USING THIS MANUAL

The information contained herein is intended for evaluation and use by technically skilled and
appropriately trained persons. Although the information is believed to be accurate as of the date of
printing, General Cable makes no representations or warranties, expressed or implied, with respect to the
accuracy or completeness of this document, nor does General Cable assume any obligation to update or
correct the same in the future. You should always consult a trained professional for the most current
industry practices and procedures unique to your application.
The numerical data, formulas and other calculations provided in this document are believed to be accurate
and concise as of the date of printing. However, normal dimensional tolerances in actual cable
constructions and variations in the installation conditions may lead to differences in the indicated values
and actual measured values.

GENERAL CABLE, DURASHEATH, UNIBLEND, UNISHIELD, UNICON FREP, and UNICON

are trademarks of General Cable Technologies Corporation.
© 2011. General Cable Technologies Corporation.
Highland Heights, KY 41076
All rights reserved. Printed in USA.
Cable Installation Manual for Power and Control Cables

Table of Contents
1. INTRODUCTION..................................................................................................................... 9

2. PRE–INSTALLATION.............................................................................................................. 9
2.1 CABLE INSPECTION....................................................................................................................9
2.2 CABLE HANDLING....................................................................................................................10
2.3 CABLE STORAGE........................................................................................................................11
2.4 PRE-INSTALLATION CHECKLIST.............................................................................................11

3. INSTALLATION..................................................................................................................... 12
3.1 INSTALLATION TEMPERATURE..............................................................................................13
3.2 EQUIPMENT................................................................................................................................13
3.2.1 Checklist.............................................................................................................................13
3.2.2 Cable Feed-In Setups..........................................................................................................14
Fig. 3.2.2.1 Proper Feed-In Setup......................................................................................14
Fig. 3.2.2.2 Improper Feed-In Setup..................................................................................14
Fig. 3.2.2.3 Effective Curvature........................................................................................15
3.2.3 Wire-Pulling Compound Suppliers.....................................................................................16
3.3 EXPOSED RUNS (OPEN WIRING)............................................................................................16
3.3.1 NEC....................................................................................................................................16
3.3.1.1 Wiring Methods.....................................................................................................16
3.3.1.1.1 Metal Clad Cable..................................................................................16
3.3.1.1.2 Medium-Voltage Cable..........................................................................17
3.3.1.1.3 Messenger-Supported Wiring................................................................17
3.3.1.1.4 TC-ER Tray Cable................................................................................17
3.3.1.2 Securing and Supporting........................................................................................17
3.3.1.3 Ampacity...............................................................................................................17
3.3.2 CEC.....................................................................................................................................17
3.3.2.1 Wiring Methods.....................................................................................................17
3.3.2.1.1 750 V or less.........................................................................................18
3.3.2.1.2 Over 750 V...........................................................................................18
3.3.2.1.3 Installation Conditions..........................................................................18
3.3.2.2 Hazardous Locations.............................................................................................18
3.3.2.3 Ampacity...............................................................................................................18
3.3.3 Non-Code Installations........................................................................................................18
3.3.3.1 Ampacity...............................................................................................................19
3.4 CABLE TRAY..............................................................................................................................19
3.4.1 NEC....................................................................................................................................19
3.4.1.1 Wiring Methods.....................................................................................................19
3.4.1.1.1 General Industrial and Commercial.......................................................19
3.4.1.1.2 Industrial Establishments......................................................................19
3.4.1.1.3 Hazardous Locations.............................................................................19
Cable Installation Manual for Power and Control Cables

