Primary Series Circuit Cables

A.06.910e

Compliance with Standards

FAA: AC 150/5345-7D (L-824) ICAO: Aerodrome Design Manual Part 5, Electrical Systems Various national standards.

Use
Primary series circuit cables are used in airfield ground lighting (AGL) series circuits to connect the constant current regulator with the primary windings of the series transformers.

General issues
The primary series circuit cable is a single-core, screened or non-screened, H.V. cable. As the output voltage of a constant current regulator can temporarily exceed 5 kV, the standard cable is designed for continuous operation at a nominal voltage of 5 kV to ground. The copper conductor cross section for 6.6 A series circuits is at least 6 mm2 / AWG 8 to limit power losses. Screened cables have a grounded metal screen over the conductor insulation. This screen protects the cable against electrical discharge phenomena and gives the cable a higher mechanical strength, specially against rodents. The cable is either drawn into conduits or directly laid in trenches. Screened cable: copper braid screen FIG. 1

Nominal voltage of the primary series circuit cable

The nominal voltage to be taken into consideration for primary series circuit cables is the continuous AC RMS working voltage between the conductor and the ground. Only FAA specification L-824 complies with this good electrical practice. A 5 kV FAA L-824 cable can operate continuously and safely at an AC RMS potential of 5 kV to ground. Other national standards define nominal voltages differently. For example: VDE0271, the German Standard applicable to PVC insulated cables rates the FLYCY AGL cables as 5.0/10.0 kV. The first figure (U0) represents the working voltage to ground, the second figure (U) the working voltage of a single-phase, multiple circuit made of two single-core FLYCY cables. According to correct AGL electrical practice this cable (5.0/10.0 kV) is in fact a 5 kV cable. British Standard (BSS) rate the AGL cables as 1.9/3.3 kV. This corresponds to a working voltage to ground of 1.9 kV, while 3.3 kV may be applied between the cores of a threephase distribution system made of 3 each single-core AGL cables. Screened cable: copper tape screen FIG. 2

Screened cable: brass tape screen

FIG. 3

Advantages of the use of screened cables

Electrical The electrical field in the insulation of non-screened cables with operating voltages in excess of 2 kV may differ over the length of the cable run. The potential differences or voltage gradients result in surface discharges, which may cause surface tracking entailing a faster deterioration of the cable insulation i.e. reduced lifetime of the cable and higher risk of electrical shockhazards to personnel. The grounded metal screen equalises the voltage gradient in the insulation over the whole cable length. As a result it eliminates surface tracking and reduces electrical shock hazards to personnel. The environment plays an important part in the surface tracking phenomenon. Therefore, shielded cables are recommended for circuits with voltages above 2 kV, when one or more of the following installation conditions prevail: in dry soil (such as in the desert) when the cable transits from conductive to non-conductive soil or conduits when the cable transits from dry to wet soil or from dry to moist conduits in moist conduits when lubricants have to be used to pull cables into conduits. Radio interference The emission of radio frequency (RF) signals is reduced by the use of screened cables. Most constant current regulators generate RF signals, particularly when operating at reduced load and/or low brilliancy. The screen strongly attenuates RF emission by the series circuit, which otherwise would act as a transmission antenna. Mechanical A screened cable has a higher mechanical resistance against termites, perforating insects and small rodents. Even a damaged outer jacket has no influence on the electrical field in the cable insulation, which is well defined between the conductor and the grounded screen. The positive effects of the screened cable can only be guaranteed if the screen is securely grounded and if its electrical continuity is ensured over the whole length of the series circuit.

PROTODUR cable Copper wires screen

FIG. 4

Non-screened cable, TPE insulation

FIG. 5

Non-screened cable, XLPE insulation

FIG. 6

Technical data
Screened cables
Code number Copper conductor PSC-S- X-5-6-CB-PE or X-5-6-CB-PV 6 mm2 X-5-8-CB-PE or X-5-8-CB-PV AWG 8 7 XLPE 5 X-5-6-CT-PE or X-5-6-CT-PV 6 mm2 7 XLPE 5 X-5-8-CT-PE or X-5-8-CT-PV AWG 8 7 XLPE 5 X-5-6-BT-PE or X-5-6-BT-PV 6 mm2 7 XLPE 5 X-5-8-BT-PE or X-5-8-BT-PV AWG 8 7 XLPE 5 P-3-6-CW-PV P-5-6-CW-PV (*) 6 mm2 1 (*) 6 mm2 1

