Pyrotenax MI Wiring Cable Installation Manual for Alloy 825 Sheath
Contents
1. Figure 24 IR test between cable sheath and conductor and between conductor pairs 36 EN PyrotenaxMlindustrialwiring IM H57987 04 13 6 Testing and Commissioning EN PyrotenaxMlindustrialwiring IM H57987 04 13 37 7 Troubleshooting Guide Symptom Insulation resistance is less than expected Short circuits and direct earth faults 38 EN PyrotenaxMlindustrialwiring IM H57987 04 13 7 Troubleshooting Guide Probable Causes 1 Rain or high humidity 2 Nicks or cuts in the cable sheath with moisture present 3 Kinked or crushed cable 4 Arcing created by damage to the cable 5 Welding splatter 6 Presence of moisture in termination or temporary seal 7 Damaged termination or temporary seal Corrective Action 1 Dry tails and face of seal Inspect power connection box for moisture or signs or track ing Dry out connections and retest 2 3 4 5 Visually inspect or fault locate cable to find dam aged section of cable Repair or replace cable or contact Pentair Thermal Management technical support for assistance 6 Remove termination or temporary seal Dry out cable following the procedure in Appendix A Replace termina tion or seal 7 Replace termination or seal 1 Physical damage to cable is causing a direct short from conductor to sheath2. 14 EN PyrotenaxMlindustrialwiring IM H57987 04 13 Installation 5 1 Following these installation instructions will con sistently produce satisfactory MI cable installa tions Further information on proper installation techniques may be obtained by contacting Pentair Thermal Management Technical Support See Section 1 1 General Installation Guidelines When subject to potentially damaging abuse pro tect the cable with a metal guard such as angle iron or steel channel Metal supports cable sheath and other metal enclosures for the cables must be metallically joined together and must be connected to all boxes fittings and cabinets so as to provide effec tive electrical continuity Ensure that you do not invalidate the listing of enclosures or other equipment if it is necessary to cut holes Moisture Absorption The magnesium oxide insulation of MI cable is hygroscopic and can absorb moisture when exposed to air causing the IR to fall Low IR can be corrected as outlined in Appendix A Expansion and Vibration Where cables may expand or contract due to tem perature changes or when connecting the cable to vibrating equipment it may be necessary to take precautions to prevent mechanical damage to MI cable Refer to Sections 5 2 and 5 3 for further details Equipment Bonding The sheath of Alloy 825 MI cable must be bonded to ground but must not be used as the equipment to ground bonding
3. 2 Misalignment of the con ductors within the seal or incorrect and untidy completion of the sheath stripping procedure during termination 3 Conductors shorted to sheath when cut at fac tory only for unterminated cables 1 Check for visual indications of damage around any area where there may have been maintenance work Repair or replace damaged cable and or terminations 2 Remake termination 3 Remove short and reseal end EN PyrotenaxMlindustrialwiring IM H57987 04 13 39 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 The cable must be heated out to remove the mois ture and bring the IR back to an acceptable level If the IR of a factory terminated cable tests below acceptable limits see Section 6 the cable termina tions must be removed before heating out the cable Follow the troubleshooting guide in Section 7 before removing the terminations r Important Moisture will not normally penetrate more than 12 in 300 mm into the cable If moisture is detected in the cable use an oxy acetylene or mapp gas torch with a large flame and heat out the cable beginning 1
4. 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 Lift or handle coils and cable reels in such a man ner that the lifting handling device does not make direct contact with the cable or its protective cov ering Coils should be placed on a skid Handle reels in a manner that prevents deteriora tion of and physical damage to the reel and to the cable Take precautions to ensure that the flange of one reel does not impact the cable on another reel V Important If a coil or reel is dropped or the pro tective covering is damaged examine the cable for damage Refer to Section 7 for the Troubleshooting Guide Damaged cables may need to be repaired or replaced Contact your local representative for more information The following lifting methods for reels are recom mended Figure 3 Insert a suitable properly secured shaft through the reel arbor hole and lift with slings using a crane or boom type equipment Use a spreader or other device to minimize sling pressure against the reel flange Move smaller narrower reels using a forklift Place fork tines so that lifting pressure is on both reel flanges not on the cable EN PyrotenaxMlindustrialwiring IM H57987 04 13 3 Storage and Handling 4 Je Reels can be hoisted with a Do not lift by a single reel properly se
