THE DOW CHEMICAL COMPANY DESIGN AID

ELECTRICAL G7C-0302-00
GLOBAL 06-DEC-2011
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PROCESS PLANT CABLING/WIRING METHODS DESIGN AID
1. General
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1.1. This standard covers the Global MET-1 for cabling/wiring methods for a chemical process plant.
This standard is to be utilized during the electrical design process. The intent of this design aid is to
assist in designing the wiring and cabling to be installed in a raceway or cable tray systems.

1.2. Design Aids that also impact wiring methodology are:

1.2.1. G7C-0303-00 - CABLE TRAY INSTALLATION DESIGN AID.

1.2.2. G7C-0304-00 - ELECTRICAL DESIGN AID FOR CABLE TRAY AND RACEWAY
SELECTION.

1.3. Codes / Standards

1.3.1. All cabling/wiring methods shall meet the respective national and local codes,
supplemented by the local jurisdiction having authority.

2. Definitions

2.1.1. Armored cable - a factory assembly of one or more insulated circuit conductors enclosed in
a metallic sheath of interlocking tape or a smooth or corrugated metallic sheath. For Canadian
CSA/CEC this is type TECK and for US UL/NEC this is type MC (Metal Clad). Typical Canadian
Dow Codes are CBT, CET1, CEMT1, and CEMT3. These cables should not be confused with
UL/NEC Type AC, which is called “armored cable”.

2.1.2. Barrier or Divider – a solid fixed strip of material compatible with the cable tray which
provides separation for cables in raceways or cable tray.

2.1.3. Electromagnetic Interference (EMI) - the interference in signal transmission or reception

caused by the radiation of electrical and magnetic fields.

2.1.4. Guarded - Covered, shielded, fenced, enclosed or otherwise protected by means of

suitable covers, casings, barriers, rails, screens, mats or platforms to remove the likelihood
dangerous approach or damage by persons or objects."
®
2.1.5. ZETABON - coated metal tapes – Trademark of the Dow Chemical. Starting in 2005,
many Dow instrument cables with coated aluminum tapes may be manufactured with tapes made
by Alcoa, instead of Dow. Steel and copper coated tapes will continue to be Dow products. The
term Zetabon is used in a generic manner to define this special cable used for lightning protection
applications, whether manufactured by Dow or others.
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3. General Wiring / Cabling Methods and Requirements

3.1. All non-armored power and control process plant cabling/wiring shall be protected by either cable
tray or raceway. This does not include the necessary cable tray to raceway transitions, which is
typically less than 18 in (45 mm).

3.2. All cables, installed in raceway or cable tray, shall be installed to ensure that minimum cable
bending radii is maintained per G7C-0318-01.

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3.3. Cable shall be installed without splices where practicable.

3.4. Wires and Conductors of Different Systems

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3.4.1. Cable Segregation. Segregate cables in raceway systems, cable trays, cable baskets
and ship ladder by the cable’s or wire’s electrical insulation rating. See the Cable Tray
Application tables in this Design Aid for more detail as for the types of cables and service to be
installed in each group.

CABLE GROUPS

Group 1 Instrumentation circuits up to and including 50 Volts including control.

Telephone / Data Highway
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Intrinsically Safe Cables (less than 50V)
Label - 50V Tray or Instrument Tray to be labeled with a prefix of “IN”

Group 2 Control Circuits of voltage above 50V through 250V which are not part of
Lighting Feeders and their associated control.
Some Motor Control cables.
Breaker control wiring (DC and AC circuits from 125VDC to 240VAC).
CT wiring (typically 110V or 120V),
PT Wiring (typically 110V or 120V),
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Instrument Power Cables (110 to 120VAC in NA or 230VAC in IEC)
RTDs associated with Motors
RTD’s associated with Heat Tracing circuits
Heat Trace power circuits (110 to 120VAC in NA or 230VAC in IEC)
Pilot Wires
Label - 250V Tray and Group 2 cable trays to be labeled with a prefix “EL”

Group 3 Motor and lighting feeders and their associated control

600 Volts for North America
1000 Volts for IEC
x
Heat Trace power circuits (440 to 600VAC in NA or 400 to 1000VAC in IEC)
Label – 600V Tray in North America or 1000V Tray for IEC applications with a
prefix “EH”

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Group 4 Medium and High Voltage Circuits

(2.4 kV through 5 kV) For North America - Label Tray prefix “MV5”
(15 kV) For North America - Label Tray prefix “MV15”
(25 kV) For North America - Label Tray prefix “MV25”
(>25 kV) For North America - Label Tray prefix “HV”

(6 kV) For IEC- Label Tray prefix “MV6”

(33 kV) For IEC - Label Tray prefix “MV33”
(>33 kV) For IEC - Label Tray prefix “HV”

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3.4.2. Group 1 cables must be protected from electromagnetic interference (EMI) with a cable
shield and physically separated from the other wire / cable groups.

