TMI 130/36-7506

INSTALLATION INSTRUCTIONHEASHRINK TRIFURCATING JOINT TO SUIT 3 CORE 12kV

XLPE/SWA/PVC CABLE TO 3 x SINGLE CORE 12kV NON ARMOURED XLPE/CWS/PVC CABLES REFERENCE TYPE: SPAJ 12X-3C-TRIF

DATE OF ISSUE: 24.01.14

THESE INSTRUCTIONS SHOULD BE FOLLOWED BY A TRAINED COMPETENT JOINTER

A PROPANE GAS TORCH IS THE PREFERRED METHOD FOR SHRINKING THESE MATERIALS

ENSURE THAT THE MATERIALS ARE KEPT CLEAN AND DRY AND ARE FREE FROM DUST, SAND AND GREASE

PLEASE CALL SHRINK POLYMER SYSTEMS FOR ANY ADVICE

TMI 130/36-7506 TMI 130/36-7506

Use free software on yoursmart phone to scan the QR code

below to watch an installation videoon 3 core to 3 core xlpe cables

Use free software on yoursmart phone to scan the QR code

below to watch an installation video on3 core Pilc to 3 x Single Core Xlpe Cables

1. Ensure the cables overlap before preparing the cables to the dimensions shown above and in accordance with the Table 1 below for conductor size. Ensure you use the same cable range dimensions as the kit supplied.

2. Before proceeding, position the outer shrink tube and clamps over the 3 core cable end and the 3 core breakout boot over the single core cables as shown above in Fig 1.

3070BA

C

XX

CABLE PREPARATIONALL DIMENSIONS SHOWN IN mm

Fig 1

3 COREBREAKOUT

BOOTOUTER

SHRINKTUBE

CONDUCTOR2SIZE (mm )

35-70

95-185

185-300

A

500

500

600

B

250

250

270

C

600

600

700

X (mm)

160

170

180

MAX CONNECTORLENGTH (mm)

100

130

140

Table 1

Note:- These joints are designed for use with MV compression ferrules and “tapered centralised conductor” mechanical connectors.

3. Lift the wire armours of the 3 core cable and apply a two bands of 212D black mastic tape as shown in Fig 2. Secure the three earth braids to the copper tape screens using the constant force springs supplied.

4. Fit the under armour support ring and fold down the armours as shown in Fig 3+4.

5. Remove the backing papers from the piece of black mastic tape labelled crutch wedge and form into a wedge. Open up the cores and insert the these as far as possible into the crutch of the cable

Apply a further layer of 212D black mastic tape over the screen earth braids, See Fig 4.

6. Prepare the cores to the dimensions shown in Fig 1 and Table 1.

7. Using a suitable tool, remove thesemi-conductive layer, taking care not to damage the primary insulation, particularly at the screen ends.

Thoroughly de-grease the exposed insulation using the cleaning tissues provided.

It may be advisable to secure the copper tape screens to prevent them from unwinding.

Note:- Screen removal tools can be provided. See website for screen removal advice/video.

X X

15

Earth Braids

Single core shown for clarity

212D BlackMastic

ArmourSupport

Ring

Mastic CrutchWedge

ArmourWires

212D BlackMastic

Fig 2

Fig 3

Fig 4

Fig 5

Fig 6

Fig 7

Fig 8

Fig 9

Fig 11

10mm 25mmStress Control

Tube

Stress ControlTube

Mechanical or CompressionType Connectors

Yellow Stress Relief Mastic

10mm

8. Stretch the yellow stress relief tape and apply over the screen cut area, extending onto the primary insulation by 10mm and catching the copper tape screens as shown in Fig 7.

9. Position the stress control tubes as shown 5mm back from the insulation and starting from the insulation end, apply heat all around the tubes using a soft flame torch. Heat until fullyrecovered.

