Trade of Electrician

Standards Based Apprenticeship

Conduit and Trunking Systems

Phase 2 Module No. 2. !nit No. 2. .".

C#!$SE N#TES

Revision 1 April 2000 Created by Charlie Walsh - Athlone TC Revised by: Charlie Walsh - Athlone TC Eugene Trindles - Cork TC Christy Ludlo - !undalk TC Revision 2" #eb 200$ by Christy Ludlo % !undalk TC Revision &" 'uly 200( by Christy Ludlo % !undalk TC Revision )* +ove,ber 201& -.LACo,plied by Lia, Carroll % Certi/i0ation 1 -tandards

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27-33 Upper Baggot Street Dublin 4 Ireland SOL S - 2!"3 All rights reserved" +o part o/ this publi0ation ,ay be reprodu0ed* stored in a retrieval syste, or trans,itted in any /or, or by any ,eans* ele0troni0* ,e0hani0al* photo0opying* re0ording or other ise* ithout the prior per,ission o/ the 0opyright o ner"

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Ta%le of Contents
STEEL TRUNKING.......................................................................................................................................4 T23E- A+! -45E- .# -TEEL TR6+74+8""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" ) AREA- .# A33L4CAT4.+""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" ( T23E- .# -633.RT"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" ( -3AC4+8 .# -633.RT-""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" 10 CA9LE CA3AC4T2 A+! -3ACE #ACT.R""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" 10 #A9R4CAT4.+ A+! 4+-TALLAT4.+ .# TEE- A+! 9E+!-""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""10 #.R:4+8 A TEE '.4+T""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" 11 #.R:4+8 A+ 4+TER+AL 9E+!"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" 12 #.R:4+8 A+ E;TER+AL 9E+!""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" 1& #.R:4+8 A #LAT 9E+!"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" 1) EART<4+8 .# -TEEL TR6+74+8""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" 1= OVERVIEW OF CONDUIT TYPES.........................................................................................................16 STEEL CONDUIT SYSTEM......................................................................................................................16 T23E- A+! -45E- .# -TEEL C.+!64T""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" 1> E!!2 C6RRE+T- 4+ -TEEL C.+!64T"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" 1> -.:E A!?A+TA8E- .# -TEEL C.+!64T"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" 1> -.:E !4-A!?A+TA8E- .# -TEEL C.+!64T """""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""1@ CA9LE CA3AC4T2 .# -TEEL C.+!64T A -3ACE #ACT.R B """""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""1@ C6TT4+8 -TEEL C.+!64T"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" 1@ T<REA!4+8 -TEEL C.+!64T"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" 1$ #4TT4+8 A+! #4;4+8 -TEEL C.+!64T""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" 1$ -3AC4+8 .# -633.RT- #.R C.+!64T-"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" 1$ -A!!LE-"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" 1( !4-TA+CE -A!!LE- """""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" 20 :6LT43LE -A!!LE- """""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" 20 TER:4+AT4.+ .# -TEEL C.+!64T T. E+CL.-6RE- """""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""21 C.63L4+8 A+! :ALE 96-< :ET<.!""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" 21 L.C7+6T A+! #E:ALE 9RA-- 96-< :ET<.!"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""21 8AL?A+4-E! -TEEL C.+!64T ACCE--.R4E-""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" 22 '.4+T4+8 -TEEL C.+!64T"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" 2& -ETT4+8 63 -EC6E+CE .# A 9E+!4+8 :AC<4+E """""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""2) 9E+!- -<.6L! 9E #.R:E! T. A+ 4+TER+AL RA!46- .# +.T LE-- T<A+ 2"= T4:E- T<E C.+!64T !4A:ETER2= :A74+8 A (0. 9E+! 4+ -TEEL C.+!64T"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""2= :A74+8 A !.69LE -ET .R .##-ET 4+ -TEEL C.+!64T""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""2@ #.R:4+8 .# A &0D .##-ET""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" 2@ #.R:4+8 A )=D .##-ET""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" 2( :A74+8 A -A!!LE -ET A'6:3B 4+ -TEEL C.+!64T """"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""&0 :A74+8 A !.69LE (0. 9E+! 4+ -TEEL C.+!64T""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""&& PVC CONDUIT ............................................................................................................................................34 C.:3.-4T4.+ .# 3?C C.+!64T"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" &) C<.4CE .# 3?C C.+!64T """""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" &) '.4+T4+8 3?C C.+!64T """"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" &) 3RECA6T4.+- W<E+ 6-4+8 A!<E-4?E- """"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""&) E;3A+-4.+ .# 3?C C.+!64T"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" &) #4TT4+8 A+! #4;4+8 .# 3?C C.+!64T"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" &= A!?A+TA8E- .# 3?C C.+!64T"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" &= !4-A!?A+TA8E- .# 3?C C.+!64T """"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" &= W.R74+8 W4T< 3?C C.+!64T """"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" &> <.T 9E+!4+8 .# 3?C C.+!64T""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" &@ UNIT RELATED ETCI RULES................................................................................................................38