5. 1 4 Approvals MI industrial wiring cables are manufactured in accordance with international standards e Factory terminated cables are cCSAus Certified Bulk cable is cULus Listed and cCSAus Certified Field installed termination kits for bulk cable are cCSAus Certified V Important ATEX certified terminations also available Warranty Pentair Thermal Management s Pyrotenax MI indus trial wiring products Limited Warranty applies to these products For details see the complete war ranty on our web site at www thermal pentair com V Important For the Pentair Thermal Management warranty and agency approvals to apply the instruc tions that are included in this manual and product packages must be followed EN PyrotenaxMlindustrialwiring IM H57987 04 13 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 com pacted magnesium oxide insulation Figure 1 This construction and the nature of the inorganic materi als used provide MI cables with characteristics that surpass those of other cable types without the need for additional protection such as conduit One of the most exceptional qualities of MI cable is its fire resistance the cable will not burn support combus tion propagate flame or emit smoke or toxic gases MI cable can be used for indoor and outdoor a
6. since these materials will fail guickly during a fire 20 EN PyrotenaxMlindustrialwiring IM H57987 04 13 m Installation The support system must provide strength and working load capabilities to meet the load require ment of the wiring system Support the cables on horizontal and vertical runs at the spacing require ments in the NEC CEC other national electrical codes and standards or per customer s specifica tions Pay special attention to fire rated installations as it may be necessary to use support spacing closer than that specified in the NEC CEC or other national electrical codes and standards Several support methods may be used however cable tray is recommended due to its wide availabil ity and familiarity among installing contractors Cable Tray Figure 11 and Figure 12 show two typical cable tray installation methods using open ladder trough type tray In Figure 11 the cable tray is supported using a rod and channel trapeze type system In Figure 12 the tray is supported using steel I beams Follow the cable tray manufacturer s installation instructions to install the tray Complete the cable tray installation before installing the MI cables Metallic cable tray systems must be electrically continuous and effectively bonded as per the requirements of the NEC CEC or other national electrical codes and standards Install cables so that the sheaths are in good elec trical contact with the tr
7. 21 5426 2917 cn thermal info pentair com WWW THERMAL PENTAIR COM EUROPE MIDDLE EAST AFRICA Tel 32 16 213 511 Fax 32 16 213 603 thermal info pentair com LATIN AMERICA Tel 1 713 868 4800 Fax 1 713 868 2333 thermal info pentair com Pentair Pyrotenax and Pyropak are owned by Pentair or its global affili ates All other trademarks are the property of their respective owners Pentair reserves the right to change specifications without prior notice 2006 2013 Pentair THERMAL MANAGEMENT SOLUTIONS EN PyrotenaxMlindustrialwiring IM H57987 04 13
8. and pulling over sharp objects Do not pull cables around corners that have sharp edges such as corners in cable trays or other obstructions Pull all cable diameters one at a time by hand Hand feed cables around corners using large sweeping bends When changing direction from horizontal to verti cal use properly sized sheaves or pulleys Protect exposed cables from any nearby or over head work that could damage the cable Do not pull cables around a radius smaller than the minimum pulling radius see Table 2 Make sure all equipment used during cable instal lation is in good operating condition For further assistance on pulling cables contact Pentair Thermal Management Technical Support see Section 1 1 EN PyrotenaxMlindustrialwiring IM H57987 04 13 11 Pre Installation 4 3 4 4 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 This will pre vent damage to the sealing pot and tails during installation Reducer from PVC pipe to gland connector Threaded PVC end Factory terminated m 1 25 mm min MI cable connector PVC pipe Figure 6 Protecting sealing pot and flexible tails Insta
9. conductor For proper equipment to ground bonding use one conductor within the sheath or use a separate equipment to ground bonding conductor EN PyrotenaxMlindustrialwiring IM H57987 04 13 15 Installation Straightening and Dressing the Cable The cable may be straightened by hand or by using a dead blow hammer and a block of wood as shown in Figure 8 Do not use a metal hammer as it may result in unsightly dents that cannot be removed Once the cable has been installed the use of stain less steel banding or cable clamps to strap the cable to the tray will help dress the cable maintaining a neat appearance 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 con duit bending tool Figure 9 may be utilized but care must be taken not to bend the cables to less than the minimum bending radius EN PyrotenaxMlindustrialwiring IM H57987 04 13 9 Installation TABLE 1 MINIMUM BENDING RADIUS FOR PERMANENT TRAINING Cable O D outside diameter 0 75 in 19 mm and smaller 6 times cable diameter Larger than 0 75 in 19 mm 12 times cable diameter MI cable Conduit bending tool Figure 9 Use conduit bending tool for sm
10. national electrical codes v ue and standards or customer specification Steel or stainless steel cable tray securely anchored to steel channel Service loop one or more loops of cable d Steel rod securely anchored to structure above MI cable secured to rungs of tray every 2 ft 610 mm Figure 11 Typical cable tray installation using trapeze supports EN PyrotenaxMlindustrialwiring IM H57987 04 13 Installation Steel or stainless steel cable tray securely anchored to beam support Support spacing per NEC CEC other national electrical codes and 4 standards or customer specification AST p l SSN gt Service loop D s one or more loops of cable e Ground conductor MI cable secured to rungs of tray every 2 ft 610 mm Steel l beam supports securely anchored to ground Figure 12 Typical cable tray installation using steel I beam supports Trapeze Support A typical trapeze system installation is shown in Figure 13 Follow the trapeze system manufacturer s installation instructions to properly install the tra peze system The trapeze system does not readily allow placement of service loops Figure 11 and Figure 12 If service loops are required for future maintenance replace ment or relocation of equipment install the cables in cable tray Complete the trapeze system installation before installing the MI cables Do not overlo
