ICEA-S-84-608-1994.pdf

STANDARD FOR TELECOMMUNICATIONS CABLE FILLED, POLYOLEFIN INSULATED, COPPER CONDUCTOR TECHNICAL REQUIREMENTS Approved by AMERICAN NATIONAL STANDARDS INSTITUTE MAY 26,1995 Publication # ANSMCEA S-84-608-1994 Q 1995 by INSULATED CABLE ENGINEERS ASSOCIATION, Inc. COPYRIGHT Insulated Cable Engineers Association, Inc Licensed by Information Handling Services COPYRIGHT Insulated Cable Engineers Association, Inc Licensed by Information Handling Services Copyrighted by the ICEA Conteas may not be reproduced in any fom without permission of the INSULATED CABLE ENGINEERS ASSOCIATION, INC. Copies of this publication maybe obtained from: INSULATED CABLE ENGINEERS ASSOCIATION, INC. P o s t B o x 4 4 0 South Yamiouth, Massachusetts 02664 Tekphone: (508) 394-4424 COPYRIGHT Insulated Cable Engineers Association, Inc Licensed by Information Handling Services COPYRIGHT Insulated Cable Engineers Association, Inc Licensed by Information Handling Services I C E A S-84-608 74 7007034 0000b73 7T2 ANSMCEA S-84-608-1994 STANDARD FOR TELECOMMUNICATIONS CABLE FILLED, POLYOLEFIN INSULATED, COPPER CONDUCTOR TECHNICAL REQUIREMENTS Published By Insulated Cable Engineers Association, Inc. Post Office Box 440 South Yarmouth, Massachusetts 02664, U.S.A. Second Edition O 1995 by ICEA Approved July 15,1994 by INSULATED CABLE ENGINEERS ASSOCIATION, Inc. Approved by 9/27/94 by ANSI ASC C-8 Approved May 26,1995 by AMERICAN NATIONAL STANDARDS INSTITUTE COPYRIGHT Insulated Cable Engineers Association, Inc Licensed by Information Handling Services COPYRIGHT Insulated Cable Engineers Association, Inc Licensed by Information Handling Services DEDICATION In recognition of his forty years of contribution to the Wre and Cable Industry and in particular for his vision in recognizing in 1984 a need for a true Industry standard, his perseverance in organizing a broad based user/rnanufacturer technical forum, and his leadership in the preparation of this document until his retirement in 1987, this Standard is gratebl!y dedicated to: E.D. (ED) METCALF i COPYRIGHT Insulated Cable Engineers Association, Inc Licensed by Information Handling Services COPYRIGHT Insulated Cable Engineers Association, Inc Licensed by Information Handling Services I C E A S-84-608 74 7007034 0000675 575 FOREWORD ICEA Standards are published in the public interest and are intended to promote product uniformity and quality throughout the industry. Existence of an ICEA publication does not in any respect preclude the manufacture or use of products not conforming to the Standard. The user of this Standard is cautioned to observe any applicable health or safety regulations and rules relative to the manufacture and use of cable made in conformity with this Standard. This Standard hereafter assumes that manufacture, testing, installation, and maintenance of cables defined by this Standard will be performed only by properly trained personnel using suitable equipment and employing appropriate safety precautions. Questions of interpretation of ICEA Standards can only be accepted in writing at Headquarters by the Secretary, and the reply shall be provided in writing. Suggestions for improvements in this Standard are welcome and should be sent to ICEA at the address on Page i¡. S-84-608 was the first standard developed by the Telecommunications Wire and Cable Standards Technical Advisory Committee whose membership consisted of technical experts from the manufacturing, user, and general interest segments of the industry. It was first approved and published as an ANSI (American National Standards Institute) standard on June 30, 1989. It and its companion standard, S-85-625 published