3.5. Group 1 Cable and Cable Tray Separation

3.5.1. To mitigate the potential effects of EMI on Group 1 cables, cable separation distances,
cable configuration, cable current, installation methods, shielding, cable tray and raceway
material, and raceway orientation should all be considered.

3.5.2. Vertical Cable Tray Separation

3.5.2.1. When installed in ladder cable tray using MET cable with MET raceway installation
methodology, Group 1 cables should maintain a 0.6m (24 in.) minimum vertical distance from
parallel runs of non-shielded power cable. When possible, a vertical distance of up to 1m
(36 in.) between trays should be evaluated if cost effective.

3.5.2.2. Where 0.6m (24 in.) vertical tray separation distances can’t be maintained for Group
1 cables in ladder tray, the distance may be reduced to 0.45m (18 in.) if:

3.5.2.2.1. Cable tray covers are used on ladder cable tray to reduce the distance to
0.45m (18 in.) if the tray cover used is positioned between the power cable and the
Group 1 cable. If covers are used, appropriate cable ampacity derating factors must be
managed and the installed covers can be maintained for the life of the installation.

3.5.2.2.2. Solid bottom or perforated solid bottomed tray may be used to reduce the
distance to 0.45m (18 in.) if the Group 1 cable tray used is positioned above the power
cable tray. If solid bottomed tray is used, appropriate cable ampacity derating factors
must be managed and covers shall be installed and maintained for the life of the
installation (tray covers are required to keep dust, dirt, and collected debris from
accumulating in the solid bottomed tray).

3.5.2.3. For Group 1 cables with a heavy foil shield, such as on Zetabon cable, at least 0.25m
(9 in.) of separation is required.

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3.5.3. Horizontal Cable Tray Separation

3.5.3.1. For horizontal metallic cable tray separation, the minimum separation requirement is
0.1m (3 in.). This is minimum space needed to install hardware and cable tray clamps.
Metallic cable tray side rails protect cables in opposing trays from EMI.

3.5.3.2. For Group 1 cables installed in non-metallic cable tray, a 0.6m (24 in.) minimum
horizontal distance from parallel runs of power cable should ideally be maintained. Cable
orientation and placement in the trays can aid in cable separations.

3.5.3.2.1. For Group 1 cables installed in non-metallic cable tray, as little as 0.3m (12 in.)
spacing is allowed between them and power cables if the power cable being evaluated is
for low current circuits (< 20 amps) such as motor space heaters, control, or lighting
circuits.

3.5.3.2.2. For Group 1 cables installed in non-metallic cable tray, as little as 0.25m (9 in.)
spacing is allowed between them and power cables if the power cable being evaluated is
shielded MET 5kV cables or greater.

3.5.3.2.3. For Group 1 cables installed in non-metallic cable tray, as little as 0.25m (9 in.)
spacing is allowed if the Group1 cable has a heavy foil shield such as Zetabon cable.

3.5.3.2.4. For non-metallic cable tray where 0.6m (24 in.) of horizontal cable separation
can’t be maintained and none of the above conditions apply, refer to the “Additional EMI
Considerations” section below for other ways to mitigate your EMI risk.

3.6. Group 1 Cable and Conduits

3.6.1. Group 1 cables shall only occupy conduits with other Group 1 cables and they shall have
the same insulation jacket voltage rating.

3.6.2. Group 1 cables installed in metal conduit are protected from EMI. Other separation
requirements for routing conduits still apply. Refer to G7C-0311-01, G7C-0311-02, and G7C-
0311-04.

3.7. Group 2, 3, and 4 Cable and Cable Tray Separation

3.7.1. The normal recommended vertical separation for ladder cable tray is 0.45m (18 in.) for
cable Groups 2, 3, and 4. This is designed to allow for ease of access and maintenance for
installing tray and pulling cables.

3.7.2. Trays that contain all MC cables have no minimum separation requirements due to EMI.
Other tray separation requirements still apply.

3.8. Additional EMI Considerations.

3.8.1. Additional considerations that impact the risks associated with EMI are:

3.8.1.1. Individually shielded cables installed in a common tray provide less protection from
EMI than Individually shielded cables with an overall shield.

3.8.1.2. Standard MET shielded cables provide less EMI protection than Zetabon or metal
clad (MC) cables.

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3.8.1.3. EMI affects cables run in parallel to each other. EMI does not affect cables running
perpendicular to each other.

3.8.1.4. The general effects of EMI are minimal for cable runs where the minimum separation
isn’t maintained for just a short distance (less that 6m or 20 ft.) over the length of the run.

3.8.1.5. Communication and instrumentation cables operating at higher speeds (frequencies)

are potentially much more noise-sensitive than AI’s, DI’s, and thermocouple wires.

3.8.1.6. Cable tray covers or solid bottom trays can provide additional EMI protection. When
employed, follow appropriate cable ampacity derating factors.