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Steel Trunking
A trunking is an en0losure that provides /or the prote0tion o/ 0ables" 4t is nor,ally sEuare or re0tangular in 0ross se0tion* and has a re,ovable lid" A trunking syste, o//ers great /leFibility hen used in 0onGun0tion ith 0onduit syste,s" Trunking /or,s the ba0kbone or /ra,e ork o/ an installation" Conduits run /ro, the trunking to a00essory outlet boFes" When an alteration or eFtension is reEuired to an installation it is easy to drill a hole in the side o/ the trunking and run a 0onduit to the ne a00essory point" +e iring 0an then be dra n through the ne 0onduit and the eFisting trunking to the supply point"

Types and Sizes of Steel Trunking

There are a nu,ber o/ types o/ steel trunking su0h as: Lighting Trunking Cable trunking :ulti-Co,part,ent trunking 9us-bar Trunking

Typi0al sur/a0e /inishes" <ot dipped galvanised 0oating 8rey ena,el on Hin0 0oating -ilver ena,el on Hin0 0oating -tainless steel

Standa d S!"#$ %& T 'n(!n) =0,, F =0,, @=,, F =0,, @=,, F @=,, 100,, F =0,, 100,, F @=,, 100,, F =0,, 100,, F 100,, 1=0,, F @=,, 1=0,, F 100,, 1=0,, F 1=0,, 200,, F 100,, 22=,, F 1=0,, 2=0,, F 1=0,, &00,, F 2=0,,

Trunking is generally supplied in & ,etre lengths" Lighting trunking is o/ten supplied in = ,etre lengths" .ther lengths are available on reEuest"

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L!)*t!n) T 'n(!n) -teel trunking ,ay be used to install lu,inaires" This type has Eui0k /it drive-in 0ouplings* hi0h allo /or /ast* easy installation o/ long runs" The trunking is installed ith the opening do n ards as sho n in #igure 1" "

Trunking &igure "

!rive-in 0oupling

A range o/ /ittings is available to a00o,,odate 0hanges in dire0tion* tees and interse0tions" These are bolted in position using at least t o bolts depending on trunking siHe" -ee #igure 2

#lat 9end &igure 2

Tee

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Cable retainers are used to prevent the 0ables /alling out o/ the trunking" -pe0ial atta0h,ents are used to /iF the lu,inaires to the trunking and also to allo the 0ables enter /or 0onne0tion" -ee #igure &

Cable Retainer &igure

Atta0h,ent

-uspension bra0kets are used to suspend the trunking at the reEuired height belo the 0eiling" End 0aps and either steel or plasti0 lids are installed to 0o,plete the en0losure" The lid is si,ply 0lipped into position" -ee #igure )

-uspension 9ra0ket &igure '

End Cap

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Ca+,# T 'n(!n) -tandard 0able trunking is si,ilar in design to lighting trunking" The lid in this 0ase is held in pla0e ith turnbu0kles" A Euarter turn o/ a large /lat s0re driver ill either /asten or loosen the turnbu0kle" -ee #igure =

&igure ( A range o/ /ittings is available to a00o,,odate 0hanges in dire0tion* tees* interse0tions and to 0ouple lengths together" These are bolted in position using at least t o bolts depending on trunking siHe" -ee #igures >

#lat 9end

4nternal 9end

EFternal 9end

Tee

)=D 9end &igure )

Coupling

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Changes in trunking siHe are si,ply ,ade by using redu0ers" Cables are easily kept in pla0e in the trunking ith 0able retainers" End 0aps are used to 0o,plete the en0losure" -ee #igure @

Redu0er

Cable Retainer &igure *

End Cap

M',t!-C%./a t.#nt t 'n(!n) The in0reasing use o/ ele0troni0s and di//ering voltage levels in industrial installations has ne0essitated the use o/ ,ulti-0o,part,ent trunking* hi0h is designed to segregate A separate B the various voltages and servi0es" -egregation o/ this nature is a reEuire,ent o/ the ETC4 Rules" #or eFa,ple* it prevents an eFtra lo voltage syste,* 0o,ing into 0onta0t ith a lo voltage syste, even in the event o/ a /ault" #igure $ sho s a typi0al se0tion o/ ,ulti-0o,part,ent trunking" Up to -! , %ables 23!-4!! , %ables %o+puter %ables

&igure +

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Areas of Application
-teel trunking syste,s are used in 0o,,er0ial and industrial pre,ises" Lighting trunking is generally used to supply and support /luores0ent /ittings* hi0h illu,inate large /loor areas" Cable trunking is installed at a suitable height around the alls o/ the building" Conduit drops are then used to supply outlet points" :ulti-0o,part,ent trunking is used here di//erent ele0tri0al servi0es are reEuired in 0lose proFi,ity to ea0h other" 4t is ideal in large o//i0es and 0lassroo,s" <ere it ,ay be used to a00o,,odate 0ables /or supplying eEuip,ent at 2&0 ?olts* plus data 0ables /or 0o,puters* printers et0" These supplies ,ust be segregated /ro, ea0h other"

Types of Support
Trunking should be se0ured by round-headed s0re s or bolts" This prevents da,age to 0ables during installations" 4n industrial installations* trunking ,ay be run overhead* supported at intervals by the lo er ,e,bers o/ the roo/ trusses" 4t ,ay be suspended /ro, or /astened dire0tly to right angle bra0kets" 4t ,ay also be /iFed dire0tly to a all sur/a0e" #igure ( sho s a nu,ber o/ /iFings* hi0h ,ay be used to support trunking"

9ea, Cla,p

?erti0al #lange <angers &igure ,

Channel spring +ut

#igure 10 sho s a run o/ trunking supported by suspension bra0kets" The threaded rod also allo s /or /inal height adGust,ent"

&igure "-

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Spacing of Supports
The spa0ing o/ trunking supports is not a si,ple topi0 as there are so ,any variables su0h as: siHe o/ trunking* siHe and nu,ber o/ 0ables to be installed* type and strength o/ support available" <o ever the /ollo ing table lists the .a0!.'. distan0es bet een supports /or steel trunking"

Maximum Support Spacing for Steel Trunking

Trunking Si.e
-! . -! 7- . -! Larger Si/es

/ori.ontal
"'73'! 3'!

