Low Voltage Cable Handling (ComRent)

Operations Policy & Procedure
Revision Date: 9/22/16

Low Voltage Cable Handling OPP # 01.02 Review Date: 10/6/16
Page 1 of 11 Revision # 0
OPP Approver:
OPP Owner: Joseph Stonestreet ________________________________________________
Joseph Stonestreet VP Operations
1.0 PURPOSE
This Policy contains the necessary information for personnel to be able to properly connect,
install, monitor and remove cables from jobsites and cable installed on rental equipment.
ComRent requires that anyone utilizing ComRent Equipment do so in accordance with these
handling & installation instructions
2.0 SCOPE
With this provided set of guidelines, all ComRent personnel and customers will be able to
properly install cables on jobsites. This will include but not be limited to ComRent rental
equipment. Customers are referenced in this policy only for information purposes so all
personnel are aware of the proper cable installation procedures. A copy of proper cable
installation instructions is included with every ComRent rental contract. ComRent cannot control
the manner in which the customer installs cable rented if ComRent personnel are not on site but
it is ComRent’ s responsibility to provide guidance if a Technician is on site. With the procedures
supplied within this document, all ComRent personnel will be able to properly and safely install
LV cable to ensure proper performance.
3.0 RESPONSIBILITIES
Shop Supervisors-
- Ensure that all personnel follow the procedures within this OPP.
- Ensure that all personnel are properly trained on all procedures and wear the proper
PPE when installing cable.
- Review or complete JSA per Program Requirements (Section 5.0)
Technicians-
- Follow all the procedures within this OPP and install cable properly when in the shop
environment or jobsite.
- Wear the proper PPE at all times when performing these tasks.
- Review or complete JSA per Program Requirements (Section 5.0)
4.0 DEFINITIONS
Low Voltage Cable- Any electrical cable that has an insulation rated value up to 2000 volts.
OPP- Operations Policy & Procedure
PPE- Personal Protective Equipment
Triplexing- grouping cables in sets of three
JSA- Job Safety Analysis
5.0 PROGRAM REQUIREMENTS

The proper PPE must be worn by personnel performing the tasks within this set of procedures.
At a minimum the following PPE must be worn:
OPP Approver:
- Safety Footwear
- Safety Glasses
- Leather/Protective Gloves
To safely install LV cables, all associated personnel must review/complete a JSA prior to the
start of performing tasks. If task is in a CRI facility, review standard JSA prior to performing task,
if on jobsite, complete the JSA in accordance with SPP 01.10b.
If, at any time during the installation process, the technician is not sure of cable or connection
condition requirements, please refer to OPP 03.02 (QA Low Voltage Cable Inspection).
6.0 PROCEDURE REQUIREMENTS
When receiving and installing ComRent rental cables there are several basic steps that must
be followed to ensure that cables are installed correctly and function properly to allow proper
and full function testing, the following must be accomplished during installation and removal.
Those steps are:
Installation
- Check cable general condition upon receipt

- Check Camlok, Anderson and NEMA Style Plugs
- Route Cables
- Make ComRent Connections
- Check for correct phasing
- Final connections (at customer point)
- QA final check- phasing and route
- Monitor on initial use
Removal
- Customer disconnect cables from customer equipment

- Roll-up
- Coil cable
- Store in shipping container
The above steps will be described in detail below. It is mandatory that all cable be handled
carefully to prevent damage.
6.1 Checking Cable General Condition
6.1.1 Inspect upon receipt. All cables should be clean, coiled neatly and neatly stored in
Buckhorn Boxes. Any issues should be reported immediately to ComRent Shop
Supervisor or Project Manager in charge of the Project / Rental.
6.1.2 Cables should be inspected in accordance with OPP # 03.02 (QA Low Voltage
Cable Inspection)
OPP Approver:
6.2 Inspect all Connector Ends

6.2.1 Camlok connectors
 Ends should remain clean at all times
 Inspect camloks in accordance with OPP # 03.02 for damage and proper
mating surfaces
 Avoid placing CAMLOK ends in or near dirt, mud or debris
 Any debris that enters CAMLOK ends should be thoroughly cleaned prior
to making any connections
6.2.2 Anderson connectors

