User manual SHRINK POLYMER SYSTEMS HEATSHRINK TERMINATION FOR 3 CORE PILC BELTED CABLES 12KV

Installation Instruction Heatshrink Termination For 3 Core Pilc Belted Cables 12kV ! ! PLEASE READ INSTRUCTIONS THOROUGHLY BEFORE PROCEEDING INSTALLATION SHOULD BE CARRIED OUT BY A TRAINED COMPETENT FITTER INDOOR OUTDOOR © UNITS P1-P3 GROVEMERE COURT BICTON INDUSTRIAL PARK KIMBOLTON CAMBS PE28 OEY TEL: +44 (1480) 861001 FAX: +44 (1480) 861002 E-MAIL: info@shrinkpolymersystems.co.uk WEBSITE: www.shrinkpolymersystems.co.uk General Fitting Instructions ! ! ! ! ! ! It is highly recommended that suitable tools are utilised for the correct preparation on Paper Cables Use a propane gas torch with a soft flame Avoid a pencil like blue flame which is caused by unregulated supply Keep the flame on the move to ensure even shrinkage of all the materials and also helps to reduce scorching Ensure that all components are kept clean and grease free during installation Allow to cool before applying any mechanical strain Remove Outer Cable Sheath: CONNECTION TYPE STRAIGHT CONNECTION CROSSED CONNECTION LENGTH INDOOR L 650mm LENGTH OUTDOOR L 650mm NOT APPLICABLE X LENGTH OF BARREL + 10% 700mm Table 1 Alternative tail lengths available upon request. Note:- If Terminations are being applied to Armoured Cable, User may wish to use the `Bolt On' Heatshrink type cylinder Gland kit. See Instructions supplied with Gland. Glands Available SPS 318 SPS 319 SPS 320 16-70mm2 Pilc Cable 95-150mm2 Pilc Cable 185-300mm2 Pilc Cable SPS 452 SPS 453 35-185mm2 Picas Cable 240-400mm2 Picas Cable Improved Clearance/Cross Core Kit A kit is available which converts Paper Belted Cable into a Screened Cable which enables greater clearances between Cores and allows a Core Cross if required. SPS 946 70-400mm 2 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. CORES 1. Installation Prepare the Cable to the dimensions shown in Fig 1 (For dimension L see Table 1). Expose the armour wires to 50mm for plumbed connections. De-grease and clean the Lead or Corrugated Aluminium sheath and armour wires. LEAD OR ALUMINIUM SHEATH ARMOUR WIRES L BREAKOUT BOOT Mechanical Earthing Option If using the Heatshrink `Bolt On' Gland with solderless earthing, prepare Cable to dimensions shown. Note:- User may wish to adjust these dimensions so that the Breakout Boot fits down within the Gland Body. See separate instruction sheets for Pilc and Picas Earthing using `Bolt On' Gland with Roll Spring (Lead) and Clamp System (Picas). 100mm 150mm ROLL SPRINGS SHRINK TUBE EARTH BRAID ARMOUR WIRES 2. Belted Cable Preparation Expose the Lead or Aluminium Sheath to a dimension of 250mm from the outer Cable Sheath. 20mm 5mm BELT PAPERS CARBON PAPERS LEAD OR ALUMINIUM SHEATH Unwind the Black Carbon Paper and remove to a binder positioned 5mm from the Metal Sheath cut. Using a further binder, remove the Belt Papers to 25mm from the Metal Sheath cut. BELL THE LEAD SHEATH Fitting the Clear Shrink Sleeves With a clean dry cloth, carefully remove any Grease from the Cores. Position the Clear Shrink Sleeves over each Core approx 50mm up from the Cable Crutch. With a suitable heat sourse, shrink the end's of the Sleeves for about 50mm, before fully shrinking, rotate the Sleeves and push down into the Crutch. Note: Ensure there are no air voids and the Sleeves are wrinkle free, also note that excessive heat may dry out and damage the Paper Insulation. CLEAR SHRINK SLEEVES Fitting the Stress Control Tubes Position the Stress Control Tubes onto the Cores at a distance of 50mm up from the Metal Sheath Cut. Shrink the Tubes one at a time, starting from the bottom working upwards. Ensure that the Tubes are evenly shrunk and aligned. 