0ertical
2'! 3'! 3'!

Cable Capacity and Space Factor

Trunking is pri,arily intended /or the installation o/ 3?C insulated 0ables" The ,aFi,u, nu,ber o/ 0ables that 0an be installed in a trunking syste, is based on only )=I o/ the available spa0e being o00upied" This does n%t ,ean that the trunking should appear to be less than hal/ /ull o/ 0able" Re,e,ber that all the uno00upied spa0e in bet een the 0ables is in0luded in the 0al0ulation" The ,ain reason /or li,iting the nu,ber o/ 0ables to this level is to eli,inate proble,s asso0iated ith an eF0essive build up o/ heat inside the trunking" 4/ too ,any 0ables are installed the 0able insulation ill su//er da,age due to overheating" There is also the possibility o/ /ire risk" The ETC4 Rules provides a handy guide to aid the 0al0ulation o/ the 0able 0apa0ity o/ trunking" 4t allo s /or a ,iFture o/ all the 0o,,on 0able siHes up to 10 ,,2" .ther 0able siHes have to be a00ounted /or on an individual basis" Re,e,ber that the overall 0able C-A ,ust be used in the 0al0ulation A not the C-A o/ the 0ondu0tor alone B" 4/ ,ulti-0ore 0ables are to be installed in trunking the )=I spa0e /a0tor still applies* eF0ept in the 0ase o/ %n# ,ulti-0ore 0able %n,1"

Fabrication and Installation of Tees and Bends

Tee and bends ,ay be /abri0ated here reEuired in lengths o/ trunking" This ,ay be ne0essary or si,ply ,ore 0onvenient* parti0ularly i/ the reEuired bend or set is non-standard" 4t takes ,ore ti,e to /abri0ate tees or bends than to bolt on ,anu/a0tured a00essories" N%t#-2 It !$ #3%..#nd#d t*at a 34 TPI *a3($a5 +,ad# +# '$#d &% 3'tt!n) $t##, t 'n(!n).

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Forming a Tee Joint

&igure ""

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Forming an Internal Bend

&igure "2

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Forming an xternal Bend

&igure "

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Forming a Flat Bend

&igure "'

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art!ing of Steel Trunking

A trunking installation ,ust be earthed" Earth 0ontinuity is ensured by the proper tightening o/ all bolts used throughout the syste," -o,e ,anu/a0tures re0o,,end that earth 0ontinuity be 0o,pleted by /iFing a 0opper or alu,iniu, strap a0ross all Goints" 4t is ,ore i,portant that all the bolts involved in the syste, are tightened" 4t is not unusual to /ind that 0opper or alu,iniu, straps are used* but are le/t loose* resulting in poor earth 0ontinuity" -ee #igure 1="

Copper Earth -trap F!)' # 16.

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#1er1ie2 of Conduit Types

A 0onduit is a tube* 0hannel or pipe in hi0h insulated 0ondu0tors are 0ontained" The 0onduit in e//e0t repla0es the 3?C outer sheath o/ a 0able* providing ,e0hani0al prote0tion /or the insulated 0ondu0tors" A 0onduit installation 0an be re ired easily or altered at any ti,e and this /leFibility* 0oupled ith ,e0hani0al prote0tion* ,akes 0onduit installations popular /or 0o,,er0ial and industrial appli0ations" EFa,ples o/ types o/ 0onduit used in ele0tri0al installation ork are as /ollo s : 3?C -teel #leFible -tainless -teel

Steel Conduit System

Types and Si.es of Steel Conduit
-teel 0onduits are ,anu/a0tured to spe0i/i0ations de/ined by the 9ritish -tandards 4nstitute A9-B" Class 4 conduit has a hot dip galvanized finish. It is of heavy gauge with a welded seam. This conduit is suitable for use in external or damp installations.This is the conduit most widely used in this country. +ote: The galvaniHed /inish on 0onduit is to prevent the steel /ro, 0orroding in nor,al use" Also ,anu/a0tured is a solid dra n sea,less 0onduit hi0h is ,ore eFpensive and only used /or spe0ial gas tight* eFplosion proo/ or /la,e proo/ installations" Conduit is nor,ally supplied in & or &"@= ,etre lengths and typi0al 0onduit eFternal dia,eters are 1>* 20* 2= and &2,," Eddy Currents in Steel Conduit :etal 0onduits in hi0h a"0" 0ir0uit iring is installed :6-T 0ontain all the 0urrent 0arrying 0ondu0tors o/ ea0h 0ir0uit in the sa,e 0onduit* to eli,inate the possibility o/ indu0ed eddy 0urrents" Eddy 0urrents 0ould result in the ,etal 0onduit and 0ables be0o,ing hot" Some Ad1antages of Steel Conduit A//ords 0ables good ,e0hani0al prote0tion 3er,its easy re iring :ini,ises /ire risks" Can be utiliHed as the Cir0uit Prote0tive Condu0tor. A CPC B

