U NIVERSITY OF W ASHINGTON Electrical

Facilities Services
Design Guide Wire, Cable and Terminations

Basis of Design
This section applies to the design and installation relating to wire and cable systems and terminations.

Design Criteria

Medium Voltage

• Review and modify the attached guide specification as required to meet the project
requirements.
• Cable and wire procurement, especially for short lengths of interlock armored cable, can take
additional time. The consultant shall include fair warning to the Contractor in the
specifications.
• Cables are subject to ambient temperatures of –20º to +40º C (0 to 105º F).
• Connection points shall be provided in all electrical vaults and manholes to allow future
facilities and other services to be connected to the primary distribution system.
• The following are typical medium voltage connections:

16G – Figure 1 16G – Figure 2

Manifold Junction Boxes Bolt-T Connectors

REV:06 – JUL2008 16G - 01

© University of Washington – Campus Engineering 2007

U NIVERSITY OF W ASHINGTON Electrical
Facilities Services
Design Guide Wire, Cable and Terminations

16G – Figure 3 16G – Figure 4

Stacked Bolt-T Connectors 15kV Link Box with Spare Ports

16G – Figure 5 16G – Figure 6

Link Box with Spare Ports Link Box with Pothead Connections
Low Voltage

• All wiring shall be in raceway systems unless otherwise noted.

• Refer to “Electrical – Raceway” section for Interlocked Armored Cable (IAC) applications.
• Refer to “Electrical – Raceway” section for Metal Clad (MC) Cable and Armored Cable (AC)
applications.
• Refer to other specification sections for signal and communication type cable and
terminations.
• Any low voltage cable in air handling spaces or plenums shall be specifically listed for use in
such places (unless in enclosed raceways or conduit).

Design Evaluation

The following information is required to evaluate the design:

• Programming: Statement of design intent, including materials and terminating devices.

• Schematic Design Phase: Description of overall distribution concept. Outline specifications.
• Design Development Phase: Preliminary one-line diagram showing conductor and cable
sizing. Preliminary plans showing distribution routing and cable schedules. Indicate the
location of connections and types of termination to the primary distribution system
Preliminary detail drawings showing connection hardware information. Draft specifications.

16G - 02 REV:06 – JUL2008

© University of Washington – Campus Engineering 2007

U NIVERSITY OF W ASHINGTON Electrical
Facilities Services
Design Guide Wire, Cable and Terminations

• Construction Document Phase: Complete one-line diagram showing conductor and cable
sizing. Complete plans showing distribution routing and cable schedules. Final details on
location of connections and types of termination to the primary distribution system. Complete
detail drawings showing connection hardware information, protection methods and grounding
information. Complete specifications.

Submittals
• For medium voltage systems, refer to attached guide specification, MV.Wire, Cable and
Terminations.
• For low voltage systems, submit standard industry requirements.

Related Chapters, Sections and References

• Facilities Services Design Guide – Electrical - Raceways
• Facilities Services Design Guide – Electrical - Identification
• Facilities Services Design Guide – Electrical - Inspection, Calibration and Testing

Products, Material and Equipment

Medium Voltage

• Refer to attached guide specification MV Wire, Cable, and Terminations.

Low Voltage

• Power conductors shall be stranded copper, 98% conductivity. Number 12 AWG is the
minimum conductor size. #12 and #10 shall be solid conductor for lighting and receptacle
branch circuits, and stranded for motor and equipment circuits and wherever vibration is a
consideration.
• Insulation THWN or XHHW (Also THHN when 1/O or smaller)
• Conductor color code per requirements in Electrical – Identification section
• 600 volt control wiring cable shall be in accordance with power conductors above, except #14
AWG shall be permitted and all control wiring shall be stranded.
• "Low voltage" and special cables shall be as specified in subsequent functional sections (e.g.
communications, fire alarm, computerized system, television, etc.)
• 600 volt splices shall be:
1) Solderless type only
2) Preinsulated "twist-on" type permitted on solid conductor size # 10 and smaller
3) Hydraulic compression long barrel type with application preformed insulated cover,
heat shrinkable tubing or plastic insulated tape for all stranded conductors
4) For stranded conductors provide terminations designed for use with stranded
conductors.
• 600V terminations:

