CU TECK90 5000V (AIA)

5kV Copper Armoured Power Cable with Aluminum Interlocked Armour

PRODUCT DESCRIPTION

CU TECK90 5000V (AIA) is a medium-voltage copper armoured power cable designed for industrial power distribution, heavy-duty electrical systems, mining, petrochemical facilities, utilities, and other demanding installations requiring robust mechanical protection and reliable electrical performance.

The cable features stranded annealed copper conductors, a high-performance XLPE insulation system, metallic shielding suitable for the selected medium-voltage construction, aluminum interlocked armour (AIA), and a durable outer jacket.

The 5000V voltage rating provides enhanced insulation performance for medium-voltage power distribution systems. The aluminum interlocked armour offers mechanical protection while maintaining a relatively low overall cable weight compared with steel-armoured constructions.

Final cable construction, shielding arrangement, dimensions, ampacity, and certification shall be confirmed according to the applicable project specification and manufacturing design.

APPLICATIONS

• Medium-voltage industrial power distribution

• Mining and mineral-processing facilities

• Oil and gas installations

• Petrochemical and chemical plants

• Power generation facilities

• Utility distribution systems

• Substations and switchgear connections

• Heavy industrial machinery

• Motor and transformer feeders

• Process plants and manufacturing facilities

• Cable tray installations

• Underground installations where permitted

• Wet and dry industrial environments where permitted

• Exposed industrial installations requiring mechanical protection

STANDARDS & COMPLIANCE

Typical reference standards may include:

• CSA C22.2 No. 131 — Metal Sheathed Cables

• CSA C22.2 No. 38 — Thermoset-Insulated Wires and Cables

• ASTM B3 — Soft or Annealed Copper Wire

• ASTM B8 — Concentric-Lay-Stranded Copper Conductors

• Applicable CSA requirements for medium-voltage cable construction

• NFPA 70 / NEC where applicable

• Applicable project, utility, and installation requirements

For 5000V applications, the final cable construction and certification shall be verified against the specific applicable standard and market requirements.

CONSTRUCTION

1. Conductor

• Material: Annealed copper

• Construction: Concentric-lay stranded

• High electrical conductivity

• Excellent flexibility compared with solid conductors

• Suitable for medium-voltage power transmission and distribution

2. Conductor Shield

A semiconductive conductor shield may be applied over the conductor to provide a controlled electrical interface between the conductor and primary insulation.

The shield helps provide a more uniform electric field and reduces localized electrical stress within the insulation system.

3. Primary Insulation

• Material: Cross-linked polyethylene (XLPE)

• Type: Thermoset insulation

• Voltage class: 5000V

• Typical maximum conductor operating temperature: 90°C

• Excellent dielectric strength

• Low moisture absorption

• Good thermal stability

• Good resistance to electrical and environmental stresses

4. Insulation Shield

A semiconductive insulation shield is applied over the XLPE insulation to provide controlled electric-field distribution and facilitate connection to the metallic shielding system.

The shielding system is designed according to the cable voltage class, conductor size, fault-current requirements, and applicable construction standard.

5. Metallic Shield

The cable may incorporate a metallic shield or concentric shielding system around the insulation shield.

Typical configurations may include:

• Copper tape shield

• Copper wire shield

• Copper tape and wire combination

• Concentric neutral or metallic shield arrangement

The exact shielding construction is selected according to the required fault-current capacity, grounding system, installation method, and project specifications.

6. Aluminum Interlocked Armour (AIA)

The cable is protected by aluminum interlocked armour formed around the cable assembly.

AIA provides:

• Mechanical protection

• Impact resistance

• Crush resistance

• Abrasion resistance

• Installation protection

• Improved cable handling

• Reduced overall weight compared with steel armour

• Corrosion resistance suitable for many industrial environments

The interlocked armour may also provide an additional grounding path when the complete cable design and installation system are properly engineered.

7. Outer Jacket

A durable thermoplastic outer jacket is applied over the armoured assembly.

Typical jacket materials may include PVC or other approved thermoplastic compounds selected according to the required environmental and mechanical performance.

