fact finding report on power over local area network type cables
TRANSCRIPT
Issued: September 25, 2015
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Fact Finding Report
on
Power over Local Area Network Type Cables (4-Pair Data / Communications Cables)
<with errata 1 revisions>
SPI: the plastics industry trade association Washington, DC
Fact-Finding Investigations are undertaken to develop facts and issue a Report for use
by the Applicant in seeking amendments in nationally recognized installation codes and
standards. The issuance of this Report does not constitute an endorsement of any
proposed amendment and in no way implies Listing, Classification or other recognition
by UL and does not authorize the use of UL Listing or Classification Marks or any other
reference to Underwriters Laboratories Inc. on, or in connection with, the product.
UL LLC, its employees, and its agents shall not be responsible to anyone for the use or
nonuse of the information contained in this Report, and shall not incur any obligation or
liability for damages, including consequential damages, arising out of or in connection
with the use of, or inability to use, the information contained in this Report.
UL LLC authorizes the above named company to reproduce this Report
provided it is reproduced in its entirety.
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Contents INTRODUCTION ............................................................................................................. 3
GENERAL ................................................................................................................... 3
OBJECTIVES .............................................................................................................. 4
DISCUSSION .............................................................................................................. 4
PLAN OF INVESTIGATION ............................................................................................ 6
General ........................................................................................................................ 6
Samples ....................................................................................................................... 6
General Test Conditions .............................................................................................. 7
TEST EQUIPMENT AND SET-UP ................................................................................ 10
TEST DATA .................................................................................................................. 13
Thermal Response to Current ................................................................................... 13
Specific Conductor Ampacities for Cables in a Bundle .............................................. 15
Configurations where only ½ of the Conductors are Powered ................................... 23
Effects of Current ....................................................................................................... 27
Different Installation Methods .................................................................................... 28
Enclosing Cables ....................................................................................................... 30
Installation Orientation ............................................................................................... 32
Firestop ...................................................................................................................... 34
Cable Comparisons ................................................................................................... 38
Cable Configurations ................................................................................................. 40
LP Cables .................................................................................................................. 41
LP CABLE REQUIREMENTS .................................................................................... 42
SUMMARY .................................................................................................................... 43
APPENDIX A - CABLE DETAILS .................................................................................. 44
APPENDIX B - TEMPERATURE TEST DATA .............................................................. 92
APPENDIX C - DATA for NEC TABLES ..................................................................... 146
APPENDIX D - CABLE HEATING TEST ..................................................................... 163
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INTRODUCTION
GENERAL
The following is a report on the heating effects of dc current on 4-pair local area network (LAN) cabling when configured in various bundle sizes and simulated installation conditions. Typically these cables are 4-pair “Category” type cables originally designed and intended for the transmission of data and communications. However, changes in technologies and equipment design have resulted in these cables increasingly being used to provide low voltage (<60 Vdc), limited power along with the data and communications signals. Power levels have been steadily increasing and are expected to continue to do so. In addition, these cables are often installed in bundles where cumulative heating effect of the numerous cables in the bundle combined with limited heat dissipation for the cables buried inside of the bundle raise concerns about exceeding the temperature ratings of the cable. The current (2014) version of the National Electrical Code (NEC), NFPA 70, covers data
and communications circuits in Articles 725 and Chapter 8 respectively. Article 725
references Table 11(B), Class 2 and Class 3 Direct-Current Power Source Limitations,
for power and current limitations on these circuits. Chapter 8 contains no specific
requirements or references on power or current limitations on these circuits. Existing
data from a number of sources has suggested that the present current limits in the NEC,
where they exist, are too high for these cabling systems and the way they are deployed.
As part of the revision cycle for the 2017 National Electrical Code (NEC), public inputs
were received related to remote powering over local area networking cable. The public
inputs suggested that the existing Class 2 limits in Table 11B of the NEC permitted
maximum currents that could result in the overheating of cables and recommended
adding ampacity limitations for these applications based on wire size (AWG) and bundle
size. In addition, the public inputs suggested that special cable designs could be
developed and that might be used as alternatives to more traditional cables and AWG
size alone with less restrictions on cable designs and the installations.
These public inputs resulted in proposed first revisions for the NEC that include
requirements for limiting the power and conductor ampacities of powering over
communications cable systems based on wire gauges and bundle sizes. In addition, a
provision was included for special cables (“LP” cables) that could be used as
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alternatives to more traditional cables that would allow for innovative cable designs and
less restrictions on the installations.
At the time of the development of the proposed first revisions, there was very little hard
data to support the inclusion of comprehensive ampacity tables. As a result, the
proposed ampacity table only included single cables and multi-cable bundles. In
addition, although “LP” cables were included as alternatives to traditional cables, there
were no listing requirements for “LP” cables or listed “LP” cables. To support the
development of more comprehensive ampacity tables and the development of listing
criteria for “LP” cables, the industry commissioned UL to conduct a fact-finding
investigation to develop data to support these objectives.
OBJECTIVES
1) Develop data to support changes to the National Electrical Code (NEC),
NFPA70, (Articles 840 and 725)
2) Development of requirements for the listing of LP cable
3) Determine what parameters affect a cable’s ability to handle current in a bundle.
a. What effect does Wire Gauge Have on Cable Heating?
b. What effect does Cable Construction Have on Cable Heating?
c. What effects do Cable Construction Materials Have on Cable Heating?
4) Determine the effects of different installations (i.e. bundle size, routing,
enclosing) on cable heating.
a. What effect does the installation have on cable heating
b. Assess the worst case installation scenarios and what conditions have the
most heat rise.
5) Investigate the combined effects of higher levels of power applied over
communications cables under typical installation practices permitted by the NEC
DISCUSSION
Powering over LAN Cable systems provide both data and power in one cable, usually
connected through an RJ45 style 8-pin connector. It encompasses any one of a number
of standardized and proprietary systems that provide data and power to low power
demand devices such as IP telephones, wireless access points, or IP cameras.
Low power systems are usually configured in a 2-pair powering configuration while
“higher” power systems (still power limited) may require a 4-pair powering scheme.
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On systems where data utilizes only 2-pairs, a 2-pair powering scheme may be carried
on the unused cable pairs or on the same conductors as the data.
2-pair (4-wire) Powering Configurations:
On higher data capacity systems, where all 4 pairs are needed for data transmission
speed, power is carried on the same -pairs as the data in either a 2-pair or 4-pair
powering scheme.
2-Pair (4-wire) and 4-Pair (8-wire) Powering Configurations
As can be seen from these circuit diagrams, the present state of implementation is to
utilize two pairs of conductors for each power circuit. This is true whether the system
applies the power to the unused conductors of a cable or applies a common-mode
voltage to the data pairs. This means that for a given circuit, the current in the circuit is
carried by two conductors and therefore the current for the circuit is halved for each
individual conductor.
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PLAN OF INVESTIGATION
General
Several possible investigation plans were considered. The first involved selecting a number of installation configurations considered to be representative of both typical installations and worst-case heating. This would be based on data already circulating on this subject. Different cable types would be tested in the various configurations. The second approach would concentrate on installation configurations, testing a wider variety of configurations using a single cable type. The results of these tests could then be used to determine a much narrower set of useful test configurations that could be used to test other cable types. Since this second approach would yield hard data that not only better supports the final test configurations but would also provide valuable data to support the NEC proposals related to powering over LAN cable, this is the approach that was chosen.
Samples
There were six distinct types of LAN cables tested as part of this investigation. Sample No. Description
1 CAT 5E 24AWG UTP (YELLOW)
2 CAT 5E 26AWG STRANDED FTP SHIELDED
PATCH (LT Grey)
3 CAT 6 23AWG UTP RISER CMR (Blue)
4 CAT 6 23AWG UTP PLENUM CMP (White, Pink)
5 CAT 6 22AWG UTP PLENUM CMP (Blue)
6 CAT 6A 23AWG SHIELDED PLENUM (Dark Grey)
These cables were selected to:
Include the lightest and heaviest wire gauges
Include different diameters which will affect the thermal characteristics Refer to Appendix A for detailed cable descriptions.
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General Test Conditions
Thermocouples
Thermocouples would be placed on the cable jacket at various positions along the cable bundle length and at various depths in the tray or bundle. For example (from CENELEC TR 50174-99-1):
In addition, a TC would be placed on an individual insulated conductor inside of the center cable. This arrangement shall provide us with the following:
Hard data showing where the greatest heating takes place
A thermal profile along the length of the cable showing where the “end effect” becomes a concern (i.e. how close to the end shall the added radiating surface area significantly affect the results?).
Data showing if the individual wire insulation is subjected to higher temperatures than the overall cable jacket.
Current
The present implementations of powering over LAN cable utilize two 2-pair wires for each powering circuit.
As a result, test conditions are often reported as having some amperes per pair. However, in the power world, power is often considered to be delivered over a single “pair” of wires; the “+” conductor and the “-” conductor.