11. 2 in 300 mm back from the end Gradually stroke toward and past the cable end Alloy 825 sheath cables should be heated to a dull red color Take care not to overheat any one area of the cable sheath as this could damage the cable Use a short sweeping motion of the torch and heat about 2 in 50 mm of cable at a time repeating 4 to 5 times Stroke the flame towards the cable end as shown in Figure 25 Do not stroke the flame in the opposite direction as this will drive the moisture into the cable Gradually move the flame toward the end while maintaining the short sweeping motion of the torch Figure 26 If you heat toward the cable end too quickly you may skip over the moisture and drive it further back into the cable Repeat the above procedure several times always beginning 12 in 300 mm back from the cable end 40 EN PyrotenaxMlindustrialwiring IM H57987 04 13 8 Appendixes Repeat 4 to 5 times 2 in 50 mm a Figure 25 Heat 2 in 50 mm at a time 2 in 50 mm M ees Figure 26 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 On comple tion check IR with a 500 Vdc megohmmeter fol lowing the instructions in Section 6 If working with shielded twisted pair cable also test IR between the sheath and inner sh
12. Conductor Cable Cables may be run in triplex or quadruplex includes a neutral or alternatively side by side configura tion The triplex quadruplex configuration is recom mended for best sheath current cancellation When single conductor cables enter a ferrous metal enclosure precautions must be taken to prevent heating by induction It is recommended that the cables be connected to nonmagnetic stainless steel junction boxes and enclosures For further informa tion on terminating single conductor cables contact Pentair Thermal Management Technical Support see Section 1 1 All conductors of the same circuit and where used the grounded conductor neutral and all conduc tors bonding equipment to ground must be con tained within the same cable tray or bundled with the cables within a trapeze system or equivalent unless otherwise permitted in accordance with the EN PyrotenaxMlindustrialwiring IM H57987 04 13 19 Installation NEC CEC or other national electrical codes and standards These requirements apply separately to parallel circuits Conductors to be joined in parallel should follow the applicable sections of the NEC CEC or other nation al electrical codes and standards Multiple circuits should be appropriately spaced for ampacity consid erations Where independent circuits are required or desired maintain proper separation and segregation from other electrical circuits Bundle single conductor M
13. I cables tightly together every 2 ft 610 mm along the entire length of cable run in groups containing one conductor per phase the neutral if used and the equipment to ground bonding conductor using stainless steel banding or stainless steel adjustable gear clamps This main tains the cable sheaths in contact throughout the length of the run which minimizes sheath currents and stabilizes the cables under short circuit and fire conditions Where parallel runs are required cable bundles must be spaced apart 2 15 cable diameters in USA and Canada Follow the applicable require ments of the NEC CEC or other national electrical codes and standards Exposed or Surface Installations The components used to support the cables through out the run must be made of steel or stainless steel In areas where the cables may be exposed to hydro carbon flash fires the support system components must be in compliance with UL1709 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 Ensure that the materials used to support the cables are compatible with the cable sheath r Important For fire rated installations do not use material such as aluminum brass copper plastic lead wood etc
14. P PENTAIR Industrial MI Wiring Cable rotena INSTALLATION MANUAL FOR ALLOY 825 SHEATH CABLE WIRING SYSTEMS WWW THERMAL PENTAIR COM THERMAL MANAGEMENT SOLUTIONS Important Safeguards and Warnings NWARNING FIRE AND SHOCK HAZARD 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 impor tant safeguards and carefully follow the installation instructions Ensure the cable has been stored properly and is in good condition prior to commencing installation Always use safe working practices when installing cables observing OSHA and other national safety rules Store cables indoors in a clean dry covered area if possible During the time that the cables are exposed and during cable pulling activities protect cables from nearby or overhead work to prevent damage to the cable sheath Do not pull cables around corners that have sharp edges such as corners in cable trays or other obstructions Prevent damage to cables by removing any abrasions or sharp edges from surface of support system Damage to cables or components can cause sustained electrical arcing or fire Do not energize cables that have been damaged Damaged cable or terminations may need to be repaired or replaced Damaged cable should b