3.8.1.7. Cable tray dividers provide some EMI protection. Where there is low risk to EMI due
to type and quantity of cables, cable tray dividers may be utilized as a separation between
Group 1 cables and Group 2 or 3 cables.

3.8.1.8. For single or small numbers of cables where EMI is a concern, MC cables may be a
more cost effective solution than dividers or tray covers.

3.8.1.9. Single conductor circuits with high current produce more EMI that may affect other
cables.

3.8.1.10. Cable separation and/or imperfect bundling of the power conductors potentially
produces more EMI than an ideal 3/C cable configuration.

3.8.1.11. Power cable with a heavy foil shield, metal clad (MC) cables, or in metallic conduit
emit little to no EMI.

3.8.1.12. Side rails of metallic trays placed side-by-side provide EMI shielding.

3.8.1.13. Power cables with a high-frequency content (such as for an unfiltered PWM VFD
cable) increase the risk for EMI.

3.8.1.14. Higher data rates used on the Group 1 cable are impacted more easily by EMI.
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3.9. Intrinsically Safe cables

3.9.1. The term "Intrinsically Safe" has more to do with system design than cable design. In
essence:

3.9.1.1. Power transfer devices have an isolating device (to be located outside of the
hazardous area) that ensures that past that device, the energy available to be produced in a
failure or short circuit will not provide enough current that an arc can be produced.

3.9.1.2. Systems designed without a power isolation device are also designed to ensure that
the energy available to be produced in a failure or shirt circuit will not provide enough current
that an arc can be produced.

3.9.2. Producers may or may not define cables to be used for their intrinsically safe systems, but
in most cases Intrinsically Safe cables would be considered a Group 1 cable. The "service" of
the cable and its operating voltage is what dictates which Group the cable falls under.

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3.9.3. Though generally classified as Group 1 cables, there are specific installation
requirements for installing intrinsically safe cables that must be followed. Option for routing or
installing intrinsically safe cables are:

3.9.3.1. Tray rated type (TC) intrinsically safe cables installed in Cable trays must be
separated from other Group 1 cables with a divider.

3.9.3.2. Metal clad or metal sheathed type (MI or MC) intrinsically safe cables may be
installed in cable trays with other Group 1 cables of the same jacket voltage rating.

3.9.3.3. Intrinsically safe cables may be routed in conduit.

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3.9.4. For IEC installations, intrinsically safe cables must have an outer jacket covering of light
blue.

3.10. In main cable tray runs, it is good engineering practice to separate Cable groups 2 and 3 into
separate trays. However, for shorter and smaller cable tray runs, where it is not cost effective, Group
2 and 3 cables may be run in the same tray without a divider if the cable insulation ratings are the
same. Refer to the cable matrix tables at the end of this document.

3.11. For long cable runs in excess of 150m (500 feet), control circuits routed with motor and power
leads can pick up enough induced voltage (due to EMI) such that high impedance interposing relays
can be made inoperable. In these cases, the control circuit cable should be separated from the
motor and power leads via a fixed divider, use of MC cable, or run in a separate cable tray.

3.11.1. For Standard Group 2 circuits installed in cable tray runs in excess of 150m (500 feet), a
divider should be installed between the Group 2 and Group 3 cables.

3.11.2. Motor leads used in VFD service, run in excess of 150m (500 feet), should be isolated
from Group 2 cables with a divider or an MC cable may be used.

3.12. In NEC applications, Group 2 and 3 Class 1 circuits may not be included in trays with Class 2
circuits without dividers separating them.

3.12.1. Group 2 and 3 armored cables do not require tray dividers if the cable insulation ratings
are the same.

3.12.2. Cable Group 3 and cables 5kV and below of Group 4 may be installed in the same cable
tray if the two groups are separated by solid fixed barriers or dividers installed in the cable tray.

3.13. For North American countries, there are separation requirements for intrinsically safe and non-
incendive wiring. The guidelines of NEC Article 504-30 or CEC Section 18-066 shall be followed.

3.14. Each Group 4 cable of a different voltage rating shall be separated by solid fixed barriers.

3.15. All installations shall comply with local code requirements to have an insulation voltage rating
equal to or exceeding the highest circuit voltage of that group of cables.
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3.16. Pneumatic tube bundles, or any pipe, tube, or equal for steam water, air, gas, drainage,
process fluids, or any service other than electrical shall not be run in the same cable tray, whether
divided or not, with any electrical conductor or with fiber optics.

3.16.1. Exception: Within Europe, when instrumentation and communication cables are tie-
wrapped and secured to the cable tray on nominal 3 m intervals, and pneumatic (air only) tube

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bundles are tie-wrapped and secured to the tray on nominal 3 m intervals, and each is separated
by at least 30 mm, they may occupy the same cable tray.