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This has led to some confusion of whether the specified current for a test is on two pairs of conductors with each conductor carrying ½ the current or on a single pair of conductors with each conductor carrying the specified current. The NEC proposals deal with power per circuit and amperes per conductor. Amperage designations would utilize amperes per conductor to avoid any confusion. This can easily be converted to any implementation later as needed. Since the original PoE specification used 175 mA/conductor, testing would be conducted starting at this current just as a benchmark. The next implementation of PoE is expected to be in the range of 60 watts which translates to 0.3 amperes per conductor so this would be another desirable data point. After that steps of 0.5 amperes per conductor and 1.0 amperes per conductor were discussed. To accommodate future technologies, the NEC is proposing Class 2 limits that would permit up to 1.6 amperes per conductor at 60 volts. However, since the NEC Class 2 current limits are based on a power limit of 100 watts and the current limits are defined as 100/V for voltages between 20-60 Vdc, the maximum permissible current changes based on the circuit voltage. Although it is expected that higher voltages would be more desirable from a loss standpoint, there could be reasons why lower voltages might be considered. For example, there is a lot of available equipment and components available for 48Vdc because of its usage in telecommunications. With these systems, the minimum operating voltage would be 40V. As a result of the above, the plan was to test each configuration over a range of 0.5 amperes to 2.5 amperes at .25 ampere increments with the addition of the original 175 mA as a reference point that might be useful for comparing results with testing already performed by others. The same test sample would be used and the current increased after temperature stabilization without shutting the test down. This is to avoid going back down to ambient temperature for every amperage setting tested, per this example.
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Test Configurations
Bundle sizes were selected based on the hexagonal densest packing structure. This
has been shown to yield the hottest temperatures due to cable density and the fact that
with this structure each new layer completely encloses the previous layer trapping heat.
This structure is characterized by the following number of cables in a bundle:
Where:
N is the total number of cables in the hexagonally densest packing structure;
n is the number of layers, surrounding the center cable. This results in N= 1, 7, 19, 37, 61, 91, 127, ....
At the high end, a bundle size of 192 was selected. This was based on 8 bundles of 24
cables that is typical of cabling coming off a server frame and considered a reasonable
worse-case bundle size.
In addition to open bundles, additional configurations were considered:
Bundles in conduit with and without fire stop
Cables in an open wire mesh rack
Cables in a closed cable tray with and without fire stop
Closed Cable tray with fire stop. The Category 5e, 24 AWG would be used for the installation configuration testing after which the other types of cables would be tested.
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TEST EQUIPMENT AND SET-UP
Test Fixtures
Test fixtures used to mount the cable bundles were constructed out of 2” schedule 40 PVC pipe.
Parachute cord was used to support the cable bundles to minimize any heat-sinking effects.
Data Acquisition
Temperature and current were measured using Agilent data acquisition / switch units and a laptop PC with suitable data acquisition software. This photo shows the typical test set-up with a laptop, Agilent data acquisition unit, precision shunt resistor and power supply. The handheld meter is just used for continuity checks.
Agilent
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Model # 34972A LXI Data Acquisition / Switch Unit
Agilent Model # 34970A Data Acquisition / Switch Unit
Power sources
Constant Current power supplies: VOLTEQ Model # HY30005EX Maximum DC voltage of 300V and 5A, and maximum DC power of 1500W
BK Precision Model # 1685 B 1-60V, 5A Switching DC Power Supply
Measuring Current
Current measurements were made via measuring the voltage across a calibrated precision shunt resistor with the Agilent data acquisition units.
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Wiring Diagram Examples
For larger bundles where the total dc resistance of the cables exceeded the power source’s ability to drive the necessary current, multiple power sources were used. The cables in the bundle were electrically divided such that the dc resistance of each set of layers would not exceed the power source’s ability to deliver the necessary current through the conductors.
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TEST DATA
Thermal Response to Current
The data shows that as the current per conductor increases, the measured temperature
on the cable increases. This is an example of the measured temperature data.
Refer to Appendix B for the complete set of temperature data.
Here is some information on how to interpret the data.
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The data shows that increases in the number of cables in a bundle resulted in increases
in measured temperatures. This chart shows and example of how the temperatures
increase with increasing bundle size for a Cat 5e, 24 AWG cable.
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Specific Conductor Ampacities for Cables in a Bundle
The data shows that overheating does not occur at 175 mA per conductor (35 watts)
regardless of the cable type, bundle size or installation method. This represents existing
implementations of powering, such as PoE and PoE+. This is clearly shown in the
accompanying chart that shows the temperature rise for a wide variety of scenarios
tested at 175mA. Overheating does not occur even if the data is corrected for a 30oC
ambient or a 45oC ambient.
The data also shows that overheating does not generally occur at 0.3 amperes per
conductor (60 watts) which represents some of the newer higher power systems. This is
clearly shown in the accompanying chart that shows the temperature rise for a wide
variety of scenarios tested at 0.3 amperes per conductor. Overheating does not occur
even if the data is corrected for a 30oC ambient or a 45oC ambient.
Even under extreme installation conditions using 576 cables very tightly packed into an
open wire cable tray it can be calculated that a 30 degrees C rise would not occur until
the current reached 0.303 amperes.
y = 321.64x2 + 3.1692x - 0.4149; For y = 30 (oC), x = 0.303 Amperes
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However, once the power goes up to the 100 watt powering range, or about 0.5
amperes per conductor, the data shows that under many installation conditions,
overheating occurs. Only a combination of smaller bundle sizes, larger wire gauges and
specialty constructions do not overheat when ambient conditions of 30oC or 45oC are
considered. This is shown in the accompanying chart that shows the temperature rise
for a wide variety of scenarios tested at 0.5 amperes per conductor. Overheating occurs
even if the data is not corrected for a 30oC ambient or a 45oC ambient.
There are systems available and more under consideration that are providing 4-pair
powering of up to 200 watts or about 1 ampere per conductor. The data shows that for a
significant number of installation conditions and cable types, cables will overheat at 1
ampere per conductor. This is shown in the accompanying chart that shows the
temperature rise for a wide variety of scenarios tested at 1 ampere per conductor.
Overheating occurs even if the data is not corrected for a 30oC ambient or a 45oC
ambient.
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In order to gather data for the development of a more detailed ampacity table for the
proposed Table 840.160(C) in the NEC first revision, testing was conducted using
cables with various AWG wire sizes configured in different size bundles. Bundle sizes
were selected based on the hexagonal densest packing structure previously described.
The bundles were enclosed in conduit representing a worst-case installation condition.
Temperatures were recorded at various current levels. In all but a few cases1 at least 4
data points were recorded for each wire gauge and bundle size and used to establish
best-fit polynomial trendline curves such as these examples.
The curves permit the identification of the current that would yield a particular
temperature. A complete set of these data graphs is provided in Appendix C.
For accuracy, rather than visually use the graphs to determine the current value, the
formula for the best-fit polynomial trendline is used with an iterative methodology to
solve for “x” at a temperature “y” of 30oC, 45oC and 60oC, representing 60, 75 and 90oC
cables. An example of the resulting table is shown below.
In this example, the “Best-fit Formula (Enclosed)”row contains the actual “y” values
generated by the formula for the curves using the “Amperes” as the “x” value. The
objective is to get as close as reasonably possible to the target temperatures. For the
19 cable bundle the best fit formula is y = 39.857x2 + 4.1207x + 0.3159. By adjusting the
1 In a few cases then cable failed (insulation melted) before accurate stabilized data could be obtained for
a particular AWG/bundle configuration. These are noted in the graphs associated with these cases.
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current “x” to 0.813 amperes, we get very close to the target temperature of 30oC
(30.0103) indicating that based on the data and the resulting curve, a current of 0.813
amperes would result in a temperature rise of 30oC for the cable.
The notation “R2” on the plots is a statistical measure of how close the data are to the
fitted trendline. When you have a scatterplot of data, and try to fit a line/curve to the
data, the "measure of goodness" for the fit is reflected in the R2 value. An R2 value of 1
is a perfect fit.
All of the data, trendline curves, formulas and tables can be found in Appendix C.
The following is a summary of the data, arranged in a style that could be used to
populate more comprehensive tables for the NEC.
