[ Update: Cables ]
Mistaken identity A
The Approved Cables Initiative (ACI) has turned its attention to the misselling of data cable products with copper clad aluminium – something that could ultimately hit contractors’ reputations and pockets
poor purchasing decision, whether made in ignorance, with misinformation, with insufficient research or even on impulse, can be rationalised and
skipped over. But where the decision leaves a longer lasting financial loss or threatens our reputation, it becomes harder to reason away. While over the past two years the Approved Cables Initiative (ACI) has highlighted many instances of defective electrical cables and their inherent safety concerns, more recently it has issued a strong warning about the growing practice of misselling data cable (Cat5e/Cat 6) products with copper clad aluminium (CCA) – a warning that some contractors continue to ignore. Such cables are non-compliant with published national and international standards and, although they don’t present a safety risk, are leaving their mark upon contractors’ reputations.
Warning signs
The potential consequences of installing Cat 5e cable manufactured with CCA, particularly within installations where Category 5e or a CLASS D network has been specifi ed, are clear, and in recent months the ACI has been advising installers to take note and be aware of the warning signs: Products described as CCA Cat 5e or Eco Cat 5e – These descriptions normally appear on the invoices or packaging but rarely on the cable product itself. If a CCA product is supplied, then it should be returned to the re-seller for an immediate refund. Cat 5e products marketed with a restricted installation length (for example, 70 metres) – In these instances, the restriction on the installation length will be as a result of the increased resistance of the CCA conductor. The ACI is aware, however, of incidents where CCA product – used to support ipCCTV cameras – has led to their failure to operate to their full potential when even short lengths of cable are deployed. Because of the increased power demand of IEEE 802.3at power over Ethernet (PoE) devices requiring up to 25.5 Watts, the increased conductor resistance of CCA products severely restricts the transmission to sub-20 metres. Problems with conductors breaking during the punch-down termination process – The reduced strength of the CCA conductor normally leads to poor retention of the wire within the insulation
24 ECA Today July 2012
Squeezed by competitive pressures, a number of wholesalers and distributors are demanding increasingly lower cost products from their supply chain, which in turn forces further compromise in terms of product quality and, ultimately, the most expensive element of the cable, the copper conductor.
If the CCA cable (pictured top) was to meet specifi cation, it should have been at least 60 per cent larger. In this case, the conductor was smaller than standard – so small it would fail to terminate. The resistance was also more than 2.5 times the standard. The bottom cable meets the specifi cation. The top cable was advertised and sold as Cat 5e, with print on the cable
displacement connector (IDC) and consequently poor termination reliability. IDC’s are designed for copper; CCA will snap off immediately or, later on, fail. Problems with oxidisation – Aluminium does oxidise, causing low- and high-frequency problems, which might not occur immediately after testing the installation. After some time, the installation could slow down or even crash. Low frequency testing problems associated with the longer installed channels – Low frequency insertion loss failures on longer channels normally represent a good indicator that CCA has been used. Products described as CCA Cat 5e or Eco Cat 5e generally do not carry a CE mark and therefore should be avoided within the UK and Europe – CE marked products are associated with reputable brand names and the CE mark should appear on the product packaging alongside other compliance statements. It is also worth remembering that CCA products are unlikely to stand up to scrutiny by an independent authority or a knowledgeable end user.
Misrepresentation
Iain Ballingall, spokesperson for the ACI, says: ‘While the dangers associated with CCA products are not life threatening, as with faulty electrical cables, they can have a disastrous effect upon a company’s reputation and livelihood. ‘Some resellers, including some established wholesale outlets, persist in the misrepresentation and misselling of CCA cables into the UK structured cabling market as Cat 5e solutions.
‘Installers should avoid non-compliance by being vigilant. They need to check documentation, including invoices and product data sheets, to ensure what they have purchased is compliant. If anyone is in any doubt regarding a product, they should contact the ACI immediately,’ continues Ballingall. Already this year, the ACI is aware of a number of installation failures that have resulted in the expensive replacement of non-compliant Cat 5e cables with compliant copper products. Quality issues associated with Cat 5e cables manufactured with CCA have been corroborated by the ACI, following sample testing of suspect products obtained from the UK market. In addition, Eco Cat 5e cables – that on fi rst sight may appear to be an environmentally friendly alternative – have also typically been found to use CCA as the conductor, and are also considered as non-compliant.
As the ACI moves on with its lobbying campaign, the issues of misselling data cable, as well as defective electrical cable, have been high on the agenda in its communication with government ministers. Those guilty of either or both issues can be assured that the ACI will continue to bring the matter to the attention of those with the power to achieve change. For further advice, contact the ACI on 020 8946 6978, email
info@aci.org.uk or visit
www.aci.org.uk
Copper (left) compared with CCA conductor (right) visible in patchcord
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