REV:06 – JUL2008 16G - 03

© University of Washington – Campus Engineering 2007

U NIVERSITY OF W ASHINGTON Electrical
Facilities Services
Design Guide Wire, Cable and Terminations

1) 2-hole long barrel compression lugs - 250 kcmil and above

2) Single hole compression lug - Below 250 kcmil
3) Conductors #12 and smaller: Provide eye or forked tongue compression lugs at
bolted or screw connections; no lugs required for compression style terminal blocks.
4) Cable ties: Nylon or equivalent, locking type. Use a torque limiting tool for
installation of ties.
• Control cable splices shall be pre-insulated crimp pigtail or butt splice connectors.
• Control cable terminations shall be locking spade, insulated, compression lugs.

Installation, Fabrication and Construction

Medium Voltage

• Refer to the attached guide specification MV Wire, Cable and Terminations.

• Medium voltage cable splices and connections are often placed in tunnels and manholes
open to non-electrical workers; thus splices shall be provided with protective covers and
junction boxes with protective cages. The Consultant shall investigate and work with
Campus Engineering in designing appropriate worker protection barriers.
• Conduits for medium voltage installations are rigid steel in buildings and street crossings;
schedule 40 PVC in direct buried or concrete encased applications; and cable tray in tunnels.
Medium voltage cable shall not be direct buried.
• Size cable junction boxes to allow future expansion of the cable system.
• Do not add link boxes for new medium voltage installations (13kV, 4.16kV, 2.4kV). Utilize
cable junction boxes.
• Use 15kV rated air-insulated sectionalizing switches, cable junction boxes or existing link
boxes for 13.8kV systems.
Low Voltage

• Provide cable ties (limit torque on ties) in panelboards, cabinets, and other unconfined
spaces. Group and lace wiring neatly, and do not tie to factory-installed wiring in equipment.
Bundle and tag multi-pole circuits in laboratory surface metal raceway.
• Branch circuits: Homeruns greater than 75 feet to first outlet shall be # 10 minimum.
• Do not use mechanical means for pulling wires. Uselubricants that do not clog conduits after
use. Splices are not allowed in Homeruns.
• Terminate conductors so that conductor information is easily visible on at least one
termination per feeder or within panel or switchboard pulling space.
• Observe cable bend radius limitations and follow lug manufacturer's installation procedure.
• Provide all control wire terminations with approved wire markers which mark the conductor
with the terminal number for the wire.
• Do not score the conductor when stripping insulation, and always pare or pencil when using
a blade. Use of a stripping tool is preferable.

16G - 04 REV:06 – JUL2008

© University of Washington – Campus Engineering 2007

U NIVERSITY OF W ASHINGTON Electrical
Facilities Services
Design Guide Wire, Cable and Terminations

• Secure and tighten all terminations in accordance with manufacturer's recommendations.

Remove unterminated wiring unless noted otherwise or specifically approved to remain.
Consult with the Engineer for precise instructions.
• Crimp terminations larger than 8awg shall be of the hexacentric type.

END OF DESIGN GUIDE SECTION

REV:06 – JUL2008 16G - 05

© University of Washington – Campus Engineering 2007

U NIVERSITY OF W ASHINGTON Electrical
Facilities Services Guide Specification
Design Guide MV Wire, Cable and Terminations

GUIDE SPECIFICATION
The following specification is intended as a guide only. The Consultant shall write the specifications to
meet the project requirements in consultation with the Owner.

ELECTRICAL − MV WIRE, CABLE AND TERMINATIONS

PART 1 - GENERAL

1.01 DESCRIPTION

A. Purpose
1. This section covers medium voltage cable and terminations for use in the University's primary
and secondary power distribution systems.

1.02 QUALIFICATIONS

A. Approved manufacturers
1. Medium voltage 5 and 15kV wire and cables
a. 5 and 15kV single conductor: Pirelli, Aetna, and Okonite
b. 5 and 15kV armored cable: Pirelli, Aetna, and Okonite
(1) Service Wire for short lengths of interlock armored cable (< 500 feet)
c. All other manufacturers shall be approved during the design prior to bidding.

1.03 RELATED SECTIONS

A. The work under this section is subject to requirements of the Contract Documents, including the
General Conditions, Supplemental Conditions, and sections under Division 1 General Requirements.