15. PyrotenaxMlindustrialwiring IM H57987 04 13 Installation 5 2 Connection to Junction Boxes and Other Equipment Locating junction boxes below grade or too low to the ground may allow moisture to enter the junc tion box resulting in cable failure All junction boxes must be mounted above grade level All cable or conduit leading to junction boxes must be installed so that water does not enter the box Avoid entering the junction box from the top as this may allow water to enter Take appropriate mea sures to ensure that moisture does not collect in the bottom of the junction box 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 If using nonmetallic junction boxes the gland connector must be con nected to a ground bushing Figure 14 to ensure that the cable sheath is bonded to ground Figure 14 Typical ground bushing for nonmetallic enclosures only Install the pot so that it extends above the bottom of the junction box Figure 15 and Figure 16 to pre vent moisture due to condensation from contami nating the face of the pot Screw the gland connector into the junction box hub and tighten the comp
16. ad the tra peze system under fire conditions the steel chan nel will sag deflect possibly damaging the cables Refer to Single Conductor Cable on page 19 and EN PyrotenaxMlindustrialwiring IM H57987 04 13 23 Installation Multiconductor Cable on page 19 for details regarding the installation of single and multiconduc tor MI industrial wiring cables 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 bun dle This ensures a neat installation prevents move ment 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 weight of the entire vertical cable run For further information on this installation method contact Pentair Thermal Management Technical Support see Section 1 1 Steel pipe conduit clamp with Steel rods securely anchored to fire rated E structure Support spacing per NEC CEC other national electrical codes _ and standards or customer specification lc E Steel or stainless wA steel channel T Steel or Multiconductor Stainless steel stainless steel MI cable banding gear washers and clamp every 2ft nuts Single 610 mm between conductor supports MI cable Figure 13 Typical installation using trapeze support 24 EN
17. aller bends The relationship between cable diameter and mini mum bending radius is shown in Figure 10 When small bends are necessary do not try to make the entire bend in one operation Bend in small incre ments Shape into final position gradually When offsetting the cable to enter a junction box equip ment via a gland connector at least 2 to 3 in 50 to 75 mm of straight cable should be left between the gland connector and the final bend to facilitate withdrawal of the gland connector from the junction box equipment EN PyrotenaxMlindustrialwiring IM H57987 04 13 17 Installation see Table 1 avava am OOOOOC Note Bending radius shown for 0 75 and smaller cables Cable O D Figure 10 Minimum bending radius 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 sys tem cable tray trapeze etc Attach the pulling rope to the end of the cable as described in Section 4 4 Pull the cable by hand throughout the desired routing Use personnel to guide the cable around corners using large sweeping hand formed bends Do not bend the cable to a radius smaller than the minimum pulling radius shown in Table 2 while pulling the cable into position When changing direc tion from a horizontal to vertica
18. ay Do not overload the cable tray follow the loading requirements in the NEC CEC or other national electrical codes and standards when installing cables in cable tray Refer to Single Conductor Cable on page 19 and Multiconductor Cable on page 19 for details regarding the installation of single and multiconduc tor MI industrial wiring cables 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 During future maintenance replacement or relocation of equip ment the extra cable can be used to service or EN PyrotenaxMlindustrialwiring IM H57987 04 13 21 Installation rewire the equipment without having to replace the cable Once the cables have been pulled into position secure the cables to the rungs of the cable tray every 2 ft 610 mm using stainless steel bands stain less steel tie wire or adjustable gear clamps 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 sec tion of cable from supporting the weight of the entire vertical cable run For further information on cable tray installations contact Pentair Thermal Management Technical Support see Section 1 1 Support spacing per NEC CEC other
19. cured shaft flange Cable or reel may be extending through both flanges damaged Cradle both reel flanges Never allow fork tines to touch between fork tines the cable surface or reel wrap Lower reels from a Never drop reels truck using a hydraulic gate hoist or fork lift LOWER CAREFULLY Right Wrong Figure 3 Reel handling DOs and DON Ts 8 EN PyrotenaxMlindustrialwiring IM H57987 04 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 Roll reel in the direction indicated by the arrow Figure 4 Reel rolling Uncoiling Cable Do not uncoil cable or transfer cable to another reel prior to installation as it will become work hardened making it less easy to install Support reel on a jack stand when uncoiling cables supplied in coils may be fed from a pay off reel Figure 5 Have someone rotate the reel or Coil to feed the cable as it is being pulled This will greatly ease the handling and prevent possible twisting bending and kinking Use appropriate precautions when uncoiling cable see Section 4 2 Handle cable carefully during uncoiling to prevent damage due to kinking or bending to a radius smaller than t