3.17. Instrument cabling applications shall comply with G7C-0452-01.

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4. General Conduit Design Recommendations
4.1. Field Contractors are generally skilled at determining and selecting the best overall conduit field
routing paths. Therefore, in general it is not cost effective to produce conduit routing layout or power
plan drawings. However, the Contractor must be guided for proper installation methodology and
installation details, so conduit routing drawings are not required as long as Electrical Design includes
the following information in the construction package:

4.1.1. Conduit installation methodology is clearly identified by including G7C-0311-01, G7C-0311-

02, G7C-0311-03, and/or G7C-0311-04 as needed.

4.1.2. The conduit Source Point location is clearly shown and understood. This is the power
panel, junction box, switchrack, motor control panel, or the begin source routing point is clearly
identified on power plans, layout plans, photographs, or some other easily identifiable locations.
Equipment elevations, where required, must be identified.

4.1.2.1. Where the conduit routing begins at a cable tray, the cable tray plans are provided
that shows those trays where conduit Source Points for conduit routing is to begin.

4.1.3. The conduit End Point location is clearly shown and understood. This is the junction box,
motor, light fixture, load device, or equipment where the conduit routing ends. Equipment
elevations, where required, must be identified.

4.1.4. The Hazardous Area Classifications and their boundaries are clearly shown so that the
contractor knows where conduit seals are required.

4.1.5. Cable Schedule or conduit schedule that clearly shows which cables are to be routed
together in common conduits, and which cables are not to be routed together in common
conduits. This must be accomplished to ensure that appropriate voltage and service separations
are maintained per G7C-0302-00.

4.2. Conduit routings shall be shown on layout or power plans if:

4.2.1. It is more cost effective to provide the conduit size, circuit, cable, and routing on the power
plan drawing instead of the above information.

4.2.2. Conduits associated with main feeder distribution cables where engineered conduit bend
radii are needed for installing proper entry points to major electrical equipment (these are typically
short routings).

4.2.3. Conduits where the local or regional engineering policies require the routings to be
identified. These are typically 2” and greater O.D. in size. Some Sites require these defined
routings for gaining acceptance for “space” in a pipe rack by the Owner (usually utility pipe racks).
Check with Site Electrical DAS.

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5. Regional Wiring Differences

5.1. Regional wiring differences are impacted by regional wiring methodologies. The following is
intended to prompt review and discussion with the Owner to confirm general wiring methodology prior
to beginning design.

5.2. Above Ground Wiring Methodology

5.2.1. In the US, Brazil and China, it is more common to use wiring methods using both conduit
and cable tray. In Canada, Europe and IEC designs, it is more common to use wiring methods
using both armored cables and cable tray without the use of conduit. The differences stem from
historical applications and their impact on raceway and cabling component availability. Both
installation methods are fully acceptable. Both methods utilize cable tray systems for main cable
routing.

5.2.2. In China, it is common to use wiring methods using armored cables installed in conduit.

5.2.3. In Brazil, it is common practice to use two separate cables for motor power and control.
Composite cables for motor power and control applications are not utilized.

5.2.4. In South America, both 50Hz and 60Hz distribution systems exist, even when IEC design
requirements are to be followed. Consult with the local Electrical DAS for system frequency
requirements.

5.2.5. In Thailand, wiring systems are installed per IEC, however, cable tray systems are
designed to NEMA standards.

5.2.6. In IEC applications where armored cable routing is more common; cable channels, cable
baskets, and shipbuilding tray is also used. These cable supports are not as structurally strong
as cable tray and therefore are typically used with fewer cables for routing from main cable trays
to field devices. Cable segregation requirements still apply. Refer to G7C-0304-00 for raceway
selection methodology.

5.2.7. United States Class 1 Circuits

5.2.7.1. The National Electric Code defines specific restriction to the installation of Class 1
circuits. Typical Class 1 circuits are communication circuits, interposing relay circuits, pilot
wires, some CT circuits, and similar power limited or remote-control or signaling circuits.

5.2.7.2. Class 1 power limited circuits (typically below 30V) are considered Group 1 circuits
and may be installed as such with no restrictions.

5.2.7.3. Class 1 remote-control or signaling circuits (< 600V, typically 120 VAC) are consider
Group 2 circuits and shall be separated from Group 3 and other Group 2 power circuits with a
divider, use of an MC cable, or by use of a separate tray.

5.2.7.4. Circuits associated with motor controls are not Class 1 circuits.

5.3. Underground Wiring Methodology

5.3.1. No cable splices are allowed in any underground wiring application below grade. Splices
shall be made at above ground pull boxes, junction boxes, or termination enclosures.

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5.3.2. In underground applications, it is more common in North America to use concrete duct
banks utilizing PVC conduit. Refer to G7C-0305-04.

5.3.2.1. Where process chemicals may attack and degrade PVC, polyethylene conduits may
be used.

5.3.3. In Europe, it is more common to use direct buried cables utilizing concrete tiles as cable
protection. Refer to G7C-0305-02.

5.3.4. Cable segregation requirements still apply.

6. Non-conductive Fiber Optic cabling

6.1. Non-Conductive fiber optic cable transmits light and neither emits nor receives electromagnetic
interference, therefore, it may be installed with any cable Group application.

