Airport Lighting Cable
Airport Lighting Cable
Illuminating Engineering Society
Aviation Lighting Committee
Fall 2003 Meeting
Topics
•Applicable Specification
•Industry Standards
•Cable design
•Cable materials
•Cable Tests
•FAA Certification Program
John R. Cancelosi
The Okonite Company
Ramsey, NJ
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2
5kV NonNon-Shielded
Construction
Applicable Industry
Specification
Conductor
US DOT
FAA Advisory Circular
150/5345150/5345-7E
Conductor Screen
Insulation
“Specification for LL-824
Underground Electrical Cable
for Airport Lighting Cable”
Cable”
Jacket
3
5kV NonNon-Shielded
Construction
4
5kV NonNon-Shielded
Construction
Conductor Screen:
• Extruded Semiconducting Layer
• To prevent discharge at the
interface of conductor and insulation
Conductor:
• Stranded Copper
• Typically #8 or #6 AWG
• Sized for current and voltage drop
Conductor
Screen
5
AirportLighting Cable
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1
Without Conductor Screen
Without Conductor
Screen
E
100%
Conductor
Void
Void
Insulation
Protrusion
7
With Conductor Screen
8
5kV NonNon-Shielded
Construction
E
100%
INSULATION
Purpose:
To withstand the electrical field
applied to the cable for its
design life & in its intended
installed environment.
Normal and Emergency Voltage and
Current
9
5kV NonNon-Shielded
Construction
Specification LL-824
Requirements from:
Insulated Cable Engineers Association
(ICEA) standards
INSULATION - Desired Characteristics
• Electrical
• Physical
• Thermal Stability
• Aging
• Moisture Resistant
• Chemical Resistant
• Economics
S-9595-658 0 to 2 kV
S-9696-659 5 kV NonNon-Shielded
S-9393-639 5 kV Shielded
ANSI standards
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AirportLighting Cable
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12
2
5kV NonNon-Shielded
Construction
Types of Insulations
• “A” Natural rubber and early
synthetic rubbers
No longer allowed
Jacket – Nonmetallic Outer Covering
Purpose –
•
• “B” Ethylene Propylene Rubber
(EPR)
•
•
•
• “C” Crosslinked Polyethylene
(XLPE)
To
To
To
To
protect insulation from Physical Damage
provide Chemical and Water Resistance
provide Discharge & Tracking Resistance
provide Flame Resistance, if needed
Thermoset and Thermoplastic
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5kV NonNon-Shielded
Construction
Types of Jackets
Thermosetting
Jacket Characteristics
• PHYSICAL
• CHEMICAL
• TEMPERATURE
• MOISTURE
• AGING
• FLAME/ SMOKE
Neoprene
Hypalon (CSPE)
Chlorinated Polyethylene (CPE(CPE-TS)
Thermoplastic
Polyvinyl Chloride (PVC)
Polyethylene (PE)
Chlorinated Polyethylene (CPE(CPE-TP)
15
Insulation Thickness - L-824
5 kV NonNon-Shielded
Table 1 – Cable Requirements
Thickness: ANSI/ICEA SS-9696-659 Table 44-2
Recommended Uses for Table 44-2 walls
given in Table 44-4 :
In Metallic Conduit:
Indoor aboveabove-grade: YES
Outdoor and/or belowbelow-grade: NO
In NonNon-metallic Conduit:
In dry, damp or wet areas: NO
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AirportLighting Cable
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ICEA SS-9696-659
1/C 5kV NonNon-shielded
Wall Thickness Requirements
Metallic conduit: Outdoor and/or belowbelow-grade
Nonmetallic conduit in dry, damp or wet areas
S-9696-659, Table 4 - 3
Insulation: 0.125”
Jacket: 0.080”
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3
Wall Thicknesses
per ANSI / ICEA SS-9696-659
“Type B”
Table Insul
Jkt
4-2
.090”
.030”
4-3
.125”
.080”
“Type C”
Uses per
Table 44-4
Dry Wet
Insul
Jkt
.110” None
YES NO
.090” .030”
.125” .080” YES YES
National Electrical Code
NEC 2002
Table 310.63 – Single
Conductor
6 & 8 AWG
Insul
Jkt
Without Jacket
0.110”
-------
With Jacket
0.090”
0.030”
0.125”
0.080”
Location
Dry
Wet or Dry
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Routine Factory Electrical
Tests
20
Cable Qualification Tests
• Conductor Resistance
• Industry Tests
