User manual SHRINK POLYMER SYSTEMS HEATSHRINK JOINT TO SUIT SINGLE CORE 7.2-36KV POLYMERIC CABLE TYPE SPAJ

INSTALLATION INSTRUCTION HEATSHRINK JOINT TO SUIT SINGLE CORE 7.2-36kV POLYMERIC CABLE TYPE SPAJ © DATE OF ISSUE: 26.11.03 CABLE PREPARATION COPPER TAPE SCREEN OR LEAD SHEATH EXTRUDED/SOLUBLE SCREEN PRIMARY INSULATION COPPER TAPE SCREEN OR LEAD SHEATH Fig 1 80 15 A X X A 15 80 COPPER WIRE/COPPER BRAID SCREEN PRIMARY INSULATION BRAID ARMOUR IF PRESENT EXTRUDED/SOLUBLE SCREEN COPPER WIRES TWISTED BACK Fig 2 30 80 A X X A 80 30 NOTE:- IN FIG 2, EXPOSE CABLE BY FURTHER 30mm ONLY IF BRAID ARMOUR IS PRESENT FOR ALUMINIUM WIRE ARMOUR (AWA) SEE FIG 13-14 VOLTAGE TABLE VOLTAGE A X 7.2kV 120mm HALF 12kV 130mm CONNECTOR 17.5kV 150mm LENGTH 24kV 170mm +5mm 36kV 220mm HEATSHRINK TUBE REQUIREMENT TCC GMT GIS TMI 1 --1 1 1 --1 1 1 1 1 1 1 1 1 1 1 2 1 1 SIZE (mm ) 16-35 50-95 120-185 240-400 500-1000 2 MAX CONNECTOR LENGTH 100mm 110mm 150mm 220mm 250mm Table 1 TCC = BLACK STRESS CONTROL TUBE GIS =INSULATION/CONDUCTIVE COMBINED TUBE GMT = RED INSULATION TUBE Table 2 TMI = OUTER SHRINK SEALING TUBE Cable Preparation 1. Ensure that the Cables overlap before proceeding. Copper Tape Screen Or Lead Sheath 2. Expose the Copper Tape Screen or Lead Sheath by 80mm and the Black Semi-Conductive Screen by a further 15mm beyond it (See Fig 1 and Table 1 for dimension A dependant on voltage class). If the Cable is Aluminium Wire Armoured expose Armours by 40mm and Inner Bedding by 35mm (See section 22-24 and Fig 13-14). Copper Wire Screen 3. Bend back the Wires onto the Outer Cable Sheath, these will be bonded at a later stage. Expose the Black Semi-Conductive Screen by 80mm (See Fig 1 and Table 1 for dimension A dependant on voltage class). Braided/Woven Copper or Phosphur Bronze Screen 4. If Cable has a Braided/Woven Copper or phosphur Bronze Screen, expose this by 30mm (See Fig 2). Expose the Black Semi-Conductive Screen by a further 80mm and the A dimension according to voltage class shown in Table 1. Black Extruded Semi-Conductive Screen Removal 5. Remove the Black Screen layer using a suitable Tool. Avoid scoring and damage to the Primary Insulation beneath. Note:- The Screen should be completely removed leaving a cleanly cut end. Do not roughen the Primary Insulation with Emery cloth. Screen removal Tools can be provided for both `Peelable' and `Bonded' Screen layers, see Shrink Polymer Systems catalogue page 38. Soluble Semi-Conductive Screen Layer 6. Using a Non-adhesive Tape, cover the top of dimension A and remove the Black Semi-Conductive soluble layer above using a clean cloth and suitable solvent. Note:- Remove all traces of Carbon and remember to remove the Tape. It is good practice to flame brush the Primary Insulation and Screen cut. This has the effect of removing any minor surface scratches or burrs that may be present. Nested Tube Sequence GIS COMBINED TUBE GMT RED INSULATION TUBE/S TCC STRESS CONTROL TUBE 7. Before proceeding, position the Connector Insulation Tubes down one or both of the Cables ends if the Tubes do not "Nest"as shown in Fig 3. Note:- Picture shows one GMT Tube making the Joint suitable for 17.5 and 24kV. For 12kV, only TCC Stress Control and GIS combined Insulation/Conductive Tubes are required. GIS Fig 3 GMT Stress Relief 8. Remove the Primary Insulation for ½ length of the Connector + 5mm. 9. Crimp the Connector with the correct Tool/Die and remove any sharp burrs. STRESS TAPE 10. De-grease the Connector and Primary Insulation with the Tissues provided. 11. Apply the Yellow TS 31785Y Stress Tape over the Connector with half width overlap and double stretch. Important:- Fill in the gap between Primary Insulation and Connector and extend onto the Primary Insulation by 15mm only. If Reducer Ferrules are used to join different Conductor sizes, ensure Stress Tape is "Tapered" from Connector to the Insulation. 