Complete wiring systems and connection solutions

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Technical Information

All Metway Wiring System products are manufactured and tested in accordance with Metway’s BS EN ISO 9001: 2008 accreditation.

STANDARDS & APPROVALS

Connectors

The Metway range of 166 G type connectors comply with current European standards such as VDE,Kema, Nemko etc and UL approvals. In addition the 166 G type range also complies with:

 EN 60 320 (appliance couplers)
 EN 61 535 (installation couplers)
 EN 61984 (engaged & disengaged under load)
 VDE 0628 (installation systems)

CABLE SPECIFICATION

Multi-core XLPE/LSF/SWA/LSF power & control cable 600/1000v, in accordance with BS6724.

Conductors: stranded Class 2 copper conductors
Insulation: XLPE insulation type GP* to BS7655
Core Identification: numbered (multi-core)
Inner sheath:

 

LSF type LTS1 to BS7655 mild galvanised steel wires to BSEN10257-1
Outer sheath: black LSF type LTS1 to BS7655
Flame retardant: to BSEN50266-2-2 & IEC60332-3-22 Cat C as a minimum
Temp Rating 90º C max conductor operating temp.

 

Number
of cores
Nominal conductor
area (mm)
Insulation thickness
(mm)
Diameter under
armour (mm)
Armours wire
size (mm)
Nominal O/D Approx. weight
(kg/km)
Min. bending
radius
4-core 2.5mm 0.7mm 10.4mm 0.9mm 15.0mm 470kg 90mm
19-core 2.5mm 0.7mm 20.0mm 1.6mm 26.6mm 1530kg 160mm
27-core 2.5mm 0.7mm 23.9mm 1.6mm 30.7mm 1960kg 190mm
37-core 2.5mm 0.7mm 27.0mm 1.6mm 33.8mm 2370kg 210mm

CABLE SPECIFICATION

Single Core – 6491b
Manufactured to BS 7211

Nominal conductor
area (mm)
Conductor construction
(mm)
Mean overall
Dia. (mm)
Rating-Amps Resistance-
Ohms/Km @20º C
1.00mm 1x 1.13mm 2.35mm 14A 18.1
1.50mm 7x 0.53mm 3.00mm 18A 12.1
2.50mm 7x 0.67mm 3.60mm 24A 7.41
4.00mm 7x 0.85mm 4.10mm 33A 4.61

Test under fire conditions – to BS 4066 part 1
Corrosive acid gas emissions – 0.5% to BS 6425
Smoke emissions – to BS7211 appendix D
Insulation resistance K value 90º C – 0.037
Voltage test to 2.5Kv @20º C

For accurate information relating to cable ratings, volt drop, resistance etc, please refer to the IEE Wiring Regulations BS7671 – latest edition.

CABLE SPECIFICATION

Control & command cable HSLH/HSLCH 300/500v.

Conductors
flexible strand of bare copper wire to: class 5 VDE0295, CEI20-29 & IEC60228
Insulation
inner cores – LSOH low smoke zero halogen compound
outer sheath – LSOH low smoke zero halogen compound
Core identification
3-core – Brown, Green/Yellow, Blue
4-core – Brown, Green/Yellow, Blue, Black
5-core – Brown, Green/Yellow, Blue, White, Red
6-core – Brown, Green/Yellow, Blue, Black, White, Red

Number of cores Nominal conductor area (mm) Nominal O/D Rating – Amps
3-core 1.00mm 6.90mm 15A
4-core 1.00mm 7.80mm 15A
5-core 1.00mm 8.50mm 15A
6-core 1.00mm 9.20mm 15A
3-core 1.50mm 7.40mm 18A
4-core 1.50mm 8.10mm 18A
5-core 1.50mm 9.30mm 18A
6-core 1.50mm 10.10mm 18A

Combustion behaviour:

- no corrosive gases (low smoke emission) to: IEC60754-2/BS EN50267-2-2/BS6425 part
- zero halogen to: IEC60754-1 / BS EN50267-2-1/BS6425 part 1
(HCL hydrochloric acid emission <0.5%)