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Some 3isad1antages of Steel Conduit 6nder 0ertain 0onditions ,oisture is liable to /or, on the inside all o/ the 0onduit" EFpensive 0o,pared ith so,e other iring syste,s" Liable to 0orrosion here subGe0t to a0ids* alkalis and 0orrosive /u,es" Ca%le Capacity of Steel Conduit 4 Space &actor 5 <aving deter,ined the 0orre0t nu,ber and 0ross-se0tional area o/ 0ables /or a given load it is ne0essary to sele0t the siHe o/ 0onduit that ill a00o,odate the," 4/ a greater nu,ber o/ 0ables are installed in the 0onduit* over-heating* insulation da,age and /ire ,ay result" As a general rule the nu,ber o/ 0ables dra n into a 0onduit should n%t be su0h as to 0ause da,age to either the 0ables or the 0onduit during the installation" The ,aFi,u, nu,ber o/ 0ables hi0h ,ay be dra n into a 0onduit 0an be 0al0ulated by using the /a0tor syste, des0ribed in the ETC4 Rules" Cutting Steel Conduit Conduit should be 0ut ith a ha0ksa * using a blade having &2 teeth J in0h" The 0ut should be ,ade at !)*t an),#$ to avoid di//i0ulty in threading the 0onduit" #igure 1" illustrates this pro0ess" <old 0onduit to be 0ut se0urely in a pipe vi0e" Avoid da,age to the galvanised 0oating" -tand sEuare to the Gob and ,ake sure your ,ove,ent is unobstru0ted" 8rip the ha0ksa lightly and apply light pressure on the /or ard 0utting stroke" 6se the /ull length o/ the blade"

F!)' # 1.

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#le$tri$al %ourse &otes - Unit 2'3'"

Threading Steel Conduit 4t is ne0essary to 0ut threads on the 0onduit ends in order to s0re the, into 0onduit 0ouplings and a00essory boFes" The 0onduit ends are threaded using sto0ks and dies" A/ter threading the ends* a,, !nt# na, +' $ .'$t +# #.%7#d to ensure that 0ables are not da,aged as they are being dra n into the 0onduits" A,, t* #ad#d #nd$ .'$t +# $3 #5#d '/ t!)*t,1 !nt% a33#$$% !#$ t% #n$' # #a t* 3%nt!n'!t1. <old the 0onduit se0urely in a pipe vi0e A ensure that pipe vi0e Ga bolts are tight B"

While threading keep the die well lubricated preferably with a manufacturers paste or tallow. Thread to re uired length and remove any burrs with a file or reamer! this will prevent sharp edges causing damage to cables while being drawn into the conduit. To ensure a 0lean* unbroken thread the die should be rotated 0ounter-0lo0k ise /reEuently and /inally run up and do n the threads to re,ove any s ar/ A ,etal /rag,ents B" &itting and &i6ing Steel Conduit Conduit ,ust be se0urely /iFed and here it is liable to ,e0hani0al da,age* it should be suitably prote0ted" !rainage outlets ,ust be provided at points here 0ondensation is likely to 0olle0t" Spacing of Supports for Conduits The table belo sho s a suggested spa0ing o/ supports /or steel 0onduits up to 2=,, in dia,eter" -upports should be positioned ithin &00,, o/ bends and /ittings" The table assu,es that the 0onduit is not subGe0t to other eFternal ,e0hani0al stresses" C%nd'!t S!"# +ot eF0eeding 1>,, 20-2=,, 8% !"%nta, R'n$ @=0,, 1@=0,, V# t!3a, R'n$ 1000,, 2000,,

1$

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#le$tri$al %ourse &otes - Unit 2'3'"

Saddles A range o/ 0lips and saddles are available /or 0onduit installations" The spa0er bar saddle* is the devi0e ,ost 0o,,only used /or /iFing 0onduit* see #igure 2" They provide a very se0ure ,ethod o/ /iFing and )#n# a,,1 should be spa0ed as per the table on the previous page"

F!)' # 4. -pa0er bar saddles in0orporate a spa0ing plate" These spa0ing plates are approFi,ately =,, thi0k" This spa0ing plate tends to align the 0onduit ith the kno0kouts in s it0h and so0ket outlet boFes" .n verti0al runs ensure that saddles are /itted the 0orre0t ay round" An i,portant /un0tion o/ the spa0er bar saddle is to keep the 0onduit out o/ 0onta0t ith plaster and 0e,ent sur/a0es" Conta0t bet een 0onduit and these sur/a0es 0ould result in 0orrosion o/ the 0onduit and dis0olour,ent o/ the sur/a0es" When a 0onduit is /iFed to 0on0rete* ,u0h installation ti,e is spent in plugging the 0on0rete /or /iFings" -pa0er bar saddles have the advantage o/ a 0entral* single-hole /iFing" The additional 0ost o/ spa0er bar saddles over the plain saddle Asee #igure &"B 0an be o//set against the saving in ti,e and e//ort reEuired in /iFing"

F!)' # 3.

