CORFLEX. Continuous Corrugated and Welded, Impervious Aluminum Sheathed PL, MC and VFD Industrial Cables. Introduction Applications...

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2 CORFLEX Continuous Corrugated and Welded, Impervious Aluminum Sheathed PL, MC and VFD Industrial Cables Introduction Applications CORFLEX PL 300V Instrumentation PLTC & ITC Rated Description Dimensions CORFLEX MC 600V Instrumentation HL Rated Description Dimensions CORFLEX MC 600V Power and Control HL Rated Description Dimensions 14 AWG to 10 AWG Multiconductor and Composite Cables and 4 Conductor Cables Conductor or Phase Identification CORFLEX VFD 600V HL Rated Description Dimensions Technical Information Electrical Properties Voltage Drop Pulling Instructions Pulling Tension Table Connector Selection Stranded Bare Copper Conductor Data Metric Conversions and Notices

3 Introduction Nexans is one of the largest wire and cable manufacturers in the world, and in North America. In North America we manufacture in locations across the United States and Canada. We design and produce a wide range of cables used in power, industrial, construction and communication applications. With more than a century of experience as a leader in the industrial and power cable markets, Nexans is contracted by heavy industry and utilities world wide to provide turnkey solutions for the bulk transmission of power from generating station through the transmission and distribution systems to commercial, residential and industrial areas. This catalog has been prepared for the convenience of those using electrical conductors in industrial applications. The information included in the many tabulations will be of particular value to the architect, engineer, electrician, and layperson alike. For your convenience, we have referenced applicable Articles and Tables from both the 2008 NEC and the 2011 NEC. Although we have listed the types of wires and cables suitable for most conditions, we are equipped to manufacture other types to suit special needs. We would be pleased to recommend the most suitable construction for any special condition that you may encounter. The determination of the correct cable size and type, and the selection of methods of installation suitable for the type and location of particular circuits, should be made in accordance with local regulations. Any questions in this respect should be directed primarily to the local Electrical Inspection Authority. We are pleased to note that all the cables in this catalog are LEAD FREE. This indicates that the Nexans cable components have less than 300 ppm of lead, which is well below the 1000 ppm level indicated in RoHS (restriction of hazardous substances) regulations and below the level requiring labeling by California Proposition #65. 2

4 Applications CORFLEX cables may be found in a variety of industrial, commercial and utility applications. Chemical, oil and gas, and forestry industries, plus commercial or high-rise buildings are areas in which CORFLEX has gained acceptance. Exceptional fire ratings (as per appropriate specifications), impactresistance, flexibility and an impervious metallic sheath are key components of this design. CORFLEX installation may be in wet or dry locations, in trays, troughs, wireways, directly buried or embedded in concrete. As well, it can be used in plenums (with no outer coverings), ducts and other airways per NEC 2008 and NEC 2011 Article The 300 volt CORFLEX PL cables can be installed in Class I, II, III & intrinsically safe locations & Division 2 as per NEC 2008 and NEC 2011 (PLTC and ITC Rated). CORFLEX PL cables are suitable for control, signal, and instrumentation circuits with 300 volt rating. The cable construction minimizes noise and signal interference to enhance performance in instrumentation, dataflow, computer & datalogging applications especially in areas where high voltages or high currents are present. CORFLEX MC cables are designed for use on power and control circuits with 600 volt rating. Cables are suitable for use as feeders and branch circuits for power, control, lighting and signalling as per NEC 2008 and NEC 2011 Articles 330, 725 & 727. CORFLEX VFD cables are designed to improve the operating performance of variable frequency drive systems. The 600 volt CORFLEX VFD cables provide excellent shielding from high frequency noise that can interfere with data and control signals. One of the advantages of the Nexans CORFLEX sheath compared to other constructions is that the cable sheath provides a long term low resistance path to ground to protect the drive system. The cable grounds provide the best cancellation and lowest net injected ground current into the drive system, protecting against common mode currents which impair the drive unit electronic performance and shorten the drive s life span. Cable grounds, in combination with the aluminum sheath, ensure a balanced, very low resistance path to ground to reduce the chance of motor failure due to bearing currents. The 600 volt and higher CORFLEX cables can be installed in hazardous locations designated Class I, II & III and Divisions 1 & 2 as per NEC 2008 and NEC 2011 (HL Rated). 3