• ac High Voltage Withstand
• Custom Tests
13 kV for 5 minutes after 6
hr immersion in water
• Customer Tests
All Accelerated Tests
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22
SSR Test
Cable Qualification Tests
for 5kV NS cable
Industry Tests (ANSI / ICEA)
•
dc Surface Resistance (SSR)
•
U-Bend Plate Discharge
•
Track Resistance (XLPE only)
Room Temperature Water
2 day Immersion
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AirportLighting Cable
dc surface resistance
measurement between
electrodes
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4
dc SSR Tap Water
XLPE
CPECPE-TS
Cable Qualification Tests
CSPE
Days
0
39,000,000
Megohms
3,300,000
660,000
1
38,000,000
1,600,000
720,000
7
38,000,000
1,700,000
210,000
14
47,000,000
2,300,000
420,000
21
3,000,000
2,600,000
260,000
28
7,200,000
2,200,000
350,000
Requirement: > 200,000 Megohms
U-Bend
Plate
Discharge
25
Cable Qualification Tests
for 5kV NS cable
U Bend Plate Discharge
ANSI / ICEA SS-9696-659
Track Resistance (XLPE only)
6 & 8 AWG
Dry
Wet
PrePre-Conditioning
None
(1) None
(2) 14 days @ 75C
U Bend Diameter
Test Voltage
14 kV
Time, hours
6
Requirement
26
6 x OD
(1) 20 kV
(2) 15 kV
100
•
Method A – Dust / Fog test
•
•
•
1500 volts for 200 hrs minimum
Method B – Dip Track Test
•
0.1% Ammonium chloride
•
2000 volts minimum tracking voltage
Either A or B
No cracks or failures
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28
Cable Qualification Tests
Cable Qualification Tests
Custom Tests
•
Needle Tracking Test
•
Long Term Moisture Resistance
Tests
Needle
Track
Resistance
Test
Test conditions: 0.2” Gap
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AirportLighting Cable
9 kV ac
30
5
Needle to Needle
Tracking Test
Cable Qualification Tests
EPR (Type B) Insulation
CSPE
CPE
XLPE1 XLPE2
Initial Gap
Resistance
3 E12
4 E12
4 E12
15 E12
15 E12
>20 E12
>20 E12 >20 E12
20 E12 20 E12
>20 E12 >20 E12
Time to
Failure,
min:sec
> 15:00
> 15
1:00
2:30
0:19
0:29
0:20
> 15:00
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32
Customer Qualification Tests
Cable Qualification Tests
Customer Tests (Deicer Tests)
•
dc Surface Resistivity
•
Drip Tracking Test
•
•
Immersed in 50 /50 solution of
KAc & Water for 28 days
Samples removed periodically for
surface resistance measurement
Requirements:
Stability & >200,000 Megohms
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34
DC SSR KAc / Water @ 30C
XLPE
Days
CPE
Megohms
0
19,000,000
5,000,000
720,000
1
760,000
780,000
220,000
7
71,000
830,000
340,000
14
93,000
320,000
380,000
21
68,000
990,000
260,000
28
76,000
950,000
300,000
Customer Requirement: > 200,000
AirportLighting Cable
Customer Qualification Tests
CSPE
•
•
•
•
•
35
Drip Track Resistance Test
Test Conducted on Slabs of Materials
Slabs Immersed in KAc 50/50 deicing
solution
Wetting rate: 0.2 cm2/minute
Applied Voltage: 100 volts/30 minutes &
increased in 100 volt steps
Requirement: >1000 volts (Median value)
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6
Customer Qualification Tests
KAc Drip Track Resistance Test
Withstand Voltage, volts
1600
1400
1200
Minimum
Requirement
1000
800
600
400
Mean Value
of 6 Samples
200
0
XLPE
CPE-TS
CSPE
37
FAA Airport Lighting Equipment
Certification Program
AC 150/5345150/5345-53B 09/08/00
•L-824 --- Certification Program
•Requires third party certification
•Audit
• Production plants
• Testing & Documentation
•QA program
•Issue Certification
•Allows “FAA LL-824” on cable
38
Airport Lighting Cable
Certification
FAA Airport Lighting Equipment
Certification Program
AC 150/5345150/5345-53B
Website
www.faa.gov/arp/publications/acs/534553
ad.htm
39
FAA Airport Lighting Equipment Website
40
Airport Lighting Cable
Illuminating Engineering Society
Aviation Lighting Committee
Fall 2003 Meeting
John R. Cancelosi
The Okonite Company
Ramsey, NJ
41
AirportLighting Cable
42
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