1(

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#le$tri$al %ourse &otes - Unit 2'3'"

3istance Saddles !istan0e saddles are designed to spa0e the 0onduit approFi,ately 10,, /ro, the all or 0eiling" These saddles are generally ,ade o/ ,alleable 0ast iron" They are ,u0h ,ore substantial than spa0er bar saddles and the additional spa0ing provides greater prote0tion against 0orrosion" The use o/ distan0e saddles eli,inates the possibility o/ dust and dirt 0olle0ting behind the 0onduit" 9y adeEuate spa0ing it is possible to keep the 0onduits /ree o/ dust and it is /or this reason distan0e saddles A#igure )AB and hospital saddles A#igure )9B are generally spe0i/ied"

F!)' # 4A

F!)' # 49

Multiple Saddles Where t o or ,ore 0onduits /ollo the sa,e route it is generally an advantage to use ,ultiple saddles* see #igure =" 3roper spa0ing o/ the 0onduits ensures that there is no need to set the 0onduits here they enter 0onduit a00essories

F!)' # 6

20

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#le$tri$al %ourse &otes - Unit 2'3'"

Termination of Steel Conduit to Enclosures T o ,ethods o/ ter,inating steel 0onduit are 0o,,only used" The 0oupling and ,ale bush ,ethod* see #igure >A A6sually used and pre/erredB The lo0knut and /e,ale bush ,ethod* see #igure >9 A6sed here spa0e is tightB Coupling and Male %ush Method The 0oupling and ,ale bush ,ethod is slightly ,ore eFpensive than the lo0knut and /e,ale bush ,ethod but it allo s ,ore iring spa0e and is a stronger /or, o/ ter,ination" 6sing this ,ethod a 0oupling is s0re ed se0urely on to a standard threaded 0onduit end and then butted against the a00essory boF" A ,ale bush is passed through the boF entry and s0re ed tightly into the 0oupling using an open-ended spanner or a bushing spanner"
Surface &inish $emo1ed Conduit

Male Brass Bush

Conduit Coupling

F!)' # 6A 7ocknut and &emale Brass Bush Method 6sing this ,ethod a lo0knut is s0re ed tightly onto a standard threaded 0onduit end and the thread passed through the hole in the a00essory boF" A se0ond lo0knut is s0re ed onto the 0onduit e//e0tively sand i0hing the all o/ the boF" To prevent da,age to 0ables* /ro, the eFposed end o/ the 0onduit* a /e,ale bush is then s0re ed onto the 0onduit thread" .ne disadvantage in using this ,ethod o/ ter,inating a 0onduit to a s it0h or so0ket boF is that the 0onduit protrudes into the boF and ,ay inhibit the /iFing o/ the s it0h or so0ket"
Conduit

7ocknut &emale Brass Bush 7ocknut or lockring

F!)' # 69 +ote: - These are earth ter,inations

21

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#le$tri$al %ourse &otes - Unit 2'3'"

8al1anised Steel Conduit Accessories #igure @A illustrates a range o/ galvanised steel 0onduit boFes* redu0ers and adaptors"

#nd Bo.

0 h ro u g h B o .

n g le B o .

0ee Bo.

% ro s s B o .

0 a n g e n t 0 h ro u g h

0angent

n g le

0angent 0ee

0angent 1

2 Bo.

U Bo.

B a $ 3 # n t r y L o o p In B o . e s

# . t e n s io n 0 h r o u g h B o .

( edu$er
F!)' # :A

d a p to r

22

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#le$tri$al %ourse &otes - Unit 2'3'"

9ointing Steel Conduit Where t o lengths o/ 0onduit are to be Goined a plain 0oupling is used" To ensure good ele0tri0al 0ontinuity and ,aFi,u, ,e0hani0al strength the tube ends ,ust tighten inside the 0oupling A:aF gap 2 ,,B* see #igure @9" Care ,ust be eFer0ised to do this ithout leaving threads outside the 0oupling"

F!)' # :9 Where neither tube 0an be turned it is ne0essary to resort to the te0hniEue kno n as the Krunning 0ouplingL * see #igure @C" A/ter tightening up the lo0kring the eFposed thread ,ust be painted to prevent 0orrosion"

F!)' # :C

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#le$tri$al %ourse &otes - Unit 2'3'"

Setting up Se:uence of a Bending Machine 3la0e the se,i-0ir0ular /or,er M9N Ato suit the siHe o/ 0onduit to be bentB in position and se0ure the 0entre-pin* see #igure $"
#or,er

F!)' # 8. 3osition the stop MCN in the 0orre0t position /or siHe o/ 0onduit* see #igure ("

C
-top

F!)' # ;. 4nsert the grooved roller in the 0orre0t position /or siHe o/ 0onduit* see #igure 10"

F!)' # 1<.