30°C Temperature Rise (60°C Cable Rating @30°C Ambient)
Conductor Size
(AWG)
Number of 4-Pair Cables in a Bundle
1 2-7 8 -19 20 - 37 38 - 61 62-91 92 - 192
26 1.98 1.001 0.707 0.549 0.460 0.449 NA
24 2.209 1.187 0.813 0.634 0.546 0.455 0.398
23 1.242 0.893 0.674 0.582 0.590 0.452
22 1.499 1.04 0.765 0.663 0.622 0.527
45°C Temperature Rise (75°C Cable Rating @30°C Ambient)
Conductor Size
(AWG)
Number of 4-Pair Cables in a Bundle
1 2-7 8 -19 20 - 37 38 - 61 62-91 92 - 192
26 2.424 1.227 0.874 0.677 0.572 0.554 NA
24 2.732 1.461 1.009 0.782 0.674 0.561 0.478
23 1.531 1.105 0.834 0.718 0.718 0.549
22 3 1.857 1.284 0.952 0.822 0.769 0.631
Revised: September 29, 2015
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60°C Temperature Rise (90°C Cable Rating @30°C Ambient)
Conductor Size
(AWG)
Number of 4-Pair Cables in a Bundle
1 2-7 8 -19 20 - 37 38 - 61 62-91 92 - 192
26 2.796 1.417 1.015 0.784 0.665 0.642 NA
24 3.172 1.692 1.174 0.907 0.781 0.651 0.549
23 1.775 1.284 0.968 0.831 0.823 0.628
22 2.158 1.489 1.11 0.955 0.893 0.717
Configurations where only ½ of the Conductors are Powered
INTRODUCTION
Some implementations of remote powering over LAN cable utilize 2-pair powering
schemes as shown in the following diagrams. These powering methods are still widely
used.
As can be seen from the diagrams, these schemes utilize only 4 conductors in the cable
(out of 8) to carry current. As a result, there is less heat generated in each cable for the
same amount of current per conductor. This would imply that the 4 conductors could
each carry more current than each of the 8 conductors in the 4-pair power configuration
to get the same heating effect. However, ½ the number of conductors carrying current
does not translate to twice the current since the heating effect is related to the current
squared.
ASSUMPTIONS & CALCULATIONS
Cable heating is a result of power dissipation given by the formula P= I2 x R
To make things simple, the following assumptions are made:
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The power dissipation is the same for both configurations to get the same
temperature. (There might be a hotter temperature “hot-spot” on the individual
conductor since it is carrying more current but in general the temperature rise on
the cable is due to the trapped heat rather than the individual conductor
temperature.
The dc resistance would remain roughly the same for both scenarios. (It will be
slightly higher for the 4-conductor scenario since the individual conductor will be
warmer but the effect will be very small.)
Given these assumptions: P8 = P4 = Power per cable (assume same for both) I8 = Current for each conductor with 8 conductors energized I4 = Current for each conductor with 4 conductors energized R = DC Resistance of each conductor (assume same for both)
For 8 conductors energized: P8= I8
2 x R x 8 (8 conductors) For 4 conductors energized: P4= I4
2 x R x 4 (4 conductors) or I4 = SQRT (P4/(R x 4)) Since the power is assumed to be the same, the formula for 8 conductor power, P8, can be substituted for P4 to get a formula for I4:
I4 = SQRT (P8/(R x 4)) = SQRT ((I82 x R x 8)/(R x 4)) = SQRT (I8
2 x 2)
Calculating I4 for a number of different I8 currents we get the following along with a
“factor” for each.
I8 I4 Factor (Factor = I4 / I8)
3 4.2426 1.4142
2 2.8284 1.4142
1.3 1.8385 1.4142
.6 .8485 1.4142
.3 .4243 1.4142
The factors are consistent, as would be expected.
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TESTING & DATA
To validate the calculations and assumptions, tests were performed on a 61 cable
bundle mounted in metal conduit and a 91 cable bundle mounted in Schedule 40 PVC
conduit with 8 conductors carrying current. The tests were repeated with no changes to
the test set-ups with 4 conductors carrying current. The results with best-fit trendline
curves are shown below.
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The curves permit the identification of the current that would yield a particular
temperature.
For accuracy, rather than visually use the graphs to determine the current value, the
formulas for the best-fit polynomial trendlines developed from the data are used with an
iterative methodology to solve for “x” at various target temperatures “y”.
The following tables were generated for various target temperatures:
The “Factor” is the ratio of the current for the 4-conductor tests divided by the current for
the 8-conductor tests.
SUMMARY
The data indicates that a factor of approximately 1.4 would be valid to estimate how
much additional current could be carried by a 4-pair cable when only ½ of the
conductors are powered.
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Effects of Current
The data shows that in many cases, very small increases in conductor current resulted
in large increases in measured temperatures.
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Different Installation Methods
This graph shows an example of how different installation configurations affect the
measured temperatures.
Photographs of Different Installation Configurations
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Enclosing Cables
The data shows that enclosing cables has a dramatic effect on the measured temperatures. These graphs show the difference between open cable and a cable enclosed in conduit. It can be seen that for the entries on the far right there is no data for the enclosed cables. This is due to the temperatures exceeding the physical limits of the insulation materials in the enclosed scenario.
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The data shows that sometimes different enclosed installations only made a minor
difference in the measured temperatures.
The following comparison shows the same cable in open air, in a 4” X 4” closed cable
routing assembly and in 4” schedule 40 PVC conduit. As expected the data shows that
enclosing the cable results in considerably higher temperatures. However, there is not
much difference between the installation in the 4” X 4” enclosed cable routing assembly
and the 4” schedule 40 plastic conduit as shown by the overlapping curves and the data
plotted on the column graph. The data shows that the 4” PVC conduit resulted in slightly
higher temperatures. This is expected since the volume of the cable routing assembly is
slightly larger than the conduit allowing for some additional heat dissipation from the
cable bundle.
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Installation Orientation
Since cables can be installed in any orientation, a comparison test was run on Cat 5e, 24 AWG cable in an open wire style cable tray. The test configuration consisted of 576 cables filling the tray with 18 layers of 32 cables. The cables were energized with 0.5 amperes per conductor with all conductors carrying current. The exact test set-up was used for both tests. Only the orientation was changed.
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Summary
The results indicate very little difference between the horizontal and vertical
orientations, with no significant difference on the cables at the center of the tray bundle
(CH 14 through CH 16).
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Firestop
When trying to compare the effects of adding firestop to cable bundles in metallic
conduit, we came across variations that did not appear to be attributable to the addition
of the firestop. For example, several of the tests showed that temperatures were lower
for the configurations with the firestop. This would not be expected since the firestop
prevents heat from escaping at the ends of the conduit. This was more pronounced for
smaller bundle configurations.
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Especially for the smaller bundles or single cables, it appears that the unexpected
temperatures are the result of a heat-sinking effect where a cable contacts the conduit
and the relative position of the thermocouples to these points affects the temperature
readings. This would not be as pronounced with larger bundles which would have a
more consistent lay and where the thermocouples are buried deep within the bundle.
Because different cable bundles were used due to cable damage when the original
open-end test was run to cable destruction, the cable lay inside of the conduit was likely
different providing a different heat-sinking profile.
To check this, tests were performed on a single cable and a 7 cable bundle in metal
conduit. Each test was first run without firestop. After thermal stabilization, firestop was
carefully added without disturbing the cable. Temperatures were again allowed to
stabilize and the results recorded. The data showed essentially no difference in the
temperatures. This was consistent with the larger cable bundles where the lay / heat
sinking effects did not appear to be significant. In these cases also, the data showed
that adding firestop had little or no effect on the measured temperatures.
Issued: September 25, 2015
Copyright © 2015 UL LLC Page 37 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
SUMMARY
The data shows that the addition of firestop at the ends of a 6 ft. conduit does not
significantly affect the temperatures near the center 3 feet of the cable. Most of the heat
is trapped at the center of the conduit in either case.
Issued: September 25, 2015
Copyright © 2015 UL LLC Page 38 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
Cable Comparisons
The data shows that the cable design and construction has as much effect on the
temperature rise as AWG size. These comparisons show some examples.
Issued: September 25, 2015
Copyright © 2015 UL LLC Page 39 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
Issued: September 25, 2015
Copyright © 2015 UL LLC Page 40 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
Cable Configurations
These tests were performed to determine the difference in measured temperatures (if
any) between a “perfect” hexagonal bundle and a more random circular bundle.
Issued: September 25, 2015
Copyright © 2015 UL LLC Page 41 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
LP Cables
As a result of the public inputs and resulting proposed first revisions to the NEC, a need
was identified to develop requirements for a special-use cable that could be used as an
alternative to traditional cables. Where the ampacity tables were sufficient for existing
installations and new installations where the use of traditional cables was desirable, it
was recognized that cables could be designed specifically to handle powering over
communications cables without all of the limitations necessary for cables of unknown
heating and heat dissipating characteristics. The objective, then, was to develop
requirements that would permit a cable to be identified specifically for this type of
installation and use.
It has been well established that cable heating can be managed via:
– Increased AWG size
– Cable design
– Material selection
– Installation Practices
It was less clear how the interaction of these elements might affect a cable’s ability to
handle increasing current levels. For example, there was little data available showing
how changing a cable’s construction without changing the AWG size might affect
temperatures or how variations in the installation might affect the temperatures for the
same cable.
Obtaining data on these variations was necessary to determine how an “LP” cable might
be evaluated. The following tests were identified as being critical in this endeavor:
Different Installations. Testing the same cable in various installation
configurations to gain a better understanding of how bundle size and routing
(open air, conduit, cable trays, cable routing assemblies, etc.) affects
temperature
Orientation. Determine the effects of horizontal vs. vertical orientation on cable
temperature in a bundle.