B. Electrical Identification

C. Inspection, Calibration and Testing

1.04 REFERENCES

A. Applicable codes, standards, and references codes, regulations and standards

1. National Electrical Testing Association – NETA
2. National Fire Protection Association – NFPA
3. National Electrical Code - NEC
4. AEIC CS6-96 (ethylene propylene rubber)
5. ICEA S-93-639 (ethylene propylene rubber)

16G - 06 REV:06 – JUL2008

© University of Washington – Campus Engineering 2007

U NIVERSITY OF W ASHINGTON Electrical
Facilities Services Guide Specification
Design Guide MV Wire, Cable and Terminations

6. IEEE STD 400-1991 (DC Testing)

7. IEEE STD 48
8. UL 1072 for physical requirements for the armor
9. UL 1008 – Automatic Transfer Switches
10. State and local codes and ordinances

1.05 COORDINATION

A. Coordinate Operations and Maintenance training times with the University.

1.06 SUBMITTALS

A. General
1. Submittals shall be in accordance with Conditions of the Contract and Division 01
Specification Sections.
2. Submit detailed maintenance manuals and drawings, which include catalog information
indicating the complete electrical and mechanical characteristics.
3. Submit current manufacturer’s AEIC pre-qualification data.
4. Submit dimensioned cross-sectional drawings (manufacturer’s data sheets are acceptable).
5. Submit finished cable tests – Manufacturer’s Certified Test Reports showing compliance with
ICEA S-68-516, Part 3, and UL 1072 for physical requirements of the armor and all AEIC final
tests, including x-y plots of corona discharge for the actual cable furnished.
6. Submit pulling calculations and plan for each medium voltage cable length.
7. Submit data sheet on crimping tools to be used.
8. Submit for approval the résumés of the medium voltage cable splicers. Qualifications should
include certification, recent work history on similar splice type and knowledge of the “Safety
Standards for Electrical Workers” (WAC 296-45).

1.07 OPERATIONS AND MAINTENANCE (O&M) MANUALS

A. Operations and Maintenance Manuals shall be in accordance with Conditions of the Contract and
Division 01 Specification Sections.

B. Operations and Maintenance Manuals shall include but not be limited to pull calculations and catalog
information indicating complete electrical and mechanical characteristics.

C. Manufacturer’s Certified Test Reports

D. Manufacturer’s AEIC Pre-qualification Data

REV:06 – JUL2008 16G - 07

© University of Washington – Campus Engineering 2007

U NIVERSITY OF W ASHINGTON Electrical
Facilities Services Guide Specification
Design Guide MV Wire, Cable and Terminations

1.08 MEETINGS

A. Pre-installation conference
1. The Contractor shall request a pre-installation conference with the University’s Campus
Engineering and University’s Physical Plant High Voltage Shop for projects with medium and
high voltage work.

B. Attend meetings with the Owner and/or Owner’s Representative as required to resolve any
installation or functional problems.

C. Within 1 month after “Notice to Proceed,” schedule a meeting with UW Representatives to review
electrical identification requirements.
PART 2 – PRODUCTS

2.01 GENERAL

A. These cable and terminations specifications are in accord with the University's policy to construct
permanent installations with long life, coupled with maximum reliability and safety. It is intended that
the best available materials be used and new and better materials adopted as they become available
and are approved by the University.

2.02 MEDIUM VOLTAGE WIRE AND CABLE

A. The following shall apply to both 5kV and 15kV medium voltage power conductors used as single
conductors or assembled into 3/c armored cable:
1. Single conductors
a. Conductors: Class B stranded, concentric, soft or annealed copper per Part 2 of ICEA S-
68-516
b. Strand screen: Extruded semi-conducting thermosetting compound applied over the
conductor. The material shall be compatible with the conductor metal, shall be uniformly
and firmly bonded to the overlying insulation, and be free of stripping from the conductor.
c. Insulation: High quality heat, moisture, ozone and corona resistant Ethylene Propylene
Rubber (EPR) compound
(1) The insulation shall contrast in color with the strand screen and insulation shield per
AEIC CS 6.
(2) Insulation level shall be 133% (115 mils for 5KV, 220 mils for 15KV).
(3) The minimum thickness of the insulation at any point shall not be less than 90% of
the specified nominal thickness.
(4) The insulation shall contain no more than 2% polyethylene.
d. Insulation shield: Extruded semi-conducting thermosetting compound applied directly
over the insulation. The material shall be compatible with the insulation and overlying
metallic shield. The insulation shield shall be clean and free of stripping from the
insulation and comply with Paragraph D.1 of AEIC CS 6.

