Fact Finding Report. Power over Local Area Network Type Cables (4-Pair Data / Communications Cables) <with errata 1 revisions>

Size: px

Start display at page:

Download "Fact Finding Report. Power over Local Area Network Type Cables (4-Pair Data / Communications Cables) <with errata 1 revisions>"

Ira Cunningham
6 years ago
Views:

1 Issued: September 25, 2015 Fact Finding Report on Power over Local Area Network Type Cables (4-Pair Data / Communications Cables) <with errata 1 revisions> SPI: the plastics industry trade association Washington, DC Fact-Finding Investigations are undertaken to develop facts and issue a Report for use by the Applicant in seeking amendments in nationally recognized installation codes and standards. The issuance of this Report does not constitute an endorsement of any proposed amendment and in no way implies Listing, Classification or other recognition by UL and does not authorize the use of UL Listing or Classification Marks or any other reference to Underwriters Laboratories Inc. on, or in connection with, the product. UL LLC, its employees, and its agents shall not be responsible to anyone for the use or nonuse of the information contained in this Report, and shall not incur any obligation or liability for damages, including consequential damages, arising out of or in connection with the use of, or inability to use, the information contained in this Report. UL LLC authorizes the above named company to reproduce this Report provided it is reproduced in its entirety. Copyright 2015 UL LLC Page 1 of 164

2 Issued: September 25, 2015 Contents INTRODUCTION... 3 GENERAL... 3 OBJECTIVES... 4 DISCUSSION... 4 PLAN OF INVESTIGATION... 6 General... 6 Samples... 6 General Test Conditions... 7 TEST EQUIPMENT AND SET-UP TEST DATA Thermal Response to Current Specific Conductor Ampacities for Cables in a Bundle Configurations where only ½ of the Conductors are Powered Effects of Current Different Installation Methods Enclosing Cables Installation Orientation Firestop Cable Comparisons Cable Configurations LP Cables LP CABLE REQUIREMENTS SUMMARY APPENDIX A - CABLE DETAILS APPENDIX B - TEMPERATURE TEST DATA APPENDIX C - DATA for NEC TABLES APPENDIX D - CABLE HEATING TEST Copyright 2015 UL LLC Page 2 of 164

3 Issued: September 25, 2015 INTRODUCTION GENERAL The following is a report on the heating effects of dc current on 4-pair local area network (LAN) cabling when configured in various bundle sizes and simulated installation conditions. Typically these cables are 4-pair Category type cables originally designed and intended for the transmission of data and communications. However, changes in technologies and equipment design have resulted in these cables increasingly being used to provide low voltage (<60 Vdc), limited power along with the data and communications signals. Power levels have been steadily increasing and are expected to continue to do so. In addition, these cables are often installed in bundles where cumulative heating effect of the numerous cables in the bundle combined with limited heat dissipation for the cables buried inside of the bundle raise concerns about exceeding the temperature ratings of the cable. The current (2014) version of the National Electrical Code (NEC), NFPA 70, covers data and communications circuits in Articles 725 and Chapter 8 respectively. Article 725 references Table 11(B), Class 2 and Class 3 Direct-Current Power Source Limitations, for power and current limitations on these circuits. Chapter 8 contains no specific requirements or references on power or current limitations on these circuits. Existing data from a number of sources has suggested that the present current limits in the NEC, where they exist, are too high for these cabling systems and the way they are deployed. As part of the revision cycle for the 2017 National Electrical Code (NEC), public inputs were received related to remote powering over local area networking cable. The public inputs suggested that the existing Class 2 limits in Table 11B of the NEC permitted maximum currents that could result in the overheating of cables and recommended adding ampacity limitations for these applications based on wire size (AWG) and bundle size. In addition, the public inputs suggested that special cable designs could be developed and that might be used as alternatives to more traditional cables and AWG size alone with less restrictions on cable designs and the installations. These public inputs resulted in proposed first revisions for the NEC that include requirements for limiting the power and conductor ampacities of powering over communications cable systems based on wire gauges and bundle sizes. In addition, a provision was included for special cables ( LP cables) that could be used as Copyright 2015 UL LLC Page 3 of 164

4 Issued: September 25, 2015 alternatives to more traditional cables that would allow for innovative cable designs and less restrictions on the installations. At the time of the development of the proposed first revisions, there was very little hard data to support the inclusion of comprehensive ampacity tables. As a result, the proposed ampacity table only included single cables and multi-cable bundles. In addition, although LP cables were included as alternatives to traditional cables, there were no listing requirements for LP cables or listed LP cables. To support the development of more comprehensive ampacity tables and the development of listing criteria for LP cables, the industry commissioned UL to conduct a fact-finding investigation to develop data to support these objectives. OBJECTIVES 1) Develop data to support changes to the National Electrical Code (NEC), NFPA70, (Articles 840 and 725) 2) Development of requirements for the listing of LP cable 3) Determine what parameters affect a cable s ability to handle current in a bundle. a. What effect does Wire Gauge Have on Cable Heating? b. What effect does Cable Construction Have on Cable Heating? c. What effects do Cable Construction Materials Have on Cable Heating? 4) Determine the effects of different installations (i.e. bundle size, routing, enclosing) on cable heating. a. What effect does the installation have on cable heating b. Assess the worst case installation scenarios and what conditions have the most heat rise. 5) Investigate the combined effects of higher levels of power applied over communications cables under typical installation practices permitted by the NEC DISCUSSION Powering over LAN Cable systems provide both data and power in one cable, usually connected through an RJ45 style 8-pin connector. It encompasses any one of a number of standardized and proprietary systems that provide data and power to low power demand devices such as IP telephones, wireless access points, or IP cameras. Low power systems are usually configured in a 2-pair powering configuration while higher power systems (still power limited) may require a 4-pair powering scheme. Copyright 2015 UL LLC Page 4 of 164

Issued: September 25, 2015 On systems where data utilizes only 2-pairs, a 2-pair powering scheme may be carried on the unused cable pairs or on the same conductors as the data.

5 Issued: September 25, 2015 On systems where data utilizes only 2-pairs, a 2-pair powering scheme may be carried on the unused cable pairs or on the same conductors as the data. 2-pair (4-wire) Powering Configurations: On higher data capacity systems, where all 4 pairs are needed for data transmission speed, power is carried on the same -pairs as the data in either a 2-pair or 4-pair powering scheme. 2-Pair (4-wire) and 4-Pair (8-wire) Powering Configurations As can be seen from these circuit diagrams, the present state of implementation is to utilize two pairs of conductors for each power circuit. This is true whether the system applies the power to the unused conductors of a cable or applies a common-mode voltage to the data pairs. This means that for a given circuit, the current in the circuit is carried by two conductors and therefore the current for the circuit is halved for each individual conductor. Copyright 2015 UL LLC Page 5 of 164

6 Issued: September 25, 2015 PLAN OF INVESTIGATION General Several possible investigation plans were considered. The first involved selecting a number of installation configurations considered to be representative of both typical installations and worst-case heating. This would be based on data already circulating on this subject. Different cable types would be tested in the various configurations. The second approach would concentrate on installation configurations, testing a wider variety of configurations using a single cable type. The results of these tests could then be used to determine a much narrower set of useful test configurations that could be used to test other cable types. Since this second approach would yield hard data that not only better supports the final test configurations but would also provide valuable data to support the NEC proposals related to powering over LAN cable, this is the approach that was chosen. Samples There were six distinct types of LAN cables tested as part of this investigation. Sample No. Description 1 CAT 5E 24AWG UTP (YELLOW) 2 CAT 5E 26AWG STRANDED FTP SHIELDED PATCH (LT Grey) 3 CAT 6 23AWG UTP RISER CMR (Blue) 4 CAT 6 23AWG UTP PLENUM CMP (White, Pink) 5 CAT 6 22AWG UTP PLENUM CMP (Blue) 6 CAT 6A 23AWG SHIELDED PLENUM (Dark Grey) These cables were selected to: Include the lightest and heaviest wire gauges Include different diameters which will affect the thermal characteristics Refer to Appendix A for detailed cable descriptions. Copyright 2015 UL LLC Page 6 of 164

Issued: September 25, 2015 General Test Conditions Thermocouples Thermocouples would be placed on the cable jacket at various positions along the cable bundle length and at various depths in the tray

7 Issued: September 25, 2015 General Test Conditions Thermocouples Thermocouples would be placed on the cable jacket at various positions along the cable bundle length and at various depths in the tray or bundle. For example (from CENELEC TR ): In addition, a TC would be placed on an individual insulated conductor inside of the center cable. This arrangement shall provide us with the following: Hard data showing where the greatest heating takes place A thermal profile along the length of the cable showing where the end effect becomes a concern (i.e. how close to the end shall the added radiating surface area significantly affect the results?). Data showing if the individual wire insulation is subjected to higher temperatures than the overall cable jacket. Current The present implementations of powering over LAN cable utilize two 2-pair wires for each powering circuit. As a result, test conditions are often reported as having some amperes per pair. However, in the power world, power is often considered to be delivered over a single pair of wires; the + conductor and the - conductor. Copyright 2015 UL LLC Page 7 of 164