Typical jacket properties include:

• Abrasion resistance

• Moisture resistance

• Mechanical durability

• Oil and chemical resistance options

• UV resistance options

• Suitable performance for industrial environments

TYPICAL AVAILABLE CONDUCTOR SIZES

Custom conductor sizes and constructions are available subject to engineering requirements.

TYPICAL CABLE CONFIGURATIONS

Common configurations may include:

• 1/C 5000V

• 3/C 5000V

• 3/C + Ground

• 3/C + Metallic Grounding Components

• Shielded single-conductor construction

• Shielded three-conductor construction

The final conductor arrangement, metallic shielding, grounding components, armour dimensions, and jacket thickness depend on the specified cable design.

ELECTRICAL CHARACTERISTICS

Electrical characteristics such as DC resistance, AC impedance, capacitance, inductance, ampacity, and short-circuit current rating shall be determined according to conductor size, cable configuration, installation conditions, shielding design, and applicable standards.

THERMAL PERFORMANCE

The XLPE insulation system provides a typical maximum continuous conductor operating temperature of:

90°C

Typical temperature characteristics:

• Continuous operation: 90°C maximum

• Emergency overload: subject to applicable standard and cable design

• Short-circuit temperature: subject to applicable standard and conductor/shield construction

Actual emergency and short-circuit ratings shall be confirmed from the final engineered cable design.

MECHANICAL PERFORMANCE

The aluminum interlocked armour provides enhanced mechanical protection against:

• Impact

• Crushing

• Abrasion

• Installation damage

• Mechanical stress

• Industrial handling conditions

The AIA construction provides a useful balance between mechanical protection and cable weight, making it suitable for installations where cable handling and installation efficiency are important.

ENVIRONMENTAL PERFORMANCE

Depending on the selected jacket compound and cable construction, the cable may be designed for:

• Wet locations

• Dry locations

• Underground installations

• Cable trays

• Industrial facilities

• Outdoor installations

• UV-exposed environments

• Oil-resistant environments

• Chemical-resistant environments

Environmental performance should be confirmed according to the selected jacket material and project requirements.

INSTALLATION

CU TECK90 5000V (AIA) should be installed by qualified personnel in accordance with applicable electrical codes, cable manufacturer requirements, and project specifications.

Important installation considerations include:

• Observe the minimum bending radius.

• Avoid excessive pulling tension.

• Use suitable cable pulling equipment.

• Maintain the designed shielding and grounding system.

• Use approved medium-voltage termination kits.

• Use compatible stress-control components.

• Properly terminate metallic shields and armour.

• Use connectors and lugs rated for copper conductors.

• Follow specified torque requirements.

• Verify phase identification before energization.

• Perform required insulation and withstand testing before commissioning.

KEY FEATURES

• 5000V medium-voltage rating

• Stranded annealed copper conductors

• XLPE thermoset insulation

• Semiconductive conductor shield

• Semiconductive insulation shield

• Metallic shielding system

• Aluminum interlocked armour

• Durable outer jacket

• High electrical conductivity

• Excellent thermal performance

• Strong mechanical protection

• Reduced weight compared with steel-armoured alternatives

• Suitable for demanding industrial environments

PRODUCT ADVANTAGES

High Electrical Conductivity

Copper conductors provide excellent electrical conductivity and efficient power transmission, making the cable suitable for demanding medium-voltage applications.

Reliable Medium-Voltage Insulation

The XLPE insulation system provides high dielectric performance, thermal stability, and long-term electrical reliability.

Controlled Electric Field

Semiconductive conductor and insulation shields help provide controlled electric-field distribution around the primary insulation.

Lightweight Armouring

Aluminum interlocked armour provides mechanical protection while generally offering lower weight than equivalent steel-armoured constructions.

Heavy-Duty Industrial Design

The combination of copper conductors, XLPE insulation, metallic shielding, AIA armour, and protective outer jacket provides a robust solution for demanding power-distribution systems.