16G - 08 REV:06 – JUL2008

© University of Washington – Campus Engineering 2007

U NIVERSITY OF W ASHINGTON Electrical
Facilities Services Guide Specification
Design Guide MV Wire, Cable and Terminations

e. Manufacturing process: The strand screen, insulation, and insulation shield shall be
applied with a triple-tandem process providing a virtual corona-free core. The EPR
insulation system shall not be exposed to the atmosphere during manufacture.
f. Metallic shield and individual jacket: .005 inch thickness of copper tape helically applied
over the insulation shield material with a 20% overlap, covered with an extruded PVC
outer jacket meeting the requirements of ICEA S-68-516 Paragraph 4.4.10.
g. Identification: The following information shall be surface-printed on the overall jacket:
Manufacturer’s name, cable size, cable type, year of manufacture and voltage rating.
2. Armored cable
a. Single conductors: Per the section above. (Note: Individual PVC jacket shall be
required for each single conductor).
b. Grounding conductors: Bare copper, stranded in accordance with ICEA S-68-516, Part 2.
Minimum size shall be in accordance with UL 1072, Table 11A. (Note to designer:
Provide a larger size, if required, to handle calculated fault current.)

¾ IMPORTANT: In the University of Washington primary distribution system the

size of main primary feeders are 500 KCM. In instances where #2/0 cable is
tapped from 500 KCM cable, to subfeed a facility or load, provide ground
conductors in #2/0 cable equal to the ground conductor of 500KCM cable.
Ground conductors shall be factory installed with the phase conductors and
shall be an integral component of the cable. This is not an industry standard and
shall be clearly indicated in the design documents. Supplemental grounding
conductor external to the interlock armored cable is not acceptable by the AHJ.

c. Filler material: Non-hygroscopic material, fine fiber, completely filling center and
peripheral interstices
d. Binder tape: Applied over assembly to provide a solid core
e. Armor: Galvanized steel or aluminum, interlocked armor in accordance with ICEA S-68-
516, Part 4 and UL 1072, Part 25.11
f. Overall jacket: Polyvinyl Chloride (PVC) in accordance with ICEA S-68-516 paragraph
4.4.10. Industry standard color by voltage class (15kV cable – red; 5kV cable – yellow).
g. Identification: The following information shall be surface printed on the overall jacket:
Manufacturer’s name, cable size, cable type, year of manufacture and voltage rating.
h. Listings: Finished cable shall be UL listed as Type MC, MV-90 and "For CT USE."
i. Color for outer jacket shall be consistent with industry standards.
3. Cable rejection
a. Cable shall be subject to inspection by the University at delivery and installation and
subject to rejection for shipping and/or installation damage including, but not limited to,
jacket penetration, armor denting, or other indications that cable integrity has been
compromised.
b. Hi-pot and Megger testing will not be the sole determining factor in the Owner accepting or
rejecting damaged cable.

REV:06 – JUL2008 16G - 09

© University of Washington – Campus Engineering 2007

U NIVERSITY OF W ASHINGTON Electrical
Facilities Services Guide Specification
Design Guide MV Wire, Cable and Terminations

2.03 SPLICES AND TERMINATIONS

A. Medium voltage
1. Medium voltage connections and terminations (armored cable and single conductor) - Long
barrel, 2-hole hydraulic crimp lugs, with Raychem "HVT" or 3M "Quick Term" series 5600
termination kits
2. Medium voltage connections and terminations (armored cable and single conductor) - Long
barrel, 2-hole hydraulic crimp lugs, with Raychem "HVT" or 3M "Quick Term" series 5600
termination kits.
3. Splices other than cold shrink are to be housed in a listed enclosure: OZ Gedney Series
SPKJR, G&W #E74 or Adalet 3AS manufactured by PLM, with fittings to suit cable.