5 CORFLEX PL Armored Instrumentation Cable UL Type PLTC & ITC, 300V, 105 C rated - Lead Free Single or multiple individually shielded pairs or triads, overall cable shield, continuous corrugated and welded, impervious aluminum sheath, PVC jacket Construction Conductor: bare, annealed copper conforming to ASTM B3 and Class B stranded in accordance with ASTM B8. Insulation: polyvinyl chloride in accordance with UL 13 and 2250, flame retardant, 105 C temperature rating. Insulation shield: aluminum foil/ polyester shield helically wrapped to provide 100% coverage and tinned copper drain wire that is two gauge sizes smaller than the circuit conductors. These shields are electrically isolated from each other. Communication wire: 22 AWG stranded soft bare copper wire covered with an orange PVC insulation in 4 pair, 4 triad and higher configurations. Assembly: pairs/triads are cabled in concentric layers with interstices filled with suitable non-hygroscopic fillers, as required. A binder tape of synthetic material assembles the core in an essentially round configuration. Overall cable shield: aluminum foil/polyester shield helically wrapped to provide 100% coverage and tinned copper drain wire that is the same size as the circuit conductors with the exception of single pair/triad constructions where the drain wire is two gauge sizes smaller than the circuit conductors. Inner jacket: polyvinyl chloride jacket, over cabled core as per UL 13 and UL 2250, 90 C temperature rating, with additional resistance to fire spread. A rip cord is laid longitudinally under the jacket to facilitate stripping. Armor: continuous corrugated and welded, impervious aluminum sheath with no more than 0.2% trace copper providing complete protection against liquid and gas ingress. It also provides excellent mechanical protection, additional electrostatic shielding, and serves as an easy means for grounding equipment. Jacket: overall black polyvinyl chloride jacket per UL 13 and UL 2250, 90 C temperature rating; low acid gas emission; limited flame spread and excellent corrosion resistance. Conductor Identification Pairs: black/white & number coded Triads: black/white/red & number coded Bending Radius Fixed position: 7 x cable overall diameter During pulling: 12 x cable overall diameter Specifications Meets UL 13 and UL 2250, rated 105 C 300V conductor Meets UL requirements for Type PLTC, power limited circuit cable and Type ITC, instrumentation tray cable Designated Type PLTC, Power Limited Tray Cable, per NEC 2008 and NEC 2011 Article 725, and ITC, Instrumentation Tray Cable, per NEC 2008 and NEC 2011 Article 727 Applications: Suitable substitute for General purpose Class 2 (CL2) and Class 3 (CL3) wiring, as well as Dwelling unit Class 2 (CL2X) and Class 3 (CL3X) wiring as per NEC 2008 and NEC 2011 Article Product Features UL approved cables Type PLTC, 300V; File No. E75731 UL approved insulated conductors Cables pass UL 1685 and IEEE 383 vertical tray fire tests at 70,000 BTU/hr, ICEA T fire test at 210,000 BTU/hr, IEC category A fire test, IEEE 1202, and CSA FT4 Cables are American Bureau of Shipping (ABS) listed as CWC MC Type PLTC Cables are marked -40C and are suitable for handling and installation below -10 degrees Celsius (based on -40 degrees Celsius impact and bend laboratory tests). Temperature rating 105 C dry Continuous, impervious aluminum sheath corrugated for flexibility, prevents ingress of moisture, gases and liquids Aluminum sheath resistance exceeds requirements of the NEC 2008 and NEC 2011 Article for equipment grounding conductor Excellent mechanical & physical properties Communication wire included for voice communication or instrument calibration Minimal noise and signal interference Sunlight resistant jacket Suitable for direct burial and use in cable tray Lead free and RoHS compliant Options The following constructions can be provided on special orders: Different conductor size Different pair or triad configurations Specially colored jackets Other constructions and combinations (some manufacturing restrictions apply) UL 1309 listing and marking

6 Armored Instrumentation Cable UL Type PLTC & ITC, 300V, 105 C rated - Lead Free CORFLEX PL UL 13 UL 2250 Multi Pairs, 300V 18 AWG (7w) Insulation Thickness: 15 mils / 0.38 mm # of Nominal Diameter Inner Jacket Nominal Diameter Nominal Diameter Outer Jacket Nominal Diameter Approximate Net Pairs over Core Thickness over Inner Jacket over Sheath Thickness over Outer Jacket Cable Weight inches mm mils mm inches mm inches mm mils mm inches mm lb/kft kg/km Multi Pairs, 300V 16 AWG (7w) Insulation Thickness: 15 mils / 0.38 mm # of Nominal Diameter Inner Jacket Nominal Diameter Nominal Diameter Outer Jacket Nominal Diameter Approximate Net Pairs over Core Thickness over Inner Jacket over Sheath Thickness over Outer Jacket Cable Weight inches mm mils mm inches mm inches mm mils mm inches mm lb/kft kg/km Multi Triads, 300V 16 AWG (7w) Insulation Thickness: 15 mils / 0.38 mm # of Nominal Diameter Inner Jacket Nominal Diameter Nominal Diameter Outer Jacket Nominal Diameter Approximate Net Triads over Core Thickness over Inner Jacket over Sheath Thickness over Outer Jacket Cable Weight inches mm mils mm inches mm inches mm mils mm inches mm lb/kft kg/km