Cable Comparison. Test different cable types and constructions under the same
installation and use conditions to obtain comparison data to better understand
the effects of cable design on temperature.
Test Variations. Study what test variations have on temperature rise and under
what conditions. For example, how does current increase affect temperatures or
the effects of different size conduits.
Issued: September 25, 2015
Copyright © 2015 UL LLC Page 42 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
LP CABLE REQUIREMENTS
As part of the fact-finding investigation, UL LLC has undertaken the development of a
method for determining the ability of a cable to carry current under reasonable worse-
case installation conditions including bundling of large numbers of cables, enclosing the
cables in raceways, cable routing assemblies or conduit and elevated ambient
temperatures. This effort has resulted in the test procedure described in APPENDIX D,
“Cable Heating Test”.
Issued: September 25, 2015
Copyright © 2015 UL LLC Page 43 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
SUMMARY
In consideration of the fact-finding character of the investigation, the foregoing Report is
to be construed as information only and should not be regarded as conveying any
conclusion or recommendations on the part of Underwriters Laboratories Inc. regarding
the acceptability of the construction or performance of the product for recognition by any
code or standard or for any other purpose.
The investigation resulted in the development of data in support of comments /
proposals related to including more extensive ampacity tables in the NEC to better
manage powering over LAN cable systems.
The investigation has identified that for certain powering over LAN cable installations
with power levels exceeding 60 watts, overheating of the cables will occur.
Cable heating can be managed via:
Increased AWG size
Cable design
Material selection
Installation Practices
The investigation produced data leading to the development of testing
requirements for “-LP” cables.
Randy Ivans Program/Project Manager Wire and Cable Commercial & Industrial UL LLC.
Anthony Tassone PE Principal Engineer (PDE) Wire & Cable Commercial & Industrial UL LLC.
Issued: September 25, 2015
Copyright © 2015 UL LLC Page 44 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
APPENDIX A - CABLE DETAILS
Issued: September 25, 2015
Copyright © 2015 UL LLC Page 45 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
Number of pages in this package ____ [including additional pages __-__] (Fill in when using printed copy as record)
TESTS TO BE CONDUCTED:
Test No.
Done3 Test Name
[ ] Comments/Parameters [x] Tests Conducted by2 [ ] Link to separate data files4
1 X DETAILED EXAMINATION: 5E 24AWG
Tim Falvey 2015-09-01
2 X DETAILED EXAMINATION: 5E 26AWG
Michael Askin 2015-09-02
3 X DETAILED EXAMINATION: 6 R 23AWG
Michael Askin 2015-09-02
4 X DETAILED EXAMINATION: 6 P 23AWG
Michael Askin 2015-09-02
5 X DETAILED EXAMINATION: 6 P 22AWG
Michael Askin 2015-09-03
6 X DETAILED EXAMINATION: 6A 23AWG
Michael Askin 2015-09-03
[X] Safety Certification - Unless specified otherwise in the individual Methods, the tests shall be conducted under the following ambient conditions. Confirmation of these conditions shall be recorded at the time the test is conducted.
Ambient Temperature, C 23 ± 5
Relative Humidity, % 50 ± 20
Barometric Pressure, mBar NA
Copyright © 2015 UL LLC Page 46 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
TEST LOCATION: (To be completed by Staff Conducting the Testing)
[x]UL or Affiliate []WTDP
[]CTDP []TPTDP []TCP []PPP
[]WMT []TMP []SMT
Company Name: UL LLC
Address: 1285 Walt Whitman Rd. Melville, NY
TEST EQUIPMENT INFORMATION
[x] UL test equipment information is recorded on Meter Use in UL’s Laboratory Project Management (LPM) database. TEST SAMPLE IDENTIFICATION:
The table below is provided to establish correlation of sample numbers to specific product related information. Refer to this table when a test identifies a test sample by "Sample No." only.
Sample Card No.
Date Received
[] Test No.+
Sample No. Manufacturer, Product Identification and Ratings
XXXX 1 1 CAT5E 24AWG UTP (YELLOW)
2 2 CAT5E 26AWG FTP SHIELDED PATCH (LT GREY)
3 3 CAT6 23AWG UTP RISER CMR (BLUE)
4 4 CAT6 23AWG UTP PLENUM CMP (WHITE)
5 5 CAT6 22AWG UTP PLENUM CMP (BLUE)
6 6 CAT6A 23AWG SHIELDED PLENUM (DARK GREY)
+ - If Test Number is used, the Test Number or Numbers the sample was used in must be identified on the data sheet pages or on the Data Sheet Package cover page.
Copyright © 2015 UL LLC Page 47 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
DETAILED EXAMINATION: UL 444, Clause 5
Sample No. 1
Ambient Temp.: 24C Humidity: 61% RH
Note: All units are expressed in terms of: [x] Inches [ ] mm
[x] Identification
Print Type: None Ink Indent Tape Other:
Print Content:
0394 FEET CAT-5E GENERAL CABLE J 2001345 CMR C(ETL)US 4PR 24AWG 75C GENSPEED 5000 IWC---VERIFIED BY UND LAB INC ONLY TO ANSI/TIA-568C.2 CAT-5E--- TESTED TO 350MHZ 03-14 302136F2 PAT 5767441 CAT-5E
Print Interval: 24.25 inches
No. of Insulated Conductors 8 No. Of Bare Conductors 0
Brief Assembly Description: Jacket, 4 pairs of solid-insulated conductors, rip cord
Copyright © 2015 UL LLC Page 48 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
DETAILED EXAMINATION (Sample #1): (CONT’D) UL 444, Clause 5
Ambient Temp.: 24C Humidity: 61% RH
Note: If additional space is required please continue under “attached Component” section
[x] Jacket Overall Jacket
Inner Jacket 1
Inner Jacket 2
Inner Jacket 3
Color Yellow n/a n/a n/a
Overall cable diameter, in. .190 n/a n/a n/a
Core diameter under jacket, in. .156 n/a n/a n/a
Major axis, in. n/a n/a n/a n/a
Minor axis, in. n/a n/a n/a n/a
Average thickness, in. .016 n/a n/a n/a
Min. thickness at any point, in. .015 n/a n/a n/a
Minimum thickness after rip, in. n/a n/a n/a n/a
Average web thickness, in. n/a n/a n/a n/a
Average web width, in. n/a n/a n/a n/a
[ ] Note: If ave. or min. point jacket thickness exceeds / is less than the
following requirement contact engineer before proceeding:
Min Ave. , in. Min Point , in.
Copyright © 2015 UL LLC Page 49 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
DETAILED EXAMINATION (Sample #1): (CONT’D) UL 444, Clause 5
Ambient Temp.: 24C Humidity: 61% RH
Sample No.
[ ] Armor [x] Assembly
Type of Armor n/a Lay of conductors, in. .5
Convolutions per inch / mm n/a Lay of conductor pairs, in. 5.7
Diameter over armor, in. n/a Lay of members, in. n/a
Diameter under armor, in. n/a
Strip width, in. n/a
Average thickness, in. n/a
Min. thickness at any point, in. n/a
[ ] Braid Parameters Braid 1 Braid 2 Braid 3
Type of braid n/a n/a n/a
Strand diameter, in. n/a n/a n/a
No. ends n/a n/a n/a
No. carriers n/a n/a n/a
Picks per inch / mm n/a n/a n/a
Core Dia. under braid inch/mm n/a n/a n/a
Calculated % coverage n/a n/a n/a
Copyright © 2015 UL LLC Page 50 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
DETAILED EXAMINATION (Sample #1): (CONT’D) UL 444, Clause 5
Ambient Temp.: C Humidity: % RH
[ ] Tapes, binders, rods, rip cords, and fillers
Type n/a n/a n/a n/a n/a
Thickness, in. n/a n/a n/a n/a n/a
Width, in. n/a n/a n/a n/a n/a
Lap, in. n/a n/a n/a n/a n/a
Overall diameter, in. n/a n/a n/a n/a n/a
Helical/longitudinal n/a n/a n/a n/a n/a
Calculated % coverage n/a n/a n/a n/a n/a
Count n/a n/a n/a n/a n/a
Major/minor axis, in. n/a n/a n/a n/a n/a
Ripcord present? n/a n/a n/a n/a n/a
Sample No.
[x] Insulation Conductor Conductor Conductor Conductor
Color ORANGE n/a n/a n/a
Separator tape present? no n/a n/a n/a
Average thickness, in. .0075 n/a n/a n/a
Minimum thickness at any point, in. .006 n/a n/a n/a
Minimum thickness after rip, in. n/a n/a n/a n/a
Average web thickness, in. n/a n/a n/a n/a
Average web width, in. n/a n/a n/a n/a
[ ] Insulation Covering
Color n/a n/a n/a n/a
Average thickness, in. n/a n/a n/a n/a
Minimum thickness at any point, in. n/a n/a n/a n/a
[ ] Note: If ave. or min. point insulation thickness exceeds/is less than
the following requirement contact engineer before proceeding:
Min Ave. , in. Min Point , in.