20. e ends once testing is complete TEST EQUIPMENT 500 Vdc megohmmeter calibrated 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 n a warm dry environment IR readings should be 200 MO or higher n an outdoor environment or indoors in wet or humid conditions IR readings should all be above 100 MQ Any large difference in readings between simi lar cables under similar conditions should be investigated Prior to initial start up commissioning mini mum 25 MA After any maintenance or repair work minimum 25 MQ F Important If IR readings are low follow the instructions in Appendix A to dry out the cable Repairs Use only Pyrotenax MI cable and components when replacing any damaged cable Repairs should be performed only by qualified personnel and to Pentair Thermal Management requirements Retest the sys tem after repairs A WARNING Damage to cables or components can cause sustained electrical arcing or fire Do not ener gize cables that have been damaged Damaged cable or terminations may need to be repaired or replaced Damaged cable should be repaired by a qualified person 34 EN PyrotenaxMlindustrialwiring IM H57987 04 13 6 Testing and Commissioning Test Procedure The megohmmeter connec
21. e protected with a similar fireproofing material at the points of entry into the junction box and actuator The intumescent material protecting the gland con EN PyrotenaxMlindustrialwiring IM H57987 04 13 29 Installation nectors is formed to shape by the manufacturer to completely cover the connector Install the protective fireproofing material in accordance with the manu facturer s installation instructions Seal all gaps and joints around the fireproofing system with a suitable fireproofing caulking Steel I beam supporting structure Seal all gaps and joints with 4 fireproof caulking gt lt Single MI cable Multiconductor gland connectors TT 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 Figure 20 Fireproofing gland connectors into junction box 30 EN PyrotenaxMlindustrialwiring IM H57987 04 13 Installation Actuator protected with intumescent fireproofing material Multiconductor MI cable Ze for power and control MI cable gland connectors protected with intumescent fireproofing cover Seal all gaps and joints with fireproof caulking Figure 21 Fireproofing gland connectors into actuator 5 5 Cable Terminations MI industrial wiring cables are typically suppli
22. e repaired by a qualified person When installing cables which may be exposed to hydrocarbon flash fires use only steel or stainless steel in the support system EN PyrotenaxMlindustrialwiring IM H57987 04 13 Table of Contents 1 General Information 1 1 1 Use of the Manual 1 1 2 Safety Guidelines 1 1 8 Approvals 2 1 4 Warranty 2 2 Introduction 3 2 1 General 3 2 2 Factory Terminated Cables 4 2 3 Field Terminated Cables 4 3 Storage and Handling 5 3 1 Storage 5 3 2 Handling 7 4 Pre Installation 11 4 1 Minimum Installation Temperature 11 4 2 Precautions 11 4 3 Factory Terminated Cables 12 4 4 Installation Equipment 12 4 5 Set Up 13 5 Installation 15 5 1 General Installation Guidelines 15 5 2 Connection to Junction Boxes and Other Equipment 25 5 3 Installation in Hazardous Areas 27 5 4 Protecting the MI Cable Terminations from Hydrocarbon Flash Fires 29 5 5 Cable Terminations 31 6 Testing and Commissioning 33 6 1 Tests 33 7 Troubleshooting Guide 38 8 Appendixes 40 Appendix A Improving Insulation Resistance IR 40 Appendix B Cable Inspection Record 42 EN PyrotenaxMlindustrialwiring IM H57987 04 13 EN PyrotenaxMlindustrialwiring IM H57987 04 13 General Information 1 1 1 2 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 cor rectly sized and the installati
23. e sheath and connections to the cable for physical damage Damaged cable must be repaired or replaced Check that no moisture is present in junction boxes and other enclosures Ensure that electrical connections are tight and grounded Ensure that the cable carries the correct circuit identification and that there have been no unau thorized modifications to the cables Verify that all junction boxes are appropriate for the area classification and correctly sealed and that the cable glands are tight and correctly fitted into junction boxes IR Test IR testing is conducted using a megohmmeter and tests the integrity of the cable between the conduc tors and the cable sheath and between conductor pairs in multiconductor cables If the terminations or heat shrinkable end caps are damaged missing or removed moisture will enter the mineral insulation resulting in low IR readings Prior to testing factory terminated cables wipe both ends of the cable sheath pot and tails with a clean dry cloth to remove any moisture which may result in erroneous results such as low IR readings When testing unterminated cables it may be neces sary to remove the heat shrinkable tubing and strip back the cable sheath from both ends to ensure that the conductors do not touch the cable sheath and EN PyrotenaxMlindustrialwiring IM H57987 04 13 33 Testing and Commissioning are spaced apart from each other Reseal th