7 CORFLEX MC Armored Instrumentation Cable UL Type MC HL, 600V, 90 C rated - Lead Free Single or multiple individually shielded pairs or triads, overall cable shield, continuous corrugated and welded, impervious aluminum sheath, PVC jacket Construction Conductor: bare, annealed copper conforming to ASTM B3 and Class B stranded in accordance with ASTM B8. Insulation: PVC/Nylon type TFN in accordance with UL 66, flame retardant, 90 C temperature rating. Insulation shield: aluminum foil/ polyester shield helically wrapped to provide 100% coverage and tinned copper drain wire that is two gauge sizes smaller than the circuit conductors. These shields are electrically isolated from each other. Assembly: pairs/triads are cabled in concentric layers with interstices filled with suitable non-hygroscopic fillers, as required. A binder tape of synthetic material assembles the core in an essentially round configuration. Overall cable shield: aluminum foil/polyester shield helically wrapped to provide 100% coverage and tinned copper drain wire that is the same size as the circuit conductors. Inner jacket: polyvinyl chloride jacket, over cabled core as per UL 1569, 90 C temperature rating, with additional resistance to fire spread. A rip cord is laid longitudinally under the jacket to facilitate stripping. Armor: continuous corrugated and welded, impervious aluminum sheath with no more than 0.2% trace copper providing complete protection against liquid and gas ingress. It also provides excellent mechanical protection, additional electrostatic shielding, and serves as an easy means for grounding equipment. Jacket: overall black polyvinyl chloride jacket per UL 1569, 90 C temperature rating; low acid gas emission; limited flame spread and excellent corrosion resistance. Conductor Identification Pairs: black/white & number coded Triads: black/white/red & number coded Bending Radius Fixed position: 7 x cable overall diameter During pulling: 12 x cable overall diameter Specifications Meets UL 66, TFN rated 90 C 600V conductors Meets UL 1569 requirements for Type MC, Metal Clad cables Meets UL 2225 for Hazardous Locations Designated Type MC as per NEC 2008 and NEC 2011 Article 330 Product Features UL approved cables Type MC, 600V; File No. E47409 UL approved insulated conductors Cables pass UL 1685 and IEEE 383 vertical tray fire tests at 70,000 BTU/hr, ICEA T fire test at 210,000 BTU/hr, IEC category A fire test, IEEE 1202 and CSA FT4 Cables are American Bureau of Shipping (ABS) listed as CWC MC Type MC Cables are marked -40C and are suitable for handling and installation below -10 degrees Celsius (based on -40 degrees Celsius impact and bend laboratory tests) Continuous, impervious aluminum sheath corrugated for flexibility, prevents ingress of moisture, gases and liquids Aluminum sheath resistance exceeds requirements of the NEC 2008 and NEC 2011 Article for equipment grounding conductor Excellent mechanical and physical properties Minimal noise and signal interference Sunlight resistant jacket Suitable for direct burial, use in cable tray and embedment in concrete Lead free and RoHS compliant Options The following constructions can be provided on special orders: Different conductor size Different pair or triad configurations Specially colored jackets Other constructions and combinations (some manufacturing restrictions apply) UL 1309 listing and marking 6

8 Armored Instrumentation Cable UL Type MC HL, 600V, 90 C rated - Lead Free CORFLEX MC UL 66 UL 1569 UL 2225 Multi Pairs, 600V 18 AWG (7w) Insulation Thickness: 15 mils / 0.38 mm PVC and 4 mils / 0.10 mm Nylon # of Nominal Diameter Inner Jacket Nominal Diameter Nominal Diameter Outer Jacket Nominal Diameter Approximate Net Pairs over Core Thickness over Inner Jacket over Sheath Thickness over Outer Jacket Cable Weight inches mm mils mm inches mm inches mm mils mm inches mm lb/kft kg/km Multi Pairs, 600V 16 AWG (7w) Insulation Thickness: 15 mils / 0.38 mm PVC and 4 mils / 0.10 mm Nylon # of Nominal Diameter Inner Jacket Nominal Diameter Nominal Diameter Outer Jacket Nominal Diameter Approximate Net Pairs over Core Thickness over Inner Jacket over Sheath Thickness over Outer Jacket Cable Weight inches mm mils mm inches mm inches mm mils mm inches mm lb/kft kg/km Multi Triads, 600V 16 AWG (7w) Insulation Thickness: 15 mils / 0.38 mm PVC and 4 mils / 0.10 mm Nylon # of Nominal Diameter Inner Jacket Nominal Diameter Nominal Diameter Outer Jacket Nominal Diameter Approximate Net Triads over Core Thickness over Inner Jacket over Sheath Thickness over Outer Jacket Cable Weight inches mm mils mm inches mm inches mm mils mm inches mm lb/kft kg/km