Table of Contents
3.4.1
NEC (cont’d)
3.4.1.2 Voltage Separation.................................................................................................20
3.4.1.2.1 600 V or Less........................................................................................20
3.4.1.2.2 Over 600 V...........................................................................................20
3.4.1.3 Tray Fill.................................................................................................................20
Table 3.4.1.3 Cable Tray Fill.................................................................................20
3.4.1.4 Splices...................................................................................................................20
3.4.1.5 Ampacity...............................................................................................................20
3.4.1.5.1 2000 V or Less......................................................................................20
3.4.1.5.2 Over 2000 V.........................................................................................20
3.4.2 CEC.....................................................................................................................................21
3.4.2.1 Conductors in Cable Trays.....................................................................................21
3.4.2.1.1 Type TC Tray Cable..............................................................................21
3.4.2.1.2 Non-Armoured Jacketed (Sheathed) Cable...........................................21
3.4.2.2 Single Conductors..................................................................................................21
3.4.2.3 Ampacity...............................................................................................................21
3.4.3 Non-Code Installations........................................................................................................22
3.5 MESSENGER-SUPPORTED WIRING........................................................................................22
3.5.1 NEC....................................................................................................................................22
3.5.1.1 Wiring Methods.....................................................................................................22
3.5.1.1.1 General Industrial and Commercial.......................................................22
3.5.1.1.2 Industrial Establishments......................................................................22
3.5.1.1.3 Hazardous Locations.............................................................................23
3.5.1.2 Splices...................................................................................................................23
3.5.1.3 Ampacity...............................................................................................................23
3.5.1.3.1 2000 V or Less......................................................................................23
3.5.1.3.2 Over 2000 V.........................................................................................23
3.5.1.3.3 Type MC Cable.....................................................................................23
3.5.2 CEC.....................................................................................................................................24
3.5.2.1 Installation.............................................................................................................24
3.5.2.2 Flame Spread.........................................................................................................24
3.5.2.3 Ampacity...............................................................................................................24
3.6 UNDERGROUND INSTALLATIONS..........................................................................................24
3.6.1 NEC....................................................................................................................................24
3.6.1.1 Installation Requirements......................................................................................24
3.6.1.2 Ampacity Calculations...........................................................................................24
3.6.1.3 Ampacity Tables....................................................................................................25
3.6.1.3.1 2000 V or Less......................................................................................25
3.6.1.3.2 2001 V to 35 kV....................................................................................25
Cable Installation Manual for Power and Control Cables

Table of Contents
3.6.2
CEC.....................................................................................................................................25
3.6.2.1 Installation Requirements......................................................................................25
3.6.2.2 Ampacity...............................................................................................................25
3.7 RACEWAYS.................................................................................................................................25
3.7.1 RMC Elbow Radius............................................................................................................26
Table 3.7.1 Manufactured RMC Elbow Dimensions...........................................................26
3.7.2 Raceway Fill Calculations...................................................................................................26
3.7.3 Mechanical Fit of Cable in Raceway...................................................................................27
3.7.3.1 Conductor Configuration.......................................................................................27
Fig. 3.7.3.1 Conductor Configurations within a Raceway.....................................27
3.7.3.2 Weight Correction Factor.......................................................................................27
Table 3.7.3.2 Weight Correction Factor Calculations.............................................28
3.7.3.3 Clearance...............................................................................................................28
Table 3.7.3.3 Clearance Calculations.....................................................................28
3.7.3.4 Jam Ratio...............................................................................................................29
Table 3.7.3.4 Jamming Possibilities.......................................................................30
3.7.3.5 Coefficient of Dynamic Friction............................................................................31
Table 3.7.3.5 Typical Coefficients of Dynamic Friction(f)....................................31
3.7.4 NEC....................................................................................................................................31
3.7.4.1 NEC Chapter 9 Tables...........................................................................................32
Table 3.7.4.1 Raceway Inside Diameter Dimensions.............................................33
3.7.4.2 Notes to NEC Chapter 9 Tables.............................................................................34
3.7.4.3 Rigid Metal Conduit Fill Tables.............................................................................34
3.7.4.3.1 Single Conductor Nonshielded 600 V and 2400 V................................35
3.7.4.3.2 Single Conductor Shielded 5 kV-35 kV................................................35
3.7.4.3.3 Three Conductor Shielded 5 kV-35 kV.................................................35
Table 3.7.4.3.1.1 DuraSheath® 1/C 600 V (Spec 5050)......................36
Table 3.7.4.3.1.2 Unicon® FREP® 1/C 600 V (Spec 5100).................37
Table 3.7.4.3.1.3 DuraSheath® 1/C 2400 V (Spec 6050)....................38
Table 3.7.4.3.2.1 Uniblend® LF 1/C 5 kV (133%) or 8 kV (100%)
(Spec 6155).............................................................39
Table 3.7.4.3.2.2 Uniblend® LF 1/C 15 kV (133%) (Spec 6355)........40
Table 3.7.4.3.2.3 Uniblend® LF 1/C 25 kV (133%) and 35 kV (100%)
(Spec 6555).............................................................41
Table 3.7.4.3.2.4 UniShield® 1/C 5 kV (133%) or 8 kV (100%)
(Spec 6100).............................................................42
Table 3.7.4.3.2.5 UniShield® 1/C 15 kV (133%) (Spec 6300)............43
Table 3.7.4.3.2.6 UniShield® 1/C 25 kV (133%) and 35 kV (100%)
(Spec 6500).............................................................44
Table 3.7.4.3.3.1 Uniblend® LF 3/C 5 kV (133%) or 8 kV (100%)
(Spec 6255).............................................................45
Cable Installation Manual for Power and Control Cables