Fire behaviour:
- flame retardant to: self extinguishing IEC60332-1/BS EN 50265-2-1
- fire resistance to: IEC60332-3-24C / BS EN50266-2-4

Temp Range:
-150C to +700 C (fixed installation)

Bend Radius:
- 4 x outer diameter

Superflex Special Control Cable 1 x 2 x 1.5 x + 4 x 1.50

Construction
1.50mm 1-pair
Conductor
stranded bare copper wire 30/0.25mm
Insulation
halogen free compound (HI 2)
colours: white & orange
diameter: 2.40mm +/- 0.10mm
Twisting
2-cores to a pair lay
length: max. 37mm
Wrapping
polyester tape
Construction
1.50mm 4-core
Conductor
stranded bare copper wire 30/0.25mm
Insulation
halogen free compound (HI 2)
colours: blue, brown, black & green/yellow
diameter: 2.40mm +/- 0.10mm
Main laying
1-pair, 4-cores & cotton fillers
Wrapping
fleece foil
Sheath
halogen free compound (type 2)
colours: blue RAL 5015
diameter: 10.00mm +/- 0.30mm
Voltage
operating: 300 volts
test: 2000 volts
Printing
LSOH control cable 1 x 2 x 1.5 + 4 x 1.5 IEC 332.3 Cat-C
TECHNICAL DETAILS
Capacitance
86nF/KM
Resistance
12.9 Ohm
Rating
16A
Inducting
0.62 Mh/KM
Temperature rating
fixed Installation: -15º C to +70º C
flexible application: -5º C to +70º C

Testing

All Metway cable assemblies and manufactured products are checked for continuity, polarity, pull/torque tests and visual inspection prior to despatch.

On site

The following recommendations were compiled by a member of the ECA technical committee.

Method Statement

Electrical Testing of Wiring Systems (Lighting) Circuits Testing of an installation should be carried out as highlighted below and in accordance with the current edition of the IEE Wiring Regulations to BS7671.

Dead tests

(to be carried out before installation of Lighting Control Modules)

1. Carry out visual inspection of the following:

  1. circuit terminations against marked up record drawings (kept on site) and MCB chart
  2. all pre-fabricated wiring systems components to ensure no damage during installation
  3. distribution boards to check corrective protective devices are installed in accordance with the fuse chart

2. Ensure no open ends of wiring system

3. Using 500v insulation resistance / continuity tester, prove each circuit identity from single cores on ‘home run’ cable at distribution board to connections at PDH position (the home run cable being the only site connection). Record test instrument serial number and calibration certificate

4. Test continuity of protective conductors

5. Test insulation resistance

6. Test polarity by continuity method

7. Test earth electrode resistance, when using and earth electrode resistance tester

Live Tests

All tests to be co-ordinated by authorised person for LV switching on site.

1. Ensure all information is completed on the test sheet prior to completing the last stage of the tests, e.g. cable size and length, MCB type & rating, etc

2. Re check polarity

3. Carry out continuity test (R1) using the wandering lead method, indicating compliance by a tick in the relevant column

4. Test earth electrode resistance when using a loop impedance tester. Readings more than 2 ohm are to be recorded and investigated further.

5. Mark distribution board live in accordance with standard live working policy

6. Carry out earth loop fault impedance on each luminaire circuit, at luminaire furthest from the distribution board on each corresponding protective device for the circuit. Record EFLI value, test instrument serial number and calibration date

7.Carry out RCD testing where installed, recording 5x setting along with instrument serial number and calibration date.

Under no circumstances should any product be modified on site without written permission from Metway.

Installation Guidelines

Electrical Installations, whether pre-wired or conventional, fall within the scope of the electricity at work regulations 1989. This is a statutory act of Parliament which states that an electrical installation must be safe and gives brief requirements. The details of how to achieve this is given in BS 7671 of the IEE wiring regulations and is applicable to all buildings. The following guidelines are recommendations only and the installation of a pre-fabricated wiring system must be installed in accordance with the current version of the IEE Wiring Regulations BS 7671.

General Guidelines

All equipment should be inspected prior to installation to ensure that it has not been damaged in transit. It should also be checked against any installation drawings and bills of materials. Any products found to be damaged or faulty should be returned to Metway for replacement. Under no circumstances should any alteration be attempted unless written approval is obtained.