50mm STRESS CONTROL TUBE Cable Crutch Preparation Remove the Grey Mastic Crutch Wedge from its container and insert well down into the Cable Crutch so that any Air gaps are eliminated. MASTIC CRUTCH WEDGE With tension, wrap the Grey Mastic Tape around the Crutch area and overlap the Stress Control Tubes and Lead or Aluminium Sheath by approx 10mm. Note:- Ensure that the space between the Bell of the Lead Sheath and the entire area between the Cores is fully covered by the Mastic tape to eliminate Air Voids. With a suitable solvent, clean the Metal Sheath before proceeding. 10mm LEAD OR CAS SHEATH 10mm 3. General Cable Preparation Installing the Breakout Boot Slide the 3 Leg Semi-Conductive Breakout Boot down the Cores and press firmly down into the Crutch. The Legs of the Boot should be in contact with the Stress Control Tubes and the Skirt should cover the Grey Mastic Tape and make contact with the Lead or Aluminium Sheath. Shrink the Boot from the centre to one end at a time. The Boot may need to be held in place during installation. SEMI-CONDUCTIVE BREAKOUT BOOT 4. Installing Cable Lugs X Allowing for dimension X (Lug Barrel + 5mm), cut the Cores to suit the fixing point on the equipment being used. Measure a distance of X (See Table 1) back from the end of each Core and remove Insulation. L + 200mm With a suitable tool, install Cable Lugs ensuring that any sharp points are removed. Note:- Where Mechanical Connectors are to be used, user should check that the Core Tubes are able to slide over prior to fitting. 5. Installing Anti-Track Tube Preheat each Cable Lug and wrap two layers of Red Sealant Tape over the Lug Barrel extending onto the Insulation by approx 10mm. Also apply a turn of Red Sealant around the tops of the Breakout Boot fingers. Position the Anti-Track Core Tubes so that they cover the Fingers of the Breakout Boot and the Barrels of the Lugs. ANTI-TRACK TUBE RED SEALANT TAPE Shrink the Tubes starting from the bottom towards the top. Keep the flame on the move to ensure an even wall thickness and that the Tubes are wrinkle free. Allow to cool to hand hot and trim at the Lug end with a sharp knife if necessary. AIR CLEARANCE REQUIRED BY LOCAL SPECIFICATION Indoor Terminations - Requirements DISTANCE (d) PHASE/PHASE & PHASE/GROUND VOLTAGE d (mm) 7.2kV 15mm 12kV 20mm 17.5kV 20mm 24kV 25mm 36kV 40mm TOP OF STRESS TUBE TO LUG BARREL E 30mm 50mm 75mm 95mm 250mm E d Table 2 Note:- Bushing protection boots will be required for the majority of installations. 6. Installation Of Rain Sheds r = SEE d DIMENSION IN TABLE 2 A Strain Relief Shed is required for Outdoor Terminations. This should be fitted first by positioning it as low down as possible but above the end of the Breakout Fingers (Approx 60mm). Continue to install the appropriate number of Rain Sheds in accordance with the details shown in Table 3. 120mm 60mm STRAIN RELIEF SHED NUMBER OF SHEDS PER PHASE VOLTAGE INDOOR OUTDOOR 7.2kV 1 12kV 1 17.5kV 1 24kV 2 36kV 1 3 Table 3 All subsequent sheds should be fitted at a distance of 80mm from edge to edge. Note:- It is advisable not to position rain sheds at the top of stress control tubes, re-position if necessary. If a termination is to be mounted for connection above the equipment i.e in the reverse position, sheds should be installed 0 through 180 as shown. 7. Core Crossing Screened Cable If the Cores on a Paper Screened Cable have to be crossed, ensure that the cross takes place within the screened area below the Stress Control Tubes. STRESS CONTROL TUBES FITTED IN A HIGHER POSITION Belted Cable Core crossing on Belted construction is not recommended unless the minimum clearances are achieved (See Table 2). Note:- Core Crossing/Improved Clearance kits utilising Heatshrink Conductive Tubings can be supplied if requested.