8 Issued: September 25, 2015 This has led to some confusion of whether the specified current for a test is on two pairs of conductors with each conductor carrying ½ the current or on a single pair of conductors with each conductor carrying the specified current. The NEC proposals deal with power per circuit and amperes per conductor. Amperage designations would utilize amperes per conductor to avoid any confusion. This can easily be converted to any implementation later as needed. Since the original PoE specification used 175 ma/conductor, testing would be conducted starting at this current just as a benchmark. The next implementation of PoE is expected to be in the range of 60 watts which translates to 0.3 amperes per conductor so this would be another desirable data point. After that steps of 0.5 amperes per conductor and 1.0 amperes per conductor were discussed. To accommodate future technologies, the NEC is proposing Class 2 limits that would permit up to 1.6 amperes per conductor at 60 volts. However, since the NEC Class 2 current limits are based on a power limit of 100 watts and the current limits are defined as 100/V for voltages between Vdc, the maximum permissible current changes based on the circuit voltage. Although it is expected that higher voltages would be more desirable from a loss standpoint, there could be reasons why lower voltages might be considered. For example, there is a lot of available equipment and components available for 48Vdc because of its usage in telecommunications. With these systems, the minimum operating voltage would be 40V. As a result of the above, the plan was to test each configuration over a range of 0.5 amperes to 2.5 amperes at.25 ampere increments with the addition of the original 175 ma as a reference point that might be useful for comparing results with testing already performed by others. The same test sample would be used and the current increased after temperature stabilization without shutting the test down. This is to avoid going back down to ambient temperature for every amperage setting tested, per this example. Copyright 2015 UL LLC Page 8 of 164

9 Issued: September 25, 2015 Test Configurations Bundle sizes were selected based on the hexagonal densest packing structure. This has been shown to yield the hottest temperatures due to cable density and the fact that with this structure each new layer completely encloses the previous layer trapping heat. This structure is characterized by the following number of cables in a bundle: Where: N is the total number of cables in the hexagonally densest packing structure; n is the number of layers, surrounding the center cable. This results in N= 1, 7, 19, 37, 61, 91, 127,... At the high end, a bundle size of 192 was selected. This was based on 8 bundles of 24 cables that is typical of cabling coming off a server frame and considered a reasonable worse-case bundle size. In addition to open bundles, additional configurations were considered: Bundles in conduit with and without fire stop Cables in an open wire mesh rack Cables in a closed cable tray with and without fire stop Closed Cable tray with fire stop. The Category 5e, 24 AWG would be used for the installation configuration testing after which the other types of cables would be tested. Copyright 2015 UL LLC Page 9 of 164

Issued: September 25, 2015 TEST EQUIPMENT AND SET-UP Test Fixtures Test fixtures used to mount the cable

Parachute cord was used to support the cable bundles to minimize any heat-sinking effects.

laptop PC with suitable data acquisition software.

10 Issued: September 25, 2015 TEST EQUIPMENT AND SET-UP Test Fixtures Test fixtures used to mount the cable bundles were constructed out of 2 schedule 40 PVC pipe. Parachute cord was used to support the cable bundles to minimize any heat-sinking effects. Data Acquisition Temperature and current were measured using Agilent data acquisition / switch units and a laptop PC with suitable data acquisition software. This photo shows the typical test set-up with a laptop, Agilent data acquisition unit, precision shunt resistor and power supply. The handheld meter is just used for continuity checks. Agilent Copyright 2015 UL LLC Page 10 of 164

Issued: September 25, 2015 Model # 34972A LXI Data Acquisition /

Power sources Constant Current power supplies: VOLTEQ Model #

of 1500W BK Precision Model # 1685 B 1-60V, 5A Switching DC Power

measuring the voltage across a calibrated precision shunt resistor

11 Issued: September 25, 2015 Model # 34972A LXI Data Acquisition / Switch Unit Agilent Model # 34970A Data Acquisition / Switch Unit Power sources Constant Current power supplies: VOLTEQ Model # HY30005EX Maximum DC voltage of 300V and 5A, and maximum DC power of 1500W BK Precision Model # 1685 B 1-60V, 5A Switching DC Power Supply Measuring Current Current measurements were made via measuring the voltage across a calibrated precision shunt resistor with the Agilent data acquisition units. Copyright 2015 UL LLC Page 11 of 164

The cables in the bundle were electrically divided such that the dc resistance of each set of layers would not

12 Issued: September 25, 2015 Wiring Diagram Examples For larger bundles where the total dc resistance of the cables exceeded the power source s ability to drive the necessary current, multiple power sources were used. The cables in the bundle were electrically divided such that the dc resistance of each set of layers would not exceed the power source s ability to deliver the necessary current through the conductors. Copyright 2015 UL LLC Page 12 of 164

13 Issued: September 25, 2015 TEST DATA Thermal Response to Current The data shows that as the current per conductor increases, the measured temperature on the cable increases. This is an example of the measured temperature data. Refer to Appendix B for the complete set of temperature data. Here is some information on how to interpret the data. Copyright 2015 UL LLC Page 13 of 164

14 Issued: September 25, 2015 The data shows that increases in the number of cables in a bundle resulted in increases in measured temperatures. This chart shows and example of how the temperatures increase with increasing bundle size for a Cat 5e, 24 AWG cable. Copyright 2015 UL LLC Page 14 of 164

15 Issued: September 25, 2015 Specific Conductor Ampacities for Cables in a Bundle The data shows that overheating does not occur at 175 ma per conductor (35 watts) regardless of the cable type, bundle size or installation method. This represents existing implementations of powering, such as PoE and PoE+. This is clearly shown in the accompanying chart that shows the temperature rise for a wide variety of scenarios tested at 175mA. Overheating does not occur even if the data is corrected for a 30 o C ambient or a 45 o C ambient. The data also shows that overheating does not generally occur at 0.3 amperes per conductor (60 watts) which represents some of the newer higher power systems. This is clearly shown in the accompanying chart that shows the temperature rise for a wide variety of scenarios tested at 0.3 amperes per conductor. Overheating does not occur even if the data is corrected for a 30 o C ambient or a 45 o C ambient. Even under extreme installation conditions using 576 cables very tightly packed into an open wire cable tray it can be calculated that a 30 degrees C rise would not occur until the current reached amperes. y = x x ; For y = 30 ( o C), x = Amperes Copyright 2015 UL LLC Page 15 of 164

18 Issued: September 25, 2015 However, once the power goes up to the 100 watt powering range, or about 0.5 amperes per conductor, the data shows that under many installation conditions, overheating occurs. Only a combination of smaller bundle sizes, larger wire gauges and specialty constructions do not overheat when ambient conditions of 30 o C or 45 o C are considered. This is shown in the accompanying chart that shows the temperature rise for a wide variety of scenarios tested at 0.5 amperes per conductor. Overheating occurs even if the data is not corrected for a 30 o C ambient or a 45 o C ambient. There are systems available and more under consideration that are providing 4-pair powering of up to 200 watts or about 1 ampere per conductor. The data shows that for a significant number of installation conditions and cable types, cables will overheat at 1 ampere per conductor. This is shown in the accompanying chart that shows the temperature rise for a wide variety of scenarios tested at 1 ampere per conductor. Overheating occurs even if the data is not corrected for a 30 o C ambient or a 45 o C ambient. Copyright 2015 UL LLC Page 18 of 164

21 Issued: September 25, 2015 In order to gather data for the development of a more detailed ampacity table for the proposed Table (C) in the NEC first revision, testing was conducted using cables with various AWG wire sizes configured in different size bundles. Bundle sizes were selected based on the hexagonal densest packing structure previously described. The bundles were enclosed in conduit representing a worst-case installation condition. Temperatures were recorded at various current levels. In all but a few cases 1 at least 4 data points were recorded for each wire gauge and bundle size and used to establish best-fit polynomial trendline curves such as these examples. The curves permit the identification of the current that would yield a particular temperature. A complete set of these data graphs is provided in Appendix C. For accuracy, rather than visually use the graphs to determine the current value, the formula for the best-fit polynomial trendline is used with an iterative methodology to solve for x at a temperature y of 30 o C, 45 o C and 60 o C, representing 60, 75 and 90 o C cables. An example of the resulting table is shown below. In this example, the Best-fit Formula (Enclosed) row contains the actual y values generated by the formula for the curves using the Amperes as the x value. The objective is to get as close as reasonably possible to the target temperatures. For the 19 cable bundle the best fit formula is y = x x By adjusting the 1 In a few cases then cable failed (insulation melted) before accurate stabilized data could be obtained for a particular AWG/bundle configuration. These are noted in the graphs associated with these cases. Copyright 2015 UL LLC Page 21 of 164

