Use of Calculated Pulling Tensions

Calculations should be made to indicate whether the pull looks easy or impossible, making the decision to pull an obvious choice. When a marginal situation is encountered, the entire pull should be reviewed. This review may include more rigorous calculations or trial pulls. A final decision should be made based on installation factors known to the end user and installer. The sizes of the conduit are determined based on the calculations of the clearances, jamming, and fill. Pulling tensions may then be evaluated by determining the maximum tension based on the pulling device used and the maximum tension that can be applied to the conductors. The lesser of these two values is the maximum allowable tension (Tm). The pulling tension (T) required to pull the cable through the conduit is then calculated and compared to the maximum allowable tension. If the pulling tension exceeds the allowable tension or sidewall pressure, then conditions should be changed to ensure a successful pull.

How to enter a cable pull into the calculator. First, enter the wires going in the conduit. Next, enter the conduit type and size. Example: 3/C SIMpull CU THHN Size 350, with a 4/0 SIMpull THHN ground wire: in GRC (Galv Rigid Conduit) size 3''. It is assumed that it takes approx. 25 lbs of force to pull the wire off the reel. Thus, incoming tension is set at 25 lb and can be changed if needed. A cable pull is divided into segments. A segment is the length of straight section of the pipe and the details of the bend or elbow. IE. Segment 1 beginning of conduit to the end of the first bend. Segment 2 start of second straight section to the end of the second bend. Last segment will always be the straight section info and no bend section info. A segment has two parts that needs to be captured. The straight section and the bend section. The straight section consists of three elements: 1. The Angle (Slope) in degrees. Zero degrees (left blank)is horizontal. 90 degrees could be straight up or straight down, . 2. Wire is being pulled; Up, Down or HZTL (horizontal). 3. The segment length; is from the beginning of straight section to the end of bend. Example of the straight section: 90 degrees up for 14'. Enter as; Angle (Slope) = 90; Wire is being pulled = UP: Length ft. = 14. Note A horizontally straight section for 30' would be . Entered as; Angle (Slope) = (blank); Wire is being pulled = HZTL; Length ft. = 30. The bend section consists of four elements: 1. The bend type; the direction of the bend / elbow is turning? VCDN = Vertical concave turning down VCUP = Vertical concave turning up HZTL = Horizontal 2. Up, Down or N/A : how the wire enters the vertical part of the bend? Wire is going UP through the bend, Down through the bend, or N/A (horizontally). 3. The degree of the elbow or bend. 90 = 90 degree elbow 4. The radius of the elbow. STD = standard radius 18 = 18'' sweep radius,
Bend is going down, the wire is going up to the bend, in a 90 degree elbow, with a standard radius.

Enter as: bend type = VCDN; Up, Down, N/A = UP; Angle = 90, Radius = std. This first segment will show Tension of 115 lb. and Sidewall Pressure of 74 lb.

Product sheets for: SIMpull CU THHN THWN-2 SIMpull CU XHHW-2 CU USE RHH RHW-2 SIMpull Aluminun THHN THWN-2 AL XHHW-2 AL USE RHH RHW-2 Southwire's complete Catalog Maxis Tools Catalog

Copy and paste the URL address below to your internet browser http://www.southwire.com/ProductCatalog/XTEInterfaceServlet?contentKey=prodcatsheet276 http://www.southwire.com/ProductCatalog/XTEInterfaceServlet?contentKey=prodcatsheet5 http://www.southwire.com/ProductCatalog/XTEInterfaceServlet?contentKey=prodcatsheet7 http://www.southwire.com/ProductCatalog/XTEInterfaceServlet?contentKey=prodcatsheet327 http://www.southwire.com/ProductCatalog/XTEInterfaceServlet?contentKey=prodcatsheet3 http://www.southwire.com/ProductCatalog/XTEInterfaceServlet?contentKey=prodcatsheet12 http://www.southwire.com/processChannel.do?channelId=2dd91dc51235df00VgnVCM1000004c026564RCRD http://www.maxis-tools.com