6.2. Non-Conductive fiber optic cable has special bending radii requirements and must be installed
per the Manufacturer’s recommendations. Long radius bends and factory fittings are typically
required.

7. Conductive Fiber Optic cables shall not be permitted to occupy the same cable tray with any cable tray
Group application.

8. Variable Frequency Drives

8.1. Though some low voltage VFD (400V, 480V, 690V) Manufacturer’s recommend the use of
shielded cables for motor leads to reduce motor bearing circulating currents, Dow has not
experienced any failures when using standard non-shielded motor leads using Dow MET cabling
methodologies on low voltage motors.

8.2. Instrument and control cables can experience EMI when routed near VFD motor leads. Use of a
divider, MC cable, or separate cable tray will mitigate this risk.

8.3. Medium voltage motor leads on VFD driven equipment require shielded cables in the following
applications.

8.3.1. All applications 5KV and greater.

8.3.2. In 2300V VFD applications with motor leads in excess of 600m (2,000 feet).

9. Use of Dow Code A THHN/THWN wire per G7D-0423-00.

9.1. Dow Code A THHN/THWN wire has a soft outer jacket. It is intended for use in non-process
applications where there is no risk for chemical exposure. It is generally routed in conduit systems,
however, Dow Code A cable above 1/0 awg does have a XLPE outer jacket and may be used in
cable tray.

9.2. Dow Code A cable shall not be used for DC applications greater than 50 VDC. Dow Code A
cable has a PVC jacket. At 50 VDC, electroendosmosis may occur, leading to insulation failure that
can cause shorts and fire. Refer to G7C-0420-01, Design Aid for Selecting Cable for VDC Service
and a discussion on Electroendosmosis in Wet/Humid Environments.

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10. Underground MV and HV cable applications

10.1. Cable between 1KV and 5KV, routed in underground applications, shall have TR-XLPE or EPR
II cable outer jackets per G7D-0441-01 or G7D-0444-01.Where underground MV and HV main
distribution cables are installed, they shall incorporate Dow specifications for underground cable,
including longitudinal water blocking to prevent migration of water in the cable, and specified
insulation material (TR-XLPE or EPR). Dow GPSRT approval is required for all underground MV
and HV cable systems.

10.2. Underground cables, including cable joints, shall be physically protected and identified by a
cable marking system per the local/regional requirements. All splices, routings, etc. shall also be
identified on the plant underground drawings.

10.3. Medium and high voltage cable joints shall not be installed underground, except in approved
manholes or vaults.

11. Protecting Instrument Circuits From Lightning Damage

11.1. The instrument cabling/wiring methodology selected shall be suitable for protection against
lightning damage for the location in which they are to be installed. Although virtually all areas are
subject to lightning strikes to some degree, those areas most prone to damage require additional
protection against lightning damage. Lightning strikes are somewhat predictable over a geographical
region and are generally related to the number of thunderstorm days per year, or Isokeraunic Level.
Electrical designers can reference Isokeraunic Level maps to determine if their project or application
warrants additional protection against lightning. The following paragraph is intended to give general
guidance in this area.

11.2. Except where specific EMETL guidance to the contrary exists, sites with an Isokeraunic level of
30 thunderstorm days per year or greater, including all U.S. Gulf Coast sites, shall be considered to
be sites with a high level of lightning exposure.

11.3. Recommended instrumentation cabling/wiring methodology practices for sites with higher
numbers of lightning storms and strikes are, in order of preference:

11.3.1. Instrument cables installed in cable tray, cable basket or other methodology described
within this design aid shall have heavy surge screens (shields). See G7C-0452-01 GBL -
Instrument Wiring Application Guide for recommended cables. Typical heavy surge screens
include coated aluminum tapes (such as 8 mil, 0.2 mm ZETABON A282); aluminum interlocked
armor, and continuously welded aluminum armor. Critical note: Surge screens must be solidly
grounded at both ends to work effectively, as re-discovered at a new plant installation in Texas
during a thunder storm where over 25 instruments were destroyed.

11.3.2. Standard instrument cables without heavy surge screens shall be installed in rigid
galvanized steel or coated rigid galvanized steel conduit. Short lengths (< 30 ft, 9 m) may be
installed in cable tray, cable basket, or channel.

12. Instrumentation Wiring Methodology from Field Junction Box to Device

12.1. The MET-1 for instrument wiring methodology is shown in G7C-0327-00, “Minimum
Requirements for Cable Support System Selection Tree for Instrumentation Wiring from Instrument to
FJB Only”. The preferred general methodology uses a combination of ladder cable tray and wire
basket tray or channel tray from the FJB to the instrument device. The primary advantages are:

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13. Cost of this installation is significantly lower than the conduit methodology from the field junction box
to the device.