22 Issued: September 25, 2015 Revised: September 29, 2015 current x to amperes, we get very close to the target temperature of 30 o C ( ) indicating that based on the data and the resulting curve, a current of amperes would result in a temperature rise of 30 o C for the cable. The notation R 2 on the plots is a statistical measure of how close the data are to the fitted trendline. When you have a scatterplot of data, and try to fit a line/curve to the data, the "measure of goodness" for the fit is reflected in the R 2 value. An R 2 value of 1 is a perfect fit. All of the data, trendline curves, formulas and tables can be found in Appendix C. The following is a summary of the data, arranged in a style that could be used to populate more comprehensive tables for the NEC. 30 C Temperature Rise (60 C Cable C Ambient) Conductor Size (AWG) Number of 4-Pair Cables in a Bundle NA C Temperature Rise (75 C Cable C Ambient) Conductor Size (AWG) Number of 4-Pair Cables in a Bundle NA Copyright 2015 UL LLC Page 22 of 164

Issued: September 25, 2015 Revised: September 29, 2015 60 C Temperature Rise (90 C Cable Rating @30 C Ambient) Conductor Size (AWG) Number of 4-Pair Cables in a Bundle 1 2-7 8-19 20-37 38-61 62-91

717 Configurations where only ½ of the Conductors are Powered INTRODUCTION Some implementations of remote powering over LAN cable utilize 2-pair powering schemes as shown in the following diagrams.

23 Issued: September 25, 2015 Revised: September 29, C Temperature Rise (90 C Cable C Ambient) Conductor Size (AWG) Number of 4-Pair Cables in a Bundle NA Configurations where only ½ of the Conductors are Powered INTRODUCTION Some implementations of remote powering over LAN cable utilize 2-pair powering schemes as shown in the following diagrams. These powering methods are still widely used. As can be seen from the diagrams, these schemes utilize only 4 conductors in the cable (out of 8) to carry current. As a result, there is less heat generated in each cable for the same amount of current per conductor. This would imply that the 4 conductors could each carry more current than each of the 8 conductors in the 4-pair power configuration to get the same heating effect. However, ½ the number of conductors carrying current does not translate to twice the current since the heating effect is related to the current squared. ASSUMPTIONS & CALCULATIONS Cable heating is a result of power dissipation given by the formula P= I 2 x R To make things simple, the following assumptions are made: Copyright 2015 UL LLC Page 23 of 164

24 Issued: September 25, 2015 The power dissipation is the same for both configurations to get the same temperature. (There might be a hotter temperature hot-spot on the individual conductor since it is carrying more current but in general the temperature rise on the cable is due to the trapped heat rather than the individual conductor temperature. The dc resistance would remain roughly the same for both scenarios. (It will be slightly higher for the 4-conductor scenario since the individual conductor will be warmer but the effect will be very small.) Given these assumptions: P 8 = P 4 = Power per cable (assume same for both) I 8 = Current for each conductor with 8 conductors energized I 4 = Current for each conductor with 4 conductors energized R = DC Resistance of each conductor (assume same for both) For 8 conductors energized: P 8 = I 8 2 x R x 8 (8 conductors) For 4 conductors energized: P 4 = I 4 2 x R x 4 (4 conductors) or I 4 = SQRT (P 4 /(R x 4)) Since the power is assumed to be the same, the formula for 8 conductor power, P8, can be substituted for P4 to get a formula for I 4 : I 4 = SQRT (P 8 /(R x 4)) = SQRT ((I 8 2 x R x 8)/(R x 4)) = SQRT (I 8 2 x 2) Calculating I 4 for a number of different I 8 currents we get the following along with a factor for each. I 8 I 4 Factor (Factor = I 4 / I 8 ) The factors are consistent, as would be expected. Copyright 2015 UL LLC Page 24 of 164

25 Issued: September 25, 2015 TESTING & DATA To validate the calculations and assumptions, tests were performed on a 61 cable bundle mounted in metal conduit and a 91 cable bundle mounted in Schedule 40 PVC conduit with 8 conductors carrying current. The tests were repeated with no changes to the test set-ups with 4 conductors carrying current. The results with best-fit trendline curves are shown below. Copyright 2015 UL LLC Page 25 of 164

methodology to solve for x at various target temperatures y.

26 Issued: September 25, 2015 The curves permit the identification of the current that would yield a particular temperature. For accuracy, rather than visually use the graphs to determine the current value, the formulas for the best-fit polynomial trendlines developed from the data are used with an iterative methodology to solve for x at various target temperatures y. The following tables were generated for various target temperatures: The Factor is the ratio of the current for the 4-conductor tests divided by the current for the 8-conductor tests. SUMMARY The data indicates that a factor of approximately 1.4 would be valid to estimate how much additional current could be carried by a 4-pair cable when only ½ of the conductors are powered. Copyright 2015 UL LLC Page 26 of 164

27 Issued: September 25, 2015 Effects of Current The data shows that in many cases, very small increases in conductor current resulted in large increases in measured temperatures. Copyright 2015 UL LLC Page 27 of 164

28 Issued: September 25, 2015 Different Installation Methods This graph shows an example of how different installation configurations affect the measured temperatures. Photographs of Different Installation Configurations Copyright 2015 UL LLC Page 28 of 164

30 Issued: September 25, 2015 Enclosing Cables The data shows that enclosing cables has a dramatic effect on the measured temperatures. These graphs show the difference between open cable and a cable enclosed in conduit. It can be seen that for the entries on the far right there is no data for the enclosed cables. This is due to the temperatures exceeding the physical limits of the insulation materials in the enclosed scenario. Copyright 2015 UL LLC Page 30 of 164

31 Issued: September 25, 2015 The data shows that sometimes different enclosed installations only made a minor difference in the measured temperatures. The following comparison shows the same cable in open air, in a 4 X 4 closed cable routing assembly and in 4 schedule 40 PVC conduit. As expected the data shows that enclosing the cable results in considerably higher temperatures. However, there is not much difference between the installation in the 4 X 4 enclosed cable routing assembly and the 4 schedule 40 plastic conduit as shown by the overlapping curves and the data plotted on the column graph. The data shows that the 4 PVC conduit resulted in slightly higher temperatures. This is expected since the volume of the cable routing assembly is slightly larger than the conduit allowing for some additional heat dissipation from the cable bundle. Copyright 2015 UL LLC Page 31 of 164

Issued: September 25, 2015 Installation Orientation Since cables can be installed in any orientation, a comparison test was run on Cat 5e, 24 AWG cable in an open wire style cable tray.

32 Issued: September 25, 2015 Installation Orientation Since cables can be installed in any orientation, a comparison test was run on Cat 5e, 24 AWG cable in an open wire style cable tray. The test configuration consisted of 576 cables filling the tray with 18 layers of 32 cables. The cables were energized with 0.5 amperes per conductor with all conductors carrying current. The exact test set-up was used for both tests. Only the orientation was changed. Copyright 2015 UL LLC Page 32 of 164

orientations, with no significant difference on the cables at the

33 Issued: September 25, 2015 Summary The results indicate very little difference between the horizontal and vertical orientations, with no significant difference on the cables at the center of the tray bundle (CH 14 through CH 16). Copyright 2015 UL LLC Page 33 of 164

For example, several of the tests showed that temperatures were lower for the configurations with the firestop.

34 Issued: September 25, 2015 Firestop When trying to compare the effects of adding firestop to cable bundles in metallic conduit, we came across variations that did not appear to be attributable to the addition of the firestop. For example, several of the tests showed that temperatures were lower for the configurations with the firestop. This would not be expected since the firestop prevents heat from escaping at the ends of the conduit. This was more pronounced for smaller bundle configurations. Copyright 2015 UL LLC Page 34 of 164

36 Issued: September 25, 2015 Especially for the smaller bundles or single cables, it appears that the unexpected temperatures are the result of a heat-sinking effect where a cable contacts the conduit and the relative position of the thermocouples to these points affects the temperature readings. This would not be as pronounced with larger bundles which would have a more consistent lay and where the thermocouples are buried deep within the bundle. Because different cable bundles were used due to cable damage when the original open-end test was run to cable destruction, the cable lay inside of the conduit was likely different providing a different heat-sinking profile. To check this, tests were performed on a single cable and a 7 cable bundle in metal conduit. Each test was first run without firestop. After thermal stabilization, firestop was carefully added without disturbing the cable. Temperatures were again allowed to stabilize and the results recorded. The data showed essentially no difference in the temperatures. This was consistent with the larger cable bundles where the lay / heat sinking effects did not appear to be significant. In these cases also, the data showed that adding firestop had little or no effect on the measured temperatures. Copyright 2015 UL LLC Page 36 of 164

conduit does not significantly affect the temperatures near the center 3

37 Issued: September 25, 2015 SUMMARY The data shows that the addition of firestop at the ends of a 6 ft. conduit does not significantly affect the temperatures near the center 3 feet of the cable. Most of the heat is trapped at the center of the conduit in either case. Copyright 2015 UL LLC Page 37 of 164

effect on the temperature rise as AWG size.

