MEDIUM VOLTAGE TERMINATIONS | Cable installation Products (Py Lid : INSTALLATION INSTRUCTIONS HEATSHRINK TERMINATION KIT FOR THREE CORE INDIVIDUALLY SCREENED XLPE ARMOURED CABLE Q Q “f VOLTAGE CLASS: 6.6kV - 36kV INDOOR & OUTDOOR — SSis kit should be visually inspected for bessible damage and installed in accordance with this installation instruction. These instructions are not Intended as a substitute for adequate training and experience in good safety practices, cf Always keep the work area and cables as clean as possible. & Use a “clean burning” torch, e.g. A Propane gas torch which does not have any deposits of conductive contaminants. ®& Adjust the torch to a soft blue flame with an orange/yellow tip, “pencitlike” blue flame should be avoided. & — Keep the torch aimed in the shrink direction to pre-heat the material, @ Always apply the heat circumferentially around and outwards on all tubes, this ensures correct heat application, which results in the correct material wall thickness. | & As heatshrink has a very thick wall the torchiflame has to be moved continuously to ensure proper shrink and avoid damage due to overheating in one place. © Shrink the tubing and molded parts as recommended and indicated in the instructions. Sf Ifthe tubing needs to be cut, always wait until the tubing has cooled and cut with a sharp knife ensuring that there are no jagged edges on the tube. &/ — Onoe shrunk, all of the tubing should be smooth and free of any wrinkles, inner components clearly defined. Signs of wrinkles indicates incorrect heating and possibly air entrapment. & Read all instructions carefully before commencing. Cable ends should have been sealed (End cap) and checked for moisture before proceeding, Always keep the cable outer sheath clean and free from dust and mud. Take extreme care not to nick or cut the XPLE core insulation when removing the copper tape screen and semi-conductive layer. Ring cuts on the copper tape screen and semi-conductive layer must leave smooth edges (not jagged). Never cut too deep when ring cutting the semi-conductive layer on an XLPE cable. Use a round file to score the semi-conductive layer. When sanding the XLPE core insulation always sand circumferencially with non-con- ductive silver oxide abrasive paper supplied. Use the cleaning tissues supplied to clean the XLPE core insulation taking care NOT ‘0 wipe onto the semi-conductive layer thus contaminating the XLPE core insulation. Clean and de-grease all surfaces that will come into contact with mastics and tubing. a’ag a R @ aq LX WAIVER: While this information contained in these instructions have been compiled éo the best of our presont nowledga, it Is not intended as reprosentative of warranty of any ikind on our part regarding the suitability of the [produets concerned for any particular sso or purpose, and nelther shall any statement contained havin lo construed as 2 recommondation to infringe any industrial property rights or aa a licence to usa any such rights, ‘Tho ‘Suitability of each product for any particular purpose must be checked before hand with our specialists, GIP. :Prepare the cable Length "L" Me o the geometry of the switch gear (Cable box) “L" = To the length of the ant-track tubing (AAT) supplied with the termination 1.2 Remove the outer sheath and armouring according to “L” and the dimensions shown in Fig! 1.3. Clean and abrade the out \ exposed armouring for a 1 200mm, 14a. Remove the inner bedding, 20mm. above the armour cut. if using cable cleats) 1.4b. Remove the inner bedding, 180mm above the armour cut. (if using cable glands) sheath and tance of NOTE4z Take care not to damage or cut “the copper tape screen when removing the inner bedding. NOTE 2: Mark and tape the top of each core so that the copper tape screens does not unwind. 4.8. Remove the cable illers at the end of inner bedding, take care not to damage the copper tape screens, S00 Omer PVC Tape Copper Tape ‘Screen jx ono Bacuing J —sisel wire Armour + oouter sheath Fig 1. | | | a khan INSTALLING THE INDIVIDUAL TINNE “ned Copper Steen Garh Gra reo <—Cruteh Lo Coppet Tape al spring ‘Sezoon Step 2 Step 3 around the core. | and core. ! CL ep Hold the tinned copper soreen earth braid (TCB) against the copper tape screen, 2.2. Place the roll spring (ARS) on top of the tinned copper screen earth braid (TCB) and wrap it once 2.3 Fold the tinned copper screen earth braid (TCB) tightly back over the rol spring (ARS). 