24. ed with factory installed terminations These cables are ready to connect into junction boxes and other equip ment as soon as they are received at the job site Where field installed terminations are required Pyropak termination kits are available with either a mastic sealing compound or epoxy sealing com pound Both kits are approved for use in hazardous and nonhazardous areas Refer to the Termination Kits data sheet H58421 for further details Prior to installing field terminations check the cable with a 500 V megohmmeter to ensure the IR is acceptable see Section 6 Follow the instructions supplied with the Pyropak kits to complete the cable termination EN PyrotenaxMlindustrialwiring IM H57987 04 13 31 Installation Cap and sleeve assemblies Gland connector Expoxy sealing compound Figure 22 Termination kit with epoxy sealing compound Cap and sleeve assemblies Gland connector Mastic sealing compound Figure 23 Termination kit with mastic sealing compound 32 EN PyrotenaxMlindustrialwiring IM H57987 04 13 Testing and Commissioning 6 1 Pentair Thermal Management recommends that the Cable Inspection Record in Appendix B be completed during testing and commissioning and kept for future reference Tests Visually inspect cables and terminations and check the insulation resistance IR prior to energizing Visual Inspection e Visually inspect the cabl
25. he minimum pulling radius see Table 2 Ensure that the cable is not twisted during installation Do not run over cable drag cable over sharp objects or subject cable to other such treatment that could cause damage EN PyrotenaxMlindustrialwiring IM H57987 04 13 9 3 Storage and Handling Reel E Right Wrong Coil e Right Wrong Figure 5 Unreeling uncoiling cable EN PyrotenaxMlindustrialwiring IM H57987 04 13 Pre Installation 4 1 4 2 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 pro vincial local and municipal laws must be followed For further information on installing MI cables contact Pentair Thermal Management Technical Support see Section 1 1 Minimum Installation Temperature A minimum installation temperature of 40 F 40 C is recommended for MI cables Precautions When installing Pyrotenax MI industrial wiring cables all appropriate precautions should be fol lowed including OSHA and other applicable national safety regulations Therefore in addition to observ ing standard safety practices observe the following Take reasonable precautions to prevent damage to the cable from severe blows with sharp instru ments
26. ield Reseal cable end with adhesive lined heat shrink tubing until ready to ter minate cable EN PyrotenaxMlindustrialwiring IM H57987 04 13 41 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 Pentair Thermal Management 7433 Harwin Drive Houston TX 77036 USA Tel 1 800 545 6258 1 650 216 1526 Fax 1 800 527 5703 1 650 474 7711 thermal info pentair com www thermal pentair com 42 EN PyrotenaxMlindustrialwiring IM H57987 04 13 8 Appendixes Voltage setting 500 Vdc Accuracy full scale IR Conductor to Conductor Date Date Date Pentair Thermal Management 250 West St Trenton Ontario Canada K8V 5S2 Tel 1 800 545 6258 1 650 216 1526 Fax 1 800 527 5703 1 650 474 7711 thermal info pentair com www thermal pentair com EN PyrotenaxMlindustrialwiring IM H57987 04 13 43 gt PENTAIR NORTH AMERICA Tel 1 800 545 6258 Fax 1 800 527 5703 Tel 1 650 216 1526 Fax 1 650 474 7711 thermal info pentair com ASIA PACIFIC Tel 86 21 2412 1688 Fax 86
27. instal lations must be in compliance with the applicable requirements of the NEC CEC and any other appli cable national or local codes and standards EN PyrotenaxMlindustrialwiring IM H57987 04 13 Installation 5 4 Explosion proof Tighten gland connector to recommended torque junction box Five engaged threads s Form excess MI cable into a loop uer ld Figure 19 MI cable connection into junction box Protecting the MI Cable Terminations from Hydrocarbon Flash Fires While MI cable will continue to function when sub jected 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 ter minations with a passive fireproofing system such as a rigid semi rigid enclosure flexible enclosure or intumescent coating such as K MASS capable of withstanding the expected temperatures For other fire rated applications where the terminations must be protected please contact Pentair Thermal Management Technical Support see Section 1 1 V Important Junction boxes actuators valves etc must be protected as required by the customer speci fication In Figure 20 and Figure 21 the junction box and valve actuator are in the fire zone and are protected with intumescent fireproofing material In both cases the MI cable gland connectors terminations must b
28. l pull use sheaves or pulleys to guide the cable around the bend The cable can be neatly arranged in the tray trapeze once it has been completely pulled into position If installing a cable with a factory termination on one end only and if space permits it is recommended that the cable pull begin at the equipment such as a valve actuator and that the cable be pulled from the unterminated end This will reduce the possibility of damage to the terminated end 18 EN PyrotenaxMlindustrialwiring IM H57987 04 13 m Installation TABLE 2 MINIMUM PULLING RADIUS Cable O D outside diameter 0 75 in 19 mm and smaller 12 times cable diameter Larger than 0 75 in 19 mm 24 times cable diameter Multiconductor Cable Multiconductor cables are typically used in industrial wiring applications Cables can be connected to any junction box valve actuator or equipment approved for the area classification Refer to Sections 5 2 5 3 and 5 4 for further details on connecting MI multi conductor cables to junction boxes and other equip ment and be sure to follow the applicable require ments of the NEC CEC or other national electrical codes and standards Twisted Pair Fire Alarm and Communication Cable Twisted pair cable is installed in the same manner as multiconductor cables When installing circuits requiring twisted pair cables ensure that the cable parameters are compatible with the equipment Single