in April, 1990, were patterned after an existing ICEA Standard, S-56-434. When these two standards were completed, some of the details contained in S-56434 were not included. The most significant of these included: (1) Requirements for 16 AWG conductors, (2) Unitized color coding including both full-count and mirror image coding schemes and, (3) Provision for spare and service pairs. This latest revision now includes those details and, in addition, the performance requirements and construction details have been updated to reflect current technologies and applications. It was approved by ICEA on July 15, 1994. With publication of this revision and the subsequent review and revision o f its companion Standard, S-85-625, the need for S-56-434 will no longer exist. It is intended that 5-56434 will be discontinued. The members of the ICEA Communications Cable Section, Working Group 647, who participated in this project were: J. S. Tyler, Chairman D. K. Baker V. B. Mascarenhas A. G. Dwyer T. McLaughlin L. Lisker J-H. Walling T. Hardin iv COPYRIGHT Insulated Cable Engineers Association, Inc Licensed by Information Handling Services COPYRIGHT Insulated Cable Engineers Association, Inc Licensed by Information Handling Services I C E A 5-84-608 94 W 9007034 0000676 401 = TELECOMMUNICATIONS WIRE AND CABLE STANDARDS TECHNICAL ADVISORY COMMITTEE Committee Chairman: Committee Vice-Chairman: N. J. Baer of Essex Group Chi-Than Nguyen of Bell Canada Individuals Who Participated in the Revision of This Standard: Adamson, J. of Southwestern Bell Allcock, E. of Independent Cable Baker, D. of Independent Cable Baker, D. K. o f Superior TeleTec Brasseaux, J. of BellSouth Telecomm. Brown, D. of AMERITECH Christensen, J. of Bellcore Dwyer, A. G. of AT&T Gurney, E. A. of GTE Telephone Operations Hardin, T. G. of ATBT Hessler, G. J. o f USDA-REA Hitchcock, R. E. o f Bellcore Hore, L. M. of Bellcore Johnsen, R. of Alcatel Kaminski, V. of Bell Atlantic Kress, K. o f Cincinnati Bell Lange, W. E. of Alcatel ticker, L. S. of American Insulated Wire Maddali, P. V. of NYNEX Mascarenhas, V. B. of Alcatel Canada Wire McKay, M. C. of US WEST McLaughlin, T. of General Cable Silva, M. of Independent Cable Tyler, J. S. of Essex Group Walling, J-H of Northern Telecom Whipple, P. H. o f Bellcore V COPYRIGHT Insulated Cable Engineers Association, Inc Licensed by Information Handling Services COPYRIGHT Insulated Cable Engineers Association, Inc Licensed by Information Handling Services ICEA S-84-608 74 m 9007034 O000677 348 CONTENTS: SECTION PAGE 1 . GENERAL 1.1 PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.2 SCOPE 1 1.3 UNITS AND TOLERANCES 2 1.4 REFERENCES . 2 1.5 QUALITY ASSURANCE 2 1.6 SAFETY CONSIDERATIONS 2 2 . CONDUCTORS 2.1 REQUIREMENTS . 3 2.2 FACTORY JOINTS 3 3 . CONDUCTOR INSULATION 3.1 INSULATION MATERIALS 4 3.1.1 Propylene/Ethylene Copolymer . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3.1.2 High-Density Polyethylene . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3.1.3 Medium-Density Polyethylene . 4 3.2 INSULATIONNPE . 4 3.2.1 Solid . 4 3.2.2 Foam 4 3.2.3 Foam-Skin 4 3.3 INSULATION DIMENSIONS. COLORS. ANDSPLICES . 4 3.4 INSULATION PHYSICAL REQUIREMENTS 5 3.4.1 Insulation Adhesion 5 3.4.2 Elongation 5 3.4.3 Compression . 6 3.4.4 Cold Bend 6 3.4.5 Shrinkback . 6 3.4.6 Thermal Oxidative Stability . 6 3.5 TWIST LENGTH AND COLOR CODING 7 4 . CORE CONSTRUCTION 4.1 CORELAYUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 vi COPYRIGHT Insulated Cable Engineers Association, Inc Licensed by Information Handling Services COPYRIGHT Insulated Cable Engineers Association, Inc Licensed by Information Handling Services CONTENTS: SECTION PAGE 4.2 BINDERS . 