Installation Instruction ESD-5713-AU-4/11

Superseded by EL 00115 v1.0
Installation Instruction
ESD-5713-AU-4/11
Raychem
Joint for 36kV Single Core
XLPE Insulated Cable
without Armour with
Integrated Fibre Optic
Cable and Composite
Sheath - 500mm2
ENDORSED BY
SIGNATURE
DATE
SIGNATURE
DATE
SIGNATURE
DATE
Wilfred Leung
Principal Engineer—Mains
RailCorp
APPROVED BY
Neal Hook
Chief Engineer - Electrical
RailCorp
APPROVED BY
Andrew Thompson
Product Manager
TE Connectivity
Tyco Electronics Raychem GmbH
TE Energy
Superseded by EL 00115 v1.0
Check List Number: CL1095-4/11
MXSU-RCP13
Qty: 1
Kit Contents
________________________________________________________________________________
4
2
2
2
2
2
1
2
4
1
1
2
3
1
2
1
1
2
6
1
1
2
2
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
EPPA-218
BOCL-20-1068
WCSM-130/36-600/S
MWTM-85/25-700/U
WCSM-105/30-700/S
WCSM-13/4-1200/S
EPPA-021-5-200
S1061-8-200
S1061-1-3000
JSCR-76/33-470-35/U
ERIH-85/34-460/U
S1189-1-150 (A1)
S1189-3-600 (A1)
WCSM-160/50-900/S
EPPA-009-6000
BSMB-500MK2
EPPA-048
BSM-25/95
EPPA-004
FOSC-500AA-S24-LT-NN
EPPA-029-3-1000
PD-CAP-1/4-0
JSCR-76/33-150/U
Cable Bundle Tape
Branch Clip
No 1 Coated Sleeve Black
No 2 Uncoated Sleeve Black
No 3 Coated Sleeve Black
Fibre Optic Protection Sleeve Black
Aluminium Foil Strip
Mastic Sealant Black 200 Long
Mastic Sealant Black 3000 Long
"X" Stress Control Tubing 470 Long
"Y" Screened Insulating Sleeve 460 Long
Void Filling Mastic 150 Long
Void Filling Mastic 600 Long
"Z" Heavy Wall Tubing 900 Long Coated
Tinned Copper Mesh - 6000 Long
Mechanical Shear Bolt Connector
Clay Pack
Mechanical Shear Bolt Connector Screen
Cleaning Tissue
Fibre Optic Splice Closure
Tie Wire
End Cap (Fibre Element)
“W” Stress Cont Tube Black Uncoated
1
x
ESD-5713-AU-4/11
Installation Instruction
_____________________________________________________________________________________________________________
TE Connectivity
TE Energy
Tyco Electronics Energy Pty Ltd
ABN 56 000 129 573
Unit 2, No 3 Corella Close
Berkeley Vale NSW 2261
02 4389 6000 tel
02 4389 6061 fax
www.energy.te.com
ESD-5713-AU-4/11 Page 2/10
ESD-1573-AU
Page : 1 of 1
Superseded by EL 00115 v1.0
Before Starting
Check to ensure that the kit you are going to use fits the cable.
Refer to the kit label and the title of the installation instruction.
Components or working steps may have been improved since you last installed this product.
Carefully read and follow the steps in the installation instruction.
General Instructions
Use a propane (preferred) or butane gas torch.
Ensure the torch is always used in a well ventilated environment.
Adjust the torch to obtain a soft blue flame with a yellow tip.
Pencil like blue flames should be avoided.
Keep the torch aimed in the shrink direction to preheat the material.
Keep the flame moving continuously to avoid scorching the material.
Clean and degrease all parts that will come into contact with adhesive.
If a solvent is used follow the manufacturer’s handling instructions.
Tubing should be cut smoothly with a sharp knife leaving no jagged edges.
Start shrinking the tubing at the position recommended in the instruction.
Ensure that the tubing is shrunk smoothly all around before continuing along the cable.
Tubing should be smooth and wrinkle free with inner components clearly defined.
The information contained in these installation instructions is for use only by installers trained to make
electrical power installations and is intended to describe the correct method of installation for this product.
However, TE Connectivity has no control over the field conditions which influence product installation.
It is the user’s responsibility to determine the suitability of the installation method in the user’s field
conditions. TE’s only obligations are those in TE’s standard Conditions of Sale for this product and in no
case will TE be liable for any other incidental, indirect or consequential damages arising from the use or
misuse of the products.
Raychem, TE Connectivity and TE connectivity (logo) are trademarks.
