CU TECK90 5000V (GSIA)

5kV Copper Armoured Power Cable with Galvanized Steel Interlocked Armour

PRODUCT DESCRIPTION

CU TECK90 5000V (GSIA) is a heavy-duty medium-voltage copper armoured power cable designed for industrial power distribution systems requiring high electrical reliability and enhanced mechanical protection.

The cable features stranded annealed copper conductors, a high-performance XLPE insulation system, semiconductive conductor and insulation shields, a metallic shielding system, galvanized steel interlocked armour (GSIA), and a durable protective outer jacket.

The 5000V voltage rating makes the cable suitable for selected medium-voltage power distribution applications, while the galvanized steel interlocked armour provides high resistance to impact, crushing, abrasion, and mechanical installation stresses.

The cable is particularly suitable for demanding industrial, mining, petrochemical, utility, power-generation, and infrastructure applications where robust mechanical protection is required.

Final cable construction, dimensions, shielding configuration, ampacity, short-circuit rating, 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

• Manufacturing facilities

• Industrial cable trays

• Underground installations where permitted

• Outdoor industrial installations

• Heavy-duty exposed installations

• Infrastructure and utility projects

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 current-carrying capability

• Good flexibility for large power cables

• Suitable for medium-voltage power transmission and distribution

2. Conductor Shield

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

The shield helps maintain a uniform electric field and reduce electrical stress at the conductor-insulation interface.

3. Primary Insulation

• Material: Cross-linked polyethylene (XLPE)

• Type: Thermoset insulation

• Voltage class: 5000V

• Typical maximum continuous conductor operating temperature: 90°C

• High dielectric strength

• Low moisture absorption

• Excellent thermal stability

• Good resistance to electrical aging

4. Insulation Shield

A semiconductive insulation shield is applied over the XLPE insulation to control the electric field surrounding the conductor insulation system.

The insulation shield forms an important part of the medium-voltage insulation system and provides a controlled interface with the metallic shielding layer.

5. Metallic Shield

A metallic shielding system is incorporated around the insulation shield.

Depending on the cable design and project requirements, typical configurations may include:

• Copper tape shield

• Copper wire shield

• Copper tape and wire combination

• Concentric metallic shielding

• Other approved metallic shielding arrangements

The metallic shield may be designed to provide grounding continuity and carry the required fault current according to the cable design.

6. Galvanized Steel Interlocked Armour (GSIA)

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

GSIA provides enhanced:

• Mechanical strength

• Impact resistance

• Crush resistance

• Abrasion resistance

• Installation protection

• Structural protection

• Resistance to mechanical deformation

• Protection against external physical damage

The galvanized steel construction provides additional corrosion resistance compared with untreated steel and is particularly useful for demanding industrial installations.

7. Outer Jacket

A durable thermoplastic outer jacket is applied over the armoured cable 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

• UV resistance options

• Oil resistance options

• Chemical resistance options

• Industrial environmental protection

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 galvanized steel interlocked armour provides a high level of mechanical protection against:

• Impact

• Crushing

• Abrasion

• External mechanical forces

• Installation damage

• Cable handling stress

• Mechanical deformation

• Industrial operating conditions

Compared with aluminum interlocked armour, GSIA generally provides greater mechanical strength and structural protection, making it suitable for installations where physical protection is a major design consideration.

ENVIRONMENTAL PERFORMANCE

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

• Wet locations

• Dry locations

• Underground installations

• Cable tray installations

• Outdoor installations

• UV-exposed environments

• Industrial facilities

• Mining environments

• Oil and gas facilities

• Chemical processing areas

Environmental performance should be confirmed according to the selected jacket material and complete cable construction.

INSTALLATION

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

Important installation considerations include:

• Observe the specified minimum bending radius.

• Avoid excessive pulling tension.

• Use suitable cable pulling equipment.

• Prevent damage to the outer jacket and armour.

• Maintain shielding and grounding continuity.

• Use approved medium-voltage termination systems.

• Use compatible stress-control components.

• Properly terminate metallic shields and armour.

• Use copper-rated connectors and lugs.

• Follow specified torque requirements.

• Verify phase identification before energization.

• Perform required electrical 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

• Galvanized steel interlocked armour

• High mechanical strength

• High impact and crush resistance

• Excellent abrasion resistance

• Durable protective outer jacket

• High electrical conductivity

• 90°C typical continuous conductor operating temperature

• Suitable for demanding industrial environments

PRODUCT ADVANTAGES

High Mechanical Protection

GSIA provides strong protection against impact, crushing, abrasion, and external mechanical forces, making the cable suitable for demanding industrial environments.

Reliable Medium-Voltage Insulation

XLPE insulation provides high dielectric strength, thermal stability, low moisture absorption, and reliable long-term electrical performance.

Controlled Electric Field

Semiconductive conductor and insulation shields provide controlled electric-field distribution within the medium-voltage insulation system.

Galvanized Steel Armour

The galvanized steel armour combines high mechanical strength with enhanced resistance to corrosion compared with uncoated steel.

Heavy-Duty Industrial Construction

The combination of copper conductors, XLPE insulation, metallic shielding, GSIA armour, and protective outer jacket creates a robust solution for demanding medium-voltage power 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

• Armour continuity 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, cable weight, shipping method, container requirements, and project 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 (GSIA)?

CU TECK90 5000V (GSIA) is a 5000V medium-voltage copper armoured power cable featuring stranded copper conductors, XLPE insulation, metallic shielding, and galvanized steel interlocked armour.

What does GSIA mean?

GSIA stands for Galvanized Steel Interlocked Armour. It is a mechanically interlocked galvanized steel armour system designed to provide strong protection against impact, crushing, abrasion, and other physical stresses.

What is the difference between GSIA and AIA?

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

Why choose GSIA for industrial applications?

GSIA is particularly useful where the cable may be exposed to significant mechanical stress, impact, crushing, abrasion, or demanding installation conditions.

What insulation is used?

The primary insulation is typically cross-linked polyethylene (XLPE), a thermoset insulation material widely 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 mining applications?

Yes. GSIA construction can be particularly suitable for selected mining and mineral-processing applications where enhanced mechanical protection is required, subject to the project specification and applicable regulations.

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.

Can the cable be supplied with different shielding systems?

Yes. Metallic shielding can be engineered according to grounding requirements, fault-current capacity, installation conditions, and applicable standards.

Can the outer jacket be customized?

Yes. Jacket materials can be selected according to requirements such as UV resistance, oil resistance, flame retardancy, chemical resistance, and other environmental performance requirements.

Can different conductor sizes be supplied?

Yes. Conductor sizes can be selected according to load current, voltage drop, short-circuit requirements, installation method, and project specifications.

What information is required for cable selection?

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

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