S HEAT SHRINK JOINT 11kV 3 CORE Armoured XLPE/EPR Copper Wire screens STRAIGHT JOINT LEGEND POWER SYSTEMS Date 11 November 2014 Instruction Number PJJ006-14C PJJ006-14C Page 1 of 10
HEAT SHRINKABLE JOINT FOR 11kV, 3 CORE, XLPE/PVC COPPER WIRE SCREEN, ARMOURED CABLE. Cable Dielectric XLPE/XLPE EPR/EPR Item # Description 1 MEDIUM WALL TUBING 2 STEEL WIRE MESH SILICON GREASE 3 STRESS CONTROL TUBING INSULATION TUBING FOR CORES 4 MUTILAYER TUBING 5 STRESS CONTROL MASTIC 6 ARMOUR CLAMPS 7 ARMOUR SUPPORT RING 7 Copper Braid Instruction No PJJ006-14C TESTED TO IEC60502-4 AS/NZ 4805 Item # Description SCREEN CONNECTOR 8 COPPER MESH ROLL SPRING 9 RED SEALANT MASTIC 10 STRESS CONTROL MASTIC 12 BLACK SEALING MASTIC 13 MECHANICAL CONNECTOR 16 TEXTILE TAPE 17 INSTRUCTIONS 18 BOM 8 Distribution Place, Seven Hills, NSW, Australia, 2147 Tel. Australia:1800 769 370, Tel. International: +61 2 9678 5000 Date: Prepared by: Checked by : Verifying engineer: 18/03/13 M Matulewicz G Smith S Harrison PJJ006-14C Page 1 of 10
Getting Started These cable joints and terminations must be installed by a skilled and competent tradesperson. Check the kit contents to ensure the termination will fit the cable to be terminated. Check the kit contents against Bills of materials (BOM), to ensure that the kit is complete. The heat shrink tubes should be smooth and free from wrinkles, scratches, jagged cuts and damage. Read the instructions before coencing as procedures could change. This instructions contains 10 pages General Tips and Instructions Always keep the work area and cables clean. When shrinking, always use a propane [preferred] or butane gas torch. Apply heat circumferentially around and from center outwards on tubes ensuring correct heat application so that the tubes shrink evenly to the correct material wall thickness. Only use the gas torch in a properly ventilated and safe environment. Ensure that the shrunk tubing are free from wrinkles and air bubbles during and after heating. Cable Preparation Tips Always keep the cable outer sheaths clean and free from dust, oil and mud. Take extreme care not too cut or nick the cable insulation during preparation. When sanding a XLPE cable, abrade circumferentially around the core insulation. Only use presoaked cleaning tissue supplied with this kit to clean XLPE insulation and heatshrink tubes. Clean and degrease all surfaces that will have mastic applied. DISCLAIMER The information provided in these instructions is for the use of competent trained installers. Legend Power Systems has no control over environmental conditions and it is the installers responsibility to determine suitable conditions for the installation of this product. Legend Power System s will not be liable for any incident indirectly, or damages arising for the miss use of this product. All the text and graphics in this instruction remain the intellectual property of Legend Power Systems, and the reproduction of any part of this instruction is prohibited. PJJ006-14C Page 3 of 10
1 Reference Line L3 1. Align the cables as shown in fig. 1, overlap by 100 and mark the reference line. Remove the outer sheath according to the lengths given by L3 and L4 in table 1. L4 100 Cable sizes L3 L4 35-95 850 550 95-240 850 550 185-400 1000 550 Table 1 2. Remove the inner PVC sheath and bedding measuring from the outer sheath cut back, according to the following dimensions, E=100. Re position the armours. Cut back to a dimension D= 30 from the outer sheath strip back, as shown in fig 2. Park the hose (jubilee) clamps [AC] over the outer sheath. Hose clamp Position armour support ring [SR] over inner bedding under the steel wire armour, pushing it down as far as possible. The support ring [SR] may require adjustment to fit the cables diameter. 3. 3. Fix the steel wire armour with copper wire [CW]. Fold back the copper wire screen and secure it to the outer sheath with PVC tape [PVC]. Copper wire binder 4 L2 L1 4.. Cut the cores to length using the measurements in table 2, L1 and L2 B B Remove the semi-conductive (insulation) screen and XLPE insulation to the dimensions according to the below table. B PVC Sheath The insulation must be free from traces of conductive material. Table 2 Cable size 35-95 95-240 Cable size 300-500 300-500 Cable voltage L1 L2 B C Cable voltage L1 L2 B C 6.35/11kV 750 450 B+5 155 6.35/11kV 750 450 B+5 175 PJJ006-14C Page 4 of 10
5 Outer Tube 5. Park 1 set of outer protection tubes [MWT] on the cable as shown in figure. Park the other set of inner tubes heat shrink tubes on the opposite side of the joint. Ensure the heat shrink tubes are parked before starting the next step. 6 6. Park the following tubes ( joint Bundle) on the longer cores, [measurement L1], in the following sequence: Stress control tube (BLACK) [SCT] Insulation tubing for cores (RED) Triple layer tubing (BLACK-RED) Stress Tube SCT Insulation Tube (22kV) Triple Layer Tube 7 7. All tubes should be parked on the cores before connecting the opposite side of the cable as shown in figure 7. 8 8. Connect both sides of the cable with the mechanical connector supplied. Shear the mechanical connector following the manufacturer s instructions. Remove burrs and clean the connector and core with wipes provided. PJJ006-14C Page 5 of 10