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#le$tri$al %ourse &otes - Unit 2'3'"

9#nd!n) St##, C%nd'!t The ,ost 0o,,on ,ethod o/ bending steel 0onduit is to use a bending ,a0hine" <o ever* /or bending &2,, dia,eter or larger 0onduits it is re0o,,ended to use a portable rat0het bender" The /ollo ing are the ,ain steps to be taken hen using a bending ,a0hine" 4nsert the 0onduit under the stop and into the groove in the /or,er" 3ull do n the handle* allo ing the roller to bend the 0onduit around the /or,er" 6se a te,plate to 0o,pare the angle o/ the bend /or,ed ith the desired angle" Bends should %e formed to an internal radius of not less than 2'- ti+es the conduit diameter Making a ,-o Bend in Steel Conduit #igure 11 illustrates a right angle bend in steel 0onduit* 200,," hi0h ,ust be /or,ed to a di,ension o/

2--mm

F!)' # 11. The /irst step is to ,ark o// 200,, /ro, the end o/ the 0onduit as illustrated in #igure 12"

&i6ed Point

Marked Point

Mark 2--mm from &i6ed Point

F!)' # 14.

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#le$tri$al %ourse &otes - Unit 2'3'"

The neFt step is to pla0e the 0onduit in the /or,er ith the ,ark to the rear" 3osition the 0onduit so that a try-sEuare* held against the ,ark tou0hes and /or,s a tangent to the edge o/ the /or,er as illustrated in #igure 1&"

Stop 4i.ed Point

5ar3ed Point

Bend do6n to 7!!

F!)' # 13. +eFt pull the lever do n until the (0D angle* is a0hieved"

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#le$tri$al %ourse &otes - Unit 2'3'"

Making a 3ou%le Set or #ffset in Steel Conduit +or,ally o//sets should be /or,ed at either &0D or )=D" A &0D o//set is pre/erred /or t o reasons: Ease o/ ,easure,ent" Ease o/ dra ing-in 0ables"

&orming of a -; #ffset #igure 1) illustrates a &0D o//set to be /or,ed in steel 0onduit" #ro, the illustration it 0an be seen that the &0D angle is one o/ three angles /or,ing a right angled triangle"

8!! 3!! 7!!

F!)' # 14.

"!!++

A rule o/ thu,b /or a right angle triangle A&0D* >0D* (0DB states that the relationship bet een the three sides is in the ratio o/ 1:2:&* see #igure 1="

2 " 3
F!)' # 16. With this in/or,ation* on0e e kno the di,ension o/ the o//set A100,, in this 0aseB e 0an no 0al0ulate and ,ark o// the distan0e bet een the t o bends" At this point take the straight pie0e o/ 0onduit and ,ark on it here you ant the /irst bend to start /ro,* then ,easure 200,, /ro, that point to here the se0ond bend starts* see #igure 1>"

"st 2!!+ +
F!)' # 16.

2nd

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#le$tri$al %ourse &otes - Unit 2'3'"

+o go to the bending ,a0hine" :ark a point on the /or,er as sho n in #igure 1@" 3la0e the 0onduit in the /or,er ,at0hing the /irst ,ark on the 0onduit ith the ,ark on the /or,er and bend to &0D as sho n in #igure 1$" +o re,ove the 0onduit and 0he0k the o//set angle against a &0D te,plate"

9 : in lin e 6 it h $ e n t r e o ; ; o r + e r <

F!)' # 1:.

"st

2nd

4 ir s t S e t

F!)' # 18. 3la0e the 0onduit ba0k in the ,a0hine pointing in the sa,e dire0tion as be/ore but inverted and ,at0h the se0ond ,ark on the 0onduit ith the ,ark on the /or,er* see #igure 1(" The se0ond o//set is no /or,ed until it is in parallel ith the /irst o//set"

S e $ o n d 5 a r3

2$

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#le$tri$al %ourse &otes - Unit 2'3'"

&orming a '(; #ffset A )=D degree o//set is /or,ed in eFa0tly the sa,e ,anner as the &0D version eF0ept that the ,easure,ents bet een the /irst and se0ond bends are 0al0ulated using the /ollo ing /or,ula 1:1:2" #igure 20 illustrates the use o/ this /or,ula* in this 0ase 2 O1)1,, or 100 F 2 O 1)1,,"

"

+ 4"

2 "

"

"!!+ +

F!)' # 4<.

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#le$tri$al %ourse &otes - Unit 2'3'"

Making a Saddle Set 49ump5 in Steel Conduit Assu,e you are reEuired to /or, a saddle set 21" ith a 0learan0e o/ &0,, as illustrated in #igure

3!++
F!)' # 41. The /irst step is to bend the 0onduit to an angle o/ )=D as sho n in #igure 22"

4-

F!)' # 44. The /ollo ing /or,ula ill help you 0al0ulate the position o/ the neFt t o bends hi0h be /or,ed in order to a0hieve the &0,, 0learan0e reEuired" -ine o/ the Angle O .ppositeJ<ypotenuse -ine 22"= <ypothenuse <ypothenuse <ypothenuse O O O O &0J<ypothenuse &0J-ine 22"= &0J"&$2@ ,, @$,," ,ust

#igure 2& illustrates the appli0ation o/ the /or,ula"

2 2 's enu t o 1 yp e

3!+ +

2 2 '-

F!)' # 43.