Copyright © 2015 UL LLC Page 51 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
DETAILED EXAMINATION: (CONT’D) UL 444, Clause 5
Ambient Temp.: 24C Humidity: 61% RH
[x] Conductor Conductor Conductor Conductor Conductor
1 2 3 4
Type (i.e. Al, Cu, etc.) cu n/a n/a n/a
Coating present? no n/a n/a n/a
Diameter of solid conductor, in. .01975 n/a n/a n/a
Diameter over insulation, in. .0346 n/a n/a n/a
Number of strands n/a n/a n/a n/a
Strand diameter, in. n/a n/a n/a n/a
Lay of strands, in. n/a n/a n/a n/a
Circular Mil Area (CMA) n/a n/a n/a n/a
AWG size 24 n/a n/a n/a
Ambient Temp.: 24C Humidity: 61% RH
METHOD: UL 444, Clause 4.1 – 4.11
Solid Conductor:
Specimen: #1
Min. #1 Diameter, in. .0197
Max. #1 Diameter, in. .0198
Min. #2 Diameter, in. .0197
Max. #2 Diameter, in. .0197
Min. #3 Diameter, in. .0198
Max. #3 Diameter, in. .0198
Average Conductor Diameter, in. .01975
Conductor AWG Size 24
Copyright © 2015 UL LLC Page 52 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
DETAILED EXAMINATION (Sample #1): (CONT’D) UL 444, Clause 5 DETAILED EXAMINATION, CONDUCTOR:
Ambient Temp.: 24C Humidity: 61% RH
Sample No.______
[x] Conductor DC Resistance
Length of specimen (ft/meter) 1
Conductor resistance (measurement 1), ohms/kft 26.85
Conductor resistance (measurement 2), ohms/kft 26.87
Conductor resistance (measurement 3), ohms/kft 26.86
Conductor resistance (measurement 4), ohms/kft 26.86
Minimum of 4 measurements, ohms/kft 26.85
Temperature of conductor, C 24
Multiplying factor for adjustment to resistance at
____C *
Conductor resistance adjusted to ____C, Ohms/1000 (ft/meter) *
*Resistomat calculated at 20c
Copyright © 2015 UL LLC Page 53 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
DETAILED EXAMINATION (Sample #1): (CONT’D) UL 444, Clause 5 DETAILED EXAMINATION, INSULATION:
Ambient Temp.: 24C Humidity: 61% RH
METHOD: UL 444, Clause 4.1 – 4.11
Insulation:
Specimen: #1
Thickness: Min #1, in. .006
Max #1, in. .009
Average Thickness, in. .0075
Outside diameter: Min #1, in. .035
Max #1, in. .035
Min #2, in. .034
Max #2, in. .035
Min #3, in. .034
Max #3, in. .035
Average Outside Diameter, in. .0346
Copyright © 2015 UL LLC Page 54 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
DETAILED EXAMINATION (Sample #1): (CONT’D) UL 444, Clause 5 DETAILED EXAMINATION, JACKET:
Ambient Temp.: 24C Humidity: 61% RH
METHOD: UL 444, Clause 4.1 – 4.11
Jacket:
Specimen: #1
Thickness: Min #1, in. .015
Max #1, in. .017
Average Thickness, in. .016
Outside diameter: Min #1, in. .184
Max #1, in. .185
Min #2, in. .189
Max #2, in. .201
Min #3, in. .175
Max #3, in. .205
Average Outside Diameter, in. .190
Core diameter: Min #1, in. .149
Max #1, in. .151
Min #2, in. .154
Max #2, in. .169
Min #3, in. .140
Max #3, in. .171
Average Core Diameter, in. .156
Copyright © 2015 UL LLC Page 55 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
DETAILED EXAMINATION: UL 444, Clause 5
Sample No. 2
Ambient Temp.: 25C Humidity: 58% RH
Note: All units are expressed in terms of: [X] Inches [ ] mm
[X] Identification
Print Type: None Ink Indent Tape Other:
Print Content: YFC FTP CAT.5E 350MHZ PATCH ISO/IEC 11801 7 EN 50288 3P
CONFORMS TO GIGABIT ETHERNET 26AWGX4 TYPE CMX(UL) C(UL) CMH E164469-F5
Print Interval: 48.5 Inches
No. of Insulated Conductors 8 No. Of Bare Conductors 1
Brief Assembly Description: JKT, POLY AL WRAP, DRAIN WIRE, CLEAR POLY WRAP,
8 INSULATED STRANDED CONDUCTORS
Copyright © 2015 UL LLC Page 56 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
DETAILED EXAMINATION (Sample #2): (CONT’D) UL 444, Clause 5
Ambient Temp.: 25C Humidity: 58% RH
Note: If additional space is required please continue under “attached Component” section
[X] Jacket Overall Jacket
Inner Jacket 1
Inner Jacket 2
Inner Jacket 3
Color GREY
Overall cable diameter, in. .230
Core diameter under jacket, in.
.
183
Major axis, in. -
Minor axis, in. -
Average thickness, in. .023
Min. thickness at any point, in. .022
Minimum thickness after rip, in. -
Average web thickness, in. -
Average web width, in. -
[ ] Note: If ave. or min. point jacket thickness exceeds / is less than the
following requirement contact engineer before proceeding:
Min Ave. , in. Min Point , in.
Copyright © 2015 UL LLC Page 57 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
DETAILED EXAMINATION (Sample #2): (CONT’D) UL 444, Clause 5
Ambient Temp.: 25C Humidity: 58% RH
Sample No.
[ ] Armor [X] Assembly
Type of Armor Lay of conductors, in. .375
Convolutions per inch / mm Lay of conductor pairs, in. 4.0
Diameter over armor, in. Lay of members, in. -
Diameter under armor, in.
Strip width, in.
Average thickness, in.
Min. thickness at any point, in.
Copyright © 2015 UL LLC Page 58 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
DETAILED EXAMINATION (Sample #2): (CONT’D) UL 444, Clause 5
Ambient Temp.: 25C Humidity: 58% RH
[X] Tapes, binders, rods, rip cords, and fillers
Type POLY AL
WRAP CLEAR POLY
Thickness, in. .0009 .0006
Width, in. .750 .813
Lap, in. .188 .250
Overall diameter, in.
Helical/longitudinal HELI HELI
Calculated % coverage TBD TBD
Count 1 1
Major/minor axis, in. - -
Ripcord present? - -
Sample No.
[X] Insulation Conductor Conductor Conductor Conductor
Color BLUE
Separator tape present? NO
Average thickness, in. .009
Minimum thickness at any point, in. .008
Minimum thickness after rip, in. -
Average web thickness, in. -
Average web width, in. -
[ ] Insulation Covering
Color
Average thickness, in.
Minimum thickness at any point, in.
[ ] Note: If ave. or min. point insulation thickness exceeds/is less than
the following requirement contact engineer before proceeding:
Min Ave. , in. Min Point , in.
