Engineering Specification Electrical Networks MESP 130400-04 TECHNICAL SPECIFICATION FOR BARE FLEXIBLE ANNEALED COPPER JUMPER WIRE 37/7/0.70 100mm 2 Version: 2 Issued: February 2016 Owner: Engineering Division Approved By: Andrew Russack Head of Engineering (Electrical) PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION
Approval Amendment Record Approval Date Version Description 09/11/2015 1 Initial issue 25/02/2016 2 Elongation average requirement corrected from 25% to 18%. Resistance and masses in table corrected. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 2 of 7
Table of Contents 1. Purpose... 4 2. Scope... 4 3. Abbreviations... 4 4. Definition... 4 5. References & Legislations... 4 6. Material... 5 7. Conductor Characteristics... 5 8. Lay... 5 9. Dimensions... 5 10. Production Test Requirements... 6 11. Quality Assurance... 6 12. Warranty... 6 13. Packing... 6 PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 3 of 7
1. Purpose This document details the specification of 100 mm² bare flexible annealed copper jumper wire for use in the Melbourne Metropolitan Overhead Wiring System. 2. Scope The scope comprises the manufacture, testing and supply of 100 mm² bare flexible annealed copper jumper wire. 3. Abbreviations NA 4. Definition Lay Ratio The ratio of the lay length to the external diameter of the corresponding layer of wires 5. References & Legislations AS 1391:2007 AS 2193:2005 AS 2738:2000 AS 3822:2002 AS/NZS 1125:2001 AS/NZS 1574:1996 Metallic Materials Tensile Testing at Ambient Temperature Calibration and Classification of Force Measuring Systems Copper and Copper Alloys - Compositions and Designations of Refinery Products, Wrought Products, Ingots and Castings Test Methods for Bare Overhead Conductors Conductors in Insulated Electric Cables and Flexible Cords Copper and Copper Alloys - Wire for Electrical Purposes AS/NZS 2857:1996 AS/NZS ISO 9001 Timber Drums for Insulated Electric Cables and Bare Conductors Quality Management Systems - Requirements PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 4 of 7
6. Material a. The chemical composition of the material used for the solid conductor shall conform to AS 2738:2000 alloy designation C11000 (annealed copper). b. The maximum resistivity at 20 C is 0.017 241 µω.m (equivalent to a conductivity of 100% IACS). c. The wire shall be clean, smooth and free from all defects detrimental to its subsequent processing and end use. d. There shall be no joints in the wire. e. The wire density at 20 C shall be 8,890 kg/m³ plus or minus 3%. f. The minimum average elongation of the wire when tested with a gauge length of 200 to 250 mm shall be not less than 18%. g. The coefficient of linear expansion is taken as 17x10-6 per C. 7. Conductor Characteristics Strand Dia. (mm) Cross-sectional area (mm²) Mass/km (kg) DC resistance/km @ 20 C (ohms) 0.7 (nom) 100 943 0.183 5 0.69 (-1%) 97.7 921 0.188 9 8. Lay Lay ratio and direction of the layers shall be: Primary bunch: 21.5 nom Right-hand lay 6-wire layer: 10.8 nom Left-hand lay 12-wire layer: 11.0 nom Right-hand lay 18-wire layer: 10.3 nom Left-hand lay 9. Dimensions Wire size and tolerances shall be in accordance with AS/NZS 1125:2001. For a 37/7/0.7 nominal conductor of 100 mm² nominal cross-sectional area, the overall wire diameter shall be 14.3 mm +/- 1%. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 5 of 7
10. Production Test Requirements For the purposes of this specification the metallurgical tests shall be in accordance with AS/NZS 1574:1996. Mechanical and electrical tests shall be in accordance with AS 1574:1996 and AS 3822:2002. 11. Quality Assurance The Supplier should meet the requirements of AS/NZS ISO 9001. 12. Warranty The Supplier shall provide a Certificate of Conformance together with a full test report as stipulated in Production Test Requirements. 13. Packing a) The jumper wire shall be wound without twists, or kinks, on drums of approved design and of sufficient size to prevent sharp bends and shall be properly protected against damage in transit. b) Typically approved design is wooden drums lined with sisal-craft in general accordance with AS 2857 and the following Metro Trains Melbourne required dimensions: o Barrel diameter 500 mm minimum o Overall diameter 1000 mm maximum o Barrel width 550 mm maximum o Overall width 660 mm maximum A mild steel reinforcing plate 400 mm 2 by 6.4 mm thick shall be bolted to the middle of each side of the drum with a minimum of 6 bolts. An 83 mm square hole shall be provided in the drum and reinforcing plates to take a 76 mm spindle. The free ends of the wire shall be suitably treated to prevent de-stranding. The inner end of the conductor shall be passed through the drum flange to the outside and stapled securely. The outer end of the conductor shall be secured to the inside of the drum flange with staples and bent back on itself to prevent it from working loose. c) Metro Trains Melbourne shall specify the length of the conductor on each drum. d) The following information shall be legibly and indelibly marked on the flange of the drums or a label securely attached thereto: (i) (ii) Supplier s name Supplier s drum serial number (iii) The conductor material and size (annealed copper, jumper wire 37/7/0.7, 100mm 2 ) (iv) (v) Length of conductor Gross mass of conductor and drum PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 6 of 7
(vi) (vii) (viii) Handling or lifting instructions. The preferred method being by means of a spindle through the spindle holes and a spreader to prevent damage to the flanges An arrow with the words 'ROLL THIS WAY' to indicate the direction in which the drum should be rolled on the flanges The Metro Trains Melbourne contract number, order number and specification number e) Alternative equivalent or superior packing system may be submitted to Metro Trains Melbourne for consideration. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 7 of 7