9 CORFLEX MC Armored Power and Control Cable UL Type MC HL, 600V, 90 C rated - Lead Free Multiple conductors and composites, with ground wire(s), continuous corrugated and welded, impervious aluminum sheath, PVC jacket Construction Conductor: bare, annealed copper conforming to ASTM B3 and Class B stranded in accordance with ASTM B8. Insulation: cross linked polyethylene type XHHW-2 per UL 44. Assembly: conductors are cabled in concentric layers with or without grounding wire(s), interstices are filled with suitable non-hygroscopic fillers, as required. A binder tape of synthetic material assembles the core in an essentially round configuration. Armor: continuous corrugated and welded, impervious aluminum sheath with no more than 0.2% trace copper providing complete protection against liquid & gas ingress. It also provides excellent mechanical protection, additional electrostatic shielding, and serves as an easy means of grounding equipment. Jacket: overall black polyvinyl chloride jacket per UL 1569, 90 C temperature rating; low gas emission; limited flame spread and excellent corrosion resistance. Conductor Identification Power and control: Multi-conductor 14 AWG to 10 AWG: Method #1-E2 per ICEA S conductor 8 AWG to 2 AWG: Method #1-E2 per ICEA S , 3 conductor 1 AWG to 750 kcmil: Method 4 per ICEA S &4 conductor 8 AWG to 750 kcmil: Method #4 per ICEA S Composite power and control: power conductors: Method #4 per ICEA S control conductors: Method #1-E2 per ICEA S See page 11 Bending Radius Fixed position: 7 x cable overall diameter During pulling: 12 x cable overall diameter Specifications Meets UL 44, XHHW-2 600V conductors Meets UL 1569 requirements for Type MC, Metal Clad cables Meets UL 2225 for Hazardous Locations Designated Type MC as per NEC 2008 and NEC 2011 Article 330 Meets CSA C22.2 No for Aluminum Sheathed Cables Meets CSA C22.2 No. 174-M1984 for Hazardous Locations Product Features UL approved cables Type MC, 600V; File No. E47409 UL approved insulated conductors Cables pass UL 1685 and IEEE 383 vertical tray fire tests at 70,000 BTU/hr, ICEA T fire test at 210,000 BTU/hr, IEC category A fire test, IEEE 1202 and CSA FT4 Cables are American Bureau of Shipping (ABS) listed as CWC MC Type MC Cables are marked -40C and are suitable for handling and installation below -10 degrees Celsius (based on -40 degrees Celsius impact and bend laboratory tests). Temperature rating of 90 C dry and wet 130 C emergency rating and 250 C short circuit rating Continuous, impervious aluminum sheath corrugated for flexibility, prevents ingress of moisture, gases and liquids Aluminum sheath resistance exceeds requirements of the NEC 2008 and NEC 2011 Article for equipment grounding conductor Sheath provides good electronic shielding so that CORFLEX can be used in certain instrumentation applications when adequately grounded Excellent mechanical & physical properties Sunlight resistant jacket Suitable for direct burial, use in cable tray and embedment in concrete Lead free Options The following constructions can be provided on special orders: Aluminum conductors Extra ground wires Special color or number coding Specially colored jackets Other constructions and combinations (some manufacturing restrictions apply) UL 1309 listing and marking 8

10 Armored Power and Control Cable UL Type MC HL, 600V, 90 C rated - Lead Free CORFLEX MC UL 44 UL 1569 UL 2225 Multiconductors, with Bare Ground(s) # of Cond. Insulation Ground Nominal Diameter Nominal Diameter Jacket Thickness Nominal Diameter Approximate Net Ampacity Cond. Size Thickness Wire Size over Core over Sheath over Jacket Cable Weight AWG mils mm AWG inches mm inches mm mils mm inches mm lb/kft kg/km amps (1,3) 2 14 (7w) (7w) * 14 (7w) x18 (7w) (7w) (7w) /25 (2) 5 14 (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) * 12 (7w) x16 (7w) (7w) (7w) /30 (2) 5 12 (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) * 10 (7w) x14 (7w) (7w) (7w) /40 (2) 5 10 (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) * In additions to UL, these 3-conductor constructions are also certified to CSA C22.2 No. 123 and CSA C22.2 No. 174 Composite 3 Power Conductors with 4 Control Conductors and 1 Bare Ground Control Insulation Power Insulation Ground Nominal Diameter Nominal Diameter Jacket Thickness Nominal Diameter Approximate Net Control Power Size Thickness Size Thickness Size over Core over Sheath over Jacket Cable Weight Ampacity Ampacity AWG mils mm AWG mils mm AWG inches mm inches mm mils mm inches mm lb/kft kg/km amps (1) amps (1) 12 (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (1) Ampacities are in accordance with NEC 2008 Table or NEC 2011 Table (B)(16) for conductors in raceway or direct buried at 30 C ambient temperature and 90 C conductor temperature. The overcurrent protection shall not exceed 15 amperes for 14 AWG, 20 amperes for 12 AWG, and 30 amperes for 10 AWG copper conductors after any correction factors for ambient temperature and number of conductors have been applied (NEC 2008 and NEC 2011 Article 240.4(D)). For correction factors for different ambient temperatures and ampacities at different conductor temperatures, see NEC 2008 Table or NEC 2011 Table (B)(16). Ampacities for cables having more than three conductors have been derated per NEC 2008 Article (B)(2)(a) or NEC 2011 Article (B)(3)(a). (2) Where the 4th conductor is the neutral of a balanced 3 phase system. (3) With load diversity of 50% (see NEC 2008 Table B or NEC 2011 Table B (B)(2)(11)). 9