Wire pull with 6 90's, 2 60's and elevation changes

533' of 3/C 350 and 1/C 4/0 SIMpull CU THHN In 3" Galvanized Rigid Conduit

Cable Pull Comparison using different Conductors

Total wt./ ft Configuration 4.233 Complex

COF 0.14
Recommended

COF 0.35
Not Recommended

COF 0.14
Recommended

COF 0.35
Not Recommended

Wt.correction factor 1.40 COF Incoming tension 0.14 25

SIMpull CU THHN No Lube Required Colored wires

Regular CU THHN Lube Required Black with phase tape

SIMpull AL THHN AL XHHW No Lube Lube Required Required Colored Black with phase wires tape

Wire pull / Segment

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Straight Section Angle (slope / degrees) 90

Bend Section Wire is being Segment Bend pulled .. Length Ft. Type UP HZTL HZTL HZTL 6 10 1 250 90 15 106 35 20 VCDN HZTL HZTL HZTL VCUP VCDN HZTL VCDN

Bend Section Up, Down, N/A UP N/A N/A N/A UP UP N/A Down

Bend Section Angle (elbow / degrees) 90 60 60 90 90 90 90 90

Bend Section Radius (in.) STD STD STD STD STD STD 18 24

tension sidewall pres. (lbs.) (lbs.) 69 94 117 441 707 1,041 1,536 2,130 2,040 44 61 76 286 455 675 785 797 797

tension (lbs.) 109 216 365 1,908 4,522 9,900 21,850 47,334 47,249

sidewall pres. sidewall pres. (lbs.) (lbs.) 71 140 237 1,236 2,931 6,417 11,164 17,718 17,718 35 47 58 184 288 425 491 498 498

sidewall pres. (lbs.) 55 105 176 789 1,850 4,044 7,021 11,138 11,138

90

HZTL UP HZTL HZTL Down

90

Total Feet

533 Desired Ampacity: 1200 amps Configuration: 4 sets of 3/C 350 & 4/0 GW Conduit: 3" Galv Rigid (23% fill) Maximum pulling force: 8074 lb. Maximum sidewall pressure: 1000 lb. Short Circuit Current @ 8 cycles: 50,712 amps

Comparison 1 1200 amps

4 sets of 3/C 350 & 4/0 GW 3" Galv Rigid (23% fill)

Comparison 2 1200 amps

4 sets of 500 & 350 GW 3" Galv Rigid (30% fill)

Comparison 3 1200 amps

4 sets of 500 & 350 GW 3" Galv Rigid (30% fill)

8074 lb. 500 lb. 50,712 amps

8880 1000 lb. 47, 384 amps

8880 500 lb. 64,365 amps

Conduit system is assumed to be clean and free of debris.

Southwire Engineering conservative Coefficient Of Friction (COF) .35 for regular THHN THWN, XHHW and USE that requires lube .16 for SIMpull XHHW that requires no lube

.14 for SIMpull THHN THWN that requires no lube

Straight Line Drawing for calculating a cable pull

Purple Areas = Input is mandatory for doing a cable pull calculation. What wire are you pulling into your raceway: number of wires, size and metal type, Insulation type, GW same info. (Example: 4/C 350 CU SIMpull THHN & 1 /C of 1/0 CU THHN GW) (Example: 1/C 350 CU 420 mil 35kV with a SIMpull PVC Jkt) What type and size of Raceway are you using. If using PVC indentify if it is schedule 40 or schedule 80. (Example: 3" Sch 40) If using Cable Tray you will need to know your radius (inches) of bend sections.

Segment # (Reel set-up to the end of the 1st bend is segment # 1, segment 2 goes from the end of # 1 to the end of the 2nd bend, and on to the end of the p Pull #1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Angle / (slope) of the pull Straight Section Bend Section Directio n Wire is being pulled : (Up, Down, Hztl) Length (Ft.) through the end of elbow Degree of Elbow Radius / bend (in.) (Standar d or Other)

Yellow = input is optional, but assumed to be ... Angel / (slope) automatically populates as 90 degrees when you select "up" or "down". Or you can select other degrees if you wish.

Radius of Elbow or bend automatically populates as "standard". Or you can select specific sweeps or enter a unique bend raduis if you w

you wish.

1 1

Copyright Southwire Company 2009. All rights reserved. See terms and conditions.