ESD-5713-AU-4/11 Page 3/10
Table A Admissible cable dimensions for joint
Conductor Ø
Core Insulation Ø
Outer Cable Ø
Superseded by EL 00115 v1.0
Kit Range
500mm2
min
max
min
max
min
max
mm
mm
mm
mm
mm
mm
22.9
29.2
40.1
46.6
44
61
Preparation of Cables with Copper Shield
Wires and Fibre Optic Cables
1
Align the cables. Make sure they are in-plane.
Mark the centre of the joint (reference line).
The cable ends have to overlap by 1.5 m on either side of
the reference line, 3 m in total
The installation will need 2.5 m of cable on either side of
the reference line.
Entirely remove the graphite coating on this cable length, if
any.
Clean & degrease the cable oversheath.
2
Slide the short sealing sleeve (1: WCSM-130/36) on each
cable end. Park the sleeves in the outermost position.
3
Cable Preparation - Side A
4
Remove the inner & outer sheath 1000 mm from the
reference line.
ESD-5713-AU-4/11 Page 4/10
Superseded by EL 00115 v1.0
Remove the bedding (if any) and separate fibre optic cable
from the shield wires. Apply PVC tape at the end of the
cable to hold the shield wires into place. Seal the end of the
fibre optic cables. Apply the heat shrink (PD) end cap to
the end of the fibre optic cable to protect it temporarily until
splicing occurs.
5
Cut a 30mm wide strip from the aluminium foil.
Remove the release paper and wrap the foil around the
fibre optic cable, 110mm from the cable oversheath.
6
Fix the fibre cable with 5 layers of cable bundle tape 60 mm
and 100 mm from the oversheath cut. Lay the fibre cable
back onto the oversheath, forming a 100mm wide arc. Fix
the fibre cable to the cable oversheath with PVC tape.
7
Slide the uncoated sleeve (2: MWTM-85/25) over the end
of the cable. Position it 200 mm away from the end of the
oversheath as shown. Shrink it into position starting at the
centre, working towards the ends.
8
Slide the coated sleeve (3: WCSM-105/30) over the end of
the cable. Position it 200 mm away from the end of the
oversheath as shown. Shrink it into position starting at the
centre, working towards the ends.
Cable Preparation - Side B
Remove the inner & outer sheath 1000 mm from the
reference line.
Repeat steps 5, 6, & 7.
9
ESD-5713-AU-4/11 Page 5/10
Superseded by EL 00115 v1.0
Slide the uncoated sleeve (2: MWTM-85/25) over the end
of the cable. Position it 200 mm away from the end of the
oversheath as shown. Shrink it into position starting at the
centre, working towards the ends.
Slide the coated sleeve (3: WCSM-105/30) over the end of
the cable. Position it 200 mm away from the end of the
oversheath as shown. Shrink it into position starting at the
centre, working towards the ends.
10
Side A:
Cut the cable at the reference line using a hacksaw.
Remove sleeves 2 and 3, 350mm from the reference line
Cut the shield wires 120mm from the end of sleeves 2 and
3.
Note: Do not bend the shield wires back over sleeves 2
and 3. Thoroughly remove the core screen 170mm from
the reference line, so that the insulation is free from all
traces of conductive material.
Clean & degrease the insulation using the cleaning tissues
provided in the kit.
Note: Do not nick the insulation.
11
Side B:
Cut the cable 500mm past the reference line.
Remove sleeves 2 and 3, 230mm from the reference line
Bend back the shield wires onto sleeves 2 and 3.
Fix the shield wires temporarily in place.
Cut the cable at the reference line using an hacksaw.
Thoroughly remove the core screen 60mm from
oversheath cut, so that the insulation is free from all traces
of conductive material.
Clean & degrease the insulation using the cleaning tissues
provided in the kit.
Note: Do not nick the insulation.
12
Slide the combined tubing set (X & Y) & the outer sleeve
(Z) over the end of side A. The plastic bag of the tubing
set shall be used as additional protection by placing it
under the tubing set.
13
X. Stress control tubing (black)
Y. Screened insulation sleeve (black and red)
Z. Outer sleeve (black)
350
60
170
230
60
Z
Remove the insulation on both cables to the dimensions
shown.
Y
X
14
70
ESD-5713-AU-4/11 Page 6/10
70
Superseded by EL 00115 v1.0
Take the yellow void filling strip from the alu foil pocket.
Remove the release papers from the strip with the pointed
ends.
Wrap the void filler around the core screen starting 20 mm
from the end of the screen and continue onto the insulation
for 10 mm.
Stretch the strip to half of its original width to achieve a fine
thin edge.
Slide the stress control tubing (W) over the plastic cable
core level with the end of the insulation cut back.
Shrink down starting from the insulation cut back towards
the oversheath as shown in the drawing.