11 Armored Power and Control Cable UL Type MC HL, 600V, 90 C rated - Lead Free CORFLEX MC UL 44 UL 1569 UL Conductors with 3 Bare Grounds* Cond. Insulation Thickness Ground Nominal Diameter Nominal Diameter Jacket Thickness Nominal Diameter Approximate Net Ampacity Size Wire Size over Core over Sheath over Jacket Cable Weight AWG/kcmil mils mm AWG inches mm inches mm mils mm inches mm lb/kft kg/km amps (1) 14 (7w) x18 (7w) (7w) x16 (7w) (7w) x14 (7w) (7w) x14 (7w) (7w) x12 (7w) (7w) x12 (7w) (7w) x10 (7w) (19w) x10 (7w) /0 (19w) x10 (7w) /0 (19w) x10 (7w) /0 (19w) x8 (7w) /0 (19w) x8 (7w) (37w) x8 (7w) (37w) x6 (7w) (37w) x6 (7w) (61w) x4 (7w) * These constructions with three grounds are excellent for use with variable frequency drives (see pages 12 and 13). In additions to UL, these 3-conductor constructions are also certified to CSA C22.2 No. 123 and CSA C22.2 No Conductors with 1 Bare Ground Cond. Insulation Thickness Ground Nominal Diameter Nominal Diameter Jacket Thickness Nominal Diameter Approximate Net Ampacity Size Wire Size over Core over Sheath over Jacket Cable Weight AWG/kcmil mils mm AWG inches mm inches mm mils mm inches mm lb/kft kg/km amps (1,2) 14 (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (7w) (19w) (7w) /0 (19w) (7w) /0 (19w) (7w) /0 (19w) (7w) /0 (19w) (7w) (37w) (7w) (37w) (7w) (37w) (7w) (61w) (19w) (1) Ampacities are in accordance with NEC 2008 Table or NEC 2011 Table (B)(16) for conductors in raceway or direct buried at 30 C ambient temperature and 90 C conductor temperature. The overcurrent protection shall not exceed 15 amperes for 14 AWG, 20 amperes for 12 AWG, and 30 amperes for 10 AWG copper conductors after any correction factors for ambient temperature and number of conductors have been applied (NEC 2008 and NEC 2011 Article 240.4(D)). For correction factors for different ambient temperatures and ampacities at different conductor temperatures, see NEC 2008 Table or NEC 2011 Table (B)(16). (2) Where the 4th conductor is the neutral of a balanced 3 phase system, otherwise the ampacity is 80% of the value shown. 10

12 Conductor or Phase Identification Per ICEA S E3.4 Method 4 Number Code Conductor Printing Details Conductor Printing Details 1st 1-ONE-1 4th 4-FOUR-4 2nd 2-TWO-2 5th 5-FIVE-5 3rd 3-THREE-3 6th 6-SIX-6 Per ICEA S E3.1 Method 1 and Table E2 (formerly K2) Colored Insulation with/without Colored Stripe Conductor Insulation Stripe Conductor Insulation Stripe 1st BLACK 19th ORANGE Blue 2nd RED 20th YELLOW Blue 3rd BLUE 21st BROWN Blue 4th ORANGE 22nd BLACK Orange 5th YELLOW 23rd RED Orange 6th BROWN 24th BLUE Orange 7th RED Black 25th YELLOW Orange 8th BLUE Black 26th BROWN Orange 9th ORANGE Black 27th BLACK Yellow 10th YELLOW Black 28th RED Yellow 11th BROWN Black 29th BLUE Yellow 12th BLACK Red 30th ORANGE Yellow 13th BLUE Red 31st BROWN Yellow 14th ORANGE Red 32nd BLACK Brown 15th YELLOW Red 33rd RED Brown 16th BROWN Red 34th BLUE Brown 17th BLACK Blue 35th ORANGE Brown 18th RED Blue 36th YELLOW Brown Note: The color code repeats at #1 BLACK as the 37th conductor (for cables with more than 36 conductors) 11

13 CORFLEX VFD Armored Variable Frequency Drive Cable UL Type MC HL, 600V, 90 C rated - Lead Free 3 conductor with 3 ground wires, continuous corrugated and welded, impervious aluminum sheath, PVC jacket CORFLEX VFD cables are designed to improve the operating performance of variable frequency drive systems. These cables provide excellent shielding from high frequency noise that can interfere with data and control signals. Nexans CORFLEX sheath provides a long term low resistance path to ground to protect the drive system. Cable grounds provide the best cancellation and lowest net injected ground current into the drive system protecting against common mode currents which impair the drive unit electronic performance and shorten the drive life span. Cable grounds also ensure a balanced, low resistance path to ground to reduce the chance of motor failure due to bearing currents. The CORFLEX VFD cable design has been shown to be the best of eight cable constructions studied for use between a VFD and the motor. This information can be found in an IEEE paper called Evaluation of Motor Power Cables for PWM AC Drives published in Construction Conductor: bare, annealed copper conforming to ASTM B3 and Class B stranded in accordance with ASTM B8. Insulation: cross linked polyethylene type XHHW-2 per UL 44. Assembly: conductors are cabled in concentric layers with three grounding wires, interstices are filled with suitable non-hygroscopic fillers, as required. A binder tape of synthetic material assembles the core in an essentially round configuration. Armor: continuous corrugated and welded, impervious aluminum sheath with no more than 0.2% trace copper providing complete protection against liquid and gas ingress. It also provides excellent mechanical protection, additional electrostatic shielding, and serves as an easy means for grounding equipment. Jacket: overall black polyvinyl chloride jacket per UL 1569, 90 C temperature rating; low gas emission; limited flame spread and excellent corrosion resistance. Conductor Identification Sizes 14 AWG to 2 AWG: Method #1-E2 per ICEA S Sizes 1 AWG to 500 kcmil: Method #4 per ICEA S See page 11 Bending Radius Fixed position: 7 x cable overall diameter During pulling: 12 x cable overall diameter Specifications Meets UL 44, XHHW-2 600V conductors Meets UL 1569 requirements for Type MC, Metal Clad cables Meets UL 2225 for Hazardous Locations Designated Type MC as per NEC 2008 and NEC 2011 Article 330 Meets CSA C22.2 No for Aluminum Sheathed Cables Meets CSA C22.2 No. 174-M1984 for Hazardous Locations 12 Product Features UL approved cables Type MC, 600V; File No. E47409 UL approved insulated conductors Cables pass UL 1685 and IEEE 383 vertical tray fire tests at 70,000 BTU/hr, ICEA T fire test at 210,000 BTU/hr, IEC category A fire test, IEEE 1202 and CSA FT4 Cables are American Bureau of Shipping (ABS) listed as CWC MC Type MC Cables are marked -40C and are suitable for handling and installation below -10 degrees Celsius (based on -40 degrees Celsius impact and bend laboratory tests). Temperature rating of 90 C dry and wet 130 C emergency rating and 250 C short circuit rating Continuous, impervious aluminum sheath corrugated for flexibility, prevents ingress of moisture, gases and liquids Aluminum sheath resistance exceeds requirements of the NEC 2008 and NEC 2011 Article for equipment grounding conductor Sheath provides good electronic shielding so that CORFLEX can be used in certain instrumentation applications when adequately grounded Excellent mechanical and physical properties Sunlight resistant jacket Suitable for direct burial, use in cable tray and embedment in concrete Lead free Options The following constructions can be provided on special orders: Special color or number coding Specially colored jackets UL 1309 listing and marking