Copyright © 2015 UL LLC Page 59 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
DETAILED EXAMINATION (Sample #2): (CONT’D) UL 444, Clause 5
Ambient Temp.: 25C Humidity: 58% RH
[X] Conductor Conductor Conducto
r Conductor Conductor
1 2 3 4
Type (i.e. Al, Cu, etc.) Cu
Coating present? NO
Diameter of solid conductor, in. .018
Diameter over insulation, in. .036
Number of strands 7
Strand diameter, in. .0060
Lay of strands, in. .438
Circular Mil Area (CMA) 252
AWG size 26
Ambient Temp.: 25C Humidity: 58% RH
Copyright © 2015 UL LLC Page 60 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
DETAILED EXAMINATION (Sample #2): (CONT’D) UL 444, Clause 5 DETAILED EXAMINATION, ROUND CONDUCTOR: (CONT’D)
Ambient Temp.: 25C Humidity: 58% RH
METHOD: UL 444, Clause 4.1 – 4.11
Stranded Conductor:
Specimen: #1
Number of Strands 7
Strand 1 – Min. Diameter, in. .00605
Max. Diameter, in. .0061
Strand 2 – Min. Diameter, in. .00585
Max. Diameter, in. .0059
Strand 3 – Min. Diameter, in. .00595
Max. Diameter, in. .00605
Strand 4 – Min. Diameter, in. .0059
Max. Diameter, in. .00595
Strand 5 – Min. Diameter, in. .0059
Max. Diameter, in. .00595
Strand 6 – Min. Diameter, in. .0059
Max. Diameter, in. .00595
Strand 7 – Min. Diameter, in. .0059
Max. Diameter, in. .00595
Average Strand Diameter, in. .0060
Total conductor area, in2 / mm2 252
Conductor AWG Size 26
Copyright © 2015 UL LLC Page 61 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
DETAILED EXAMINATION (Sample #2): (CONT’D) UL 444, Clause 5 DETAILED EXAMINATION, insulation:
Ambient Temp.: 25C Humidity: 58% RH
METHOD: UL 444, Clause 4.1 – 4.11
Insulation:
Specimen: #1
Thickness: Min #1, in. .008
Max #1, in. .010
Average Thickness, in. .009
Outside diameter: Min #1, in. .03553
Max #1, in. .03585
Min #2, in. .03601
Max #2, in. .03601
Min #3, in. .03641
Max #3, in. .03643
Average Outside Diameter, in. .036
Copyright © 2015 UL LLC Page 62 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
DETAILED EXAMINATION (Sample #2): (CONT’D) UL 444, Clause 5 DETAILED EXAMINATION, JACKET:
Ambient Temp.: 25C Humidity: 58% RH
METHOD: UL 444, Clause 4.1 – 4.11
Jacket:
Specimen: #1
Thickness: Min #1, in. .022
Max #1, in. .024
Average Thickness, in. .023
Outside diameter: Min #1, in. .225
Max #1, in. .227
Min #2, in. .228
Max #2, in. .228
Min #3, in. .229
Max #3, in. .242
Average Outside Diameter, in. .230
Core diameter: Min #1, in. .181
Max #1, in. .182
Min #2, in. .183
Max #2, in. .183
Min #3, in. .183
Max #3, in. .184
Average Core Diameter, in. .183
Copyright © 2015 UL LLC Page 63 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
DETAILED EXAMINATION: UL 444, Clause 5
Sample No. 3
Ambient Temp.: 25C Humidity: 58% RH
Note: All units are expressed in terms of: [X] Inches [ ] mm
[X] Identification
Print Type: None Ink Indent Tape Other:
Print Content: CAT-6 GENERAL CABLE J 2001345 CMR C(ETL)US CMG 4PR 23AWG
GENSPEED 6 IWC VERIFIED BY UND LAB INC ONLY TO ANSI/TIA-568C.2 CAT-6
Print Interval: 24 inches
No. of Insulated Conductors 8 No. Of Bare Conductors 0
Brief Assembly Description: JKT, RIP CORD, FLAT FILLER, 8 INS CON
Copyright © 2015 UL LLC Page 64 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
DETAILED EXAMINATION (Sample #3): (CONT’D) UL 444, Clause 5
Ambient Temp.: 25C Humidity: 58% RH
Note: If additional space is required please continue under “attached Component” section
[X] Jacket Overall Jacket
Inner Jacket 1
Inner Jacket 2
Inner Jacket 3
Color BLUE
Overall cable diameter, in. .228
Core diameter under jacket, in. .191
Major axis, in. -
Minor axis, in. -
Average thickness, in. .019
Min. thickness at any point, in. .018
Minimum thickness after rip, in. -
Average web thickness, in. -
Average web width, in. -
[ ] Note: If ave. or min. point jacket thickness exceeds / is less than the
following requirement contact engineer before proceeding:
Min Ave. , in. Min Point , in.
Copyright © 2015 UL LLC Page 65 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
DETAILED EXAMINATION (Sample #3): (CONT’D) UL 444, Clause 5
Ambient Temp.: 25C Humidity: 58% RH
Sample No.
[ ] Armor [X] Assembly
Type of Armor Lay of conductors, in. .375
Convolutions per inch / mm Lay of conductor pairs, in. 4.0
Diameter over armor, in. Lay of members, in. -
Diameter under armor, in.
Strip width, in.
Average thickness, in.
Min. thickness at any point, in.
Copyright © 2015 UL LLC Page 66 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
DETAILED EXAMINATION (Sample #3): (CONT’D) UL 444, Clause 5
Ambient Temp.: 25C Humidity: 58% RH
[X] Tapes, binders, rods, rip cords, and fillers
Type FLAT
FILLER
Thickness, in. .0012
Width, in. .171
Lap, in. -
Overall diameter, in. -
Helical/longitudinal HELI
Calculated % coverage -
Count 1
Major/minor axis, in. -
Ripcord present? -
Sample No.
[X] Insulation Conductor Conductor Conductor Conductor
Color BLUE
Separator tape present? NO
Average thickness, in. .008
Minimum thickness at any point, in. .007
Minimum thickness after rip, in. -
Average web thickness, in. -
Average web width, in. -
[ ] Insulation Covering
Color
Average thickness, in.
Minimum thickness at any point, in.
[ ] Note: If ave. or min. point insulation thickness exceeds/is less than
the following requirement contact engineer before proceeding:
Min Ave. , in. Min Point , in.
Copyright © 2015 UL LLC Page 67 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
DETAILED EXAMINATION (Sample #3): (CONT’D) UL 444, Clause 5
Ambient Temp.: 25C Humidity: 58% RH
[X] Conductor Conductor Conducto
r Conductor Conductor
1 2 3 4
Type (i.e. Al, Cu, etc.) Cu
Coating present? NO
Diameter of solid conductor, in. .0218
Diameter over insulation, in. .038
Number of strands -
Strand diameter, in. -
Lay of strands, in. -
Circular Mil Area (CMA) -
AWG size 23
Ambient Temp.: 25C Humidity: 58% RH
METHOD: UL 444, Clause 4.1 – 4.11
Solid Conductor:
Specimen: #1
Min. #1 Diameter, in. .02175
Max. #1 Diameter, in. .0219
Min. #2 Diameter, in. .0219
Max. #2 Diameter, in. .02195
Min. #3 Diameter, in. .0217
Max. #3 Diameter, in. .02175
Average Conductor Diameter, in. .0218
Conductor AWG Size 23
Copyright © 2015 UL LLC Page 68 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
DETAILED EXAMINATION (Sample #3): (CONT’D) UL 444, Clause 5 DETAILED EXAMINATION, INSULATION:
Ambient Temp.: 25C Humidity: 58% RH
METHOD: UL 444, Clause 4.1 – 4.11
Insulation:
Specimen: #1
Thickness: Min #1, in. .007
Max #1, in. .009
Average Thickness, in. .008
Outside diameter: Min #1, in. .03752
Max #1, in. .03825
Min #2, in. .03828
Max #2, in. .03837
Min #3, in. .03839
Max #3, in. .03882
Average Outside Diameter, in. .038
Copyright © 2015 UL LLC Page 69 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
DETAILED EXAMINATION (Sample #3): (CONT’D) UL 444, Clause 5 DETAILED EXAMINATION, JACKET:
Ambient Temp.: 25C Humidity: 58% RH
METHOD: UL 444, Clause 4.1 – 4.11
Jacket:
Specimen: #1
Thickness: Min #1, in. .018
Max #1, in. .020
Average Thickness, in. .019
Outside diameter: Min #1, in. .225
Max #1, in. .226
Min #2, in. .228
Max #2, in. .229
Min #3, in. .229
Max #3, in. .231
Average Outside Diameter, in. .228
Core diameter: Min #1, in. .188
Max #1, in. .190
Min #2, in. .190
Max #2, in. .192
Min #3, in. .193
Max #3, in. .194
Average Core Diameter, in. .191
Copyright © 2015 UL LLC Page 70 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
DETAILED EXAMINATION: UL 444, Clause 5
Sample No. 4
Ambient Temp.: 25C Humidity: 58% RH
Note: All units are expressed in terms of: [X] Inches [ ] mm
[X] Identification
Print Type: None Ink Indent Tape Other:
Print Content: CAT-6 GENERAL CABLE J CMP 90C C(UL)US 4PR 23AWG GENSPEED
6 PLENUM VERFIED (UL) ANSI/TIA-568C.2 CAT6
Print Interval: 24 inches
No. of Insulated Conductors 8 No. Of Bare Conductors 0
Brief Assembly Description: JKT, RIP CORD, FLAT FILLER, 8 INS CON
Copyright © 2015 UL LLC Page 71 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
DETAILED EXAMINATION (Sample #4): (CONT’D) UL 444, Clause 5
Ambient Temp.: 25C Humidity: 58% RH
Note: If additional space is required please continue under “attached Component” section
[X] Jacket Overall Jacket
Inner Jacket 1
Inner Jacket 2
Inner Jacket 3
Color WHITE
Overall cable diameter, in. .210
Core diameter under jacket, in. .179
Major axis, in. -
Minor axis, in. -
Average thickness, in. .015
Min. thickness at any point, in. .0145
Minimum thickness after rip, in. -
Average web thickness, in. -
Average web width, in. -
[ ] Note: If ave. or min. point jacket thickness exceeds / is less than the
following requirement contact engineer before proceeding:
Min Ave. , in. Min Point , in.
Copyright © 2015 UL LLC Page 72 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
DETAILED EXAMINATION (Sample #4): (CONT’D) UL 444, Clause 5
Ambient Temp.: 25C Humidity: 58% RH
Sample No.
[ ] Armor [x] Assembly
Type of Armor Lay of conductors, in. .375
Convolutions per inch / mm Lay of conductor pairs, in. 4.0
Diameter over armor, in. Lay of members, in. -
Diameter under armor, in.
Strip width, in.
Average thickness, in.
Min. thickness at any point, in.
[ ] Braid Parameters Braid 1 Braid 2 Braid 3
Type of braid
Strand diameter, in.