 Inspect Anderson connectors in accordance with OPP # 03.02 for
damage and proper mating surfaces
 Avoid placing Anderson ends in or near dirt, mud or debris
 Any debris that enters Anderson ends should be thoroughly cleaned
prior to making any connections
6.2.3 NEMA Style Connectors

 Inspect NEMA style connectors in accordance with OPP # 03.02 for
damage and proper mating surfaces
 Avoid placing NEMA connector ends in or near dirt, mud or
debris
 Any debris that enters Nema connector ends should be thoroughly cleaned
prior to making any connections
6.3 Cable Routing – Note: For the purpose of this document only camlok style cable
will be covered. Routing is critical to ensure that cables are capable of carrying
their full amperage rating.
It is recommended that a site walk be completed prior to any cable installation to

review cable path and installation with customer. Walk the intended cable path
and note any obstacles that must be avoided, traffic areas, and connection
points. Any site specific obstacles must be addressed, some of these are:
- Required vertical runs or cable suspended from structures
- Is any edge protection required?
- Any sharp bending radius requirements
- Will cables be suspended over water and if so what are the tide levels if
cable is being run to a ship/vessel. Leave slack for high and low tide.
- Will cable be run through doorways, down hallways, upstairs, through
cable troughs?
OPP Approver:
- There are many factors that contribute to cable capacity. The most
common critical factors are:
6.3.1 Cable Run Length – Should be as short as possible. The longer the length of
cable, the more voltage drop is possible. Cable run length is proportional to
voltage drop and therefore power delivered.
6.3.2 Ambient Temperature– Temperature above the 86C ambient will de-rate cable
ampacity. Per NEC/NFPA70 table 310.15 (B) 17:
 4/0 type W cable is rated @ 405 amperes 90C rise (194F) over a 30C
(86F) ambient (in free air).
 1/0 type W cable is rated @ 260 amperes 90C rise (194F) over a 30C
(86F) ambient (in free air).
 For Ambient temperatures above 30C (86F), utilize the derating table
below:

- Ambient temperature (research temperature on date of install and projected
temperatures during operations). If temp is 70°F on date of install, and rental is
2 months, will projected weather pattern indicates that temps will rise to
100°F? If so, the above Temperature Correction Table must be utilized.
OPP Approver:
6.3.3 Cable Placement
 Correct Placement
ComRent practices a method known as the “Triangular Triplex” method. This means
that the cables are routed A/B/C – A/B/C – A/B/C – etc.… in a triangular pattern. This
ensures that the cables will operate with the least risk, lowest temperature, and the
lowest cable current de-rating.

Triangular Triplex Method
 Incorrect Cable Placement
 Cables shall not be placed all A phase, then all B phase and C
phase (or all piled on top of each other). This will result in a
reduction of the current carrying capacity of the cables.
Extreme caution should be taken to avoid this occurrence. Note that the amperage
rating ComRent utilizes is per NEC/NFPA70, which is in “free air”.
 If the proper layout is not used, the following will result:

 Inductance in the cable ends, which could hog the load and overheat
and cause a fire.
 A reduction of the current carrying capacity of the cables.
 Severe damage to insulation which may result in electric shock.
 Cables may not be coiled when energized. Energizing coiled cables
can create induction and cause a fire which will destroy the cable.
OPP Approver:

Improper Cable Layout Proper Cable Layout

6.3.4 Installation Guide:
 Cable Layout
 Begin by plotting your cable route, but be sure to
consider the following:
 Choose the shortest path
 Avoid heat sources or exhaust discharge
 Avoid sharp edges or other obstructions
 Customer traffic
 Vertical path/runs- see Attachment (A)
 Once the path has been established, run one phase

separately to establish how all other cables will be placed. Note: if
multiple cables are being run per phase, just run one cable to
determine path and then tri-plexing (below) will come into play.
Note: When installing cables, it is imperative to communicate with the customer the
intended cable route to eliminate the possibility of the cable being placed in a traffic
area. Cables CAN NOT be walked on by pedestrians or driven over by forklifts,
vehicles, etc. This will damage cable and is considered a safety hazard.
 Grouping and Tri-plexing
 Once three conductor-phase passes have been

made, use the lanyard (located on each cable) to tie
the cables into the triangular tri-plexed pattern as
discussed in the previous section.
OPP Approver:
 When grouping the conductor passes, be sure to follow these