Table of Contents
3.7.4.3.3 Three Conductor Shielded 5 kV – 35 kV (cont’d)
Table 3.7.4.3.3.2 Uniblend® LF 3/C 15 kV (133%) (Spec 6455)........46
Table 3.7.4.3.3.3 Uniblend® LF 3/C 25 kV (133%) and 35 kV (100%)
(Spec 6605).............................................................47
3.7.4.4 Supporting Conductors in Vertical Raceways........................................................48
Table 3.7.4.4 Maximum Spacing for Conductor Supports in Vertical Raceways...48
3.7.4.5 Ampacity...............................................................................................................49
3.7.4.5.1 2000 V or Less......................................................................................49
3.7.4.5.2 Over 2000 V.........................................................................................49
3.7.5 CEC.....................................................................................................................................51
3.7.5.1 CEC Raceway Tables.............................................................................................51
3.7.5.1.1 Radii of Bends in Raceways..................................................................51
Table 3.7.5.1.1 Radius of Conduit Bends..............................................51
3.7.5.1.2 Cross-Sectional Areas of Conduit and Tubing.......................................51
3.7.5.2 CEC Raceway Fill Tables......................................................................................51
3.7.5.2.1 Maximum Allowable Raceway Fill.......................................................51
3.7.5.2.2 Maximum Number of Conductors.........................................................51
3.7.5.2.3 Cable Dimensions.................................................................................52
3.7.5.3 Supporting Conductors in Vertical Raceways........................................................52
Table 3.7.5.3 Maximum Spacing for Conductor Supports in Vertical Raceways...52
3.7.5.4 Ampacity of Conductors Rated 2000 Volts or Less...............................................52
3.7.5.5 Ampacity Correction Factors.................................................................................52
3.7.6 Non-Code Installations........................................................................................................53
3.7.6.1 Schedule 40 PE/PVC Conduit...............................................................................53
Table 3.7.6.1 Schedule 40 PE/PVC Conduit Information......................................53
3.7.6.2 Duct Information...................................................................................................54
Table 3.7.6.2 Rigid Duct Dimensional Data..........................................................54
3.7.6.3 Supporting Conductors in Vertical Raceways........................................................55
3.8 GENERAL CABLE INSULATED CONDUCTOR AND CABLE DIMENSIONS......................55
3.9 PHYSICAL LIMITATIONS OF CABLES....................................................................................55
3.9.1 Maximum Pulling Tensions.................................................................................................56
3.9.1.1 Allowable Tension on Pulling Device....................................................................56
3.9.1.2 Allowable Tension on Conductor..........................................................................56
Table 3.9.1.2 Conductor Pulling Tensions..............................................................56
3.9.1.2.1 Conductor Diameters.............................................................................58
Table 3.9.1.2.1.1 Nominal Conductor Diameters (in.)...........................58
Table 3.9.1.2.1.2 Nominal Conductor Diameters (mm).........................59
3.9.1.2.2 Conductors in Parallel or in Assemblies................................................60
Table 3.9.1.2.2 Maximum Allowable Pulling Tensions (lb)..................61
3.9.1.2.3 Multi-Conductor Cables........................................................................61
Table 3.9.1.2.3 Maximum Allowable Pulling Tensions (lb)..................62
Cable Installation Manual for Power and Control Cables