Cross section

Insulation

Screen

Outer sheath or jacket Outer Approx. (mm) diameter Net weight Copper (kg/km) Cable Packing Size of drum per km Gross weight (kg) Gross volume (m3) Figure

Number 7 of strands Material XLPE Rated 5 voltage to ground (kV AC RMS) Thickness (mm) 2.3 Material Copper braid Thickness (mm) 0.20 Material PE or PVC Thickness (mm) 1.2 11.5 108 183 0,8 250 0.45 1

PVC (PROTODUR) PVC (PROTODUR) 3 5

2.3 Copper braid 0.20 PE or PVC 1.2 12.0 137 216 0,9 276 0.66 1

2.3 Copper tape 0.08 PE or PVC 1.2 11.1 81 160 0,8 208 0.45 2

2.3 Copper tape 0.08 PE or PVC 1.2 11.6 108 190 0,9 237 0.45 2

2.3 Brass tape 0.08 PE or PVC 1.2 11.1 81 160 0,8 208 0.45 3

2.3 Brass tape 0.08 PE or PVC 1.2 11.6 108 190 0,9 237 0.45 3

3 Copper wires 0.36 PVC 1.8 13.5 121 280 450 1.3 4

4 Copper wires 0.36 PVC 1.8 17.5 161 425 740 2.85 4

*: FLYCY type according to VDE 0271 (PROTODUR cable)

Non-screened cables
Code number Copper PSC-N- Cross section conductor Number of strands Material Voltage to ground (kV AC RMS) Thickness (mm) Approx. (mm) T-5-8-NO-NO X-5-6-NO-NO X-5-8-NO-NO AWG 8 19 TPE 5 2.8 9.5 84 135 0.8 175 0.45 5 6 mm2 7 XLPE 5 2.8 8.9 58 110 0.6 158 0.21 6 AWG 8 7 XLPE 5 2.8 9.4 84 140 0.7 183 0.35 6

Size of export drums in meters*

Size 0.6 0.7 0.8 0.9 1.0 1.1
*: non-binding.

Insulation

Dia. 0.64 0.74 0.84 0.94 1.04 1.14

Width 0.53 0.65 0.65 0.76 0.76 0.76

Outer diameter Net weight Copper (kg/km) Cable Packing per km

Size of drum Gross weight (kg) Gross volume (m3)

Figure

XLPE= Cross linked polyethylene (also called PRC) PVC = Polyvinyl-chloride TPE = Thermoplastic elastomer PE = Polyethylene

Conclusions
In case of doubt, as to the actual nominal voltage to ground of an AGL cable, the thickness of the insulation will constitute the decisive factor. A cable rated 5 kV to ground should have the following minimum radial insulation thickness: 2.29 mm: XLPE (cable with separate outer sheath) 2.79 mm: XLPE or TPE (cable without outer sheath) 3.94 mm: PVC Cable termination and jointing The connection between primary series circuit cables can be realised on the spot with dedicated connectors (see catalog leaflet A.06.930e). Some cable types can also be supplied with factory moulded connectors and thus reduce the assembling time on site (see catalog leaflet A.06.960e).

Ordering Code
PSC - S - X - 5 - 6 - BT - PE - S Primary series circuit cable = PSC Screen: Screened =S Non-screened = N Insulation: XLPE =X TPE = T (only for non-screened cable) PVC = P (only for (PROTODUR) screened cable) Nominal voltage: 3 kV = 3 (only for PVC insulation) 5 kV = 5 Cross section: 6 mm2 = 6 (not for TPE insulation) AWG 8 = 8 (not for PVC insulation) Screen or shield: None = NO (always for nonscreened cable) Brass tape = BT (only for XLPE insulation) Copper braid = CB (only for XLPE insulation) Copper tape = CT (only for XLPE insulation) Copper wires= CW (only for PVC insulation) Outer sheath: NO = NO (always for non-screened cable) PE = PE PVC = PV (always for PVC insulation) Special requirements to be specified in full text = S Note: Other lower voltage rated cables are available on request. However, very often the small difference in price does not compensate for the advantages offered by the uni-formity of the installation and the built-in flexibility for future upgrades or extensions. Registered Trade Mark of Siemens AG Complete, delete or modify as necessary.

N.V. ADB S.A. Leuvensesteenweg, 585 - B 1930 Zaventem - Belgium Tel : 32/2/722.17.11 - Fax : 32/2/722.17.64 - Telex : 22154 Companies in France and U.S.A. - Agents all over the world.

1/05.01. Subject to modifications. 11U1963 95D95250 PA 05013.

Order Nr. E10001-T95-A93-V1-7600 Dispo 21649 SEK 21856