procedures.
 Use each cable’s lanyard at the beginning, middle, and front

of each 50-foot pass
.
 Keep the triangular pattern consistent throughout each run.
 Identifying Phases
NOTE: The use of bright colored ‘zip-ties” is recommended to secure

cable and assist in signaling a trip hazard
Cross-Phasing is a hazard that is easily caused, but it is even

easier to prevent.
 Run each phase individually and marking
 Color code your conductors with phase tape on each pass

as you are running the cable, not after the fact.
 In addition to color coding each conductor, you can color code each tri-plexed
group. This will help identify any issues that may be caused by loose
connections.
 Finished Cable Pass
 After finishing the first tri-plexed group cable

pass, now is a good time to re-check the
following:
 Cable Connections
 Phase and group identifiers
 Female end is on the Load Bank side and
the Male end is on the customer connection
end or power source end.
6.4 QA Check Phasing
6.4.1 After all cables have been connected to the ComRent equipment (but not
customer equipment) a continuity check shall be completed to ensure that no
cross phasing has occurred during installation. At the customer end, take a hand
OPP Approver:
held multimeter and do a continuity check of each phase cable to ensure that
they connected properly.
Example: If you have multiple cables per phase run to the ComRent equipment and
the phases are marked as follows:
A phase- Brown
B phase- Orange
C phase- Yellow
Ground- Green
6.4.2 Check all of the A phase (Brown) cables to ensure continuity.

Once this has been confirmed, perform the same function on the other phases
and ground.
6.4.3 If, during anytime, it is discovered that any of the cables for that phase do not
have continuity, mark the cable and continue with the remaining cables. Once
going through all the cables, you should discover the other cable(s) without
continuity with the assigned phase, this will help eliminate the possibility of
rework. Once the cables have been verified, correct and relabel the cable with
the correct phase tape, etc.
6.4.4 After the continuity check has been verified, check a cable from each phase to
other phases and ground for a possible short, this will verify that there are no
phase to phase or phase to ground shorts. Do not be alarmed if an initial test
indicates a short, if you get continuity, check the equipment schematics, there
may be a control power transformer or meter in the circuit causing an short. If
that is the case, remove the fuses for that component and recheck. Please
make sure any items removed are replaced at the end of the testing.
6.5 Make Customer Connections

6.5.1 ComRent by rule, does not make connections to the customer equipment, it
is the customers responsibility to make those connections. ComRent
personnel can run cables and connect to all of the rental gear under
ComRent’ s authority but not the customer final connection point. ComRent
shall have all cable laid out and marked properly for the customer to make
connections. ComRent personnel to review all phasing and cable layout with
customer prior to connections being made.
6.6 Final Cable Install QA Check

6.6.1 Once all connections are made and cable run, ComRent shall review the
entire cable installation and indicate any possible weak points and correct.
6.6.2 Recheck all cable connections for proper connection.
OPP Approver:
6.7 Initial Use Cable Monitoring
6.7.1 ComRent/ Customers should monitor individual cables with an ammeter

and thermal gun once connected and placed under load. The purpose of
this is to enable the technician to identify cables with possible loose
connections.
6.7.2 Technicians should observe that the cables are not showing any physical
signs of malfunction such as: arcing, burning, or changing color.
6.7.3 When cables do have amperage differences, immediately remove
power and check for cable connection and cable end cleanliness.
WARNING: NEVER DISCONNECT ANY POWER CABLES WITHOUT ENSURING POWER

HAS BEEN REMOVED AND PROPER LOTO HAS BEEN COMPLETED. THIS MUST BE
DONE BY “SELF CONFIRMATION” AND “SELF VERIFIED”.
EXAMPLE: if there are six (6) cables per phase and one is detected to be carrying
very little amperage and the others are carrying more than the calculated load then
there is a possibility that the one carrying the low amperage has a loose connection.
This can cause higher than normal resistance which will limit the current flow. The
procedure for this is to mark this cable, remove all load then double check the cable to
ensure a proper connection, re-apply the load and confirm that the correction made
has improved the current carrying capacity of the cable.

