R

Installation Instruction
ESD-2112-1/97

Transition Joints
for 3-Core Unscreened
Plastic Insulated Cables
to 3-Core Screened
Rubber Insulated Cables
up to 6 kV

Tyco Electronics Raychem GmbH u Hrvatskoj: Tyco Electronics Raychem GmbH

ENCRON d.o.o. Energietechnik
Ulica grada Vukovara 39 Finsinger Feld 1
10 000 Zagreb 85521 Ottobrunn
Tel.: (01) 6115 277 i (01) 6115 278 Telefon: ++49-89-6089-0
Fax.: (01) 6115 250 Telefax: ++49-89-6096345
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, Tyco Electronics 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. Tyco Electronics' only obligations are those in Tyco Electronics' standard Conditions of
Sale for this product and in no case will Tyco Electronics be liable for any other incidental, indirect
or consequential damages arising from the use or misuse of the products.
Raychem is a trade mark.

ESD-2112-1/97 page 2/7

Cable Preparation A1 reference line
A. Unscreened cable with CU wire shield

Overlap the cables to be jointed by about 200 mm.

Mark the reference line.
screened side

insulating tubing
200
outer sleeve

Core Preparation
Remove the oversheath to the dimension a and b as given in Table 1.
Fold back the earth leads to the oversheath and fix the end with PVC tape.
Slide the insulating tubing (black) and outer sealing sleeve over one cable end.
Remove the bedding of both cables up to 20 mm from the oversheath cut.
Shape and position the cores as shown in drawing below. Cut the cores at the reference line.
Thoroughly remove the core screen according to the dimension c given in Table 1, so that the insulation surface is free
from all traces of conductive material.
Note: Do not nick the insulation.

Table 1
Cross Section a b c
[mm] [mm] [mm] [mm]
35-50 370 220 120

70-185 450 250 140

240-300 520 370 150

A
insulation reference line insulation

core screen core screen

bedding bedding
earth lead oversheath

screened side unscreened side

20 20
c

a b

ESD-2112-1/97 page 3/7

Cable Preparation B1 reference line

Overlap the flexible cables to be jointed by about a+100 mm. screened side unscreened side
See Table 1.
Mark the reference line.

a+100

Core Preparation
Remove the oversheath to the dimension a and b as given in Table 1.
Fold back the earth leads to the oversheath and fix the end with PVC tape.
Slide the insulating tubing (black) and outer sealing sleeve over one cable end.
Position a wire binder on the metal tape shield according to dimension 40 mm as given in the drawing.
Unwind the metal tape shield up to this point and tear it off against the edge of the wire binder.
Remove the bedding of both cables up to 20 mm from the oversheath cut.
Shape and position the cores as shown in drawing below. Cut the cores at the reference line.
Thoroughly remove the core screen according to the dimension c given in Table 1, so that the insulation surface is free
from all traces of conductive material.
Note: Do not nick the insulation.

Table 1
Cross Section a b c
[mm] [mm] [mm] [mm]
35-50 370 220 120

70-185 450 250 140

240-300 520 370 150

B
insulation reference line insulation

core screen tape shield if any

bedding bedding
earth lead oversheath

screened side unscreened side

20
20
c 40

a b

ESD-2112-1/97 page 4/7

Screened cable only
Remove the release paper from the short void filling tape
2
(yellow) and wrap it around the core screen starting 20
mm from the end of the screen and continue onto the in-
sulation for 10 mm. Stretch the strip to half of its original
width to achieve a fine thin edge. 20 10

Completion of Joint 3 insulating sleeve

Slide an insulating sleeve (red) over each long cable centre line
core.
Remove the insulation on all cores to dimension I = half
length of connector + 5 mm.
See table 2 for max. connector dimensions.

I I

Joint the conductors by crimping, soldering or any other

equivalent method.
Remove any sharp edges.
4 centre line

Clean and degrease the connector and the insulation.

Table 2 Max. connector dimensions

Connector
Cross Section diameter length
[mm] [mm] [mm]
50-70 20 110
70-185 30 130
240-300 35 170
5
Remove one release paper from the long void filling tape
(yellow) and roll it up. Apply the tape with a 50% overlap
stretching it to about half of its original width. Fill up the 5 5
connector area continuing onto the insulation for not
more than 5 mm.

Note: Do not use too much void filler.

The final diameter should be only slightly greater than the centre line
core or connector diameter, whichever is larger.

Remove one of the release paper from the red tape roll it 6
up. Wrap the tape with a 50% overlap stretching it to centre line
about half of its original width. Cover the unscreened
yellow tape
core with red tape from end of the yellow tape to 190 mm red tape
from the centre line. See drawing.

190

ESD-2112-1/97 page 5/7

Position the insulating sleeves (red) centrally over the 7
connector area.
Start shrinking in the center, working towards the ends.

Relay the cores as far as possible. 8

A.Cable with wire shield A
Position the insulating tubing (black) over the unscreened
cores with the end of the tubing against the shield wires.
B. Cable with tape shield
Position the insulating tubing (black) over the unscreened
cores with the end of the tubing against the tape shield
B
cut.
40

A. Unscreened cable with CU wire shield A9-1

Wrap two layers of copper mesh with a 50% overlap
around the whole joint area.

Connect the wire shield and the earth leads with crimping A9-2
or any other equivalent method.
Cover the connector with tape or copper mesh.

B. Unscreened cable with CU tape shield B9-1

Wrap two layers of copper mesh with a 50% overlap
around the whole joint area starting at the copper tape
shield.

ESD-2112-1/97 page 6/7

 b
Remove the insulation from the earth leads over a length B9-2
of 80 mm. 80
Position the earth leads across the joint area. a
Lay the wires of the earth leads onto the copper tape
while overlapping the oversheath by 40 mm.
Wrap twice the roll spring round the wires. Bend back the
wires over the roll spring. Wrap the rest of the roll spring
round the wires, twist it and fix it in place with a PVC
tape.

Clean and degrease the ends of the oversheath for a 10

length of 200 mm.
Center the outer sleeve (black)over the joint area.
Start shrinking in the center, workink towards the ends.

Joint completed. 11
Allow the joint to cool before applying any mechanical
strain.

Please dispose of all waste according to

environmental regulations.

ESD-2112-1/97 page 7/7