Table of Contents
3.9.1.3 Tension Calculations..............................................................................................63
3.9.1.3.1 Vertical Bend, Pulling Up......................................................................64
Fig. 3.9.1.3.1 VUCD and VUCU..........................................................64
3.9.1.3.2 Vertical Bend, Pulling Down.................................................................64
Fig. 3.9.1.3.2 VDCD and VDCU..........................................................64
3.9.1.3.3 Horizontal Pull......................................................................................65
3.9.1.3.4 Incline Pull............................................................................................65
3.9.1.3.5 Horizontal Bend....................................................................................65
3.9.1.3.6 Bend Approximation.............................................................................65
3.9.1.3.7 Arches...................................................................................................65
Fig. 3.9.1.3.7 Arches.............................................................................65
3.9.1.3.8 Bend Multiplier.....................................................................................66
3.9.1.3.9 Calculations Correlation........................................................................66
3.9.2 Allowable Sidewall Bearing Pressure.................................................................................66
Fig. 3.9.2 Sidewall Loading................................................................................................67
Table 3.9.2 Sidewall Bearing Pressure (Sidewall Loading).................................................67
3.9.3 Training and Bending..........................................................................................................68
3.9.3.1 NEC.......................................................................................................................68
Table 3.9.3.1 Minimum Bending Radius...............................................................69
3.9.3.2 CEC.......................................................................................................................69
Table 3.9.3.2 Minimum Bending Radius – High-Voltage Cable............................70
3.9.3.3 Non-Code Applications.........................................................................................70
Table 3.9.3.3.1 Minimum Bending Radii – Nonshielded Conductors....................70
Table 3.9.3.3.2 Minimum Bending Radii – Shielded Conductors..........................71
3.9.4 Sample Calculations............................................................................................................71
3.9.5 Installation Checklist...........................................................................................................75
3.9.5.1 Raceways...............................................................................................................75
3.9.5.2 Direct Buried.........................................................................................................75
3.9.5.3 Cable Pulling.........................................................................................................76

4. POWER CABLES...........................................................................................................................................76
4.1 SHIELDING..................................................................................................................................76
4.1.1 Nonshielded Cables.............................................................................................................76
4.1.2 Shielded Cables...................................................................................................................77
4.2 SPLICING AND TERMINATING................................................................................................77
4.3 EMERGENCY OVERLOAD CURRENT GUIDELINES............................................................79

5. TESTING GUIDELINES FOR LOW-VOLTAGE CABLES..................................................................................79

5.1 NONDESTRUCTIVE INSULATION RESISTANCE...................................................................79
Table of Contents
6. TESTING GUIDELINES FOR MEDIUM-VOLTAGE CABLES...................................................................................80
6.1 PRE-TEST GUIDELINES............................................................................................................80
6.1.1 Testing Equipment...............................................................................................................80
6.1.2 Recommended Testing Procedures......................................................................................81
6.1.3 Preparation for Testing........................................................................................................81
6.2 HI-POT TESTING PROCEDURES..............................................................................................81
6.2.1 Continuous Method.............................................................................................................81
6.2.2 Step Method........................................................................................................................81
6.2.3 Recommended Testing Procedure.......................................................................................81
6.2.3.1 Acceptance Testing................................................................................................82
Table 6.2.3.1 ICEA dc Field Test Voltages............................................................82
6.2.3.2 Maintenance Testing..............................................................................................83
6.3 COMMON TESTING PROBLEMS.............................................................................................83
6.4 FAULT LOCATING......................................................................................................................84
6.5 TESTING CHECKLIST................................................................................................................84

7. ANNEX...................................................................................................................................................................84
7.1 DEFINITIONS..............................................................................................................................84
7.1.1 NEC....................................................................................................................................84
7.1.2 CEC.....................................................................................................................................85
7.2 DESIGN CONSIDERATIONS......................................................................................................88
7.2.1 Dynamometer Correction....................................................................................................88
7.2.2 Diameter of Multi-Conductor Assemblies...........................................................................89
Table 7.2.2 Multiplying Factor for Multi-Conductor Assembly..........................................89
7.2.3 Diameter of Outer Interstice in Multi-Conductor Assembly...............................................90
Table 7.2.3 Outer Interstice Conductor Diameter Factor.....................................................90
7.3 PURGING WATER FROM CONDUCTOR STRAND OR SHIELD............................................90
7.3.1 Cables Not Installed............................................................................................................90
7.3.2 Installed Cables...................................................................................................................91
Fig. 7.3 Setup for Purging Water from Strand or Shield......................................................91
7.4 TYPE MC METAL CLAD (CCW®), 300 V – 35 KV ARMORED CABLE FOR
HAZARDOUS LOCATIONS SHEATH REMOVAL GUIDELINES.................................92
7.5 TYPE MV-105, EPR 5 – 35 KV WIRE SHIELD POWER CABLE (UNISHIELD®) TERMINATION
AND INSTALLATION PREPARATION GUIDELINES......................................................98
The information contained herein is intended for evaluation by technically skilled persons. Any person relying on this
document does so at their own independent discretion and sole risk, assumes all risks and liability whatsoever in connection
with such use, and General Cable will have no liability with respect thereto, whether the claim is based in contract, tort or other
legal theory.
General Cable makes no representations or warranties, expressed or implied, with respect to the accuracy, completeness or
reliability of this document.