It is good practice to site the Primary Distribution Hubs first and work the home run back to the distribution board. Coiling excess length of home run is not permitted and must be cut to the required length.

Components can be fixed to soffits, floor slabs and building structure and should not rely upon a suspended ceiling for support.

Manufacturers’ guidelines should be followed for maximum deflection of the cables between suspension points, which may vary according to the type and construction of the cable used.

Upon completion, the installation must be tested as if it were a fixed installation in accordance with BS 7671.

Installation Method

Primary Distribution Hubs shall be securely fixed to the building fabric and sited so that they remain accessible for future testing/maintenance. Home runs must either be supported by a suitable tray/basket system or clipped directly to the building fabric. Recommended fixing centres 1.2m. Lighting control modules should be securely fixed to the building fabric or suspended on drop rods and sited so that they remain in an accessible area.

All cabling must be suitably supported in order that no undue stress is placed upon the connection points. It is recommended that a fixing be placed within 150mm of the connection point and at 1.2m intervals. If cables are laid directly upon the suspended ceiling then the ceiling system should be checked to ensure that it is suitable to take the additional weight. (This method is not recommended).

Excess lengths of cables should be avoided and correct lengths used wherever possible. Excess cable should be coiled in one large loop only and not to exceed minimum bending radius. Cable loops should not be hung over cable ladder/unistrut as this will act as a coil. Bunching of cables should be avoided and laid flat horizontal if greater than three cables. The joining of prefabricated leads is discouraged and correct lengths should be used to minimise connections and resistance.

Tee modules should be fixed directly to the equipment they serve or mounted nearby and the cables supported to ensure there is no strain on the connection points.

Any deviation from the original layout drawings should be approved and fully recorded. Any deviation from the original installation will be subject to review and re-testing.

(ALL CONNECTIONS MUST BE FULLY ENGAGED OR PUSHED “HOME” AND LATCHED IF APPLICABLE)

 

The following statement is taken from BS 61535: 2006 Annex B3 – Installation.

  • Ensure that the installation couplers are fully engaged and the retaining means are reliably locked after connecting installation plugs and installation sockets.
  • Ensure that the installation couplers are not under excessive strain. In case of doubt, fix the cable.
  • Ensure that the installation coupler is not dangerously compatible with other systems used at the site (with different installation coupler systems nor with domestic plug & socket outlet systems).
  • Statement if the installation coupler is not suitable for installation in readily accessible areas and statement if additional parts or precautions are necessary for use in readily accessible areas.
  • Notice that installation coupler systems are not replacements for national domestic plug & socket outlet systems.

(NOTE – use of installation couplers and testing (initial verification) should be carried out to the national wiring rules. This must be done by a skilled person.)

System Configuration

Metway will assist with scheme configuration, product recommendations and a system to meet the supplied specification taking into consideration technical, commercial and electrical issues. Metway will liaise with the electrical consultant, installation contractor, lighting control specialist and luminaire manufacturer (if applicable/required) to ensure compatibility of products and system with the specification and that products arrive on site adapted/fitted with the required pre-fabricated components to ensure rapid onsite installation.

Disclaimer

  1. Metway accepts no responsibility for scheme design (including lux levels,PIR/luminaire spacings).
  2. It is the responsibility of the electrical consultant/customer/installation contractor to ensure that the products and system supplied by Metway are fit for purpose and comply with the specification and installation wiring regulations.
  3. It is the responsibility of the electrical consultant/customer/installation contractor to ensure that cable sizing, volt drop, grouping, circuit protective devices, circuit lengths, loading & total calculated Zs comply with current wiring regulations and do not exceed permitted values.
  4. Metway will take no responsibility for any product or system if a product has been altered, modified or adapted in any way or the installation of a product or system has not be installed or fitted in accordance with the Metway installation guidelines/method, manufacturer’s instructions or the current version of the IEE wiring regulations (BS7671) or installation couplers intended for permanent connection in fixed installations (BS 61535).
  5. Metway will not accept responsibility for connections made between its connectors and other unapproved manufacturers connectors. For details of approved connectors contact Metway.