Enter Voltage Drop Info in purple areas

Amperage @ load (one set ) System Voltage Circuit Length

SIMpull CU THHN Single Phase

Three Phase

Phase Wire Attributes

0
Attributes can change based on wire type, size and Mfg 0 Acceptable Megger Readings Dielectric Constant (SIC) Max Oper Temp for Dry Use Max Oper Temp for Wet Use Min Bend Radius (in.) Min Installation Temp Vertically Support every

0 120 0 0.0% 120.00

http://budurl.com/SimpullCalrw (28 Minutes)

480 0 0.0% 480.00

0 0 0 0 0 0 0 0 0 0 0 0 0 0
Stranding

Enter wire info in purple areas that will go into the raceway
# of wires Phase Wires Neutral Wire Ground Wire Total Cables 0 Wire Type Wire Size
1 1 1

Wire OD

Wire Wt/ ft.

1 SIMpull CU THHN 1 SIMpull CU THHN 1 SIMpull CU THHN

0.000 0.000 0.000

0.00 0.00 0.00

Voltage Drop % Volts at Load

Power Factor for Voltage Drop is: 0.80

Cable Pull Calculated Values

Maximum Pulling Force (lb.) Max Sidewall Pres. (lb.) Jam Probability 0 0 0.00

Riser MC Requires No Vertical Supports Sunlight Resistant CT Rated UL NEMA RoHS Compliant 75 C Ampacity (310.16) 90 C ampacity (310.16) Coefficient Of Friction 0

15

CU 4/0 CU AL 350 AL

Very Small

GW sizing (NEC 250.122) w/o VD considerations

1600 amps

Phase Wire Ampacity Considerations

Short Circuit Current (amps) Adjust for Ambient Temp Adjust for # of Current

Enter raceway info in purple areas

Raceway Type Raceway Size
1

0 4 4 cycles / .0667 0 2 26-30C (78-86F)

1/2

Min Conduit Maxis Size Grip

#N/A Min size conduit using 4 grips & jacket

Conduit ID % Conduit Fill

0.622 0.0%

Carrying Conductors Max Allowable Ampacity for this Scenario 2011 NEC 310.15 (B) (16)

1-3

Copy this url address to get Southwire's most current calc =

http://www.southwire.com/support/SIMpullCablePullCalculator.htm

SIMpull Cable Pull Calculator for 600V 3.6

Yellow areas = you have the ability to change data. Purple areas = input required.
Total wt./ ft Configuration Wt.correction factor COF Incoming tension 0.000
4

0' of In 0.5" EMT

0 COF 0 Recommended SIMpull CU THHN No Lube Required Max Sidewall Pres. (lb.) 0 Jam Probability Very Small

1.40 0.00 25

Maximum Pulling Force (lb.)

Notes:

Straight Section Angle (Slope) Wire is being pulled Segment Length ft. Bend Type

Bend Section
Up, Down, Degree of elbow N/A

Colored wires continious tension (lbs.) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 sidewall pressure (lbs.) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Begin new pull in this segment

Wire pull / Segment 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Radius (in.)

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4

Total Length

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Southwire / Maxis recommended wire pulling equipment.

1. Southwire factory installed SIMpull Heads for pre-cut paralleled reels 2. Minumum size cable puller and maximum rope size Maxis 3K has a maximum pulling force of 3,000 lb. and pulls Continious Tensions up to 2,000lb. Use a 9/16 inch rope. Maxis 6K has a maximum pulling force of 6,000 lb. and pulls Continious Tensions up to 4,500lb. Use a 5/8 inch rope. Maxis 10K has a maximum pulling force of 10,000 lb. and pulls Continious Tensions up to 8,500lb. Use a 7/8 inch rope.

http://www.maxis-tools.com/

Conduit system is assumed to be clean and free of debris.

Southwire Engineering conservative Coefficient Of Friction (COF) .35 for regular THHN THWN, XHHW and USE; all requiring lube as recommended .16 for SIMpull XHHW that requires no lube .14 for SIMpull THHN THWN that requires no lube

#DIV/0! Determines Unique Bend Radius

Unique Bend Radius

enter as FEET UBR # 1 = 0.0 UBR # 2 = 0.0 UBR # 3 = 0.0 UBR # 4 = 0.0

Unique Bend Degree Enter as Degree 0 0 0 0

Unique Angle (Slope)

Degree of bend Distance of bend (Ft.)