Thermal Gun AMP clamp

6.8 Removal of Cable
WARNING: NEVER DISCONNECT ANY POWER CABLES WITHOUT ENSURING POWER

HAS BEEN REMOVED AND PROPER LOTO HAS BEEN COMPLETED. THIS MUST BE
DONE BY “SELF CONFIRMATION” AND “SELF VERIFIED”.
6.8.1 Customer Disconnect- ComRent by rule, does not make connections to the
customer equipment, it is the customers responsibility to make those
connections and disconnect. ComRent personnel can roll up cables and
OPP Approver:
disconnect to all of the rental gear under ComRent’ s authority but not the
customer final connection point. The customer must disconnect all cables
from customer equipment prior to ComRent rolling up cables.
6.8.2 Disconnect all cables from rental equipment after verification of NO
POWER to equipment. If a cable winder is not available, the technician is to
roll up all cable in small rolls that will allow storage. Utilize cables straps to
secure cable and store in buckhorn
boxes.
Proper Cable Storage Improper Cable Storage
6.9 Returning Cable:

6.9.1 It is the Customer’s responsibility to ensure that allcables are returned in the
same satisfactory condition in which they were delivered. It is also ComRent
personnel’s responsibility to do the same when at a jobsite.
6.9.2 Cables will be counted at jobsite to ensure no cables have been removed or
stolen from site. If any missing cable are discovered notify the site contact,
Shop Supervisor and Project Manager if applicable.
6.9.3 ComRent location when returned. Customers will be notified of missing

cables and will be given the opportunity to locate the missing cables.
Customer will be subject to rental charges until the missing cables are
returned to ComRent.
NOTE: When a ComRent Technician is on a jobsite to assist with or perform the cable layout,
they are not to make any connections to the customer’s equipment. ComRent Employees are
only authorized to connect to ComRent Equipment. It is the Customer’s responsibility to make
all cable connections to the equipment being tested.
OPP Approver:
7 TRAINING REQUIREMENTS
All Operations personnel shall be trained on all steps within this policy to ensure that
cables are installed properly. The Shop Supervisor shall ensure that a full review of all of
the requirements within this policy are reviewed with each technician and a demonstration
is completed of each step to ensure that all technicians are aware of the requirements.
8 References
-SPP # 01.10b- Safety Policy JSAs

-OPP # 03.02- QA Low Voltage Cable Inspection Procedures
-NEC/NFPA70- National Electric Code
-NEC/NFPA70 table 310.15(B)17- Allowable Ampacities of Single Conductors Rated up to
2KV in Free Air
-Cable/Temporary Installation Reference Sheet- Attachment (A)

Low Voltage Cable Handling (ComRent)

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Operations Policy & Procedure

Revision Date: 9/22/16

5.0 PROGRAM REQUIREMENTS

6.0 PROCEDURE REQUIREMENTS

- Check cable general condition upon receipt

- Customer disconnect cables from customer equipment

6.1 Checking Cable General Condition

6.2 Inspect all Connector Ends

6.2.2 Anderson connectors

6.2.3 NEMA Style Connectors

It is recommended that a site walk be completed prior to any cable installation to

6.3.3 Cable Placement

 Incorrect Cable Placement

 If the proper layout is not used, the following will result:

 Once the path has been established, run one phase

 Grouping and Tri-plexing

 Once three conductor-phase passes have been

 When grouping the conductor passes, be sure to follow these

 Use each cable’s lanyard at the beginning, middle, and front

NOTE: The use of bright colored ‘zip-ties” is recommended to secure

Cross-Phasing is a hazard that is easily caused, but it is even

 Run each phase individually and marking

 Color code your conductors with phase tape on each pass

 Finished Cable Pass

 After finishing the first tri-plexed group cable

6.4 QA Check Phasing

6.4.2 Check all of the A phase (Brown) cables to ensure continuity.

6.5 Make Customer Connections

6.6 Final Cable Install QA Check

6.7 Initial Use Cable Monitoring

6.7.1 ComRent/ Customers should monitor individual cables with an ammeter

WARNING: NEVER DISCONNECT ANY POWER CABLES WITHOUT ENSURING POWER

WARNING: NEVER DISCONNECT ANY POWER CABLES WITHOUT ENSURING POWER

Proper Cable Storage Improper Cable Storage

6.9 Returning Cable:

6.9.3 ComRent location when returned. Customers will be notified of missing

-SPP # 01.10b- Safety Policy JSAs

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