EPP-0843-10/11 RAYCHEM JOINT KIT | AKBAR TRADING EST. SAUDI ARABIA|

Installation InstructionEPP-0843-10/11

Joint for Single-CorePolymeric InsulatedCables 12 to 36 kVwith Aluminium WireArmour

Type: SXAW

Tyco Electronics Raychem GmbHEnergy DivisionFinsinger Feld 185521 Ottobrunn/Germany0049-89-6089-0 tel0049-89-6096-345 faxwww.te.com

MOHD. BIN AHMED AKBAR TRADING EST.

(Electrical, Automation & Instrumentation)

Al Sahaba Street | P.O Box 30073 | Jubail 31951 | Kingdom of Saudi Arabia

Tel: 00966 (0) 13 3635225, 13 3618081 | Fax: 00966 (0) 13 363 3883 |

[email protected] | www.akbartrading.com

EPP-0843-10/11 Page 2/8

Before StartingCheck to ensure that the kit you are going to use fi ts 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 InstructionsUse 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 fl ame with a yellow tip.

Pencil-like blue fl ames should be avoided.

Keep the torch aimed in the shrink direction to preheat the material.

Keep the fl ame 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 defi ned.

The Information contained in these installation instructions is for use only by installers trained to make electrical power installationsand is intended to describe the correct method of installation for this product. However, TE Connectivity has no control over the fi eld conditions which infl uence product installation. It is the user’s responsibility to determine the suitability of the installation method in the user’s fi eld conditions. TE Connectivity’s only obligations are those in TE Connectivity’s standard Conditions of Sale for this product and in no case will TE Connectivity 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. © 2011 Tyco Electronics Raychem GmbH.




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EPP-0843-10/11 Page 3/8

Remove the oversheath of both cables to dimension a, measured from the reference line.Clean the remaining oversheath of both cables for about 600 mm.

Cable 1: Do not cut the armour wires. Carefully bend them back away from the joint area.

Cable 2: Cut partly through the armour wires at the oversheath cut. Bend and break them off at this position.

Cable OverlapOverlap the cables to be jointed according to dimensions in drawing.For dimension a see table below.

Mark the reference line as shown in drawing.Cable 1

Cable 2

Reference line

100

a a

Reference lineInner sheath

AL-wire armour

Oversheath

Cable Preparation

a + 200

Dimensions in mm

Table 1

Voltage Kit No Kit-Range[mm2]

a[mm]

b[mm]

12 kV SXAW-3121 95-185 300 200SXAW-3131 185-300 310 210SXAW-3141 400-500 330 230SXAW-3151 630 370 270

17.5 kV SXAW-3121 70-120 300 200SXAW-3131 150-240 310 210SXAW-3141 300-400 330 230SXAW-3151 500-630 370 270

24 kV SXAW-5121 50-95 300 200SXAW-5131 120-185 310 210SXAW-5141 185-400 360 260SXAW-5151 500-630 370 270

36 kV SXAW-6122 50-95 360 260SXAW-6132 120-240 360 260SXAW-6142 300-630 410 310




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EPP-0843-10/11 Page 4/8

Cut the cores at the reference line. Remove the inner sheath to dimension b (see Table 1).Place a wire binder temporarily over the copper tape screen 40 mm away from the inner sheath cut.Remove the copper tape screen against the wire binder. Thoroughly remove the core screen to the dimension given in drawing, so that the insulation surface is free from all traces of conductive material.Note: Do not nick the insulation!

40 20 20 40

b b

Reference lineCore screen

Tape screen

Inner sheath

A. Cable with copper tape screen

Inner sheath

Al-wire armour

Oversheath

Wire screen

Core screen

Reference line

b b

60 60

Remove the inner sheath to dimension b (see Table 1). Bend back the screen wires onto the oversheath. Cover the sharp wire ends with plastic tape. Cut the cores at the reference line.Thoroughly remove the core screen to the dimension given in drawing, so that the insulation surface is free from all traces of conductive material.Note: Do not nick the insulation!

B. Cable with copper wire screen




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EPP-0843-10/11 Page 5/8

2

3

Cut back the insulation to dimension I = half length of connector + 5 mm. See table below.

Joint the conductors by crimping.Remove any sharp edges.Clean and degrease the connector and insulation.

Completion of jointSlide the combined tubing set and the outer sleeve over the cable end where the armour wires are still covered. The plastic bag of the tubing set can be used as additional protection by placing it under the tubing set.

1. Stress control tubing (black)2. Screened insulating sleeve (black and red)3. Inner sleeve (black)4. Outer sleeve (black)

Note: If the tubings cannot all be nested together as shown, position them behind each other, so that they can be installed in the sequence 1,2,3 and 4.Do not park any tubings on the other cable side.