14 Armored Variable Frequency Drive Cable UL Type MC HL, 600V, 90 C rated - Lead Free CORFLEX VFD UL 44 UL 1569 / CSA C22.2 No. 123 UL 2225 / CSA C22.2 No. 174 ICEA S (Color Coding) 3 Conductors with 3 Bare Grounds Cond. Insulation Thickness Ground Nominal Diameter Nominal Diameter Jacket Thickness Nominal Diameter Approximate Net Ampacity Size Wire Size over Core over Sheath (T1) over Jacket Cable Weight (D1) (D2) (D3) AWG/kcmil mils mm AWG inches mm inches mm mils mm inches mm lb/kft kg/km amps (1) 14 (7w) x18 (7w) (7w) x16 (7w) (7w) x14 (7w) (7w) x14 (7w) (7w) x12 (7w) (7w) x12 (7w) (7w) x10 (7w) (19w) x10 (7w) /0 (19w) x10 (7w) /0 (19w) x10 (7w) /0 (19w) x8 (7w) /0 (19w) x8 (7w) (37w) x8 (7w) (37w) x6 (7w) (37w) x6 (7w) (1) Ampacities are in accordance with NEC 2008 Table or NEC 2011 Table (B)(16) for conductors in raceway or direct buried at 30 C ambient temperature and 90 C conductor temperature. The overcurrent protection shall not exceed 15 amperes for 14 AWG, 20 amperes for 12 AWG, and 30 amperes for 10 AWG copper conductors after any correction factors for ambient temperature and number of conductors have been applied (NEC 2008 and NEC 2011 Article 240.4(D)). For correction factors for different ambient temperatures and ampacities at different conductor temperatures, see NEC 2008 Table or NEC 2011 Table (B)(16). 13

15 CORFLEX Electrical Properties 300V Shielded Pairs/Triads with an overall Cable Shield Pairs Capacitance Conductor Size DC Resistance Conductor Conductor Conductor Shield Conductor Conductor Conductor Shield (AWG) 20 C) (pf/ft) (pf/ft) (pf/ft) (pf/ft) Triads 600V Shielded Pairs/Triads with an overall Cable Shield Capacitance Pairs Triads Conductor Size DC Resistance Conductor Conductor Conductor Shield Conductor Conductor Conductor Shield (AWG) 20 C) (pf/ft) (pf/ft) (pf/ft) (pf/ft) V 3 and 4 Conductors AC Resistance Inductive Reactance Conductor 90 C, Hz Capacitance (AWG/kcmil) (ohms/kft) (ohms/kft) µf/kft / / / / Product Data CORFLEX PL and MC Instrumentation CORFLEX MC and VFD Insulation Inner Jacket Outer Jacket Insulation Jacket Polymer Type PVC PVC PVC XLPE PVC Temperature Rating 105 C 90 C 90 C 90 C 90 C Applicable Standard UL 13 UL 13 UL 13 UL 44 UL 1569 ICEA S ICEA S ICEA S ICEA S ICEA S Tensile Strength psi min Elongation % min