9 Fill with putty 9. If needed, fill mechanical shear off heads with putty, filling any voids on the top of the connector. Fill the gaps between the connector and core insulation with Yellow Stress Control Mastic [SCM]. The gap should not be any more than 5 Stress Control Mastic (SCM) 10 10. Remove the backing paper from the yellow stress mastic. Place the mastic at the Semi Conductive (Insulation) screen cut and apply the yellow Stress Control mastic tape[scm] for a length of 10 onto the semi-conductive (Insulation) with a stretch of 50% of it s width. Keep wrapping until you achieve 10 onto the XLPE(EPR), insulation. Apply Stress Control Mastic yellow tape [SCM] to the connector. Stretch to 50% of its width and use 50% overlap wrapping the whole length of the connector. Apply 10 onto insulation as shown in figure10. 11 11. Apply a thin layer of silicone grease [SG], covering the core insulation (XLPE or EPR) and connector only, as shown in figure11. NOTE, avoid applying Silicone Grease on to the Stress control mastic in the Semi Conductive (Insulation) screen area, and also the link area. PJJ006-14C Page 6 of 10
12 12. Slide the black stress tube from the parked position along the connected core. Position the Stress Control tube (Black SCT) centrally over the connectors. The black stress tube should sit evenly, either side of the Semi Conductive (Insulation) screen. Shrink down starting from the center and working in a circular motion using a soft yellow tip flame, towards the end of the black stress tube. Ensure the tubes are evenly shrunk down, and free of winkles. 12a 12a. Slide the red insulation tube from the parked position along the connected core, over the shrunk down black stress tube. Start to shrink the tube from the center of the tube in a circular motion using a yellow tip flame, towards the end of the red insulation tube. Ensure the red tubes are evenly shrunk down. 13 13. Slide the remaining black-red tube from the parked position along the connected core, over the shrunk red insulation tube. Position the multilayer tubing [red-black] over the center of the connector and shrink down, with a smooth brushing motion of a yellow tip flame, Ensure all the tubes have been shrunk evenly. Post heat to ensure tubes are evenly and fully recovered DO NOT APPLY FLAME TO RED LAYER! DO NOT SCORCH THE BLACK OUTER LAYER 14 14. Remove the release paper and apply the red sealant mastic tape [RSM] to both ends of the multilayer tube with 50% overlap. Profile by overlapping onto the tube and the core by 10 as shown in fig 14. PJJ006-14C Page 7 of 10
15 15. Allow the joint bundles to cool. Apply the Tinned Copper Mesh [CM] with 50% overlap over the complete joint (splice) from one side of the copper wire screen to the opposite side. Wrap all three joint bodies together in one wrap. Secure Tinned Copper Mesh at Opposite end with either constant force spring or copper binder. 16 16. Fold back the screen wires and make an Earth lead with the screen wires across the joint. Connect together, both ends of screen wires into the mechanical link and shear mechanical bolts off, as per manufacturer s instructions. If required, form black mastic into a wedge shape and insert into the crutch at both ends of the joint. 17 17. Continue the wrap of Tinned Copper Mesh across the joint ( Splice), and secure at the opposite end with either a constant force spring or copper wire binder. Secure the three cores together with the textile tape [TEXT]. 18 50 Black Sealant Mastic [BSM] 15. Slide the outer protective tubing 1 [MWT] over the joint (splice), ensuring that the tube covers the PVC inner sheath by 70. Shrink the tube working circumferentially from the end inwards to the middle of the joint (splice). Inner PVC Sheath Remove the release paper and apply a strip of black sealant mastic[bsm] tape on the shrunk tube at the edge of the shrunk tube, at the middle of joint (splice). 19 16. Position the second outer protective tubing [MWT] over Inner PVC Sheath the joint (splice), ensuring that the tube covers the inner PVC sheath. Shrink the tube working circumferentially from the end towards the middle of the joint. The two outer protective tubes are required to cover the full length of the joint. Trim if necessary Inner PVC Sheath PJJ006-14C Page 8 of 10
20 20. Wrap a piece of Copper mesh [CM] around both ends of the armours. Attach Copper earth braid with a wire binder at each end of the armours as shown. 21 Hose ( jubilee) Clamp 21 Wrap the steel wire mesh [SWM] around the joint starting at the outer sheath cut on one side to the outer sheath cut on the other side. 22 22. Position the Armour Hose (jubilee) clamps onto the Armour as shown in fig, 22 on both ends for, about 15 before the cut back, and tighten firmly. Use abrasive paper [AP] to abrade the outer sheath for 100. 13.1 100 23 23.Apply black mastic tape [BSM] for at least 20 onto the outer sheath and cover the Armour hose (jubilee) clamps. Stretch with 50% overlap covering the clamp. This is to avoid any sharp edges at both ends of the joint (splice). PJJ006-14C Page 9 of 10
24 Black Sealant Mastic [BSM] 24. Slide the outer protective tubing 1 [MWT] over the joint (splice), ensuring that the tube covers 150 of the cable outer sheath. Shrink the tube working circumferentially from the cable outer sheath (jacket) towards the middle of the joint (splice). Remove the release paper and apply a strip of black sealant mastic[bsm] tape on the shrunk tube at the edge of the shrunk tube, at the middle of joint (splice). 25 25. Position the outer protective tubing [MWT] over the joint (splice), ensuring that the tube covers 150 of the cable outer sheath. Shrink the tube working circumferentially from the cable outer sheath (jacket) towards the middle of the joint. The two outer protective tubes are required to cover the full length of the joint. Allow to cool before applying tension. The joint is complete using LEGEND POWER PRODUCTS. Please dispose of all waste To environmental standards PJJ006-14C Page 10 of 10