User manual SHRINK POLYMER SYSTEMS HEATSHRINK TERMINATION FOR 3 CORE POLYMERIC CABLES 7.2KV TO 36KV

Installation Instruction Heatshrink Termination For 3 Core Polymeric Cables 7.2kV to 36kV * PLEASE READ INSTRUCTIONS THOROUGHLY BEFORE PROCEEDING * 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 General Fitting Instructions ! ! ! ! ! ! It is highly recommended that a tool suitable for the removal of the semi-conductive screen is used to provide a reliable discharge free termination screen point 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: VOLTAGE 7.2kV 12kV 17.5kV 24kV 36kV INDOOR L 650mm 650mm 650mm 650mm 800mm OUTDOOR L 650mm 650mm 650mm 800mm 800mm LENGTH OF LUG BARREL + 10% X Table 1 Short Cable Boxes Where Short Cable Boxes are used, we would recommend the following minimum distances are maintained from the Stud of the Bushing to the bottom of Cable Box Gland Plate. Voltage phase-phase (kV) Max size of Conductor mm2 11kV 95 11kV 300 600 700 22kV 300 700 --33kV 300 750 --- Min height with straight connection (mm) 550 Min height with crossed connections (mm) 600 The minimum distances shown above can be reduced by 150mm by using Shrink Polymer Systems "Bolt On Earth Glands" type SPS 180 (16-95mm2 at 11kV) and SPS 193 (120-300mm2 at 11kV). This is achieved by positioning the 3 Core Breakout within the body of the Gland which is situated below the Cable Box Gland Plate. 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. 1. Installation X Strip off the outer sheath of the cable to the dimensions in Table 1. Standard length dimensions = L+X leave 200mm for the cable breakout boot and armour wires. Remove any cable fillers. De-grease cable end for a distance of 100mm below the outer sheath cut. Note:- User may wish to alter bedding dimensions to suit the type of gland being fitted. L 100mm 100mm 2. Screen Preparation Copper Wire Screen 30mm Apply one layer of sealant tape around the outer cable sheath 30mm below the sheath cut. Bend back each screen wire and press them into the sealant tape. Apply another layer of tape over the bent back wires. SEALANT TAPE Copper Tape Screen ROLL SPRINGS COPPER TAPE SCREEN Secure the earth braids to the copper tape screens so that the solder block is positioned upon the cable bedding. A turn of mastic tape should be applied beneath and on top of the solder block. If roll spring method is used the spring should preferably be positioned above the fingers of the breakout boot. SEALANT TAPE COPPER BRAIDS Remove the copper tape screen to length B as indicated in Table 2. Note:- We highly recommend that the alternative dimensions given in section 10 are used, which enables the stress control tubes to be fitted in a higher position, which in turn offers many advantages. VOLTAGE 7.2kV 12kV 17.5kV 24kV 36kV B 115mm 115mm 115mm 165mm 215mm A 135mm 135mm 135mm 185mm 235mm B Table 2 3. Conductive Layer Treatment Extruded Conductive Layer Remove the semi-conductive screen layer using a suitable tool to dimension A as indicated in Table 2. Note:- It is very important that the screen is removed leaving a clean cut end and that no scoring and damage is done to the primary insulation. The smallest `Nick' can produce very high levels of discharge, therefore we highly recommend the use of approved screen removal tools (see page 38 in our general catalogue). Soluble Layer Using either non adhesive tape or tape turned backwards, cover the top of dimension A and remove the soluble layer above using a clean cloth and suitable solvent. Note:- Remember to remove the tape STRESS TAPE 10mm A A It is good practice to flame brush the primary insulation and conductive screen cut. This has the effect of removing any minor surface scratches or burrs that may be present. Apply Stress Control Tape 10mm COPPER TAPE SCREEN Remove the release paper from the TS31785Y Yellow Stress Tape. Stretch and apply the tape around the end of each core screen to cover the copper tape (If present) and insulation by 10mm either way. 4. Stress Control Tubes Position the stress control tubes onto each core so that the bottom of each tube is a distance C from the outer sheath cut as indicated in Table 3. Shrink each tube one at a time and keep the flame on the move to ensure an even wall thickness. C C VOLTAGE 7.2kV 12kV 17.5kV 24kV 36kV C 100mm 100mm 100mm 150mm 200mm Table 3 5. Installing Cable Lugs Remove the insulation from each core to the X dimension in Table 1. Install cable lug and remove any burrs or sharp points that may be present. Preheat each lug and wrap two layers of red sealant tape over the lug barrel and extend onto the insulation by approx 10mm. ROLL SPRINGS X 6. Installing The Breakout Boot Slide the three legged boot over the cores and push down into the crutch of the cable. Shrink from the centre of the skirt to the cable sheath and from the turrets to the cores. Apply a turn of red sealant tape around each breakout turret as shown. 7. Installing The Anti-Track Tube Position the anti-track tubes so that they cover the turrets of the breakout boot and the barrels of the lugs. 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 the tubes to cool to hand hot and trim at the lug end with a sharp knife if necessary. RED SEALANT TAPE ANTI-TRACK TUBE AIR CLEARANCE TO LOCAL SPEC Indoor Terminations To ensure long term performance of medium voltage terminations, certain separation distances are required as indicated in Table 4. 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 220mm E d d Table 4 d= SEE TABLE 4 Note:- Bushing protection boots will be required for the majority of installations. 8. Installation Of Rain Sheds 80mm On outdoor terminations the sheds should be fitted from the bottom up as indicated in the drawing opposite. Indoor 36kV terminations are supplied with one shed per phase and four sheds per phase for outdoor. NUMBER OF SHEDS PER PHASE VOLTAGE INDOOR OUTDOOR 7.2kV 2 12kV 2 17.5kV 2 24kV 3 36kV 1 4 200mm Table 5 The first shed should be fitted at a distance 200mm from the lower edge of the anti-track tube to the edge of the shed. 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 through 1800 as shown. 9. Cable Bending Radius MIN BENDING RADIUS r = 15xD If required, the cable can be heated to approximately 700C to enable a bend to be introduced. See the drawing opposite. 10. Alternative Screen Preparation If the screens are terminated at a higher point on the cable it offers many advantages:A) Improved clearance dimensions at the top of the stress control tubes. D B) The ability to core cross whilst retaining the required clearances. C) More room between the cores whilst using screen removal tools. D) More likelihood of achieving even shrinkage of the materials at the screen cut. Therefore we recommend that the semiconductive screen is removed in accordance with the dimensions shown in the picture opposite and indicated in Table 6. Dimension A should be taken from the bottom of the lug barrel. If the cable has copper tape screens, these tapes should be removed to a point 20mm below the conductive screen as shown. VOLTAGE 7.2kV 12kV 17.5kV 24kV 36kV A 110mm 185mm 185mm 310mm 460mm X LUG BA RREL LENGTH + 5mm X A 20mm X A Table 6 Fitting The Stress Control Tubes After applying the stress control tape as shown in section 3. Position each tube at a point approximately 5mm past the Stress Tape, overlapping onto the Copper Tape Screens and shrink one at a time starting at the bottom. Continue with the installation from section 5 onwards.