Mineral Insulated Metal Sheathed cable

Introduction

Mineral insulated cables consist of high conductivity copper conductors insulated

by a highly compressed white powder (magnesium oxide). A seamless copper
sheath encapsulates the conductors and powder. This type of cable originated in
France and was introduced into the UK in 1936. The first company to market
these cables in the UK was Pyrotenax and from this name came the term 'pyro'
which is sometimes still used when referring to this cable. The cable is made by
placing solid copper bars in a hollow copper tube. The magnesium oxide powder
is then compacted into the tube and finally the whole tube, powder and copper
bars are drawn out by pulling and rolling. This reduces the overall size whilst
further, compressing the powder. In this handout we will look at the following

• Properties of MIMS cables

• Terminating MIMS cables
• Practical termination of MIMS cables
• Running of cables
• Testing and fault finding

Properties of MIMS cables

Mineral insulated cables have very good fire resisting properties; copper can
withstand 1000°C and magnesium 2800°C. The limiting factor of the whole cable
system is in fact the seal and where a higher working temperature is required
special seals must be used.
The cable is very robust and can be bent, or twisted within reasonable limits.
Relative spacing between the conductors and sheath is maintained when the
cable is flattened hence maintaining the cable’s insulation properties.
MI cables are non ageing (many cables installed in the 1930s are still in
operation today).

The cable is completely waterproof although where it is to be run underground or

in ducts a PVC oversheath must be used.
Bare copper unsheathed MI Cables do not emit smoke or toxic gases in fires.
For a given a cross sectional area, MI Cables have a very high current carrying
capacity.

Where PVC oversheath is used the reduced volume of PVC in comparison with
PVC insulated cables keeps down smoke output. Special oversheaths are also
available where a further reduction of flame propagation is required.
The copper sheath can be used for earth continuity saving the need for a
separate protective conductor.

Terminating MIMS cables

Mineral insulated cables must be sealed at each end otherwise the magnesium
oxide insulator will absorb moisture resulting in a low insulation resistance
reading. A complete termination comprises of two sub assemblies each
performing a different function.

Seal

The purpose of the seal is to exclude moisture from the cable. The seal consists
of a brass pot with a disc to close the mouth and sleeves to insulate the
conductor tails. Compound is used to fill the pot as shown in diagram 1 below.

Gland

This is used to connect or anchor the cable; the gland consists of three brass
components.

Practical termination of MIMS cables

The first thing that must be done when terminating MI cables is to strip off the
copper sheath. If the cable has a PVC oversheath, then this must be removed
before the copper sheath. Stripping off the copper sheath can be carried out in
several ways although all of them require practice before the task can be carried
out in a reasonable time.

Stripping

Using stripping bar (Fork ended stripper)

First the cable sheath is started or broken away with side cutting pliers as above.
Then the torn off sheath portion is flattened and the slot of the stripping bar
pushed into the torn off sheath. The stripping bar is then rotated whilst keeping
the bar at a 45° to the cable. Diagram 3 illustrates this method.
Diagram 3

Using rotary stripping tools (Joistripper)

Rotary stripping tools are available in many shapes and forms. They are much
easier to use than either side cutters or the stripping bar but can be difficult to set
up. This is no problem if the same size cables are being used all the time.
Rotary strippers usually require a good square end to the cable. The stripper is
then pushed over the cable a little pressure applied and then rotated. If the
sheath is to be stripped for a longer distance, then the sheath being removed
should be cut away at intervals to avoid fouling the tool. Another advantage of
the stripping tool is that a ringing tool is not required. When the stripping tool has
reached a required position a pair of pliers are applied to the cable sheath and
the stripper is further turned. Diagram 4 illustrates one type of rotary stripping
tool.

Diagram 4
Ringing cable sheath

Before the pot can be fixed the sheath must have a good clean circular end. To
achieve this we use a ringing tool, which makes an indent in the sheath. This will
be required when the sheath is stripped with either side cutters or the stripping
bar, but is not necessary as previously mentioned when rotary strippers are
used. Diagram 5 overleaf the ringing tool method.