Table 2

Voltage Kit No Kit-Range[mm2]

max. connector dimensions [mm]

Diameter Length12 kV SXAW-3121 95-185 28.5 140

SXAW-3131 185-300 34 180SXAW-3141 400-500 44 220SXAW-3151 630 52 250

17.5 kV SXAW-3121 150-240 28.5 140SXAW-3131 150-240 34 180SXAW-3141 300-400 44 220SXAW-3151 500-630 52 250

24 kV SXAW-5121 50-95 23 120SXAW-5131 120-185 28.5 140SXAW-5141 185-400 38.5 220SXAW-5151 500-630 52 250

36 kV SXAW-6122 50-95 23 120SXAW-6132 120-240 32 160SXAW-6142 300-630 52 250

1

4321

l l

EPP-0843-10/11 Page 6/8

A4

50

check

a b

c d

1

2 3 4 5

B4

5

6

7

B. Cable with wire screen

Open the small aluminium bag and take the short yellow void fi lling strips with the pointed ends.

Remove the release papers of each strip and wrap the void fi ller 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 fi ne thin edge.

Position the screened insulating sleeve (black and red) centrally over the previously installed tubing.

a. Start shrinking the sleeve in the centre (1).b. Check if fully shrunk by twisting the end.

The sleeve should not move from its position.c. Continue shrinking by working towards one side (2),

stopping 50 mm from the end. Shrink the other half in the same way (3).

d. Shrink down the fi rst end (4) and fi nally the second (5).The sleeve should be fully shrunk withoutleaving ridges.

Open the large aluminium foil bag and remove one release paper from the void fi lling tape (yellow) and roll it up.Wrap it around the conductor 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 5 mm.

Note: Do not use too much void fi lling tape.

The fi nal diameter should be only slightly greater than the core or connector diameter, whichever is larger, but ensure a minimum thickness of 2 mm on top of the connector.

Pull the stress control tubing (black) from the inside of the tubing set and position it centrally over the connector. Start shrinking in the centre working towards the ends.

The tubing should be fully shrunk and wrinkle free.

A. Cable with tape screen

Remove the wire binder from the end of the copper tape screen.

Open the small aluminium foil bag and remove the release papers from the short yellow void fi lling strip with the pointed ends. Fix the metal tape screen into place by wrapping the yellow void fi ller for 5 mm around it. Continue over the core screen covering the insulation for 10 mm.

Stretch the strip to half of its original width to achieve a fi ne thin edge.

10 20 5

2010

5 5

1

2

EPP-0843-10/11 Page 7/8

A8-1

A8-2

B8-1

B8-2

9

A. Cable with tape screen

Wrap two layers of copper mesh with a 50 % overlap round the joint area, continuing for 30 mm onto the copper tape screen.

Position the earth lead across the joint and secure temporarily with a PVC-tape. Fix a roll spring over the copper mesh and the earth lead where they cover the copper tapescreen of the cable. Wrap the roll spring twice over the copper mesh and the individual earth lead. Fold the end of the earth lead back over the roll spring. Wrap the rest of the roll spring over the earth lead and tighten with a twisting action.Fix it into place with two layers of adhesive tape.

Centre the inner sleeve (black) over the joint area.Start shrinking in the centre, working towards the ends.This sleeve is to seal on to the cable inner sheath.

B. Cable with wire screen

Wrap one layer of mesh tape round the joint with a 50% overlap so that the whole joint area is covered.

Bend the screen wires back over the joint area.

Gather the ends of the screen wires together and connect them on the side of the joint by crimping or any other equivalent method.

Distribute the screen wires evenly over the joint area. Wrap a second layer of mesh tape round the joint with a 50% overlap so that the whole joint area is covered.

3

30 30

EPP-0843-10/11 Page 8/8

11

12

13

14

Thoroughly clean the armour wires from cable 1.

Separate the armour wires and form equal bunches,according to the number of the mechanical connectors supplied with the kit.

Fold back the long armour wires tightly across the joint, cut to length, and connect them using the mechanical connectors provided. Shear off the connector bolts.

The joint is now completed. Allow to cool before moving.

Wrap a piece of the inner bedding of the cable sheath over the connectors.

Using the adhesive cotton tape provided, ensure all the wires are close to the cable and tubing set over the length of the joint and that there are no sharp edges.

Abrade and degrease the cable jacket for 100 mm at both sides of the joint.

Position the outer sealing sleeve centrally, then shrink the sleeve down starting in the centre and working towardsthe ends.

Carefully remove 100 mm of the oversheath on cable side 2. Do not cut the armour wires.

Lift the armour wires and thoroughly clean.

Separate the armour wires and form equal bunches to suit the number of armour wire connectors included in the joint kit.

Please dispose of all waste according toenvironmental regulations.

10

4

Side 2

100

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EPP-0843-10/11 RAYCHEM JOINT KIT | AKBAR TRADING EST. SAUDI ARABIA|