Bend Radius (Ft.) is =

0 0 0

Enter as degree(s) Angle # 1 = 0 Angle # 2 = 0 Angle # 3 = 0 Angle # 4 = 0

Note: Rollers or sheaves are found in drop down of "Radius (in.)" Example; a 12" diameter roller is 6" RR" (radius roller)

0' of In 0.5" EMT

SIMpull Cable Pull Comparison using different Conductors

Total wt./ ft Configuration 0.000 COMPLEX

COF 0
Recommended

COF .35
Not Recommended

COF .14
Recommended

COF .35
Not Recommended

Wt.correction factor 1.40 COF Incoming tension 0.00 25

SIMpull CU THHN No Lube Required Colored Wires

CU THHN Lube Required Black with phase tape

SIMpull AL THHN No Lube Required Colored Wires

AL XHHW Lube Required Black with phase tape

Wire pull / Segment

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Straight Section Angle (slope / degrees)

Bend Section Wire is being Segment Bend pulled .. Length Ft. Type

Bend Section Up, Down, N/A

Bend Section Angle (elbow / degrees)

Bend Section Radius (in.)

tension (lbs.)

sidewall pres. (lbs.)

tension (lbs.)

sidewall pres. (lbs.)

sidewall pres. (lbs.)

sidewall pres. (lbs.)

Total Feet

0 Configuration: NEC Minumum SizeConduit: Maximum pulling force: Maximum sidewall pressure: Short Circuit Current @ 8 cycles: /C 0 & 0 GW
#N/A

Comparison 1 /C 0 & 0 GW
#N/A

Comparison 2 /C 0 & 0 GW
#N/A

Comparison 3 /C 0 & 0 GW
#N/A

0 lb. 0 lb. 0 amps

0 lb. 500 lb. 0 amps

0 lb. 0 lb. 0 amps

0 lb. 0 lb. 0 amps

Conduit system is assumed to be clean and free of debris.

Southwire Engineering conservative Coefficient Of Friction (COF) .35 for regular THHN THWN, XHHW and USE that requires lube .16 for SIMpull XHHW that requires no lube

.14 for SIMpull THHN THWN that requires no lube

Maximum Pulling Force (lb.)

Max Sidewall Pres. (lb.) ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ###

1 1

Copyright Southwire Company 2009. All rights reserved. See terms and conditions.

Phase wire / cable information Product Sheet (URL address) Southwire stock #
http://www.southwire.com/ProductCatalog/XTEInterfaceServlet?contentKey=prodcatsheet166

Southwire Product Type RHH or RHW/CT GW in the cable Armor Jacket

1

Enter wire info in purple areas that will go into the raceway
# of cables Phase Conductor Ground Wire Total Cables 0
1.000 1

Wire Size

CU or AL
1

Cable Conductor Count

Voltage/ Ins Level / Shield

OD

WT/ Ft.

NEC Ampacity Tables Duct 90C NEC 310.16 In Cable Tray Free Air NEC 392.11 CT Rated Maximum reel length (feet) Reel Size = Diameter X Width (inches) Approx. gross wt (lb.) for max length

AMPS

1 1 /1.000 CU C SIMpull1 CU THHN

1 No 600V RHH RHW USE (XLP) 1 No

0.000

0.000 0.000

0 0 0

GW sizing (NEC 250.122) w/o VD considerations

CU 4/0 1600 amps CU

15

Enter raceway info in purple areas

Raceway Type Raceway Size Conduit ID % Conduit Fill

You can possibly eliminate splices and vaults when ordering wire with a SIMpull PVC Jacket and No Lube will be necessary for installation. Use a COF of .20 SIMpull PVC Jacket in conduit

Conductor Short Circuit Rating (Amps) Shield Short Circuit Rating (Amps) High Potential Testing per Table 4 of IEEE N/A standard 400 Min bend radius of cable (inches) Coefficient of Friction (COF) in conduit