38 Issued: September 25, 2015 Cable Comparisons The data shows that the cable design and construction has as much effect on the temperature rise as AWG size. These comparisons show some examples. Copyright 2015 UL LLC Page 38 of 164

40 Issued: September 25, 2015 Cable Configurations These tests were performed to determine the difference in measured temperatures (if any) between a perfect hexagonal bundle and a more random circular bundle. Copyright 2015 UL LLC Page 40 of 164

41 Issued: September 25, 2015 LP Cables As a result of the public inputs and resulting proposed first revisions to the NEC, a need was identified to develop requirements for a special-use cable that could be used as an alternative to traditional cables. Where the ampacity tables were sufficient for existing installations and new installations where the use of traditional cables was desirable, it was recognized that cables could be designed specifically to handle powering over communications cables without all of the limitations necessary for cables of unknown heating and heat dissipating characteristics. The objective, then, was to develop requirements that would permit a cable to be identified specifically for this type of installation and use. It has been well established that cable heating can be managed via: Increased AWG size Cable design Material selection Installation Practices It was less clear how the interaction of these elements might affect a cable s ability to handle increasing current levels. For example, there was little data available showing how changing a cable s construction without changing the AWG size might affect temperatures or how variations in the installation might affect the temperatures for the same cable. Obtaining data on these variations was necessary to determine how an LP cable might be evaluated. The following tests were identified as being critical in this endeavor: Different Installations. Testing the same cable in various installation configurations to gain a better understanding of how bundle size and routing (open air, conduit, cable trays, cable routing assemblies, etc.) affects temperature Orientation. Determine the effects of horizontal vs. vertical orientation on cable temperature in a bundle. Cable Comparison. Test different cable types and constructions under the same installation and use conditions to obtain comparison data to better understand the effects of cable design on temperature. Test Variations. Study what test variations have on temperature rise and under what conditions. For example, how does current increase affect temperatures or the effects of different size conduits. Copyright 2015 UL LLC Page 41 of 164

42 Issued: September 25, 2015 LP CABLE REQUIREMENTS As part of the fact-finding investigation, UL LLC has undertaken the development of a method for determining the ability of a cable to carry current under reasonable worsecase installation conditions including bundling of large numbers of cables, enclosing the cables in raceways, cable routing assemblies or conduit and elevated ambient temperatures. This effort has resulted in the test procedure described in APPENDIX D, Cable Heating Test. Copyright 2015 UL LLC Page 42 of 164

43 Issued: September 25, 2015 SUMMARY In consideration of the fact-finding character of the investigation, the foregoing Report is to be construed as information only and should not be regarded as conveying any conclusion or recommendations on the part of Underwriters Laboratories Inc. regarding the acceptability of the construction or performance of the product for recognition by any code or standard or for any other purpose. The investigation resulted in the development of data in support of comments / proposals related to including more extensive ampacity tables in the NEC to better manage powering over LAN cable systems. The investigation has identified that for certain powering over LAN cable installations with power levels exceeding 60 watts, overheating of the cables will occur. Cable heating can be managed via: Increased AWG size Cable design Material selection Installation Practices The investigation produced data leading to the development of testing requirements for -LP cables. Randy Ivans Program/Project Manager Wire and Cable Commercial & Industrial UL LLC. Anthony Tassone PE Principal Engineer (PDE) Wire & Cable Commercial & Industrial UL LLC. Copyright 2015 UL LLC Page 43 of 164

45 Issued: September 25, 2015 Number of pages in this package [including additional pages - ] (Fill in when using printed copy as record) TESTS TO BE CONDUCTED: Test No. Done 3 Test Name 1 X DETAILED EXAMINATION: 5E 24AWG 2 X DETAILED EXAMINATION: 5E 26AWG 3 X DETAILED EXAMINATION: 6 R 23AWG 4 X DETAILED EXAMINATION: 6 P 23AWG 5 X DETAILED EXAMINATION: 6 P 22AWG 6 X DETAILED EXAMINATION: 6A 23AWG [ ] Comments/Parameters [x] Tests Conducted by 2 [ ] Link to separate data files 4 Tim Falvey Michael Askin Michael Askin Michael Askin Michael Askin Michael Askin [X] Safety Certification - Unless specified otherwise in the individual Methods, the tests shall be conducted under the following ambient conditions. Confirmation of these conditions shall be recorded at the time the test is conducted. Ambient Temperature, C 23 ± 5 Relative Humidity, % 50 ± 20 Barometric Pressure, mbar NA Copyright 2015 UL LLC Page 45 of 164

46 TEST LOCATION: (To be completed by Staff Conducting the Testing) [x]ul or Affiliate []WTD []CTDP []TPTDP []TCP []PPP P []WMT []TMP []SMT Company Name: UL LLC Address: 1285 Walt Whitman Rd. Melville, NY TEST EQUIPMENT INFORMATION [x] UL test equipment information is recorded on Meter Use in UL s Laboratory Project Management (LPM) database. TEST SAMPLE IDENTIFICATION: The table below is provided to establish correlation of sample numbers to specific product related information. Refer to this table when a test identifies a test sample by "Sample No." only. Sample Card No. Date Received [] Test No.+ Sample No. Manufacturer, Product Identification and Ratings XXXX 1 1 CAT5E 24AWG UTP (YELLOW) 2 2 CAT5E 26AWG FTP SHIELDED PATCH (LT GREY) 3 3 CAT6 23AWG UTP RISER CMR (BLUE) 4 4 CAT6 23AWG UTP PLENUM CMP (WHITE) 5 5 CAT6 22AWG UTP PLENUM CMP (BLUE) 6 6 CAT6A 23AWG SHIELDED PLENUM (DARK GREY) + - If Test Number is used, the Test Number or Numbers the sample was used in must be identified on the data sheet pages or on the Data Sheet Package cover page. Copyright 2015 UL LLC Page 46 of 164

47 DETAILED EXAMINATION: UL 444, Clause 5 Sample No. 1 Ambient Temp.: 24 C Humidity: 61% RH Note: All units are expressed in terms of: [x] Inches [ ] mm [x] Identification Print Type: None Ink Indent Tape Other: Print Content: 0394 FEET CAT-5E GENERAL CABLE J CMR C(ETL)US 4PR 24AWG 75C GENSPEED 5000 IWC---VERIFIED BY UND LAB INC ONLY TO ANSI/TIA-568C.2 CAT-5E--- TESTED TO 350MHZ F2 PAT CAT-5E Print Interval: inches No. of Insulated Conductors 8 No. Of Bare Conductors 0 Brief Assembly Description: Jacket, 4 pairs of solid-insulated conductors, rip cord Copyright 2015 UL LLC Page 47 of 164

48 DETAILED EXAMINATION (Sample #1): (CONT D) UL 444, Clause 5 Ambient Temp.: 24 C Humidity: 61% RH Note: If additional space is required please continue under attached Component section [x] Jacket Overall Jacket Inner Jacket 1 Inner Jacket 2 Inner Jacket 3 Color Yellow n/a n/a n/a Overall cable diameter, in..190 n/a n/a n/a Core diameter under jacket, in..156 n/a n/a n/a Major axis, in. n/a n/a n/a n/a Minor axis, in. n/a n/a n/a n/a Average thickness, in..016 n/a n/a n/a Min. thickness at any point, in..015 n/a n/a n/a Minimum thickness after rip, in. n/a n/a n/a n/a Average web thickness, in. n/a n/a n/a n/a Average web width, in. n/a n/a n/a n/a [ ] Note: If ave. or min. point jacket thickness exceeds / is less than the following requirement contact engineer before proceeding: Min Ave., in. Min Point, in. Copyright 2015 UL LLC Page 48 of 164

49 DETAILED EXAMINATION (Sample #1): (CONT D) UL 444, Clause 5 Ambient Temp.: 24 C Humidity: 61% RH Sample No. [ ] Armor [x] Assembly Type of Armor n/a Lay of conductors, in..5 Convolutions per inch / mm n/a Lay of conductor pairs, in. 5.7 Diameter over armor, in. n/a Lay of members, in. n/a Diameter under armor, in. n/a Strip width, in. n/a Average thickness, in. Min. thickness at any point, in. n/a n/a [ ] Braid Parameters Braid 1 Braid 2 Braid 3 Type of braid n/a n/a n/a Strand diameter, in. n/a n/a n/a No. ends n/a n/a n/a No. carriers n/a n/a n/a Picks per inch / mm n/a n/a n/a Core Dia. under braid inch/mm n/a n/a n/a Calculated % coverage n/a n/a n/a Copyright 2015 UL LLC Page 49 of 164