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#le$tri$al %ourse &otes - Unit 2'3'"

:ark the 0onduit as sho n in #igure 2)"

" 5 a r3 3 a t 7 = + + ;ro + 5 a r3 " 3 3!+ +

5 a r3 " 0 h e $ e n tre o ; th e e . is tin g 4 - ! b e n d 5 a r3 2 a t 7 = + + ;ro + 5 a r3 " 2

F!)' # 44. :arks 2 and & ,ay also be lo0ated using a straight edge or other ,ethod" 3la0e the 0onduit in the ,a0hine so that ,ark 2 is opposite the eFisting ,ark on the /or,er* and bend do n ards as sho n in #igure 2="

5 a r3 3 5 a r 3 2 o n $ o n d u it 4 o r+ e r 5 a r3 5 a r3 " S e$ond Set

F!)' #46.

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#le$tri$al %ourse &otes - Unit 2'3'"

Reverse the 0onduit in the /or,er and ,at0h ,ark & ith the eFisting /or,er ,ark" 9end do n until the edges o/ the 0onduit are in line* see #igure 2>"

5 a r 3 3 o n $ o n d u it 4 o r+ e r 5 a r3

F!)' # 46.

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#le$tri$al %ourse &otes - Unit 2'3'"

Making a 3ou%le ,-o Bend in Steel Conduit :easure,ents /or a double (0D bend in steel 0onduit 0an be taken using any o/ the three ,ethods sho n in #igure 2@"

A ll a r e 2 - - m m

C e n tre to C e n tre

# u t s id e t o <n s id e

<n s id e t o # u t s id e

F!)' # 4:. 4/ you add the outside dia,eter o/ the 0onduit A20,,B to the 0entre to 0entre ,easur,ents A200,,B e 0an no ,ark the position o/ the se0ond bend A220,,B* see #igure 2$" 9end do n until the (00 angle is a0hieved"

22!+ +

2 ! ! + + % e n tre to % e n tre
F!)' # 48. +ote: - The above ,ethods ,ay reEuire adGust,ents due to ,anu/a0turerNs toleran0es and in di//erent bending ,a0hines ear

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#le$tri$al %ourse &otes - Unit 2'3'"

P0C Conduit
Composition of P0C Conduit The basi0 ,aterial is poly-vinyl-0hloride A 3?C B hi0h is produ0ed in both /leFible and rigid /or,s" 4t is i,pervious to a0ids* alkalis* oil* aggressive soils* /ungi and ba0teria and is una//e0ted by sea* and air" 4t ithstands all pests and does not attra0t rodents" 3?C 0onduit ,ay be buried in li,e* 0on0rete or plaster ithout har,/ul e//e0ts" Choice of P0C Conduit The 0hoi0e is dependant on the type o/ ork being undertaken and the Gob spe0i/i0ation" <eavy gauge round 0onduit is nor,ally used in sur/a0e ork and /or /or,ing on-site" Light gauge round 0onduit is suitable /or 0on0ealed ork" .val 0onduit is nor,ally 0hosen /or use in plaster alls and 0an be used /or drops in sur/a0e ork"

Typi0al ele0tri0al installations use a heavy guage standard i,pa0t tube ,anu/a0tured to 9- )>0@" The 0onduit siHes and range o/ /ittings are the sa,e as those available /or ,etal 0onduit" 9ointing P0C Conduit 3?C 0onduit is ,ost o/ten Gointed by pla0ing the end o/ the 0onduit into the appropriate /itting" 'oints into a00essories 0an be easily ,ade dry or by the use o/ sili0one grease or a per,anent solvent* dependant on the installation 0onditions" The sili0one grease should be used /or eFpansion 0ouplings and here an installation ,ay be subGe0t to /uture alteration" Precautions =hen !sing Adhesi1es Care should be taken hen using adhesives* hi0h are pro-0he,i0al based* and as su0h are Euite /la,,able and volatile" Repla0e the lid on the tin i,,ediately a/ter use" 6se in a ventilated area a ay /ro, naked /la,e" Und# n% 3! 3'.$tan3# $*%',d 1%' $.%(# 5*!,# 5% (!n) 5!t* t*!$ ad*#$!7#. 4/ adhesive should get into your eyes* seek /irst-aid i,,ediately" E6pansion of P0C Conduit EFpansion 0ouplings should be used /or sur/a0e installations at a re0o,,ended ,aFi,u, o/ 4 .#t # intervals" Where /reEuent variations in a,bient te,perature are likely to o00ur this distan0e ,ust be greatly redu0ed" N%t#2 3?C 0onduit is n%t suitable /or installations subGe0t to te,peratures belo 66%C -6%C or above

&)

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#le$tri$al %ourse &otes - Unit 2'3'"

&itting and &i6ing of P0C Conduit A range o/ /iFings /or 3?C 0onduit is available as sho n in #igure 2("