14. Maintenance costs for the cable tray wiring methodology are lower than the conduit wiring
methodology. In existing conduit systems, the process of pulling in new cables can cause damage to
other cables in the conduit system and can be labor-intensive. Further complications can arise due to
existing cables typically being twisted together. When conduit wiring methods are used, it may be
necessary to take existing instrumentation out of service to install the new cable(s).

15. Higher reliability of the instrument loop. This conduit methodology has significant issues related to
water or chemical intrusion from condensation, rain, or process leaks entering the conduit system. Such
liquid intrusions can cause conduit internal or external corrosion or liquid intrusion into the instrument
itself. Wiring methodologies that use either cable gland or cord connections to the instrument greatly
reduce or eliminate these problems.

15.1. The preferred instrumentation wiring methodology from the field junction box to the instrument is
using instrument cable and a combination of ladder cable tray, cable channel tray or wire basket tray
as described in G7C-03XX-XX. See section 10 for cable screen (shield) requirements for sites with
severe lightning exposure and G7C-0452-01 for cable selection.
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15.2. The second best option is to install instrument cable as shown in G7C-0315-10 and G7C-
0315-11. See section 10 for cable screen (shield) requirements for sites with severe lightning
exposure and G7C-0452-01 for cable selection. In accordance with the previous references, standard
instrument cables should not be installed in an un-shielded raceway, such as FRP cable tray, in
excess of 9m (30 feet), due to concerns about lightning exposure. Past experience show that
problems have been experienced by plants (such as the Freeport Texas’ Chlorine 5 plant) when the
project chose to run standard instrument cable from the field devices straight to the field junction box
or MOD Remote.

15.3. Open wire or cable lengths from the device to either a raceway or cable tray is determined by
cable type. Excluding the maintenance loop, these are the length restrictions:

17. Allowed
16. Instrumentation Cable
length
19. 30 mm (12
18. Standard
in.)
21. 45 mm (18
20. With longitudinally folded coated metal tape (e.g. ZETABON)
in.)
22. With interlocked or continuously welded aluminum armor, 23. 90 mm (36
galvanized wire armor, and similar in.)

24. Armored Cable Installation Methods

24.1. Armored cable may be installed using conduit sleeves or cable tray for support.

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25. Cable definition for the groups.

25.1. The following table contains descriptions of the cables allowed in a Group 1 tray:

Group 1 Cables
Cable
Insulation
DOW Voltage
Code Rating Cable Service Comments
CE1 300 Instrumentation, analog or digital I/O Canadian
CET1 300 Instrumentation, analog or digital I/O Canadian Armored
E1 300 Instrumentation, analog or digital I/O PLTC
E2 300 Instrumentation, digital I/O PLTC
E3 300 Instrumentation, digital I/O CM - In indoor tray only
E4 300 CRJB Cable Not a tray cable
E5 300 MOD wiring w/ small ducts
xviii
E71,
EM71
EM72 300 Instrumentation, analog or digital I/O IEC, In indoor tray
xix
E71A
EM71A
EM72A 300 Instrumentation, analog or digital I/O IEC, In Outdoor tray
EM1 300 Instrumentation, analog or digital I/O PLTC individual pair or triad
EM2 300 Instrumentation, analog or digital I/O PLTC multi-pair or triad
EMC 300 Instrumentation, analog or digital I/O PLTC Twisted pair
EMC1 300 Instrumentation, analog or digital I/O PLTC Multi Twisted pair
EMZ1 300 Instrumentation, analog or digital I/O PLTC Zetabon
EMZ2 300 Instrumentation, digital I/O PLTC Zetabon
Instrument uA, mV, and high speed
EMZ3 300 applications Individual and overall shield.
Instrumentation, 4-20mA, DO, DI
EMZ4 300 applications Overall shield.
EX 300 Thermocouple PLTC
EZ1 300 Instrumentation analog or digital I/O PLTC Zetabon
JX 300 Thermocouple PLTC
KX 300 Thermocouple PLTC
NX 300 Thermocouple PLTC
TX 300 Thermocouple PLTC
JXM 300 Thermocouple PLTC multi-pair
KXM 300 Thermocouple PLTC multi-pair
NXM 300 Thermocouple PLTC multi-pair
TXM 300 Thermocouple PLTC multi-pair
EXM 300 Thermocouple PLTC multi-pair
EM1 300 Motor RTD’s PLTC
EM1 300 RTD’s for process control PLTC
EM1 300 RTD’s for heat tracing PLTC

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Group 1 Cables
Cable
Insulation
DOW Voltage
Code Rating Cable Service Comments
In control rooms or termination
300 Network cables / ETHERNET rooms only
300 Power Limited Fire Alarm circuits Less than 50 V
Usual for ABB Low Voltage
300 VFD control circuits <50 volts Drives.
This does not include composite
power/control/fiber optic data
N/A Non-Conductive Fiber Optic Cable cables.