50 DETAILED EXAMINATION (Sample #1): (CONT D) UL 444, Clause 5 Ambient Temp.: C Humidity: % RH [ ] Tapes, binders, rods, rip cords, and fillers Type n/a n/a n/a n/a n/a Thickness, in. n/a n/a n/a n/a n/a Width, in. n/a n/a n/a n/a n/a Lap, in. n/a n/a n/a n/a n/a Overall diameter, in. n/a n/a n/a n/a n/a Helical/longitudinal n/a n/a n/a n/a n/a Calculated % coverage n/a n/a n/a n/a n/a Count n/a n/a n/a n/a n/a Major/minor axis, in. n/a n/a n/a n/a n/a Ripcord present? n/a n/a n/a n/a n/a Sample No. [x] Insulation Conductor Conductor Conductor Conductor Color ORANGE n/a n/a n/a Separator tape present? no n/a n/a n/a Average thickness, in n/a n/a n/a Minimum thickness at any point, in..006 n/a n/a n/a Minimum thickness after rip, in. n/a n/a n/a n/a Average web thickness, in. n/a n/a n/a n/a Average web width, in. n/a n/a n/a n/a [ ] Insulation Covering Color n/a n/a n/a n/a Average thickness, in. n/a n/a n/a n/a Minimum thickness at any point, in. n/a n/a n/a n/a [ ] Note: If ave. or min. point insulation thickness exceeds/is less than the following requirement contact engineer before proceeding: Min Ave., in. Min Point, in. Copyright 2015 UL LLC Page 50 of 164

51 DETAILED EXAMINATION: (CONT D) UL 444, Clause 5 Ambient Temp.: 24 C Humidity: 61% RH [x] Conductor Conductor Conductor Conductor Conductor Type (i.e. Al, Cu, etc.) cu n/a n/a n/a Coating present? no n/a n/a n/a Diameter of solid conductor, in n/a n/a n/a Diameter over insulation, in n/a n/a n/a Number of strands n/a n/a n/a n/a Strand diameter, in. n/a n/a n/a n/a Lay of strands, in. n/a n/a n/a n/a Circular Mil Area (CMA) n/a n/a n/a n/a AWG size 24 n/a n/a n/a Ambient Temp.: 24 C Humidity: 61% RH METHOD: UL 444, Clause Solid Conductor: Specimen: #1 Min. #1 Diameter, in Max. #1 Diameter, in Min. #2 Diameter, in Max. #2 Diameter, in Min. #3 Diameter, in Max. #3 Diameter, in Average Conductor Diameter, in Conductor AWG Size 24 Copyright 2015 UL LLC Page 51 of 164

52 DETAILED EXAMINATION (Sample #1): (CONT D) UL 444, Clause 5 DETAILED EXAMINATION, CONDUCTOR: Ambient Temp.: 24 C Humidity: 61% RH Sample No. [x] Conductor DC Resistance Length of specimen (ft/meter) 1 Conductor resistance (measurement 1), ohms/kft Conductor resistance (measurement 2), ohms/kft Conductor resistance (measurement 3), ohms/kft Conductor resistance (measurement 4), ohms/kft Minimum of 4 measurements, ohms/kft Temperature of conductor, C 24 Multiplying factor for adjustment to resistance at C * Conductor resistance adjusted to C, Ohms/1000 (ft/meter) * *Resistomat calculated at 20c Copyright 2015 UL LLC Page 52 of 164

53 DETAILED EXAMINATION (Sample #1): (CONT D) UL 444, Clause 5 DETAILED EXAMINATION, INSULATION: Ambient Temp.: 24 C Humidity: 61% RH METHOD: UL 444, Clause Insulation: Specimen: #1 Thickness: Min #1, in..006 Max #1, in..009 Average Thickness, in Outside diameter: Min #1, in..035 Max #1, in..035 Min #2, in..034 Max #2, in..035 Min #3, in..034 Max #3, in..035 Average Outside Diameter, in Copyright 2015 UL LLC Page 53 of 164

54 DETAILED EXAMINATION (Sample #1): (CONT D) UL 444, Clause 5 DETAILED EXAMINATION, JACKET: Ambient Temp.: 24 C Humidity: 61% RH METHOD: UL 444, Clause Jacket: Specimen: #1 Thickness: Min #1, in..015 Max #1, in..017 Average Thickness, in..016 Outside diameter: Min #1, in..184 Max #1, in..185 Min #2, in..189 Max #2, in..201 Min #3, in..175 Max #3, in..205 Average Outside Diameter, in..190 Core diameter: Min #1, in..149 Max #1, in..151 Min #2, in..154 Max #2, in..169 Min #3, in..140 Max #3, in..171 Average Core Diameter, in..156 Copyright 2015 UL LLC Page 54 of 164

55 DETAILED EXAMINATION: UL 444, Clause 5 Sample No. 2 Ambient Temp.: 25 C Humidity: 58% RH Note: All units are expressed in terms of: [X] Inches [ ] mm [X] Identification Print Type: None Ink Indent Tape Other: Print Content: YFC FTP CAT.5E 350MHZ PATCH ISO/IEC EN P CONFORMS TO GIGABIT ETHERNET 26AWGX4 TYPE CMX(UL) C(UL) CMH E F5 Print Interval: 48.5 Inches No. of Insulated Conductors 8 No. Of Bare Conductors 1 Brief Assembly Description: JKT, POLY AL WRAP, DRAIN WIRE, CLEAR POLY WRAP, 8 INSULATED STRANDED CONDUCTORS Copyright 2015 UL LLC Page 55 of 164

56 DETAILED EXAMINATION (Sample #2): (CONT D) UL 444, Clause 5 Ambient Temp.: 25 C Humidity: 58% RH Note: If additional space is required please continue under attached Component section [X] Color Jacket Overall Jacket GREY Overall cable diameter, in Core diameter under jacket, in. 183 Major axis, in. - Minor axis, in. - Average thickness, in..023 Min. thickness at any point, in..022 Minimum thickness after rip, in. - Average web thickness, in. - Average web width, in. - Inner Jacket 1 Inner Jacket 2 Inner Jacket 3 [ ] Note: If ave. or min. point jacket thickness exceeds / is less than the following requirement contact engineer before proceeding: Min Ave., in. Min Point, in. Copyright 2015 UL LLC Page 56 of 164

57 DETAILED EXAMINATION (Sample #2): (CONT D) UL 444, Clause 5 Ambient Temp.: 25 C Humidity: 58% RH Sample No. [ ] Armor [X] Assembly Type of Armor Lay of conductors, in..375 Convolutions per inch / mm Lay of conductor pairs, in. 4.0 Diameter over armor, in. Lay of members, in. - Diameter under armor, in. Strip width, in. Average thickness, in. Min. thickness at any point, in. Copyright 2015 UL LLC Page 57 of 164

58 DETAILED EXAMINATION (Sample #2): (CONT D) UL 444, Clause 5 Ambient Temp.: 25 C Humidity: 58% RH [X] Tapes, binders, rods, rip cords, and fillers Type POLY AL WRAP CLEAR POLY Thickness, in Width, in Lap, in Overall diameter, in. Helical/longitudinal HELI HELI Calculated % coverage TBD TBD Count 1 1 Major/minor axis, in. - - Ripcord present? - - Sample No. [X] Insulation Conductor Conductor Conductor Conductor Color BLUE Separator tape present? NO Average thickness, in..009 Minimum thickness at any point, in..008 Minimum thickness after rip, in. - Average web thickness, in. - Average web width, in. - [ ] Insulation Covering Color Average thickness, in. Minimum thickness at any point, in. [ ] Note: If ave. or min. point insulation thickness exceeds/is less than the following requirement contact engineer before proceeding: Min Ave., in. Min Point, in. Copyright 2015 UL LLC Page 58 of 164

59 DETAILED EXAMINATION (Sample #2): (CONT D) UL 444, Clause 5 Ambient Temp.: 25 C Humidity: 58% RH [X] Conductor Conductor Conducto r Conductor Conductor Type (i.e. Al, Cu, etc.) Cu Coating present? NO Diameter of solid conductor, in..018 Diameter over insulation, in..036 Number of strands 7 Strand diameter, in Lay of strands, in..438 Circular Mil Area (CMA) 252 AWG size 26 Ambient Temp.: 25 C Humidity: 58% RH Copyright 2015 UL LLC Page 59 of 164