Diagram 5

Actions prior to fitting the pot

Before fitting the pot a check should be made that the gland nut and olive are in
position. If the cables have the PVC over sheath then a shroud must be fitted.

Fitting the pot

The following describes the fitting of a screw on pot. Pots are best fitted using a
pot wrench. This ensures that the pot goes on square. The pot has an internal
thread, which screws onto the copper sheath. The pot should be screwed onto
the copper sheath until it just lines up in the inside of the pot. Finally the pot is
tapped to empty the pot of any filings or loose powder. Do not be tempted to
blow into the pot as the moisture in your breath could reduce the insulation
resistance of the magnesium oxide causing a short circuit at a later stage.
Diagram 6 below illustrates fitting of the pot seal.
Diagram 6

Actions prior to sealing

Before sealing, the conductors should be wiped with a clean dry rag to remove
any loose powder. If the cables have become twisted they should be
straightened by being firmly pulled with pair of pliers. Care should be taken when
pulling conductors so that they are not stretched, resulting in a reduced (cross
sectional area) and subsequent reduction in current carrying capacity.
Cable insulation and disc should be prepared. The insulation is usually neoprene
rubber sleeving and this is cut to the required length. The sleeving is then fitted
to the disc. The disc also ensures the conductors are kept apart whilst the
compound is inserted into the pot. Diagram 7 below illustrates this

Diagram 7

Sealing the pot

Filling of the pot with compound affects the sealing. It is important that the
compound is filled from one side only, directed towards and in between the
conductors. This avoids air locks, which could lead to condensation problems.
Hands should be clean when using the compound and the compound should be
kept covered to avoid entry of dirt. Diagram 8 illustrates sealing the pot.

Diagram 8

Crimping

Before the crimping tool is applied any excess compound should be removed.
The crimping tool is applied and gradually tightened whilst keeping it straight.
The operation should be stopped at intervals to allow the compound to seep out.
Diagram 9 overleaf illustrates the crimping tool.

Diagram 9
Finished seal and identification

When crimping is completed the seal should be tested to ensure a high value of
insulation resistance between cores and from cores to the copper sheath.
Having done this, the cable can be run out and the other end sealed. The whole
cable is then insulation tested and the conductors are given a continuity test to
indicate which conductor is which before identification.

Gland connection

When the cable has been tested and conductors identified, the gland must be
tightened up and connected into the equipment or accessory in which it is being
terminated. After the conduit thread has been tightened into the accessory the
back nut must also be tightened. This will compress the olive ring inside the
gland thereby providing earth continuity. Once this has been tightened it is very
difficult to remove.

Types of gland

Standard glands are usually used and have their sizes stamped on them e.g. 2LI
meaning 2 core, light duty, 1 mm² csa or 4H6 meaning 4 core, heavy duty 6-mm²
csa. The size of the conduit thread will depend on the overall size of the cable
being used.

Running of cables

One of the advantages of MI cables is that they can be run on the surface as well
as being run under plaster. When they are run on the surface, for neat
appearance it is imperative that they are run straight. Lines should be run out
before fixings are made and care should be taken not to twist the cable
unnecessarily before installation. Fixings are made either with one-hole clips or
two hole saddles. Screws are usually brass round heads. Where a large
number of cables are run together an adjustable saddle is available that will take
many cables. Often MI cables are run on cable tray. This is used to provide
easier fixing, neat appearance and cleanliness. It also means that a great
number of cables can be run together. Where several cables leave or enter an
enclosure e.g. at a distribution board, the cable should be distributed equally. If
there are too many cables to fit into one row, two staggered rows of holes should
be drilled.

Testing and fault finding

The seal should be visually inspected for obvious defects. If there is a minor fault
e.g. incomplete crimping it may be practicable, just to repeat the operation.
However it may be necessary to remove the seal and re-terminate. After both
ends of the cable have been terminated with permanent seals, the cable should
be subjected to an insulation resistance test using a voltage appropriate to the
intended operating voltage in accordance with BS7671. The purpose of this
initial test is to check for major faults e.g. short circuit within the pot, in which
case the fault should be located and rectified. The insulation resistance should
be noted and compared with the value measured at least 24 hours later. The
second reading should be at least 100MΩ and have risen from the initial value.