25.2 The following table contains descriptions of the cables allowed in a Group 2 tray (>50 to 250
volts only):

Group 2 Cables

Cable
Insulation
DOW Voltage
Code Rating Cable Service Comments
C, C-1 or VFD Remote Control or Signaling
600
IC1 >50V – 250V Control
>50V – 250V Remote Control or
C, C-1 or Signaling, DI’s, DO’s, PLC 120V
600
IC1 I/O, … Switchgear I/O, MCC I/O to
MCJB
IMZ 600 Pilot Wire Relay
BG, BG-
600 DC power
1, or C,
C or IC1 600 Relay control wires
Could be installed in either
Group 2 or Group 3 Cable
Trays. Ok to run with power
IMZ4 600 3 wire Motor RTD’s
for drop to motor. LPP
prohibits us from running in
Group 1 tray.
BG, C,
C-1 or 600 Power, 120V Instrument, Devices.
IC1
BG, C,
C-1 or 600 Power, 120V Lighting
IC1

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Group 2 Cables

Cable
Insulation
DOW Voltage
Code Rating Cable Service Comments
LPP prohibits us from running
in Group 1 tray. Group 2 tray
ICM1 600 Heater or Heat Tracing RTD’s
selected to reduce probability of
EMI.
LPP prohibits us from running
in Group 1. Group 2 tray
ICM2 600 Heater or Heat Tracing RTD’s
selected to reduce probability of
EMI.
C 600 Motor control
C-1 600 Motor control
Could be Group 2 if 300V
Special 600 Communications (Gai-tronics) service or Group 3 if 600V
service.
Could be Group 2 if 300V
BG, BG-
600 UPS power (120v) service or Group 3 if 600V
1, or C,
service.
Could be Group 2 if 300V
BG, BG-
600 UPS power (208V - 240V) service or Group 3 if 600V
1, or C,
service.
Could be Group 2 if 300V
BG, BG-
600 Heat tracing power circuits (120V) service or Group 3 if 600V
1, or C,
service.
Could be Group 2 if 300V
BG, BG- Heat tracing power circuits (208V -
600 service or Group 3 if 600V
1, or C, 240V)
service.
xx RTDS associated with Motors or
EM72A 300V IEC, In Outdoors cable tray
heat tracing
Could be Group 2 if 300V
Non power limited up to 250 volts
600 service or Group 3 if 600V
Fire Alarm circuits
service.
Do Not Install in Tray since it is
no cable tray rated. If you need
Quadriplex w/ messenger >50 to
A7 600 to install via messenger& tray,
250 volt
use A-7's triplex or Quadriplex
with messenger.

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25.3 The following table contains descriptions of the cables allowed in a Group 3 tray (>250 to 600 volts
only):

Group 3 Cables
Cable
Insulation
DOW Voltage
Code Rating Cable Service Comments
Could be installed in either
Group 2 or Group 3 Cable
Trays. Ok to run with power
for drop to motor. LPP
prohibits us from running in
IMZ4 600 3 wire Motor RTD's Group 1 tray.
BG, C,
C-1 or
IC1 600 Power 120V Lighting
Could be installed in either
Group 2 or Group 3 Cable
Trays. This does not,
however, intend to require the
motor control cables to be
installed in a Group 2 Cable
C 600 Motor control Tray.
Could be installed in either
Group 2 or Group 3 Cable
Trays. This does not,
however, intend to require the
motor control cables to be
installed in a Group 2 Cable
C-1 600 Motor control Tray.
Special 600 Communications (Gai-tronics)
BG, BG-
1, or C, 600 UPS power (120v)
BG, BG-
1, or C, 600 UPS power (208V - 240V)
BG, BG-
1, or C, 600 Heat tracing power circuits (120V)
BG, BG- Heat tracing power circuits (208V -
1, or C, 600 600V)
Non power limited up to >250 to
600 600 volts Fire Alarm circuits
BG, DG,
BG-1, or
DG-1 600 480 volt motor power
A5 or A7 600 480 volt motor power
BG, DG,
BG-1, or 480 Volt power to Loads (not
DG-1 600 motors)
A, A5, or 480 Volt power to Loads (not
A7 600 motors)

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xxi
IEC
cable 400 volt or 690 v motors or other
codes loads. 230/400 volt Lighting
per G7D- feeders.230 volt motor control,
0430-00 600/1000 230 v instrument power

Group 3 Cables
L 600 Lighting Power 4/c with Gnd
If you need to install via
messenger & tray, use A-7's
Quadriplex w/ messenger >50 to triplex or Quadriplex with
A7 600 600 volt messenger.

25.4 The following table contains descriptions of the cables allowed in a Group 4:

Group 4 Cables
Cable
DOW Voltage
Code Rating Cable Service Comments
F2 or F5 5 KV 1/C CABLE TC Shielded
G2 or G5 5 KV 3/C CABLE TC Shielded

F-44 2.4 KV 1/C CABLE TC Non-shielded

G-44 2.4 KV 3/C CABLE TC Non-shielded

H1, H2,
HA1or
HA2 15 KV 1/C or 3/C TC Shielded

Note 1 - Group 4: All cables above 1000V shall be segregated by cable insulation voltage rating, either by
barrier within the same cable tray or by installing in separate cable trays. 2.4kV unshielded cables shall
be installed in separated cable trays or with a fixed barrier from shielded 2400 V cables.