60 DETAILED EXAMINATION (Sample #2): (CONT D) UL 444, Clause 5 DETAILED EXAMINATION, ROUND CONDUCTOR: (CONT D) Ambient Temp.: 25 C Humidity: 58% RH METHOD: UL 444, Clause Stranded Conductor: Specimen: #1 Number of Strands 7 Strand 1 Min. Diameter, in Max. Diameter, in Strand 2 Min. Diameter, in Max. Diameter, in Strand 3 Min. Diameter, in Max. Diameter, in Strand 4 Min. Diameter, in Max. Diameter, in Strand 5 Min. Diameter, in Max. Diameter, in Strand 6 Min. Diameter, in Max. Diameter, in Strand 7 Min. Diameter, in Max. Diameter, in Average Strand Diameter, in Total conductor area, in 2 / mm Conductor AWG Size 26 Copyright 2015 UL LLC Page 60 of 164

61 DETAILED EXAMINATION (Sample #2): (CONT D) UL 444, Clause 5 DETAILED EXAMINATION, insulation: Ambient Temp.: 25 C Humidity: 58% RH METHOD: UL 444, Clause Insulation: Specimen: #1 Thickness: Min #1, in..008 Max #1, in..010 Average Thickness, in..009 Outside diameter: Min #1, in Max #1, in Min #2, in Max #2, in Min #3, in Max #3, in Average Outside Diameter, in..036 Copyright 2015 UL LLC Page 61 of 164

62 DETAILED EXAMINATION (Sample #2): (CONT D) UL 444, Clause 5 DETAILED EXAMINATION, JACKET: Ambient Temp.: 25 C Humidity: 58% RH METHOD: UL 444, Clause Jacket: Specimen: #1 Thickness: Min #1, in..022 Max #1, in..024 Average Thickness, in..023 Outside diameter: Min #1, in..225 Max #1, in..227 Min #2, in..228 Max #2, in..228 Min #3, in..229 Max #3, in..242 Average Outside Diameter, in..230 Core diameter: Min #1, in..181 Max #1, in..182 Min #2, in..183 Max #2, in..183 Min #3, in..183 Max #3, in..184 Average Core Diameter, in..183 Copyright 2015 UL LLC Page 62 of 164

63 DETAILED EXAMINATION: UL 444, Clause 5 Sample No. 3 Ambient Temp.: 25 C Humidity: 58% RH Note: All units are expressed in terms of: [X] Inches [ ] mm [X] Identification Print Type: None Ink Indent Tape Other: CAT-6 GENERAL CABLE J CMR C(ETL)US CMG 4PR Print Content: 23AWG GENSPEED 6 IWC VERIFIED BY UND LAB INC ONLY TO ANSI/TIA-568C.2 CAT-6 Print Interval: 24 inches No. of Insulated Conductors 8 No. Of Bare Conductors 0 Brief Assembly Description: JKT, RIP CORD, FLAT FILLER, 8 INS CON Copyright 2015 UL LLC Page 63 of 164

64 DETAILED EXAMINATION (Sample #3): (CONT D) UL 444, Clause 5 Ambient Temp.: 25 C Humidity: 58% RH Note: If additional space is required please continue under attached Component section [X] Color Jacket Overall Jacket BLUE Overall cable diameter, in..228 Core diameter under jacket, in..191 Major axis, in. - Minor axis, in. - Average thickness, in..019 Min. thickness at any point, in..018 Minimum thickness after rip, in. - Average web thickness, in. - Average web width, in. - Inner Jacket 1 Inner Jacket 2 Inner Jacket 3 [ ] Note: If ave. or min. point jacket thickness exceeds / is less than the following requirement contact engineer before proceeding: Min Ave., in. Min Point, in. Copyright 2015 UL LLC Page 64 of 164

65 DETAILED EXAMINATION (Sample #3): (CONT D) UL 444, Clause 5 Ambient Temp.: 25 C Humidity: 58% RH Sample No. [ ] Armor [X] Assembly Type of Armor Lay of conductors, in..375 Convolutions per inch / mm Lay of conductor pairs, in. 4.0 Diameter over armor, in. Lay of members, in. - Diameter under armor, in. Strip width, in. Average thickness, in. Min. thickness at any point, in. Copyright 2015 UL LLC Page 65 of 164

66 DETAILED EXAMINATION (Sample #3): (CONT D) UL 444, Clause 5 Ambient Temp.: 25 C Humidity: 58% RH [X] Tapes, binders, rods, rip cords, and fillers Type FLAT FILLER Thickness, in Width, in..171 Lap, in. - Overall diameter, in. - Helical/longitudinal HELI Calculated % coverage - Count 1 Major/minor axis, in. - Ripcord present? - Sample No. [X] Insulation Conductor Conductor Conductor Conductor Color BLUE Separator tape present? NO Average thickness, in..008 Minimum thickness at any point, in..007 Minimum thickness after rip, in. - Average web thickness, in. - Average web width, in. - [ ] Insulation Covering Color Average thickness, in. Minimum thickness at any point, in. [ ] Note: If ave. or min. point insulation thickness exceeds/is less than the following requirement contact engineer before proceeding: Min Ave., in. Min Point, in. Copyright 2015 UL LLC Page 66 of 164

67 DETAILED EXAMINATION (Sample #3): (CONT D) UL 444, Clause 5 Ambient Temp.: 25 C Humidity: 58% RH [X] Conductor Conductor Conducto r Conductor Conductor Type (i.e. Al, Cu, etc.) Cu Coating present? NO Diameter of solid conductor, in Diameter over insulation, in..038 Number of strands - Strand diameter, in. - Lay of strands, in. - Circular Mil Area (CMA) - AWG size 23 Ambient Temp.: 25 C Humidity: 58% RH METHOD: UL 444, Clause Solid Conductor: Specimen: #1 Min. #1 Diameter, in Max. #1 Diameter, in Min. #2 Diameter, in Max. #2 Diameter, in Min. #3 Diameter, in Max. #3 Diameter, in Average Conductor Diameter, in Conductor AWG Size 23 Copyright 2015 UL LLC Page 67 of 164

68 DETAILED EXAMINATION (Sample #3): (CONT D) UL 444, Clause 5 DETAILED EXAMINATION, INSULATION: Ambient Temp.: 25 C Humidity: 58% RH METHOD: UL 444, Clause Insulation: Specimen: #1 Thickness: Min #1, in..007 Max #1, in..009 Average Thickness, in..008 Outside diameter: Min #1, in Max #1, in Min #2, in Max #2, in Min #3, in Max #3, in Average Outside Diameter, in..038 Copyright 2015 UL LLC Page 68 of 164

69 DETAILED EXAMINATION (Sample #3): (CONT D) UL 444, Clause 5 DETAILED EXAMINATION, JACKET: Ambient Temp.: 25 C Humidity: 58% RH METHOD: UL 444, Clause Jacket: Specimen: #1 Thickness: Min #1, in..018 Max #1, in..020 Average Thickness, in..019 Outside diameter: Min #1, in..225 Max #1, in..226 Min #2, in..228 Max #2, in..229 Min #3, in..229 Max #3, in..231 Average Outside Diameter, in..228 Core diameter: Min #1, in..188 Max #1, in..190 Min #2, in..190 Max #2, in..192 Min #3, in..193 Max #3, in..194 Average Core Diameter, in..191 Copyright 2015 UL LLC Page 69 of 164

70 DETAILED EXAMINATION: UL 444, Clause 5 Sample No. 4 Ambient Temp.: 25 C Humidity: 58% RH Note: All units are expressed in terms of: [X] Inches [ ] mm [X] Identification Print Type: None Ink Indent Tape Other: CAT-6 GENERAL CABLE J CMP 90C C(UL)US 4PR 23AWG Print Content: GENSPEED 6 PLENUM VERFIED (UL) ANSI/TIA-568C.2 CAT6 Print Interval: 24 inches No. of Insulated Conductors 8 No. Of Bare Conductors 0 Brief Assembly Description: JKT, RIP CORD, FLAT FILLER, 8 INS CON Copyright 2015 UL LLC Page 70 of 164

71 DETAILED EXAMINATION (Sample #4): (CONT D) UL 444, Clause 5 Ambient Temp.: 25 C Humidity: 58% RH Note: If additional space is required please continue under attached Component section [X] Color Jacket Overall Jacket WHITE Overall cable diameter, in..210 Core diameter under jacket, in..179 Major axis, in. - Minor axis, in. - Average thickness, in..015 Min. thickness at any point, in Minimum thickness after rip, in. - Average web thickness, in. - Average web width, in. - Inner Jacket 1 Inner Jacket 2 Inner Jacket 3 [ ] Note: If ave. or min. point jacket thickness exceeds / is less than the following requirement contact engineer before proceeding: Min Ave., in. Min Point, in. Copyright 2015 UL LLC Page 71 of 164

72 DETAILED EXAMINATION (Sample #4): (CONT D) UL 444, Clause 5 Ambient Temp.: 25 C Humidity: 58% RH Sample No. [ ] Armor [x] Assembly Type of Armor Lay of conductors, in..375 Convolutions per inch / mm Lay of conductor pairs, in. 4.0 Diameter over armor, in. Lay of members, in. - Diameter under armor, in. Strip width, in. Average thickness, in. Min. thickness at any point, in. [ ] Braid Parameters Braid 1 Braid 2 Braid 3 Type of braid Strand diameter, in. No. ends No. carriers Picks per inch / mm Core Dia. under braid inch/mm Calculated % coverage Copyright 2015 UL LLC Page 72 of 164