15
20 10
16
W
Installation of the mechanical connector
17
Check before installation if the conductor can be inserted
into the connector.
Check core diameter in accordance with Table A.
Clean and abrade the surface of the exposed
conductors.Insert conductors so that the insulation butts up
with the end of the connector. Hand tighten the shear bolts
so that the connector stays in place.
For connectors using more than one shear bolt per side,
tighten the bolts alternately and shear them off starting with
the outer bolts (see also sequence shown in the drawing).
Note:

When a cordless impact wrench is in use the
tightening intervals should be in the range of 2
seconds.

Avoid core bending by using a support tool
available such as IT-1000-019 or similar.
Smooth out any sharp edges of protruding bolts where
appropriate. Clean and degrease the connector area and
the insulation with a cleaning wipe.
18
1
2
3
Support Tool
19
It could be possible that the bolt shears but the top is
retained in the connector body. In that case unscrew the
head of the bolt until it is removed from the connector.
ESD-5713-AU-4/11 Page 7/10
6
5
4
Superseded by EL 00115 v1.0
Clean and degrease the cable cores and the connector.
Fill Raychem clay over the sheared off bolts to obtain a
smooth finish.
20
Remove one of the release papers from the void filling tape
(yellow). Apply the tape with a 50% overlap stretching it to
about half of its original width.
Fill up the connector area continuing onto the insulation for
not more than 10 mm. Use the filler to achieve a smooth
transition from the connector onto the insulation.
Note: Do not use too much void filler, max. 2 mm over the
connector.
21
Position the stress control tubing (X) centrally over the
connectors. Start shrinking in the centre working towards
the ends. The tubing should be fully shrunk & wrinkle free.
Note: Take care not to accidentally shrink the parked
tubing at this stage.
22
Position the screened insulating sleeves (Y) centrally over
the stress control tubing.
a. Start shrinking the sleeves in the centre (1).
b. Check if fully shrunk by twisting the end. The sleeves
should not move from its position.
c. Continue shrinking by working towards one side (2),
stopping 50 mm from the end.
d. Shrink the other half in the same way (3).
e. Shrink down the first end (4) and finally the second (5).
The sleeves should be fully shrunk without leaving ridges.
23
ESD-5713-AU-4/11 Page 8/10
Y
Side A.
Remove the binding wire from the end of the shield wires.
Lift the shield wires away from cable and wrap one layer of
copper mesh across the joint, with a 50% overlap. Gather
the wires together to make to 2 equal size earth leads.
24
Superseded by EL 00115 v1.0
Wrap a short length of oversheath over the copper mesh
where the connector sit on top of the core screen.
Side B.
Bend the shield wires back over the joint area as 2 equal
size earth leads.
Connect the shield wires together using the mechanical
connectors. Tighten the bolt until the head shear off.
Wrap a second layer of copper mesh across the joint with
a 50% overlap.
Clean and degrease the ends of sleeves 2 and 3 for a
length of about 150 mm using the cleaning tissues provided
in the kit.
Centre the outer sleeve (Z) over the joint area.
Start shrinking in the centre, working towards the ends.
25
Z
Allow the joint to cool. Position the fibre optic cable housing
centrally on the joint and attach it by means of 6 layers of
cable bundle tape.
26
Side B:
Lay back the fibre optic cables towards the centre of the
joint.
Slide the protection tubing (WCSM-13/4) over the end of
the fibre optic cable and position the end level with the end
of the first rejacketing sleeve. Shrink into position starting at
the end level with the rejacketing sleeve, working to wards
the end of the fibre cable.
27
ESD-5713-AU-4/11 Page 9/10
Superseded by EL 00115 v1.0
Wrap the short sealant mastic (black) strip around the end
rejacketing tubing. Lay the fibre onto the mastic and fix it
into position, level with the end of the mastic, using the
cable bundle tape.
28
Apply two rolls of black mastic over the exposed screen
wire area. Starting 50mm onto the oversheath, continue
across the exposed wire shield and 50mm onto the
oversheath.
29
Centre the sealing sleeve (1: WCSM-130/36) over the
mastic area. Insert the branch-off clip. Shrink the sleeve
into position starting in the centre, working towards the
ends.
Note: Additional heat is required in the clip area to ensure
the adhesive on the clips has melted.
30
Side A:
Repeat steps 27-30
For INSTALLING the FIBRE OPTIC CABLES inside the SPLICE HOUSING, see corresponding
INSTALLATION INSTRUCTION.
31
The fibre optic cables are to be installed and connected according to the installation instruction of the splice housing.
Joint complete.
Allow the joint to cool before applying any mechanical
strain.
Please dispose of all waste according to
environmental regulations.
ESD-5713-AU-4/11 Page 10/10