2.4, Wrap the remainder of the roll spring (ARS) around the tinned copper sereon earth braid (TCB) 2.5 Release the tension on the roll spring (ARS), Pull down on the tinned copper screen earth braid (TCB), and slide the roll spring (ARS) down into the crutch. ttn Pac Py ea 23.2 8 42. Apply one layer of grey buly! mastic (AGEN) fo the inner bedeing, under the three tinned copper screen earth braids (TCB). Ailach the mein tinned copper earth braid (TCB) and the three tinned copper screen earth braids (TCB) to the sleo! wire armour (SWA) by means of a roll spring (ARS). Remove any exoe8s material ofthe small braids after clamping. Apply one layer of grey butyl mastic (AGFM) over the three tinned copper screen earth braids (TCB), overlap slighty onto the edge ofthe steel wire armour. Apply a layer of red buly! mastic (ARAM) under and over the mi tinned copper earth bratwater block (FCB) at the point of the solder SEE Ae aka block on the outer sheath, ea) as oll Spring (ARS) Tinned Copper Screen Earth Braid (TB) ey Buy Masts (AGI) Fig 3. Position the semi-conductive breakout booi (ABR) over the three cores and Dull it as far into the crutch as possible. Ensure that the skirt of the semi- conductive breakout boot (ABR) covers the red butyl mastic (ARAM) that was applied to the outer sheath, Shrink the semi-conductive breakout boot (ABR) into place, first healing the shoulder then the skiri and finally the spouts. Apply heal circumferentially and outwards until the semi-conductive breakout boot (ABR) is fully recovered ‘and has achieved a uniform wall thickness, $$ __somi-conelactve Broakout Bool (ABR) ain Tinned Copper Eesth Baid?Water black ree) Fig 4, - CiP.5:4 Place the cable into its final position to determine its length. INDOOR: Shape and cut the cores to their final position, (Relevant to phase colours and bushings) NOTE 1: Hang the lugs from the bushings to determine the final length and position. NOTE2: Ifthe cores have to be crossed see step 10, OUTDOOR: Shape and cut the cores to their final position, 5.2 Using thin copper binding wire or roll springs (ARS) remove the copper tape screen to dimension “A” depending on the voltage class. NOTE: Take cargnot to leave any jagged edges 3 i VOLTAGE CLASS “A” MINIMUM 3.8/6.6 KV” 250mm 6.35/71 KV 250mm 12.7122 kV 360mm 19/33 kV 480mm 5.3 Measure 20mm from the end of the copper tape screen and remove the semi-conductive layer, by scoring circumferentially (round file) at the ‘mark, then tram-line (wo or three lines longitudinally, 5.4 When removing the semi-conductive layer, take care not to cut or nick the XLPE insulation, 5.5 Ifthe XLPE insulation is damaged uring removal of the semi-conductive layer the damage must be sanded out by abrading the XLPE insulation radially with the abrasve paper supplied. 5.6 Clean the XLPE insulation thoroughly with the cleaning tissue supplied. When using the fluid soaked cloth take care ot fo touch the semi-conductive layer with the cloth, Final Position / Length | GIP. : }-——XLPE Insulation Semi-Conductve | Layer Copper Tape Screen a o6.1 Measure 20mm from the end of the Copper tape screen and “MARK” onto | __ the copper tape screen, | 62. Before appiying the yellow stress reliet | mastic (AYSM), ensure that the XLPE insulation is thoroughly cleaned and iree of soretches and nicks | 63 Apply 20% stretched, haif overiapped layers of yellow stress relief mastic (AYSIU) starting 5mm onto the copper {epe screen, over the semi-conductive layer and overlapping 10mm onto the XLPE insulation, sure that no air is trapped at the semi-conductive screen cut and that the slop has been smoothly file. Position the stress control tubes (ASC) with the bottom of the stress control |. tubes (ASC) on the “MARI” | 66. Shrink the stress control tubes (ASC) into place, Commence by applying heat circumferentialy, starting at the botiom ‘and then outwards unl he tubes have fully recovered, have achieved a Lniform wall thickness and are without voids. ress conto! “Tue (ASC). MARK "TE: Under no circumstances must the stress control tubes (ASC) ever be cut. 7.1. Using the string supplied cut and remove the XLPE insulation to a dimension of “3” where “B"= the length ofthe lug barrel ng cmecetg ee plus Smm, Teke care nol lo damage or nick TEM | the conductor, 7.2 Minimum Distances: From the top of the stress control tube | (ASC) to the bottom of the Lug = “4” ; VOLTAGE CLASS H” MINIMUM 4 aren 3.8/6.6 kV 120mm Mirerum} 6.35/11 kV 420mm, Pislanoe 12.7122 kV 200mm + 19/33 kV 250mm 7.3. Ifusing crimp lugs insert a small bell of red butyl mastic (ARAM) into the barrel of the connector/lug and push the connectorilug onto the conductor until the red butyl mastic (ARAM) fils the inspection hole. Altach/erimp the connectorilug in accordance with locally approved methods, remove any sharp edges. Fig 7. i supplied, clean the connector/lug and | XLPE insulation, 7.8 Apply one overlapped layer of red butyl f mastic (ARAM) over the lug barrel enc ‘cs ena Seco || ote! Torque sheer ligs are recommended. : : 7 | 7.4 Using the pre-soaked cleaning wipes —_— a On sana catia aPC pros Seaiosteee tan eins mS | 40mm onto the XLPE insulation. Cc ie ‘Pp Sel seae hr a A | J8.1 Apply one layer of red butyl mastic (ARAM) over the Sora, spout of the semi-concluctive breakout boot (ABR), < rs 8.2 Place the anll-track tubes (AAT) over each core, and position them so that they cover the red butyl mastic Seay (ARAM) applied to both the lug barrel and the semi-conductive breakout boot (ABR) spout. 0 mdaon 8.2 Shrink the anti-track tubes (A/T) into place. ‘Commence at the bottom of the tubes and apply heat circumferentially into the crutch and then upwards towards the lugs/connectors until the antisrack tubes (AAT) ace fully recovered and have achieved a uniform wall thickness. 8.4 Cut and remove any excess antijtrack tubing (AAT) to Stove aa ‘expose the lug palm, only after the ant-track lubes (AAT) bade! have cooled sufficiently. 8.5 Fitthe identification tabel onto the outer sheath by means of @ cable tie, NOTE: See Step 10 for details on core crossing and minimum ‘core clearances. THE 11kV INDOOR TERMINATION IS NOW COMPLETE (All 22 & 33 KV, refer to step 9) ALL OUTDOOR TERMINATIONS ies 941 The antrack ran sheds (AAS) must be installed whilst oe {he anibtrack tubing (AAT) i tll warm. Ifthe antirack tube (AAT) isnot warm, fst re-heat the antirack tube (AAT) and ‘hen install the ant-rack rain sheds (AAS). 8:2 The antrack ren sheds (AAS) shouldbe staggered to ensure thel the anl-track rain sheds (AAS) of opposite Phases DO NOT fouch one anather once the termination ‘sin ls final poston NOTE: Always maintain clearances as per the minimum core Clearances indicated in step 10. 83 The no of antitrack ran sheds (AAS) neoded are indicated Inthe table below. fe INTTRACK RAIN SHEDS PER CORE) vouTAge ie me 38.5 A o. f Serine 2 z ‘erreai| a Cras i z 4 2.4 Slide the ‘st (most bottom) ant-rack rain shed (AAS) into position by placing il atthe bottom af the stress control tubes (ASC) and shrink into position by applying heat crcumferen- tilly to the spouts until they have achieved a uniform wall thickness and are fully recovered, 8.5 Strategically positon the other antt-rack rain sheds (ASS) according to the dimensions shown in the diagram £76mmn apatt and in accordance with the minimum core clearances in step 10. 2.6 Shrink the remainder of the ant-rack rain sheds (AAS) inivduatty into positon by applying hest circumfecentially 'o the spouts until the rin sheds are fully recovered and have achieved a uniform wall thickness, ‘NOTE:Only the spout of the antirack rain shed (AAS) will shrink. 8.7 In the event of inverted installations, the anti-track rain sheds (AAS) must bo inverted, THE OUTDOOR & 22/33 kV INDOOR TERMINATION IS NOW COMP! ciP stn Pact Py ta Fig 8.|| When the cores of a XLPE termination have ‘o be crossed lo enable the correct phasing, || acways TH CROSS T/ | a E AREA. This is th || area below the stress control tubes (ASC), Refer to: | SaNss762013 — NRS ota: 2013, TABLE: 4 and TABLE: 5 0n pg 10 Figures: C1, C2, C4 on pgs 23 and 24 “2° Minimum phigroundlearth clearances ‘must be maintained above the slress control tubes (ASC); >" Minimum phiph clearances atthe bottom of ‘he sitess control tubes(ASC) 3.8/6.6 KV = damm 6.35111 KV = 55mm | 12.7122 kV = 110mm | 19133” ky = 165mm Note? Do not under any circumstances place any materials/objects Inbetween the cores to force separate the cores. Note 2. These dimensions also apply to the clearance botween the aanti-traci rain sheds (AAS). Note 3, Before shaping/bending the cores, reheat them to approx, , 70 deg C. | Note 4, Minimum bending radius = 45 x diameter of cable.