73 DETAILED EXAMINATION (Sample #4): (CONT D) UL 444, Clause 5 Ambient Temp.: 25 C Humidity: 58% RH [X] Tapes, binders, rods, rip cords, and fillers Type FLAT Thickness, in..012 Width, in..173 Lap, in. - Overall diameter, in. - Helical/longitudinal HELI Calculated % coverage - Count 1 Major/minor axis, in. - Ripcord present? - Sample No. [X] Insulation Conductor Conductor Conductor Conductor Color BLUE Separator tape present? NO Average thickness, in..009 Minimum thickness at any point, in Minimum thickness after rip, in. - Average web thickness, in. - Average web width, in. - [ ] Insulation Covering Color Average thickness, in. Minimum thickness at any point, in. [ ] Note: If ave. or min. point insulation thickness exceeds/is less than the following requirement contact engineer before proceeding: Min Ave., in. Min Point, in. Copyright 2015 UL LLC Page 73 of 164

74 DETAILED EXAMINATION (Sample #4): (CONT D) UL 444, Clause 5 Ambient Temp.: 25 C Humidity: 58% RH [X] Conductor Conductor Conducto r Conductor Conductor Type (i.e. Al, Cu, etc.) Cu Coating present? NO Diameter of solid conductor, in Diameter over insulation, in..039 Number of strands - Strand diameter, in. - Lay of strands, in. - Circular Mil Area (CMA) - AWG size 23 Ambient Temp.: 25 C Humidity: 58% RH METHOD: UL 444, Clause Solid Conductor: Specimen: #1 Min. #1 Diameter, in Max. #1 Diameter, in Min. #2 Diameter, in Max. #2 Diameter, in Min. #3 Diameter, in Max. #3 Diameter, in Average Conductor Diameter, in Conductor AWG Size 23 Copyright 2015 UL LLC Page 74 of 164

75 DETAILED EXAMINATION (Sample #4): (CONT D) UL 444, Clause 5 DETAILED EXAMINATION, insulation: Ambient Temp.: 25 C Humidity: 58% RH METHOD: UL 444, Clause Insulation: Specimen: #1 Thickness: Min #1, in Max #1, in..010 Average Thickness, in..009 Outside diameter: Min #1, in Max #1, in Min #2, in Max #2, in Min #3, in Max #3, in Average Outside Diameter, in..039 Copyright 2015 UL LLC Page 75 of 164

76 DETAILED EXAMINATION (Sample #4): (CONT D) UL 444, Clause 5 DETAILED EXAMINATION, JACKET: Ambient Temp.: 25 C Humidity: 58% RH METHOD: UL 444, Clause Jacket: Specimen: #1 Thickness: Min #1, in Max #1, in..016 Average Thickness, in..015 Outside diameter: Min #1, in..207 Max #1, in..208 Min #2, in..208 Max #2, in..209 Min #3, in..212 Max #3, in..216 Average Outside Diameter, in..210 Core diameter: Min #1, in..176 Max #1, in..177 Min #2, in..177 Max #2, in..178 Min #3, in..181 Max #3, in..186 Average Core Diameter, in..179 Copyright 2015 UL LLC Page 76 of 164

77 DETAILED EXAMINATION: UL 444, Clause 5 Sample No. 5 Ambient Temp.: 25 C Humidity: 58% RH Note: All units are expressed in terms of: [X] Inches [ ] mm [X] Identification Print Type: None Ink Indent Tape Other: GenSPEED EfficienC MAX CAT 6 ENHANCED POE++ E Print Content: L CMP (UL) C(UL) 4PR 22AWG 90C VERIFIED (UL) ANSI/TIA-568C.2 CAT6 Print Interval: 24 inches No. of Insulated Conductors 8 No. Of Bare Conductors 0 Brief Assembly Description: JKT, RIP CORD, FLAT FILLE, 8 INS CON Copyright 2015 UL LLC Page 77 of 164

78 DETAILED EXAMINATION (Sample #5): (CONT D) UL 444, Clause 5 Ambient Temp.: 25 C Humidity: 58% RH Note: If additional space is required please continue under attached Component section [X] Color Jacket Overall Jacket BLUE Overall cable diameter, in..221 Core diameter under jacket, in..193 Major axis, in. - Minor axis, in. - Average thickness, in..015 Min. thickness at any point, in..014 Minimum thickness after rip, in. - Average web thickness, in. - Average web width, in. - Inner Jacket 1 Inner Jacket 2 Inner Jacket 3 [ ] Note: If ave. or min. point jacket thickness exceeds / is less than the following requirement contact engineer before proceeding: Min Ave., in. Min Point, in. Copyright 2015 UL LLC Page 78 of 164

79 DETAILED EXAMINATION (Sample #5): (CONT D) UL 444, Clause 5 Ambient Temp.: 25 C Humidity: 58% RH Sample No. [ ] Armor [ ] Assembly Type of Armor Lay of conductors, in..375 Convolutions per inch / mm Lay of conductor pairs, in. 4.5 Diameter over armor, in. Lay of members, in. - Diameter under armor, in. Strip width, in. Average thickness, in. Min. thickness at any point, in. [ ] Braid Parameters Braid 1 Braid 2 Braid 3 Type of braid Strand diameter, in. No. ends No. carriers Picks per inch / mm Core Dia. under braid inch/mm Calculated % coverage Copyright 2015 UL LLC Page 79 of 164

80 DETAILED EXAMINATION (Sample #5): (CONT D) UL 444, Clause 5 Ambient Temp.: 25 C Humidity: 58% RH [X] Tapes, binders, rods, rip cords, and fillers Type FLAT Thickness, in..011 Width, in..173 Lap, in. - Overall diameter, in. - Helical/longitudinal HELI Calculated % coverage TBD Count 1 Major/minor axis, in. - Ripcord present? - Sample No. [X] Insulation Conductor Conductor Conductor Conductor Color BLUE Separator tape present? NO Average thickness, in..009 Minimum thickness at any point, in..008 Minimum thickness after rip, in. - Average web thickness, in. - Average web width, in. - [ ] Insulation Covering Color Average thickness, in. Minimum thickness at any point, in. [ ] Note: If ave. or min. point insulation thickness exceeds/is less than the following requirement contact engineer before proceeding: Min Ave., in. Min Point, in. Copyright 2015 UL LLC Page 80 of 164

81 DETAILED EXAMINATION (Sample #5): (CONT D) UL 444, Clause 5 Ambient Temp.: 25 C Humidity: 58% RH [X] Conductor Conductor Conducto r Conductor Conductor Type (i.e. Al, Cu, etc.) Cu Coating present? NO Diameter of solid conductor, in Diameter over insulation, in..042 Number of strands - Strand diameter, in. - Lay of strands, in. - Circular Mil Area (CMA) - AWG size 22 Ambient Temp.: 25 C Humidity: 58% RH METHOD: UL 444, Clause Solid Conductor: Specimen: #1 Min. #1 Diameter, in Max. #1 Diameter, in Min. #2 Diameter, in Max. #2 Diameter, in Min. #3 Diameter, in Max. #3 Diameter, in Average Conductor Diameter, in Conductor AWG Size 22 Copyright 2015 UL LLC Page 81 of 164

82 DETAILED EXAMINATION (Sample #5): (CONT D) UL 444, Clause 5 DETAILED EXAMINATION, INSULATION: Ambient Temp.: 25 C Humidity: 58% RH METHOD: UL 444, Clause Insulation: Specimen: #1 Thickness: Min #1, in..008 Max #1, in..010 Average Thickness, in..009 Outside diameter: Min #1, in Max #1, in Min #2, in Max #2, in Min #3, in Max #3, in Average Outside Diameter, in..042 Copyright 2015 UL LLC Page 82 of 164

83 DETAILED EXAMINATION (Sample #5): (CONT D) UL 444, Clause 5 DETAILED EXAMINATION, JACKET: Ambient Temp.: 25 C Humidity: 58% RH METHOD: UL 444, Clause Jacket: Specimen: #1 Thickness: Min #1, in..014 Max #1, in..016 Average Thickness, in..015 Outside diameter: Min #1, in..215 Max #1, in..219 Min #2, in..220 Max #2, in..222 Min #3, in..224 Max #3, in..227 Average Outside Diameter, in..221 Core diameter: Min #1, in..187 Max #1, in..191 Min #2, in..191 Max #2, in..194 Min #3, in..195 Max #3, in..199 Average Core Diameter, in..193 Copyright 2015 UL LLC Page 83 of 164