Note 2 - Multiconductor cables and bundled single conductor cables #4/0 (107.2 mm) and larger shall be
arranged in a single layer and no other cables installed above them.

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i
01-DEC-2008; MOC 2008_06802; By: Gary Johnson; Supersedes Issue Date 22-AUG-2008; Reviewed
with updates throughout in almost every heading.
ii
27-AUG-2008; MOC 2008_06472; By: Gerald Silvester; Supersedes Issue Date 01-NOV-2006;
Reviewed with extensive updates.
iii
08-JUL-2003, MOC2003.0300.104, By: Mick Bayer, Supersedes Issue Date 12-MAR-2003, CHANGES:
1. Clarified definition of armored cable in CEC and NEC.
2. Added a section to allow Group2 and Group3 in same tray with divider.
3. For ‘Cable that is not in raceway or cable trays’ made separate sections for Power/control
and Instrument.
4. Added more background information from 2002 NEC about ‘open wiring’.
5. Minor ‘wordsmithing’ in other paragraphs.
iv
11-MAR-2003, MOC2003.0300.103, By: Joyce Blom, Supersedes Issue Date 15-NOV-1994, Combined
G7C-0302-00 and G 7C-0302-01 into one document. Deleted G 7C-0302-01.
v
02-03-2006; MOC 2006_03579, By: Joyce Blom, Supersedes Issue Date 15-NOV-2005; Para 1.1 added
GLOBAL
vi
02-03-2006; MOC 2006_03579, By: Joyce Blom, Supersedes Issue Date 15-NOV-2005; Changed Para
1.4 wording
vii
02-03-2006; MOC 2006_03579, By: Joyce Blom, Supersedes Issue Date 15-NOV-2005; Added a Table
and updated the descriptions for the different Groups
viii
2-Feb-2011; MOC 2010_09837; By: K.Katikaneni; Supersedes Issue Date 09-Jun-2009; Added
"Intrinsically Safe Cables" in Cable Group-1.
ix
2-Feb-2011; MOC 2010_09837; By: K.Katikaneni; Supersedes Issue Date 09-Jun-2009; Added
instrument power in Cable Group-2; (added - Instrument Power Cables (110 to 120VAC in NA or 230VAC
in IEC) , RTDs associated with Motors, RTD’s associated with Heat Tracing circuits, and Heat Trace
power circuits)
x
2-Feb-2011; MOC 2010_09837; By: K.Katikaneni; Supersedes Issue Date 09-Jun-2009; Added
instrument power in Cable Group-3 (added: Heat Trace Power Circuits)
xi
02-03-2006; MOC 2006_03579, By: Joyce Blom, Supersedes Issue Date 15-NOV-2005; Added
paragraphs 1.4.3, 1.4.4, 1.4.5 and 1.4.6.
xii
2-Feb-2011; MOC 2010_09837; By: K.Katikaneni; Supersedes Issue Date 09-Jun-2009; Added section
titled, "Intrinsically Safe Cables".
xiii
06-DEC-2011; MOC 2011_10860; By: Gary Johnson; Supersedes Issue Date 03-FEB-2011;
Added section for installing intrinsically safe cables.
xiv
06-DEC-2011; MOC 2011_10860; By: Gary Johnson; Supersedes Issue Date 03-FEB-2011;
Added section for outer jacket covering for intrinsically safe cables.
xv
17-FEB-2005, MOC 2005_02649, By: Joyce Blom, Supersedes Issue Date 08-JUL-2003, Added
paragraph 1.4.3 to clarify cables and tubing routing in cable trays.
xvi
09-JUN-2009; MOC 2009_07410; By: Gary Johnson; Supersedes Issue Date 22-AUG-2008; Added
Section 4, renumbered remaining document.
xvii
01-NOV-2006; MOC 2006_04281; By: Joyce Blom; Supersedes Issue Date 27-MAR-2006; Para 4.3
deleted ‘no flex’ and added reference to G7C-0315-10 & 11.
xviii
2-Feb-2011; MOC 2010_09837; By: K.Katikaneni; Supersedes Issue Date 09-Jun-2009; Added cable
code in Cable Group 1.
xix
2-Feb-2011; MOC 2010_09837; By: K.Katikaneni; Supersedes Issue Date 09-Jun-2009; Added cable
code in Cable Group 1.
xx
2-Feb-2011; MOC 2010_09837; By: K.Katikaneni; Supersedes Issue Date 09-Jun-2009; Added EM72A
in Cable Group-2.
xxi
2-Feb-2011; MOC 2010_09837; By: K.Katikaneni; Supersedes Issue Date 09-Jun-2009; Added IEC
power cable code in Cable Group-2

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