10. Fit the approved MV ‘tapered’ connectors using the appropriate tool. Clean and de-grease before proceeding.

11. Stretch and apply the yellow stress relief mastic over the connector area with a 50%overlap. Extend onto the short stress control tubes by 10mm, as shown in Fig 9.

Important:- Fill in the gap between primary insulation and ensure a smooth taper to the connector. Also if mechanical connectors used, fill any voids that the bolts leave after they have been sheared with the grey hv mastic tape supplied.

12. Stretch and apply the short red mastic tape pieces at the end’s of the stress control tubes as shown in Fig 10, so that the red/black tubes sit upon it. This will create an additional moisture seal.

13. Finally, centrally position the red/black dual wall tubes so that they cover the screen end points. Starting in the middle and working towards the ends, shrink them whilst keeping the flame moving all around the tubes to ensure an even recovery and wall thickness.

DUAL WALL RED/BLACK TUBE

5mm

STRESS CONTROL TUBE STRESSCONTROL

TUBE

Yellow Stress Relief Mastic

STRESS CONTROL TUBE STRESS CONTROL TUBE

STRESS CONTROL TUBE STRESS CONTROL TUBE

Fig 10

RED/BLACKDUAL WALL

TUBE

RED/BLACKDUAL WALL

TUBE

3 COREBREAKOUT

BOOT

KM50 Copper Mesh

Fig 12

Black MasticRoll

75mm

Fig 13

212D BlackMastic

Armourclamps

212D BlackMastic

GREY MASTICTAPE

Fig 14

14. Starting from the single core end, wrap each core insulation tube with the tinned copper mesh applied with a slight overlap. Extend onto thecopper screens on the 3 core side as shown inFig 12.

With an open spiral take the tinned copper mesh and wrap around the armours.

15. Secure the tinned copper mesh tails, screen earth braids and one end of the long earth braid/s, to the armours, using the worm drive clampsprovided.

16. Using a suitable connector, join the 3 single core wire earth screens to the tinned copper earth braid/s as shown in Fig 13.

17. Abrade the outer sheaths for approximately 100mm on each side.

18. Create a roll from the 212D black mastic tape and insert between the 3 single cores, approx. 75mm from the sheath cut. Apply a layer of black mastic over the cables as shown in Fig 13.

Apply a further layer of black mastic over the worm drive clamps on the 3 core side.

19. Position the large 3 core breakout just onto the cable sheaths. Using a suitable heat source shrink the main body before shrinking the legs to the single core cables.

Apply a band of the grey mastic tape over the breakout body as shown in Fig 14.

3 COREBREAKOUT

BOOT

3 COREBREAKOUT

BOOT

OUTERSHRINK

TUBE

OUTERSHRINK

TUBE

OUTERSHRINK

TUBE

Apply Grey MasticOver Connector

20. Position the outer shrink tube centrally so that once recovered, it overlaps the main body of the3 core breakout and the outer sheath of the3 core cable. Note: abrade the cable jacket to ensure a good sealant bond.

Start shrinking from the middle to one end at a time. Apply heat evenly all around the tube. Once fully recovered sealant should be visible at the ends of the tube.

Allow the joint to completely cool before applying any mechanical strain.

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 thesuitability of the product for his or her intended use and User assumes all risk and liability whatsoever in connection therewith.

UNIT E3 CROWN WAY CROWN PARK INDUSTRIAL ESTATE RUSHDEN NORTHANTS NN10 6FDTEL: +44 (0)1933 356758 FAX: (0)1933 413821 E-MAIL: info@shrinkpolymersystems.co.uk

WEBSITE: www.shrinkpolymersystems.co.uk

OUTER SHRINK TUBE OUTER SHRINK TUBE

Fig 15

OUTER SHRINK TUBE

Important: user/circuit designer should determine whether or not special earthing requirements are needed to reduce the possible effects of induced sheath voltages or circulating currents in armoured cables. The decision to single point earth/solid point earth or install cross bonding kits needs to be considered once length of run, loading and positioning of cables is known.