16 CORFLEX Voltage Drop The voltage drop table contained in this publication is applicable to aluminum armored CORFLEX cables. The table on this page shows voltage drop factors for 3-conductor CORFLEX cables with copper conductors, 3-phase, 60 hertz. The voltage drop for 4-conductor cables, such as in a 3-phase, 4-wire grounded neutral system, may be taken from the same table for a 3-conductor cable, where the fourth conductor carries only unbalance current of a 3-phase system. The K Factor table was generated using the following formula: K = RcosƟ + XLsinƟ (Volts/1000-ampfeet) where: R = AC resistance (ohms/kft) X L = inductive reactance (ohms/ kft) Ɵ = load power factor angle (N.B.: 100cosƟ = 100% load power factor) Since the curves are based on a 3-phase line-to-neutral system, the following system correction factor (f) must be used in the voltage drop calculation: Correction System Factor (f) 1 phase, 2 wire (120V branch circuits) 2 1 phase, 3 wire (240V residential circuits) 2 1 phase, 3 wire line-to-line 2 3 phase, 3 wire line-to-line phase, 4 wire line-to-line phase, 4 wire line-to-neutral 1 The following example is given to illustrate the proper use of the voltage drop formula and factors: Example: Find the voltage drop and percent drop give the following: 3 phase circuit at 480/277 volts, length of circuit 1000 feet, cable 3-conductor CORFLEX MC, size 250 kcmil, in air load 200 amps at 90% load power factor. Solution: Find the K factor from the K Factor Table; for 250kcmil conductor at 90% Load Power Factor, the K factor is: K =.057 volts per 1000 amp-feet therefore, from the voltage drop formula we calculate the voltage drop as: Voltage Drop (phase to phase) = = 19.7 volts 1000 OR Voltage Drop (phase to phase) = % = 4.10% 480 To calculate the net voltage drop for a specific application the following formula must be used to account for systems other than 3-phase, circuit length and current: Net Voltage Drop = f K I L 1000 where: f = system correction factor (see below) K = voltage drop factor from table (Volts/1000-amp-feet) I = current carried by one conductor (amps) L = circuit length (ft) K Factor (Volts / 1000-amp-feet) Size Load Power Factor (AWG/kcmil) 80% P.F. 90% P.F. 100% P.F / / / / Note: These K Factors are for phase to neutral voltage drop. 15

17 CORFLEX Pulling Instructions Certain installations require the pulling of CORFLEX into ducts or trays. These installations require careful planning and execution. The following provides information on how to calculate tensions developed during pulling and what precautions to take to prevent damage to the cable. Pulling Tension The maximum tension applied to a cable is limited to prevent damage or distortion of cable components which could reduce the life or reliability of the cable. The method of pulling is significant in that different methods will result in different stresses on critical cable components for the same overall tension. Nexans recommends that, CORFLEX PL cables are pulled by means of the aluminum sheath and jacket with a grip applied over the jacketed core, sheath and overall jacket. CORFLEX MC and VFD cables should be pulled by means of the conductors, aided with a grip over the outer aluminum sheath. The conductors and the sheath are to be pulled together. Maximum allowable pulling tensions for CORFLEX cables should never exceed the values shown in pulling tension table). Calculating Pulling Tensions The tension developed in any Straight Section of duct is calculated as: T = L x W x f lbf where L = section length (feet) W = cable weight per unit length (lb/foot) f = coefficient of dynamic friction The tension developed in any Bend is calculated as: T = T 1 x e fa lbf where T 1 = tension at bend entrance (lbf) e = base of natural logarithms ( ) f = coefficient of dynamic friction a = angle of bend (radians) or e fa is given in the following table for common conditions: Bend Angle (degrees) f = 0.15 f = 0.30 f = 0.35 f = Coefficients of dynamic friction with lubricant are given in the following table for common duct and cable jacket materials. These coefficients can be used for calculation of tensions. One Cable Duct Type Cable Jacket per Duct PVC PVC 0.50 PE PVC 0.30 FIBRE PVC 0.40 ASBESTOS PVC 0.70 CEMENT Considerations must be given to Side Wall Bearing Pressure (SWBP) when pulling CORFLEX through a bend. The SWBP is calculated as follows: SWBP = Pulling Tension Cable at Bend Exit (lbf) Radius of Bend (feet) For CORFLEX, Nexans recommends a maximum SWBP of 500 pounds force/foot. During installation of the CORFLEX cable, it is recommended that the bend radii be as noted in the cable descriptions. Pulling in Duct It is extremely important for the success of any pull in duct to use approved lubricants. Lubricants must be compatible with the cable jacket and duct material. Lubricating the pulling rope will decrease the tension on the pulling equipment and more importantly will reduce the risk of damage to the inside of the duct which in turn can damage the cable. When designing the duct layout, it is suggested that the bends be concentrated near the end from which the cable is to be pulled. This practice will result in lower tensions. In some cases, the tensions resulting from alternative directions should be calculated. Pulling in Trays and Trenches For the installation of CORFLEX in trays, rollers are normally used. Using well lubricated rollers and long radius sheaves at bends will result in a lower coefficient of friction when compared to duct. A coefficient of friction of 0.15 can be used when calculating pulling tension using rollers. For long pulls with bends it may be necessary to install assist pullers before the bends to reduce the tension on the cable entering a bend and reducing the risk of damage from excessive SWBP. The recommendations given above are intended to cover a wide variety of pulling conditions. It is possible, under ideal conditions, and with experienced supervision, to exceed these limits. For further guidance, see IEEE Paper 84 T & D 365-3, or contact Nexans. 16