9 4.3 SPAREPAIRS 10 4.4 COREWRAP . 11 4.5 FILLING COMPOUND . 11 4.5.1 Type Filling Compound 12 4.5.2 Adequacy of Fill . 12 4.6 FLOODING COMPOUND 12 4.7 WATER SWELLABLE MATERIALS . 12 5 . INTERNAL SCREENS 5.1 DESCRIPTION 12 5.2 SCREEN MATERIAL 12 5.2.1 Film Adhesion . 13 5.2.2 Film Delamination 13 5.3 SERVICEPAIRS 13 6 . SHIELDS 6.1 SHIELDING SYSTEMS 13 6.2 SHIELD MATERIALS . 14 8-mil Bare Aluminum Tape 14 8-mil Coated Aluminum Tape 14 6.2.3 5-mil Copper Tape . 14 6.2.4 5-mil Copper Clad Alloy Steel Tape . 14 6.2.1 6.2.2 6.2.5 5-mil Copper Clad Stainless 6.2.6 SteelTape . 15 6- and 7-mil 194 Copper Alloy Tape . 15 6.2.7 6-mil Bare Steel Tape . 15 6.2.8 6-mil Coated Steel Tape . 16 6.3 SHIELD APPLICATION 16 6.3.1 Shield Corrugation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 6.3.2 Shield Overlap 16 6.3.3 Shield Splices . 17 6.4 CORRUGATION EXTENSIBILITY 17 COPYRIGHT Insulated Cable Engineers Association, Inc Licensed by Information Handling Services COPYRIGHT Insulated Cable Engineers Association, Inc Licensed by Information Handling Services CONTENTS: SECTION PAGE 7 . POLYETHYLENE INNER AND OUTER JACKET 7.1 INNER JACKET . 18 7.1.1 Material and Test Requirements 18 7.1.2 Inner Jacket Thickness Requirement . 18 OUTERJACKET . 19 7.2.1 RawMaterial 19 7.2.2 Outer Jacket Thicknes Requirement . 19 7.2.3 Completed Cable Material Requirements 21 7.2.4 Shrinkback . 22 7.2.5 Sheath Adherence-Unbonded 22 7.2.6 Sheath Adherence-Bonded . 22 8 . ELECTRICAL REQI JIREMENTS 8.1 DC RESISTANCE 23 8.2 DC RESISTANCE UNBALANCE . 23 8.3 MUTUAL CAPACITANCE 23 Final Product 100% Testing . 24 8.3.1 8.4 CAPACITANCE DIFFERENCE 24 8.5 PAIR-TO-PAIR CAPACITANCE UNBALANCE . 24 8.6 PAIR-TO-GROUND CAPACITANCE UNBALANCE 24 8.7 AlTENUATION 24 8.8 UNITCROSSTALK . 25 8.8.1 Crosstalk Qualification Test . 26 8.9 BEWEEN-COMPARTMENT CROSSTALK FOR SCREENED CABLES 27 8.9.1. Requirements for all Applications 28 8.9.2 Requirements for T-1 C and Similar Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 8.9.3 Qualification Test Procedure 28 8.10 SCREEN INTEGRITY DIRECT CAPACITANCE TEST 28 8.1 1 INSULATION RESISTANCE 28 viii COPYRIGHT Insulated Cable Engineers Association, Inc Licensed by Information Handling Services COPYRIGHT Insulated Cable Engineers Association, Inc Licensed by Information Handling Services _ I C E A S-84-608 74 W 7007034 O000680 732 CONTENTS: SECTION PAGE 8.12 CONDUCTOR-TO-CONDUCTOR DC PROOF TEST . 29 8.13 CORE-TO-SHIELD DC PROOF TEST . 29 8.14 CORE-TO-SCREEN DC PROOF TEST 29 8.1 5 SHIELD RESISTANCE 29 8.16 CONTINUITY OF METALLIC CABLE ELEMENTS . 30 9 . MECHANICAL REQUIREMENTS 9.1 COMPOUND FLOW 30 9.2 WATER PENETRATION . 30 9.3 CABLE BEND TEST 30 Cold Bend Test 31 Hot Bend Test . 31 9.3.1 9.3.2 9.4 CABLE IMPACT . 31 9.5 JACKET NOTCH TEST FOR STEEL SHIELDED CABLE . 31 9.6 CABLE TORSION . QUALIFICATION REQUIREMENT 32 10 . GENERAL REQUIREMENTS 10.1 IDENTIFICATION AND MARKING 33 10.1.1 Manufacturer Identification 33 10.1.2 Year of Manufacture 33 10.1.3 Aiiernate Identification . 33 10.1.4 Jacket Marking 33 10.1.5 Length Marking 34 Defective Pair Marking . 34 10.1.7 Communication Cable Identifier 35 10.1.6 10.2 END SEALING 35 10.3 THERMALWRAP 35 10.4 INFORMATION ACCOMPANYING THE REEL . 36 10.5 OPTIONAL REQUIREMENTS . 36 10.5.1 Physical Reel Protection . 36 10.5.2 Pulling Eyes 36 ix COPYRIGHT Insulated Cable Engineers Association, Inc Licensed by Information Handling Services COPYRIGHT Insulated Cable Engineers Association, Inc Licensed by Information Handling Services I C E A S-84-608 94 9007024 0000b8L 879 = CONTENTS: SECTION PAGE Table 1: Specifications Referenced in ThisStandard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Figure 1 : Forming of Steel Tape Overlap . . . . . . . . . . . . . . . . . . . . . . . . . 