2 cycles / .0333 sec. 2

for 0.0333 sec

1/2
1

Min Conduit #N/A

0.622 0.0%

0.35

Min installation temp - 40C (-40F)

SIMpull Cable Pull Calculator for Power Cable 3.6

Yellow areas = you have the ability to change data. Purple areas = input required.
Total wt./ ft Configuration Wt.correction factor COF Incoming tension
4

0' of 0 cable(s) 0 CU 1 / C 600V RHH RHW USE (XLP) Non Armored Non Jacketed In 0.5" EMT
Maximum Pulling Force (lb.) 0 Max Sidewall Pres. (lb.) 500 Jam Probability Very Small

0.000

1.40 0.35 25

COF 0.35 Recommended

Notes:

Straight Section Angle (Slope) Wire is being pulled Segment Length ft. Bend Type

Bend Section
Up, Down, Degree of elbow Radius N/A Continious 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Sidewall Pressure (lb.) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Begin new pull in this segment

Wire pull / Segment

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

(in.) Tensions (lb.)

1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 0

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Southwire / Maxis recommended wire pulling equipment.

1. Southwire factory installed SIMpull Heads for pre-cut paralleled reels 2. Minumum size cable puller and maximium rope size
Continious Tensions up to 2,000lb. Continious Tensions up to 4,500lb.

Maxis 3K has a maximum pulling force of 3,000 lb. and pulls Use a 9/16 inch rope. Maxis 6K has a maximium pulling force of 6,000 lb. and pulls Use a 5/8 inch rope. Maxis 10K has a maximium pulling force of 10,000 lb. and pulls Use a 7/8 inch rope.

http://www.maxis-tools.com/

Continious Tensions up to 8,500lb.

Unique Bend Radius

enter as feet 0.0 UBR # 1 = UBR # 2 = UBR # 3 = UBR # 4 = 0.0 0.0 0.0

Unique Degree of Bend

enter as degree of bend

Total Length

Degree = Degree = Degree = Degree = Determines Unique Bend Radius

Degree of bend = 0 Distance (Ft.) of bend = 0

0 0 0 0

Conduit system is assumed to be clean and free of debris.

Note: Rollers or sheaves are found in drop down of "Radius (in.)" Example; a 12" diameter roller is 6" RR (radius roller)

Unique Angle (Slope) enter as degree of angle

Angle # 1 = Angle # 2 = 0 0

Angle # 3 = Angle # 4 =

0 0

Unique Bend Radius (Ft.) is = 0

#DIV/0!

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

0' of 0 cable(s) 0 CU 1 / C 600V RHH RHW USE (XLP) Non Armored Non Jacketed In 0.5" EMT

SIMpull Cable Pull Comparison using different Conductors of 1/C MV ONLY

Configuration Wt.correction factor COF for SIMpull Incoming tension 25 1.40

COF 0.35
Recommended

COF .35
Not Recommended

COF .20
Highly Recommended

1 / C CU with SIMpull Jkt No Lube needed

1 / C CU with standard PVC Jkt Lube required

1 / C N/A Aluminum with SIMpull Jkt No Lube needed

Maximum Pulling Force (lb.)

Wire pull / Segment

Straight Section Angle (slope / degrees)

Wire is being pulled ..

Segment Length Ft.

Bend Section Bend Type

Bend Section Up, Down, N/A

Bend Section Angle Bend (elbow / Section degrees) Radius (in.)

Total Feet

0 Maximium pulling tension (lb.)

tension sidewall pres. (lbs.) (lbs.) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Comparison 1 0

tension

(lbs.)

sidewall pres. (lbs.)

tension (lbs.)

sidewall pres. (lbs.)

Max Sidewall Pres. (lb.) ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ###

Comparison 2 0

Comparison 3 #N/A
Note: You may need a different AL size conductor than what has been selected above. The values above are based on the same size conduit you chose for option # 1, which may be too small per NEC for this Al size conductor.

Conduit system is assumed to be clean and free of debris.

Southwire Engineering conservative Coefficient Of Friction (COF) .35 for regular PVC that requires lube .20 for SIMpull PVC that requires no lube