¾ IMPORTANT: Specifier to add Exact Requirements for Cable

4. Method of crimp termination for #8 awg and larger shall be performed with correctly sized
hexacentric die only.
a. Approved manufacturers: 3M, Elastimold; all other manufacturers shall be approved prior
to bidding.
PART 3 – EXECUTION

3.01 REQUIREMENTS

A. General installation
1. Identification
a. Reference section Electrical - Wire, Cable and Terminations
2. Installation
a. Only personnel qualified and experienced in this type of work shall make connections.
b. The installation of cables shall be done with care to avoid damage.
(1) Cables showing damage after installation shall be replaced.
(2) Rollers and spools shall be used in adequate numbers for pulling in cables.
(3) The tension limitations, side wall pressure, and minimum bending radius as given by
the cable manufacturer shall be observed.
c. Cable pulling
(1) In no case will strands be removed to attach pulling eyes.
(2) Tension is limited to 1000 lbs. using basket grips.
(3) Lubrication shall be as approved for the insulation and raceway material.
(4) Prior to pulling, calculations of pulling tension and side wall pressure shall be
submitted.

16G - 010 REV:06 – JUL2008

© University of Washington – Campus Engineering 2007

U NIVERSITY OF W ASHINGTON Electrical
Facilities Services Guide Specification
Design Guide MV Wire, Cable and Terminations

(5) A dynamometer shall be used and tension recorded for all MV pulls.
(6) Use no mechanical means for pulling #8 and smaller AWG conductors.
d. Cable pulling setups and operations shall be witnessed by the University Physical Plant
High Voltage Shop and Campus Engineering.
e. Interlocked armor cable shall be pulled only when both the armor and conductors are
gripped. Remove cable similarly.
f. All cable that leaves a tray shall be taped/wrapped with Scotch 77, MAC AP30, or Quelcor
“Quelpyre” fireproofing tape.

B. Medium voltage cable terminations

1. Phase mark each conductor, secure conductors adequately and observe cable bend radius
limitations. University will identify the West Receiving Station phase rotation convention.
2. System Phase Sequence is C-B-A.
3. MV switch phase terminations shall be A-B-C left to right when facing the front of the switch.
4. Junction box phase terminations are A-B-C left to right.
5. Standard link box phase terminations are A-B-C left to right, top to bottom, front to back.
Some existing link box phase terminations are not standard, especially on the 2.4kV normal
and emergency power system.
6. The Physical Plant Department High Voltage Shop will identify the phase designation of the
existing primary distribution system conductors to which the Contractor is to make a
connection.
a. They will also check the Contractor's work to ensure the accuracy of the connections.
b. The Contractor shall arrange with the University for the times when their services will be
required, and under no circumstances shall the Contractor connect to the existing system
without their knowledge.
c. The proper connection of the wires and cables to other systems as specified is entirely the
responsibility of the Contractor.
d. In the event the connections cannot be made as specified, the Contractor shall make the
necessary corrections at his own expense.
7. Install cable terminations per manufacturer's recommendations.
8. Medium voltage cable splices shall be made only when absolutely necessary. When
necessary, splices shall be made only by personnel qualified and experienced in this type of
work.
9. Each high voltage splice or connection shall be permanently labeled with the following
information:
a. Contract or project designation
b. Contractor doing work
c. Name of splicer and date

REV:06 – JUL2008 16G - 011

© University of Washington – Campus Engineering 2007

U NIVERSITY OF W ASHINGTON Electrical
Facilities Services Guide Specification
Design Guide MV Wire, Cable and Terminations

10. Do not score the conductor when stripping insulation and always pare or pencil when using a
blade. Use of a stripping tool is preferable.
11. All terminations shall be secure and tightened in accordance with the manufacturer's
recommendations.

C. Mounting and electrical connections

1. In accordance with manufacturer's installation instructions
2. Coordinate remote control and annunciation with the University

D. Training
1. Provide operation and maintenance training for two 2-hour sessions of on-site training for a
total of 6 maintenance personnel.
2. Include troubleshooting, repair and maintenance manuals for each participant.

E. Testing
1. Provide factory field startup and testing services to assist the ETC (Electrical Testing
Contractor) per Section Electrical - Inspection, Calibration and Testing.

END OF GUIDE SPECIFICATION SECTION

16G - 012 REV:06 – JUL2008

© University of Washington – Campus Engineering 2007