29. led termination kits are available with the epoxy sealing compound or mastic sealing com pound shown in Section 5 5 and should be selected based on the application Identification tags are not supplied EN PyrotenaxMlindustrialwiring IM H57987 04 13 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 the following storage measures Initial Inspection When the cables are received Inspect the factory applied protective covering on the cable for evidence of shipment damage Keep the protective cover in place until removal is abso lutely necessary Where possible check the cable sheath for evi dence of shipment damage Verify that terminations or heat shrinkable end caps are not damaged missing or removed Verify that factory terminated cables are correctly labeled and have the appropriate gland connector fittings for the intended use Check the insulation resistance IR for the pres ence of moisture in the cable using a megohm meter damage to the sheath end caps or ter minations will cause moisture to enter the cable See Section 6 fo
30. llation Equipment Pulling Equipment It is recommended that all sizes of cables be hand pulled into position one at a time using pulling ropes securely attached to the cable end When pull ing cables around corners hand feed cables using large sweeping bends Mechanical pulling equip ment such as tuggers is not recommended Sheaves Use sheaves or pulleys of the proper diameter where required to avoid damage to the cable Pulling Rope Use non stretch pulling rope with a capacity large enough to handle the force required to pull the cable It is recommended that the pulling rope be attached to the cable sheath using a series of six half hitch knots and the knots and rope be securely taped to the sheath to prevent movement during the pull 12 EN PyrotenaxMlindustrialwiring IM H57987 04 13 Pre Installation 4 5 When pulling cables from a factory terminated end ensure that the end is protected with a short length of PVC pipe see Figure 6 and securely attach the pulling rope to the cable sheath to avoid damage to the termination Install cable grips swivels and pulling eyes if used according to manufacturer s instructions Set Up Examine cable trays trapeze support systems and other support systems for acceptability prior to pull ing activities Install permanent supports properly to ensure the rigidity of the cable tray trapeze or other support system so that neither the support syste
31. m nor the cable will be subjected to damage during the pulling process Before installation verify that the cable s can be installed according to the designed routing and mini mum bending radius requirements Where it is not practical to completely remove the cable from the reel set up the reel using sheaves or pulleys as shown in Figure 7 The first sheave must be installed at a point higher than the support sys tem Use a roller at the entry and exit points of the tray trapeze system The setup should ensure that the cable is not kinked or bent beyond the minimum pulling radius see Table 2 or subject to excessive twisting force Minimize the amount of tension necessary to pull a cable as follows Pullin the proper direction Where practical a cable pull should begin nearest the end having the least degrees of bends and exit the end having the greater degrees of bends if at all possible Also in vertical sections an upward pull is preferred Minimize the number and degrees of bends the cable is pulled around under tension Accomplish this by finding the straightest route possible using the least amount of bends EN PyrotenaxMlindustrialwiring IM H57987 04 13 13 4 Pre Installation AN Roller f 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
32. of MI cable explod ing gases or vapors and liquids under continuous pressure cannot travel through it When terminated with an approved termination for hazardous areas MI cable is a proven gas path block and is used for wiring to equipment and junction boxes in hazard ous areas without the requirement for conduit and special seals MI cable can be used in place of braided flexible couplings in areas where limited flexibility is needed Where the termination is subjected to vibration such as when connecting to a motor a large expan sion loop as shown in Figure 18 is recommended In cases of severe differential vibration the cable should be terminated into a junction box adjacent EN PyrotenaxMlindustrialwiring IM H57987 04 13 27 Installation to the vibrating equipment and the final connection made via a flexible conduit and or cable Large expansion loop Explosion proof 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 If making a field termination ensure that the termination kit is the correct type for the area classification see Figure 22 and Figure 23 Use up excess cable by forming the cable into a loop as shown in Figure 19 All
33. on properly designed Installers must be trained and familiar with relevant codes and standards and generally accepted good practice for handling and installing power cables For installations or situations that are not covered in this guide please contact Pentair Thermal Management for guidance For additional information contact Pentair Thermal Management 7433 Harwin Drive Houston TX 77036 USA Tel 1 800 545 6258 Tel 1 650 216 1526 Fax 1 800 527 5703 Fax 1 650 474 7711 thermal info pentair com www thermal pentair com Safety Guidelines The safety and reliability of an MI cable system depend on the proper design and installation of the system and use of proper materials for support as well as the quality of the cable selected Incorrect design or installation or use of inappropriate sup port materials can result in a system that may not perform satisfactorily and in the case of a fire rated system it may not perform under fire conditions Install all wiring in accordance with the latest edi tion of national electrical codes and standards such as the National Electrical Code NEC or Canadian Electrical Code CEC and or the Authority Having Jurisdiction and the instructions in this manual Pay special attention to the following Important instructions are marked V Important Warnings are marked A WARNING EN PyrotenaxMlindustrialwiring IM H57987 04 13 1 General Information 1 3