No. ends
No. carriers
Picks per inch / mm
Core Dia. under braid inch/mm
Calculated % coverage
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DETAILED EXAMINATION (Sample #4): (CONT’D) UL 444, Clause 5
Ambient Temp.: 25C Humidity: 58% RH
[X] Tapes, binders, rods, rip cords, and fillers
Type FLAT
Thickness, in. .012
Width, in. .173
Lap, in. -
Overall diameter, in. -
Helical/longitudinal HELI
Calculated % coverage -
Count 1
Major/minor axis, in. -
Ripcord present? -
Sample No.
[X] Insulation Conductor Conductor Conductor Conductor
Color BLUE
Separator tape present? NO
Average thickness, in. .009
Minimum thickness at any point, in. .0085
Minimum thickness after rip, in. -
Average web thickness, in. -
Average web width, in. -
[ ] Insulation Covering
Color
Average thickness, in.
Minimum thickness at any point, in.
[ ] Note: If ave. or min. point insulation thickness exceeds/is less than
the following requirement contact engineer before proceeding:
Min Ave. , in. Min Point , in.
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DETAILED EXAMINATION (Sample #4): (CONT’D) UL 444, Clause 5
Ambient Temp.: 25C Humidity: 58% RH
[X] Conductor Conductor Conducto
r Conductor Conductor
1 2 3 4
Type (i.e. Al, Cu, etc.) Cu
Coating present? NO
Diameter of solid conductor, in. .0219
Diameter over insulation, in. .039
Number of strands -
Strand diameter, in. -
Lay of strands, in. -
Circular Mil Area (CMA) -
AWG size 23
Ambient Temp.: 25C Humidity: 58% RH
METHOD: UL 444, Clause 4.1 – 4.11
Solid Conductor:
Specimen: #1
Min. #1 Diameter, in. .02175
Max. #1 Diameter, in. .02190
Min. #2 Diameter, in. .0219
Max. #2 Diameter, in. .0220
Min. #3 Diameter, in. .0218
Max. #3 Diameter, in. .0219
Average Conductor Diameter, in. .0219
Conductor AWG Size 23
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DETAILED EXAMINATION (Sample #4): (CONT’D) UL 444, Clause 5 DETAILED EXAMINATION, insulation:
Ambient Temp.: 25C Humidity: 58% RH
METHOD: UL 444, Clause 4.1 – 4.11
Insulation:
Specimen: #1
Thickness: Min #1, in. .0085
Max #1, in. .010
Average Thickness, in. .009
Outside diameter: Min #1, in. .03855
Max #1, in. .03894
Min #2, in. .03902
Max #2, in. .03907
Min #3, in. .03916
Max #3, in. .03980
Average Outside Diameter, in. .039
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DETAILED EXAMINATION (Sample #4): (CONT’D) UL 444, Clause 5 DETAILED EXAMINATION, JACKET:
Ambient Temp.: 25C Humidity: 58% RH
METHOD: UL 444, Clause 4.1 – 4.11
Jacket:
Specimen: #1
Thickness: Min #1, in. .0145
Max #1, in. .016
Average Thickness, in. .015
Outside diameter: Min #1, in. .207
Max #1, in. .208
Min #2, in. .208
Max #2, in. .209
Min #3, in. .212
Max #3, in. .216
Average Outside Diameter, in. .210
Core diameter: Min #1, in. .176
Max #1, in. .177
Min #2, in. .177
Max #2, in. .178
Min #3, in. .181
Max #3, in. .186
Average Core Diameter, in. .179
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DETAILED EXAMINATION: UL 444, Clause 5
Sample No. 5
Ambient Temp.: 25C Humidity: 58% RH
Note: All units are expressed in terms of: [X] Inches [ ] mm
[X] Identification
Print Type: None Ink Indent Tape Other:
Print Content: GenSPEED EfficienC MAX CAT 6 ENHANCED POE++ E105765-L CMP
(UL) C(UL) 4PR 22AWG 90C VERIFIED (UL) ANSI/TIA-568C.2 CAT6
Print Interval: 24 inches
No. of Insulated Conductors 8 No. Of Bare Conductors 0
Brief Assembly Description: JKT, RIP CORD, FLAT FILLE, 8 INS CON
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DETAILED EXAMINATION (Sample #5): (CONT’D) UL 444, Clause 5
Ambient Temp.: 25C Humidity: 58% RH
Note: If additional space is required please continue under “attached Component” section
[X] Jacket Overall Jacket
Inner Jacket 1
Inner Jacket 2
Inner Jacket 3
Color BLUE
Overall cable diameter, in. .221
Core diameter under jacket, in. .193
Major axis, in. -
Minor axis, in. -
Average thickness, in. .015
Min. thickness at any point, in. .014
Minimum thickness after rip, in. -
Average web thickness, in. -
Average web width, in. -
[ ] Note: If ave. or min. point jacket thickness exceeds / is less than the
following requirement contact engineer before proceeding:
Min Ave. , in. Min Point , in.
Copyright © 2015 UL LLC Page 79 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
DETAILED EXAMINATION (Sample #5): (CONT’D) UL 444, Clause 5
Ambient Temp.: 25C Humidity: 58% RH
Sample No.
[ ] Armor [ ] Assembly
Type of Armor Lay of conductors, in. .375
Convolutions per inch / mm Lay of conductor pairs, in. 4.5
Diameter over armor, in. Lay of members, in. -
Diameter under armor, in.
Strip width, in.
Average thickness, in.
Min. thickness at any point, in.
[ ] Braid Parameters Braid 1 Braid 2 Braid 3
Type of braid
Strand diameter, in.
No. ends
No. carriers
Picks per inch / mm
Core Dia. under braid inch/mm
Calculated % coverage
Copyright © 2015 UL LLC Page 80 of 164 Copyright © 2015 SPI: The Plastics Industry Trade Association 20150930
DETAILED EXAMINATION (Sample #5): (CONT’D) UL 444, Clause 5
Ambient Temp.: 25C Humidity: 58% RH
[X] Tapes, binders, rods, rip cords, and fillers
Type FLAT
Thickness, in. .011
Width, in. .173
Lap, in. -
Overall diameter, in. -
Helical/longitudinal HELI
Calculated % coverage TBD
Count 1
Major/minor axis, in. -
Ripcord present? -
Sample No.
[X] Insulation Conductor Conductor Conductor Conductor
Color BLUE
Separator tape present? NO
Average thickness, in. .009
Minimum thickness at any point, in. .008
Minimum thickness after rip, in. -
Average web thickness, in. -
Average web width, in. -
[ ] Insulation Covering
Color
Average thickness, in.
Minimum thickness at any point, in.
[ ] Note: If ave. or min. point insulation thickness exceeds/is less than
the following requirement contact engineer before proceeding:
Min Ave. , in. Min Point , in.
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DETAILED EXAMINATION (Sample #5): (CONT’D) UL 444, Clause 5
Ambient Temp.: 25C Humidity: 58% RH
[X] Conductor Conductor Conducto
r Conductor Conductor
1 2 3 4
Type (i.e. Al, Cu, etc.) Cu
Coating present? NO
Diameter of solid conductor, in. .0245
Diameter over insulation, in. .042
Number of strands -
Strand diameter, in. -
Lay of strands, in. -
Circular Mil Area (CMA) -
AWG size 22
Ambient Temp.: 25C Humidity: 58% RH
METHOD: UL 444, Clause 4.1 – 4.11
Solid Conductor:
Specimen: #1
Min. #1 Diameter, in. .02515
Max. #1 Diameter, in. .02540
Min. #2 Diameter, in. .02415
Max. #2 Diameter, in. .02420
Min. #3 Diameter, in. .02410
Max. #3 Diameter, in. .02415
Average Conductor Diameter, in. .0245
Conductor AWG Size 22
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DETAILED EXAMINATION (Sample #5): (CONT’D) UL 444, Clause 5 DETAILED EXAMINATION, INSULATION:
Ambient Temp.: 25C Humidity: 58% RH
METHOD: UL 444, Clause 4.1 – 4.11
Insulation:
Specimen: #1
Thickness: Min #1, in. .008
Max #1, in. .010
Average Thickness, in. .009
Outside diameter: Min #1, in. .04152
Max #1, in. .04155
Min #2, in. .04218
Max #2, in. .04224
Min #3, in. .04224
Max #3, in. .04262
Average Outside Diameter, in. .042
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DETAILED EXAMINATION (Sample #5): (CONT’D) UL 444, Clause 5 DETAILED EXAMINATION, JACKET:
Ambient Temp.: 25C Humidity: 58% RH
METHOD: UL 444, Clause 4.1 – 4.11
Jacket:
Specimen: #1
Thickness: Min #1, in. .014
Max #1, in. .016
Average Thickness, in. .015
Outside diameter: Min #1, in. .215
Max #1, in. .219
Min #2, in. .220
Max #2, in. .222
Min #3, in. .224
Max #3, in. .227
Average Outside Diameter, in. .221
Core diameter: Min #1, in. .187
Max #1, in. .191
Min #2, in. .191
Max #2, in. .194
Min #3, in. .195
Max #3, in. .199
Average Core Diameter, in. .193
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DETAILED EXAMINATION: UL 444, Clause 5
Sample No. 6
Ambient Temp.: 25C Humidity: 58% RH
Note: All units are expressed in terms of: [X] Inches [ ] mm
[X] Identification
Print Type: None Ink Indent Tape Other:
Print Content: GENERAL CABLE L GENSPEED 10MTP CATEGORY 6A 4PR/23AWG UTP
PLENUM CABLE C(UL)US CMP 90C VERIFIED(UL) ANSI/TIA-568C.2 CAT-6A PAT 5767441,
8354590, 8183462 10MTP.US
Print Interval: 24 inches
No. of Insulated Conductors 8 No. Of Bare Conductors 0
Brief Assembly Description: JKT, POLY AL WRAP, POLYESTER WRAP, STAR FILLER,
8 INS CON
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DETAILED EXAMINATION (Sample #6): (CONT’D) UL 444, Clause 5
Ambient Temp.: 25C Humidity: 58% RH
Note: If additional space is required please continue under “attached Component” section
[X] Jacket Overall Jacket
Inner Jacket 1
Inner Jacket 2
Inner Jacket 3
Color GREY
Overall cable diameter, in. .281
Core diameter under jacket, in. .249
Major axis, in. -
Minor axis, in. -
Average thickness, in. .016
Min. thickness at any point, in. .015
Minimum thickness after rip, in. -
Average web thickness, in. -
Average web width, in. -
[ ] Note: If ave. or min. point jacket thickness exceeds / is less than the
following requirement contact engineer before proceeding:
Min Ave. , in. Min Point , in.