# p e n S a d d le

S p a c e r B a r S a d d le

# 1 a l S tra p S a d d le

# 1 a l C lip

$ o u n d > ! > C lip

F!)' # 4;. 3?C 0onduit is /iFed in the sa,e ay as ,etal 0onduit" All horiHontal runs should be saddled at not ,ore than ;<< .. intervals unless high a,bient te,peratures or rapid 0hanges in te,perature are likely to be en0ountered* hen the intervals should be redu0ed" ?erti0al runs should be saddled at not ,ore than 14<< .. intervals eF0ept here dire0tional 0hanges are ,ade" -addles should be installed approFi,ately 16< .. either side o/ a bend" Conduit should be able to ,ove /reely in the saddle" Ad1antages of P0C Conduit Light eight and easy to handle Easy to 0ut and deburr -i,ple to /or, and bend !oes not reEuire painting :ini,al 0ondensation due to lo ther,al 0ondu0tivity in all o/ 0onduit" -peed o/ installation EF0ellent ele0tri0al and /ire resistant properties 3isad1antages of P0C Conduit Care ,ust be taken hen glueing Goints to avoid /or,ing a barrier a0ross the inside o/ the 0onduit" 4/ insu//i0ent adhesive is used the Goints ,ay not be aterproo/" 3?C eFpands about = ti,es as ,u0h as steel and this eFpansion ,ust be allo ed /or" 3?C does not o//er the sa,e level o/ ,e0hani0al prote0tion as steel" A separate Cir0uit 3rote0tive Condu0tor ,ust be run inside the 0onduit"

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#le$tri$al %ourse &otes - Unit 2'3'"

=orking 2ith P0C Conduit 3?C 0onduit is easily 0ut using a Gunior ha0k sa " Any roughness o/ 0ut and burrs should be re,oved ith the aid o/ kni/e blade or si,ply by iping ith a 0loth" There are proprietary tools available /or 0utting 3?C 0onduit" Cold bending o/ 3?C 0onduit ,ay be 0arried out on 0onduit siHes up to 2=,, dia,eter using a bending spring* see #igure &0" 4t is essential to use the 0orre0t siHe bending spring and it should be noted that springs /or heavy guage 0onduit are 0olour 0oded green and those /or light gauge 0onduit are 0olour 0oded hite" T*#1 a # n%t !nt# 3*an)a+,#" 4t is i,portant that the spring is not da,aged or kinked" A /aulty spring 0an 0ause the 0onduit to kink and /ra0ture" The spring 0an also Ga, inside the bend" The radius o/ the bends should be as near as possible to that o/ a si,ilar bend /or,ed in steel 0onduit o/ a si,ilar siHe"

F!)' # 3<. <aving inserted the spring into the 0onduit* grip the 0onduit on either side o/ the proposed bend and bend the 0onduit $,%5,1* as illustrated in #igure &1"

F!)' # 31.

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#le$tri$al %ourse &otes - Unit 2'3'"

The 0onduit should be bent to a ,ore a0ute angle than the angle /inally desired be0ause o/ the tenden0y o/ 3?C to Kre0overL a/ter bending" This tenden0y lessens as the te,perature de0reases" 4n very 0old eather it is re0o,,ended that the 0onduit is ar,ed slightly by rubbing ith a 0loth held in the hand" 4/ the 0onduit is bent too Eui0kly there is a risk o/ kinking and J or /ra0turing o/ the 0onduit and possible da,age to the bending spring" 4/ the 0onduit is intended /or sur/a0e ork it should be saddled and /iFed as soon as possible a/ter bending" .n0e a bend has been /or,ed it should not be /or0ed ba0k ards as this 0an da,age both the 0onduit and the spring" To re,ove the spring* t ist it in an anti-0lo0k ise dire0tion" This ill redu0e the dia,eter o/ the spring and ,ake it possible to pull the 0onduit and spring apart" 4/ the spring Ga,s during this operation do not pull hard on it* other ise the spring ill be da,aged" /ot Bending of P0C Conduit <ot bending o/ 0onduit should be 0arried out on siHes over 2=,, dia,eter" A bending spring o/ the 0orre0t siHe should be used" Apply a gentle heat pre/errably ith a hot air tor0h* ele0tri0 heating ele,ent or hot ater" 9end the 0onduit in a00ordan0e ith above instru0tions and #ig" &1" Care should be taken to avoid the dire0t appli0ation o/ /la,e to the 0onduit" When the 0onduit is in a pliable state it should be slo ly bent around a suitable /or,er and held in position /or about one ,inute until set" A/ter setting* the bending spring ,ay be t isted anti-0lo0k ise and re,oved"

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#le$tri$al %ourse &otes - Unit 2'3'"

!nit $elated ETC< $ules

T1/#$ %& W! !n) S1$t#. 641 =21"=* =21"="1* =21"="2 =21">* =21">"1* =21">"2* =21">"& =21">")* =21">"= =21"10 S#,#3t!%n and E #3t!%n !n R#,at!%n t% 644 E0t# na, In&,'#n3#$ =22"&"2 =22"$"2* =22"$"=* =22"$">* =22"$"11 E,#3t !3a, C%nn#3t!%n$ 646 =2>"2"& =2>"&"& S#,#3t!%n and E #3t!%n %& W! !n) 64: S1$t#.$ t% .!n!.!$# t*# $/ #ad %& F! # =2@"1"2* =2@"1"& A ite, 2 B =2@"2* =2@"2"1* =2@"2"2* =2@"2"& P #3a't!%n$ a)a!n$t D#t !.#nta, E&&#3t$ 648 & %. Ad=a3#nt S# 7!3#$ =2$"1* =2$"1"1 ite,s a* 0* and e P %t#3t!7# C%nd'3t% $ Ann#0 Ta+,#$ 643 =)&"2"1 A ite,s 2 and > B* =)&"2") 64A 649-4 A ite, & B U V W > Y ?

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(e)ision 4* &o)e+ber 2!"3