34. pplica tions in industrial installations It is extensively used in petrochemical plants where the integrity of power and control wiring to emergency block valves and emergency equipment must be maintained during a hydrocarbon flash fire The solid construction of MI cable makes it suitable for use in hazardous areas to prevent the passage of explosive gases In addi tion it is used in pulp and paper plants electricity generation plants and in mines and manufacturing where resistance to extreme heat and corrosion is required For further information on using and installing MI cable refer to the applicable sections of the NEC CEC or other national electrical codes and standards if outside the US and Canada Alloy 825 sheath Magnesium oxide MgO insulation Solid nickel clad copper or nickel conductors Figure 1 MI industrial wiring cable EN PyrotenaxMlindustrialwiring IM H57987 04 13 Introduction 2 2 2 3 Factory Terminated Cables Factory terminated cables can be connected as received to junction boxes and other equipment The standard factory termination utilizes the epoxy seal ing compound shown in Figure 22 The cables are supplied with a metal identification tag showing the cable specifications and approvals Field Terminated Cables Cables that are to be terminated in the field are supplied with temporary heat shrinkable end caps that seal the ends against moisture ingress Field instal
35. r testing guidelines and record the results of the tests in the Cable Inspection Record in Appendix B If moisture is present fol low the instructions in Appendix A to remove the moisture or contact Pentair Thermal Management for guidance EN PyrotenaxMlindustrialwiring IM H57987 04 13 5 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 mov ing vehicles and other hazards Store factory terminated cables in a manner that prevents damage to the sealing pot and flexible tails Do not remove the heat shrinkable end caps from bulk cable until the cable is ready to be terminated Do not stack coils or reels Do not store coils or reels flat Store coils upright and reels upright on their flanges Figure 2 Ensure that both ends of the cable are securely fastened to the reel flange Store reels on a firm surface paved if possible or on planking to prevent reels from rotting SS p Always load and store reels Laying heavy reels flat upright on their flanges can cause damage and block securely Right Wrong Figure 2 Store reels upright on flanges EN PyrotenaxMlindustrialwiring IM H57987 04 13 Storage and Handling 3 2 Handling Moving Coils and Reels Handle and install cables within suitable tempera ture limits See Section 4 1
36. res sion nut rear nut on gland connector to the torque value shown on the tag supplied with the factory ter minated cable or field termination kit This ensures that the cable sheath is properly bonded to ground and provides a proper flame path in hazardous areas EN PyrotenaxMlindustrialwiring IM H57987 04 13 25 Installation V Important Minimize handling the tails to avoid breakage Metal junction box Ground screw Threaded hub a Pot Gland connector a Mlcable Figure 15 Connection to metal junction box Nonmetallic Ground screw junction box N Pot extend above bottom of junction box t PC gt A E Pot extend Threaded above bottom of ground bushing junction box Gland connector a MI cable Uv g Figure 16 Connection to nonmetallic junction box 26 EN PyrotenaxMlindustrialwiring IM H57987 04 13 Installation Junction box 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 Gland connector MI cable 5 3 Drip loop Figure 17 Drip loop at point of entry into junction box Installation in Hazardous Areas Due to the solid construction
37. tion to check the IR of the MI cable between the conductors and the cable sheath and between conductor pairs is shown in Figure 24 Insulation Resistance Test d 2 10 11 12 Set megohmmeter test voltage at 0 Vdc Connect the positive earth lead to the cable sheath Connect the negative Line lead to one conductor Turn on the megohmmeter and set the voltage to 500 Vdc apply the voltage for one minute Meter needle should stop moving Rapid deflection indicates a short Note the insulation resistance value It should correspond to the values shown under Test Criteria Turn off the megohmmeter If testing a single conductor cable proceed to Step 7 If testing a multiconductor cable proceed to Step 8 Testing is complete If the megohmmeter does not self discharge discharge phase connec tion to ground with a suitable grounding rod Disconnect the megohmmeter If testing a multiconductor cable repeat Steps 3 through 5 for remaining conductors Next remove the positive earth lead from the cable sheath and connect it to one of the other conductors Test the cable as in Steps 3 through 5 Repeat for all conductor pair combinations Testing is complete If the megohmmeter does not self discharge discharge phase connec tion to ground with a suitable grounding rod Disconnect the megohmmeter EN PyrotenaxMlindustrialwiring IM H57987 04 13 35 Testing and Commissioning
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