QUALITY CONTROL

Typical quality-control procedures may include:

• Conductor resistance testing

• Conductor dimensional inspection

• Insulation dimensional inspection

• Insulation electrical testing

• Shield continuity testing

• High-voltage testing

• Partial-discharge testing where specified

• Metallic shield inspection

• Armour dimensional inspection

• Jacket thickness inspection

• Jacket electrical testing

• Finished cable dimensional inspection

• Final visual inspection

Routine and type tests shall be performed according to the applicable cable standard and customer specification.

PACKAGING

Cable may be supplied on:

• Wooden drums

• Steel-wood drums

• Heavy-duty export drums

• Custom reel configurations

Packaging can be selected according to cable diameter, shipping method, project length, container requirements, and installation requirements.

Typical supply options include:

• Standard production lengths

• Project-specific lengths

• Custom drum lengths

• Export packaging

CUSTOMIZATION

The cable can be engineered according to project requirements, including:

• Conductor size

• Number of conductors

• Copper conductor construction

• Insulation thickness

• Shielding configuration

• Metallic shield cross-section

• Armour material

• Armour dimensions

• Jacket material

• Jacket color

• Oil resistance

• UV resistance

• Flame-retardant requirements

• Special environmental requirements

• Custom drum length

TECHNICAL SUPPORT

For project applications, the following technical information can be provided upon request:

• Cable construction drawings

• Dimensional data

• Conductor resistance

• Cable weight

• Overall diameter

• Ampacity data

• Short-circuit ratings

• Shielding specifications

• Armour specifications

• Minimum bending radius

• Pulling tension recommendations

• Electrical test reports

• Routine test documentation

• Project-specific technical datasheets

FAQ

What is CU TECK90 5000V (AIA)?

CU TECK90 5000V (AIA) is a 5000V medium-voltage copper armoured power cable featuring XLPE insulation, metallic shielding, and aluminum interlocked armour for industrial power distribution.

What does AIA mean?

AIA stands for Aluminum Interlocked Armour. It refers to an interlocked aluminum armour layer installed around the cable assembly to provide mechanical protection while helping reduce overall cable weight.

What is the difference between AIA and GSIA?

AIA uses aluminum interlocked armour and generally provides a lighter cable construction with good corrosion resistance. GSIA uses galvanized steel interlocked armour and generally provides greater mechanical strength, impact resistance, and crush protection.

What insulation is used?

The primary insulation is typically cross-linked polyethylene (XLPE), a thermoset insulation material commonly used for medium-voltage power cables.

What is the typical conductor operating temperature?

The XLPE insulation system is typically designed for a maximum continuous conductor operating temperature of 90°C, subject to the final cable construction and applicable standard.

Is the cable suitable for underground installation?

It may be suitable for underground installation where permitted by the applicable cable construction, installation code, environmental conditions, and project specification.

Is the cable suitable for mining applications?

Yes. The combination of copper conductors, XLPE insulation, metallic shielding, aluminum interlocked armour, and protective jacket can make the cable suitable for selected mining and mineral-processing applications, subject to the specific project requirements.

Can the cable be supplied in different conductor sizes?

Yes. A wide range of copper conductor sizes can be manufactured according to electrical load, voltage-drop requirements, short-circuit requirements, installation conditions, and project specifications.

Can the shielding system be customized?

Yes. Metallic shielding can be configured according to grounding requirements, fault-current capacity, electrical design, and applicable standards.

Is AIA suitable for outdoor installations?

AIA can be used in many outdoor industrial applications when combined with an appropriate outer jacket and when the complete cable construction is suitable for the environmental conditions.

Can the cable be supplied with a flame-retardant or low-smoke jacket?

Yes. Specialized jacket compounds and additional performance requirements can be considered according to the applicable project specification.

What information is required for cable selection?

Typical selection information includes rated voltage, conductor size, number of cores, load current, installation method, ambient temperature, burial depth, grounding system, short-circuit requirements, environmental conditions, and applicable standards.

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CU TECK90 5000V AIA Copper Armoured Medium Voltage Power Cable

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CU TECK90 5000V (AIA) is a medium-voltage copper armoured power cable featuring stranded copper conductors, XLPE insulation, metallic shielding, and aluminum interlocked armour for demanding industrial power distribution applications.

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