40 Figure 2: Minimum Extensibility (EXT) for Aluminum . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Figure 3: Minimum Extensibility (EXT) forsteel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Figure 4: Sheath Adherence Sample Preparation . . . . . . . . . . . . . . . . . . . 43 Figure 5: Sample Preparation for Notch Test . . . . . . . . . . . . . . . . . . . . . . 44 Appendix A: Test Procedure for Wicking . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Test Procedure for Hygroscopicity . . . . . . . . . . . . . . . . . . . . . . 45 Figure A-1 . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . 46 Appendix B: Adhesion Between Screen Aluminum and Coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Appendix C: Standard Internally Screened (IS) Cable Pair Counts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Appendix D: Metallic Tape Splice Breaking Strength, Percent Retention . . . . . . . . . . . . . . . . . . . . . . . . . . 49 X COPYRIGHT Insulated Cable Engineers Association, Inc Licensed by Information Handling Services COPYRIGHT Insulated Cable Engineers Association, Inc Licensed by Information Handling Services - I C E A S-BY-bOB 94 - 9007024 0000682 705 ICEA STANDARD FOR FILLED, POLYOLEFIN INSULATED, COPPER CONDUCTOR TELECOMMUNICATIONS CABLE TECHNICAL REQUIREMENTS SECTION 1 GENERAL 1.1 PURPOSE: The purpose of this Standard is to establish generic technical requirements that may be referenced by individual telecommunications cable specifications covering products intended for normal outside plant use. The parameters covered provide material, construction, and performance requirements that are applicable to filled, polyolefin insulated and jacketed cables of all pair counts, including a variety of shield and jacket combinations and optional compartmental screening. Because this Standard does not cover all details of individual cable design, it cannot be used as a single document for procurement of product. It is intended to be used in conjunction with an individual product specification that provides complete design details for the specific cable type and designates the applicable performance requirements. Such individual cable specifications may be prepared either by the user or the manufacturer. The specification designated for procurement is at the option of the user. 1.2 SCOPE: This Standard covers mechanical and electrical requirements for filled, polyolefin insulated, copper conductor telecommunications cable. It provides alternative choices for type of insulation, type of filling compound, core lay-ups, color code, sheath design (shielding materials, single or double jackets, and jacket thicknesses), and screened or non-screened core. This Standard is arranged in Sections covering one specific area of cable requirement and may be referenced as complete Sections or as individual parag rap hs. Sections of this Standard where the user must specify a particular option are listed below: 3.2 Insulation Type 4.1.3 Color Code, Super-units (Multi-Units) 4.5.1 Type Filling Compound 5.3.3 Color Code, Service Pairs 6.1 Shielding Systems 7.1 Inner Jacket 7.2.1 Outer Jacket (Material Type) 1 COPYRIGHT Insulated Cable Engineers Association, Inc Licensed by Information Handling Services COPYRIGHT Insulated Cable Engineers Association, Inc Licensed by Information Handling Services I C E A S-84-608 94 = 9007034 0000683 643 1.3 1.4 1.5 1.6 UNITS AND TOLERANCES: US. customary units, except for temperature, are specified throughout this Standard. Approximate Internati