15 15 Fig 4 10mm 15mm 12. Stretch the Yellow TS 31785Y Stress Relief Tape to double its length and apply with ½ width overlap around each Black Semi-Conductive Screen edge so that it overlaps for a distance of 15mm onto the Copper Tapes or Lead Sheath and the Primary Insulation by 10mm as shown in Fig 5. Fig 5 Connector Insulation Tube Sequence 13. Position the Stress Control Tube (TCC) centrally over the Connector overlapping the end of Screen points and onto the Copper Tape Screens (If present) or Lead Sheath. With a suitable heat source, shrink from the centre working all around the Tube to one end at a time. Note:- Allow the Tube to cool before cleaning the surface with the Tissues provided (This improves electrical performance). GIS TCC Fig 6 14. If voltage is higher than 12kV position the required number of Red GMT Tubes one at a time, centrally over the Stress Control Tube and shrink in an even manner (See Table 1 for Tube requirement). GIS Fig 7 15.Position the Combined Insulation/Conductive Tube (GIS) centrally over the Stress Control Tube (Or Red GMT Tube depending on voltage) and shrink as previous. Keep the flame on the move to ensure an even wall thickness. 4SC HV GREY TAPE GIS 20 16. Take the two pieces of 4SC HV Grey Mastic Tape and apply whilst stretching to the ends of the GIS Tubes and Copper Tape Screens (If present) or Lead Sheath by approx 10mm each as shown in Fig 8. Fig 8 Screening - Copper Tape Screen KM 50 COPPER SCREENING BANDAGE DWHV DWHV SCT Fig 9 ROLL SPRING 17. Wrap two layers of Copper Screening Bandage (KM 50) with 50% overlap over the Joint area and secure to the Copper Tape Screens or Lead Sheath by either Soldering or the preferred Roll Spring method. Screening - Copper Wire Screen DWHV SCT Fig 10 BINDING WIRE 18. Wrap a layer of KM50 Copper Screening Bandage over the joint area and secure. Bend the Copper Wire Screen back over the Joint and twist the ends together to form a stranded Conductor. Join the two Wire Screens with a Crimp Ferrule as shown in Fig 10. Wrap a further layer of Screening Bandage over the Joint and secure at each end with binding wire. Screening - Copper/Phosphur Bronze Braid Screen KM 50 COPPER SCREENING BANDAGE DWHV DWHV SCT Fig 11 ROLL SPRING BRAID SCREEN 19. Wrap two layers of Copper Screening Bandage (KM 50) with 50% overlap over the Joint area and secure to the Copper/Phosphur Bronze Braid Screens by either Soldering or the preferred Roll Spring method. Outer Sealing OUTER SHRINK TUBE Fig 12 20. Clean and De-grease the outer Cable Sheaths. Position the Outer adhesive lined Shrink Tube centrally over the joint gap. Start shrinking from the centre to one end at a time. Keep the flame on the move to ensure an even wall thickness. The Tube should be wrinkle free and Sealants should be visible at Tube ends. 21. Allow the completed Joint to cool before applying any mechanical strain. If Armour Earthing Required See Fig 13-14 212 D MASTIC TAPE 50 35 Fig 13 22. Fit the Armour Support Rings before wrapping the Heavy Duty Aluminium Cage tightly around the joint gap. Secure to both ends with the Clamps provided. Apply the remaining pieces of 212D Black Tape over the Clamps and any sharp points as shown in Fig 14. Note: Depending on length of Connector used which effects the joint gap, user may need to trim the Cage 212 D MASTIC TAPE 24. Refer back to section 20 and Fig 12 for the installation of the Outer Shrink Tube. Fig 14 ARMOUR CAGE © IMPORTANT NOTICE TO PURCHASER:- Sellers and Manufacturere's only obligation shall be to replace such quantity of the product proved to be defective. Neither the Seller nor Manufacturer shall be liable for any injury, loss or damage, direct or consequential, arising out of the use or inability to use the product. Before using, User shall determine the suitability of the product for his or her intended use and User assumes all risk and liability whatsoever in connection therewith. UNITS P1-P3 GROVEMERE COURT BICTON INDUSTRIAL PARK KIMBOLTON CAMBS PE28 OEY TEL: +44 (0) 1480 861001 FAX: +44 (0) 1480 861002 EMAIL: info@shrinkpolymersystems.co.uk WEB: www.shrinkpolymersystems.co.uk