84 DETAILED EXAMINATION: UL 444, Clause 5 Sample No. 6 Ambient Temp.: 25 C Humidity: 58% RH Note: All units are expressed in terms of: [X] Inches [ ] mm [X] Identification Print Type: None Ink Indent Tape Other: Print Content: GENERAL CABLE L GENSPEED 10MTP CATEGORY 6A 4PR/23AWG UTP PLENUM CABLE C(UL)US CMP 90C VERIFIED(UL) ANSI/TIA-568C.2 CAT-6A PAT , , MTP.US Print Interval: 24 inches No. of Insulated Conductors 8 No. Of Bare Conductors 0 Brief Assembly Description: 8 INS CON JKT, POLY AL WRAP, POLYESTER WRAP, STAR FILLER, Copyright 2015 UL LLC Page 84 of 164

85 DETAILED EXAMINATION (Sample #6): (CONT D) UL 444, Clause 5 Ambient Temp.: 25 C Humidity: 58% RH Note: If additional space is required please continue under attached Component section [X] Color Jacket Overall Jacket GREY Overall cable diameter, in..281 Core diameter under jacket, in..249 Major axis, in. - Minor axis, in. - Average thickness, in..016 Min. thickness at any point, in..015 Minimum thickness after rip, in. - Average web thickness, in. - Average web width, in. - Inner Jacket 1 Inner Jacket 2 Inner Jacket 3 [ ] Note: If ave. or min. point jacket thickness exceeds / is less than the following requirement contact engineer before proceeding: Min Ave., in. Min Point, in. Copyright 2015 UL LLC Page 85 of 164

86 DETAILED EXAMINATION (Sample #6): (CONT D) UL 444, Clause 5 Ambient Temp.: 25 C Humidity: 58% RH Sample No. [ ] Armor [X] Assembly Type of Armor Lay of conductors, in..344 Convolutions per inch / mm Lay of conductor pairs, in. 4.0 Diameter over armor, in. Lay of members, in. - Diameter under armor, in. Strip width, in. Average thickness, in. Min. thickness at any point, in. Copyright 2015 UL LLC Page 86 of 164

87 DETAILED EXAMINATION (Sample #6): (CONT D) UL 444, Clause 5 Ambient Temp.: 25 C Humidity: 58% RH [X] Tapes, binders, rods, rip cords, and fillers Type POLY AL WRAP WOVEN POLYESTER WRAP Thickness, in Width, in Lap, in Overall diameter, in Helical/longitudinal HELI HELI Calculated % coverage TBD TBD Count 1 1 Major/minor axis, in. - - Ripcord present? - - Sample No. [X] Insulation Conductor Conductor Conductor Conductor Color BLUE Separator tape present? NO Average thickness, in..010 Minimum thickness at any point, in..009 Minimum thickness after rip, in. - Average web thickness, in. - Average web width, in. - [ ] Insulation Covering Color Average thickness, in. Minimum thickness at any point, in. [ ] Note: If ave. or min. point insulation thickness exceeds/is less than the following requirement contact engineer before proceeding: Min Ave., in. Min Point, in. Copyright 2015 UL LLC Page 87 of 164

88 DETAILED EXAMINATION (Sample #6): (CONT D) UL 444, Clause 5 Ambient Temp.: 25 C Humidity: 58% RH [x] Conductor Conductor Conducto r Conductor Conductor Type (i.e. Al, Cu, etc.) Cu Coating present? NO Diameter of solid conductor, in..023 Diameter over insulation, in..042 Number of strands - Strand diameter, in. - Lay of strands, in. - Circular Mil Area (CMA) - AWG size 23 Ambient Temp.: 25 C Humidity: 58% RH METHOD: UL 444, Clause Solid Conductor: Specimen: #1 Min. #1 Diameter, in Max. #1 Diameter, in Min. #2 Diameter, in Max. #2 Diameter, in..023 Min. #3 Diameter, in Max. #3 Diameter, in..023 Average Conductor Diameter, in..023 Conductor AWG Size 23 Copyright 2015 UL LLC Page 88 of 164

89 DETAILED EXAMINATION (Sample #6): (CONT D) UL 444, Clause 5 DETAILED EXAMINATION, INSULATION: Ambient Temp.: 25 C Humidity: 58% RH METHOD: UL 444, Clause Insulation: Specimen: #1 Thickness: Min #1, in..009 Max #1, in..011 Average Thickness, in..010 Outside diameter: Min #1, in..042 Max #1, in..042 Min #2, in..042 Max #2, in..043 Min #3, in..043 Max #3, in..043 Average Outside Diameter, in..042 Copyright 2015 UL LLC Page 89 of 164

90 DETAILED EXAMINATION (Sample #6): (CONT D) UL 444, Clause 5 DETAILED EXAMINATION, JACKET: Ambient Temp.: 25 C Humidity: 58% RH METHOD: UL 444, Clause Jacket: Specimen: #1 Thickness: Min #1, in..015 Max #1, in..017 Average Thickness, in..016 Outside diameter: Min #1, in..273 Max #1, in..274 Min #2, in..283 Max #2, in..283 Min #3, in..286 Max #3, in..287 Average Outside Diameter, in..281 Core diameter: Min #1, in..241 Max #1, in..244 Min #2, in..250 Max #2, in..252 Min #3, in..253 Max #3, in..255 Average Core Diameter, in..249 Copyright 2015 UL LLC Page 90 of 164

91 DETAILED EXAMINATION (Sample #6): (CONT D) UL 444, Clause 5 STAR FILLER DIMENSIONS: Ambient Temp.: 25 C Humidity: 58% RH d w l Thickness at any point, mils 41 Average Thickness, mils 20 Minimum Thickness at any point, mils 17 Maximum Thickness at any point, mils 24 Average Thickness, mils 70 Minimum Thickness at any point, mils 65 Maximum Thickness at any point, mils 74 Copyright 2015 UL LLC Page 91 of 164

93 Thermocouple Placement - General TC6 and TC7 are at the center of the cable bundle length. TC7 is inside the jacket on the individual wire insulation. TC6 is on the outside of the cable jacket. Copyright 2015 UL LLC Page 93 of 164

163 APPENDIX D - CABLE HEATING TEST The proposed requirements for the UL Standard(s) for Safety are to be considered as tentative and are only meant to demonstrate the form and content of such a proposal. They have not been presented to the relevant industry nor subjected to UL's standards development procedure. The requirements are shown only as examples and are based on the results given in this Report (NEW) Cable Heating Test When tested as described in this section, the temperatures measured on the insulation and jacket of the cables, after being corrected to an ambient of 45 o C, shall not exceed the temperature rating of the cable The cables shall be arranged in a bundle consisting of 192 cables and electrically connected in series to a power supply capable of providing the rated current marked as part of the LP rating. The inner 37 cables shall be arranged as shown in Figure 4. The remaining cables shall be evenly distributed in a random fashion to form a 192 cable bundle. The bundle shall be placed in a 6 foot long (1.83 m) commercially available non-metallic conduit (Schedule 40) with the minimum diameter needed to install the bundle without putting pressure on the cables. Each end of the conduit shall be filled with insulation The temperatures shall be measured on the outer jacket and conductor insulation of the center cable at the midpoint of the cable. In addition, temperatures shall be measured on the jacket and conductor insulation on the center cable two feet (0.6 m) on each side of center thermocouple Temperatures are to be measured by means of thermocouples consisting of iron and constantan wires not larger than 24 AWG (0.21 mm 2 ) and not smaller than 30 AWG (0.05 mm 2 ). When thermocouples are used in determining temperatures in electrical equipment, it is common practice to employ thermocouples consisting of 30 AWG iron and constantan wires with a potentiometer-type of indicating instrument. This equipment is to be used whenever a referee measurement of temperature is necessary. Copyright 2015 UL LLC Page 163 of 164

7.24.5 The thermocouples and related instruments are to be accurate and calibrated in accordance with standard laboratory practice.

164 The thermocouples and related instruments are to be accurate and calibrated in accordance with standard laboratory practice. The thermocouple wire is to conform to the requirements specified in the Tolerances on Initial Values of EMF versus Temperature tables in the Standard Specification and Temperature-Electromotive Force (emf) Tables for Standardized Thermocouples, ANSI/ASTM E230/E230M A thermocouple junction and adjacent thermocouple lead wire are to be securely held in good thermal contact with the surface of the material whose temperature is being measured. In most cases, acceptable thermal contact results from securely taping or cementing the thermocouple in place Example of Cable Heating Test Copyright 2015 UL LLC Page 164 of 164

TEK Brief July Is there a difference in installation requirements between communications cables with and without the LP designation?

TEK Brief July Is there a difference in installation requirements between communications cables with and without the LP designation? BECAUSE YOUR BUSINESS RUNS THROUGH US TEK Brief July 2016 LP Cabling: Frequently Asked Questions Table of Contents Introduction Prior to the beginning of the review cycle of the 2017 National Electrical