 18: Expansion loop at cable end to absorb vibration To connect MI cable to a junction box, motor, or other equipment approved for use in hazardous areas, screw the gland connector into the threaded hub and tighten to the recommended torque.

  • Page 32: Protecting The Mi Cable Terminations From Hydrocarbon Flash Fires

    5 INSTALLATION 5.4 Protecting the MI Cable Terminations from Hydrocarbon Flash Fires While MI cable will continue to function when subjected to fire, the terminations must be protected from the fire. To maintain the functionality of the terminations in installations where they may be exposed to a hydrocarbon flash fire, protect the terminations with a passive fireproofing system, such as a rigid / semi-rigid enclosure, flexible enclosure, or intumescent coating...
  • Page 33 5 INSTALLATION Steel I-beam supporting structure Seal all gaps and joints with fireproof caulking Single MI cable Multiconductor gland connectors MI cable protected with individual intumescent Junction box Multiple MI cable gland fireproofing protected with connectors protected covers intumescent with a single intumescent fire-proofing fireproofing cover material...

  • Page 34: Cable Terminations

    5 INSTALLATION 5.5 Cable Terminations MI industrial wiring cables are typically supplied with factory installed terminations. These cables are ready to connect into junction boxes and other equipment as soon as they are received at the job site. Where field installed terminations are required, two types of Pyropak ®...
  • Page 35 5 INSTALLATION Cap and sleeve assemblies Gland connector Pots Gray sealing compound Figure 23: Termination kit with gray sealing compound nVent.com | 31...

  • Page 36: Testing And Commissioning

    6 TESTING AND COMMISSIONING nVent recommends that the Cable Inspection Record in Appendix B be completed during testing and commissioning and kept for future reference 6.1 Tests Visually inspect cables and terminations and check the insulation resistance (IR) prior to energizing. Visual Inspection •...
  • Page 37 6 TESTING AND COMMISSIONING Test Criteria The minimum insulation resistance for a clean, dry, properly installed cable should reflect the values shown below, regardless of the cable length. • When cables are received (also when terminating bulk cable). –In a warm, dry environment, IR readings should be 200 MΩ...
  • Page 38 6 TESTING AND COMMISSIONING Insulation Resistance Test 1. Set megohmmeter test voltage at 0 Vdc. 2. Connect the positive (+) (earth) lead to the cable sheath. 3. Connect the negative (-) (line) lead to one conductor. 4. Turn on the megohmmeter and set the voltage to 500 Vdc;...

  • Page 39: Testing And Commissioning

    6 TESTING AND COMMISSIONING 1000 1500 2000 1000 2500 1500 2000 2500 Figure 24: IR test between cable sheath and conductor and between conductor pairs nVent.com | 35...

  • Page 40: Troubleshooting Guide

    7 TROUBLESHOOTING GUIDE Symptom Insulation resistance is less than expected Short circuits and direct earth faults 36 | nVent.com...
  • Page 41 Probable Causes Corrective Action 1. Rain or high humidity. (1) Dry tails and face of seal. Inspect power connection 2. Nicks or cuts in the cable box for moisture or signs or sheath, with moisture tracking. Dry out connections present. and retest.

  • Page 42: Appendixes

    8 APPENDIXES Appendix A: Improving Insulation Resistance (IR) To maintain the high performance of MI cable, the cable must be properly stored and the ends must remain sealed. Damaged terminations or heat shrinkable end caps that are damaged, missing, or removed will cause the magnesium oxide insulation (white powder) to absorb moisture, lowering the IR.
  • Page 43 8 APPENDIXES Repeat 4 to 5 times 2 in (50 mm) Figure A.1: Heat 2 in (50 mm) at a time 2 in (50 mm) Figure A.2: Stroke flame towards end When first heated, the IR of the cables will decrease; however, after the flame has been removed and the cable cools, the IR will increase to an acceptable level if the moisture has been driven out.

  • Page 44: Appendix B: Cable Inspection Record

    8 APPENDIXES Appendix B: Cable Inspection Record Megohmmeter manufacturer/model Megohmmeter date of last calibration INSULATION RESISTANCE TEST (Receipt of Cables) Note: See Section 6 for minimum IR readings Cable Reference No. Tag No. IR Conductor to Sheath Performed by Company Witnessed by Company nVent...
  • Page 45 Voltage setting: 500 Vdc Accuracy/full scale IR Conductor to Conductor Date Date Date Canada nVent 250 West St. Trenton, Ontario Canada K8V 5S2 Tel: +1.800.545.6258 Fax: +1.800.527.5703 nVent.com | 41...
  • Page 46 42 | nVent.com...
  • Page 47 nVent.com | 43...
  • Page 48 North America Europe, Middle East, Africa +1.800.545.6258 +32 16 213 511 Fax +1.800.527.5703 Fax +32 16 213 604 thermal.info@nvent.com thermal.info@nvent.com nVent.com ©2018 nVent. All nVent marks and logos are owned or licensed by nVent Services GmbH or its affiliates. All other trademarks are the property of their respective owners. nVent reserves the right to change specifications without notice.

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