18 CORFLEX Pulling Tension Table CORFLEX PL No. of Max. Pulling Size Pairs/Triads Tension (AWG) (lbf*) 18 2 pr pr pr pr pr pr pr pr pr pr pr pr pr pr pr pr pr tr tr tr tr tr 412 * lbf = pounds force CORFLEX MC No. of Max. Pulling Size Conductors Tension (AWG) (lbf*) /10 4/ /8 4/ /6 4/ /4 4/ /2 4/ CORFLEX MC 3 Conductors 4 Conductors Size (AWG/kcmil) Max. Pulling Tension (lbf*) / / / /

19 CORFLEX Connector Selection Explosion Proof Fittings for Hazardous Locations Sheath Diameter Overall Diameter Thomas & Betts Appleton Adalet / PLM Crouse Hinds Hawke inches mm inches mm Spin-on X MCJXS Series PSX Series TMCX Series 711 Series N/A N/A N/A A MCJXS-4850 PSX TMCX165 A MCJXS-4850 PSX TMCX165 A MCJXS-7875 PSX TMCX285 B MCJXS-9075 PSX TMCX3112 C MCJXS PSX TMCX4140 C MCJXS PSX TMCX4140 C MCJXS PSX TMCX5161 D MCJXS PSX TMCX6206 D MCJXS PSX TMCX6206 E MCJXS N/A TMCX7247 E MCJXS N/A TMCX8302 F MCJXS N/A TMCX8302 F MCJXS N/A TMCX8302 F MCJXS N/A TMCX9352 H MCJXS N/A TMCX9352 N/A MCJXS N/A TMCX9352 N/A MCJXS N/A TMCX10402 N/A MCJXS N/A TMCX10402 N/A MCJXS N/A TMCX10402 N/A MCJXS N/A TMCX10402 N/A N/A MCJXS N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A Fittings for Wet Locations Sheath Diameter Overall Diameter Thomas & Betts Appleton Adalet / PLM Crouse Hinds Hawke inches mm inches mm Spin-on X MCJ Series JAG Series TMC Series 701 Series N/A JAG N/A A MCJ-4850 JAG TMC165 A MCJ-4850 JAG TMC165 A MCJ-7875 JAG TMC285 B MCJ-9075 JAG TMC3112 C MCJ JAG TMC4140 C MCJ JAG TMC4140 C MCJ JAG TMC5161 D MCJ JAG TMC6206 D MCJ JAG TMC6206 E MCJ JAG TMC7247 E MCJ JAG TMC8302 F MCJ JAG TMC8302 F MCJ JAG TMC8302 F MCJ JAG TMC9352 H MCJ JAG TMC9352 N/A MCJ JAG TMC9352 N/A MCJ JAG TMC10402 N/A MCJ JAG TMC10402 N/A MCJ JAG TMC10402 N/A MCJ JAG TMC10402 N/A N/A MCJ JAG N/A N/A N/A N/A JAG N/A N/A N/A N/A N/A N/A N/A 18

20 CORFLEX Stranded Bare Copper Conductors Conductors Wires Nominal Conductor Diam. Approximate Net Average DC Area Diameter Compressed Round Conductor Weight 25 C Size lbs per kg per ohms per ohms per AWG/kcmil Circ.mils mm 2 sq.in. Number inches mm inches mm 1000ft 1000m 1000ft 1000m / / / /

21 Metric Conversions Length Area Volume Mass mils x = mm (millimeters) inches x 25.4 = mm feet x = m (meters) miles x = km (kilometers) circular mils x = mm 2 (square millimeters) sq. in. x = mm 2 sq. ft. x = m 2 (square meters) sq. yd. x = m 2 sq. mi. x = km 2 (square kilometers) cu. in. x = cm 3 (cubic centimeters) cu. ft. x = m 3 (cubic meters) gallons x = l (liters) pounds x = kg (kilograms) tons (2000 lbs.) x = t (metric tons) Mass per unit length lb/1000 ft x = kg/km (kilograms per kilometer) lb/mi x = kg/km mm 2 x 8.89 = kg/km (for copper) mm 2 x 2.70 = kg/km (for aluminum) mm 2 x 7.83 = kg/km (for steel) Force or Tension Force per unit area (Stress, pressure, tensile strength, etc.) pounds (force) x = N (newtons) mass (in kg) x = N (Weight at or near sea level) lbf/in 2 = (psi) x = kpa (kilopascals) lbf/in 2 x = MPa (megapascals) N/mm 2 = MPa Temperature F to C: C = ( F minus 32) x 5 / 9 C to F: F = ( C x 9 / 5) plus 32 Note: Kilopascals are used generally for fluid pressures. Megapascals are used generally for stress in materials, i.e. for tensile stress, modulus of elasticity, etc. WARNING FLAMMABLE Non-metallic covering of electrical cables will burn and under certain conditions may transmit fire when ignited. TOXIC Burning non-metallic coverings may emit acid gases, which are highly toxic, and may generate dense smoke. NOTICE Nexans has endeavoured to ensure the accuracy of the data in this publication, however we cannot be liable for the consequences of errors or omissions. All data is subject to change without notice. The installer and/or user assumes all liability for the consequences of the installation and/or use of any of our products in contravention of any applicable law, regulation or code. CORROSIVE Emission of acid gases may corrode metal in the vicinity, such as sensitive instruments and reinforcing rod in concrete. 20

22 PRINTED IN CANADA 07/2011 w w w. n e x a n s. u s

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