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DETAILED EXAMINATION (Sample #6): (CONT’D) UL 444, Clause 5
Ambient Temp.: 25C Humidity: 58% RH
Sample No.
[ ] Armor [X] Assembly
Type of Armor Lay of conductors, in. .344
Convolutions per inch / mm Lay of conductor pairs, in. 4.0
Diameter over armor, in. Lay of members, in. -
Diameter under armor, in.
Strip width, in.
Average thickness, in.
Min. thickness at any point, in.
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DETAILED EXAMINATION (Sample #6): (CONT’D) UL 444, Clause 5
Ambient Temp.: 25C Humidity: 58% RH
[X] Tapes, binders, rods, rip cords, and fillers
Type
POLY AL WRAP
WOVEN POLYESTER
WRAP
Thickness, in. .0032 .0063
Width, in. 1.0 .750
Lap, in. .250 .188
Overall diameter, in. .239 .230
Helical/longitudinal HELI HELI
Calculated % coverage TBD TBD
Count 1 1
Major/minor axis, in. - -
Ripcord present? - -
Sample No.
[X] Insulation Conductor Conductor Conductor Conductor
Color BLUE
Separator tape present? NO
Average thickness, in. .010
Minimum thickness at any point, in. .009
Minimum thickness after rip, in. -
Average web thickness, in. -
Average web width, in. -
[ ] Insulation Covering
Color
Average thickness, in.
Minimum thickness at any point, in.
[ ] Note: If ave. or min. point insulation thickness exceeds/is less than
the following requirement contact engineer before proceeding:
Min Ave. , in. Min Point , in.
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DETAILED EXAMINATION (Sample #6): (CONT’D) UL 444, Clause 5
Ambient Temp.: 25C Humidity: 58% RH
[x] Conductor Conductor Conducto
r Conductor Conductor
1 2 3 4
Type (i.e. Al, Cu, etc.) Cu
Coating present? NO
Diameter of solid conductor, in. .023
Diameter over insulation, in. .042
Number of strands -
Strand diameter, in. -
Lay of strands, in. -
Circular Mil Area (CMA) -
AWG size 23
Ambient Temp.: 25C Humidity: 58% RH
METHOD: UL 444, Clause 4.1 – 4.11
Solid Conductor:
Specimen: #1
Min. #1 Diameter, in. .0229
Max. #1 Diameter, in. .02295
Min. #2 Diameter, in. .02295
Max. #2 Diameter, in. .023
Min. #3 Diameter, in. .02295
Max. #3 Diameter, in. .023
Average Conductor Diameter, in. .023
Conductor AWG Size 23
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DETAILED EXAMINATION (Sample #6): (CONT’D) UL 444, Clause 5 DETAILED EXAMINATION, INSULATION:
Ambient Temp.: 25C Humidity: 58% RH
METHOD: UL 444, Clause 4.1 – 4.11
Insulation:
Specimen: #1
Thickness: Min #1, in. .009
Max #1, in. .011
Average Thickness, in. .010
Outside diameter: Min #1, in. .042
Max #1, in. .042
Min #2, in. .042
Max #2, in. .043
Min #3, in. .043
Max #3, in. .043
Average Outside Diameter, in. .042
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DETAILED EXAMINATION (Sample #6): (CONT’D) UL 444, Clause 5 DETAILED EXAMINATION, JACKET:
Ambient Temp.: 25C Humidity: 58% RH
METHOD: UL 444, Clause 4.1 – 4.11
Jacket:
Specimen: #1
Thickness: Min #1, in. .015
Max #1, in. .017
Average Thickness, in. .016
Outside diameter: Min #1, in. .273
Max #1, in. .274
Min #2, in. .283
Max #2, in. .283
Min #3, in. .286
Max #3, in. .287
Average Outside Diameter, in. .281
Core diameter: Min #1, in. .241
Max #1, in. .244
Min #2, in. .250
Max #2, in. .252
Min #3, in. .253
Max #3, in. .255
Average Core Diameter, in. .249
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DETAILED EXAMINATION (Sample #6): (CONT’D) UL 444, Clause 5 STAR FILLER DIMENSIONS:
Ambient Temp.: 25C Humidity: 58% RH
d Thickness at any point, mils ______41______ w Average Thickness, mils _____20_______ Minimum Thickness at any point, mils _____17_______ Maximum Thickness at any point, mils _____24_______ l Average Thickness, mils ______70______ Minimum Thickness at any point, mils _____65_______ Maximum Thickness at any point, mils _____74_______
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APPENDIX B - TEMPERATURE TEST DATA
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Thermocouple Placement - General
TC6 and TC7 are at the center of the cable bundle length. TC7 is inside the jacket on
the individual wire insulation. TC6 is on the outside of the cable jacket.
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TEMPERATURE TEST DATA
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TEMPERATURE TEST DATA
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TEMPERATURE TEST DATA
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TEMPERATURE TEST DATA
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APPENDIX C - DATA for NEC TABLES
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APPENDIX D - CABLE HEATING TEST
The proposed requirements for the UL Standard(s) for Safety are to be considered as tentative and are only meant to demonstrate the form and content of such a proposal. They have not been presented to the relevant industry nor subjected to UL's standards development procedure. The requirements are shown only as examples and are based on the results given in this Report. 7.24 (NEW) Cable Heating Test
77.24.1 When tested as described in this section, the temperatures measured on the insulation and
jacket of the cables, after being corrected to an ambient of 45oC, shall not exceed the temperature
rating of the cable.
7.24.2 The cables shall be arranged in a bundle consisting of 192 cables and electrically connected in
series to a power supply capable of providing the rated current marked as part of the LP rating. The
inner 37 cables shall be arranged as shown in Figure 4. The remaining cables shall be evenly
distributed in a random fashion to form a 192 cable bundle. The bundle shall be placed in a 6 foot
long (1.83 m) commercially available non-metallic conduit (Schedule 40) with the minimum diameter
needed to install the bundle without putting pressure on the cables. Each end of the conduit shall be
filled with insulation.
7.24.3 The temperatures shall be measured on the outer jacket and conductor insulation of the center
cable at the midpoint of the cable. In addition, temperatures shall be measured on the jacket and
conductor insulation on the center cable two feet (0.6 m) on each side of center thermocouple.
7.24.4 Temperatures are to be measured by means of thermocouples consisting of iron and
constantan wires not larger than 24 AWG (0.21 mm2) and not smaller than 30 AWG (0.05 mm2).
When thermocouples are used in determining temperatures in electrical equipment, it is common
practice to employ thermocouples consisting of 30 AWG iron and constantan wires with a
potentiometer-type of indicating instrument. This equipment is to be used whenever a referee
measurement of temperature is necessary.
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7.24.5 The thermocouples and related instruments are to be accurate and calibrated in accordance
with standard laboratory practice. The thermocouple wire is to conform to the requirements specified
in the Tolerances on Initial Values of EMF versus Temperature tables in the Standard Specification
and Temperature-Electromotive Force (emf) Tables for Standardized Thermocouples, ANSI/ASTM
E230/E230M.
7.24.6 A thermocouple junction and adjacent thermocouple lead wire are to be securely held in good
thermal contact with the surface of the material whose temperature is being measured. In most
cases, acceptable thermal contact results from securely taping or cementing the thermocouple in
place
Example of Cable Heating Test