Mounting Instruction: Termination Type: Cable Type: Drawing: Highest Voltage For The Equipment (Um)

Mounting
IBrugg
nstructio Kab
Drawin
Termination-‐type:TFD 245 kV
HE 4180
Mounting IBrugg
nstructio Kab
Cabletype: Drawin
Drawing:
Cable type:
Termination-‐type:TFD
1 x 400-‐2500245
(DB) kV
mm2
All polymeric cable types HE 4180
Mounting IBrugg
nstructio Kab
Termination type:
Cabletype: Highest Voltage for Drawin

the Equipment (Um):
1 x 400-‐2500245
(DB) kV
mm2
All polymeric cable types HE 4180
Mounting IBnstructio
230 kV
Cabletype: Drawin
FR 1.245-11
1 x 400-‐2500245
(DB) kV
mm2
HE 4180
HE5271 Rev. aa
All polymeric cable types
Brugg Kab
Drawin
Revision 00 01 02 03 04
Cabletype:Sk,stb
Written
2014-‐09-‐26
XDRAL-ALT 1x400DB mm2
1 x 400-‐2500245
(DB) kV
mm2
Verified All polymeric cable types HE 4180
Released
Brugg Kab
MOUNTING INSTRUCTION
Cabletype: Drawin
Revision 00 01 02 03 04
Sk,stb
Version: 2014-‐09-‐26
READ THIS MANUAL BEFORE STARTING TO MOUNT!

Original Mounting Instruction
Written
2014-‐09-‐26
1 x 400-‐2500245
(DB) kV
mm2
Verified All polymeric cable types HE 4180
Released
Mounting Instruction FR 1.245-11
Version control |
1 Version control
Rev. Author Verifie Released chapter / description of change
section
0 mma,05.07.19 met,09.07.19 mma,10.07.19 all 1st release
2
Version control |
Table of Contents
1 Version control�� 2
2 Information on this Document�� 4
3 Safety�� 6
4 High Voltage Tools�� 8
5 Product Overview�� 12
6 Cable & Casing Preparation�� 13
6.1 Cable cutting�� 13
6.2 Screen Preparation�� 14
6.2.a XDRAL-ALT.................................................................................................................................. 14
7 Conductor & Insulation Preparation�� 15

8 Assembly�� 18
8.1 Preparing an Edgeless Transition from Semiconductive Layer to Cable Insulation�� 18
8.2 �� 21
8.3 Mounting Connector�� 25
Shear Bolt Connector - One Piece ............................................................................................... 26
8.4 Insulating Gland and Connector�� 27

8.4.a Assembly XDRAL-ALT.............. ................................................................................................... 30
8.5 Mounting Insulator und Baseplate�� 31
9 Filling and Fixing�� 36

10 Quality Certificat �� 41
3
Mounting Instruction for
High Voltage Terminations
Information on this Document |
2 Information on this Document

Validity/Cable Explanation
This Document is valid for the following cable types:
XLPE insulated cable with copper/aldrey screen wires

XDRAL-ALN
and a laminated aluminium/copper sheath
Identificatio Plate
The informations on the Identification Plate of your product provide all necessary information to identify you
product in case of contacting Brugg Cables Helpdesk because of service needs.
FR 1.245-11 XXX
xx kV 2018
XXXXXX D1
Intended use
Before using this product, you must evaluate it and determine if it is suitable for your intended application. You
assume all risks and liability associated with such use. Never use a product if you are not sure whether it is
suitable for your purpose or if maximum values this product is tested and qualified for could be exceeded
Modifications/Reconstructio
It is not allowed to modificat or reconstruct brugg products without permission of the
Brugg Cables AG. In case of deviation of this instruction, changing or omitting instruction
steps Brugg Cables AG can not guarantee a safe or long life performance.
These mounting instructions / test instructions may be amended by Brugg at any time.
Amendments shall be applicable upon notice to the customer for all mounting and quality
control of the assembly carried out thereafter.
4
Information on this Document |

Applicability of General Terms and Conditions of Erection,
Supervision, and Commissioning
The General Terms and Conditions of Erection, Supervision, and Commission dated November 7th, 2014
(“General Terms and Conditions of Erection, Supervision and Commissioning”) as well as the subsidiary
General Terms and Conditions of Sales and Delivery dated January 1st, 2017 (“Sale and Delivery Terms
and Conditions”) are applicable to the extent that they do not conflict with these mounting instructions / test
instructions.
Liability and Restriction of Liability

The Brugg AG will not be liable for damage that has occured for the following reasons:
• Mounting by personnel, which has not participated a Brugg training and do not hold a valid certificate
• Attached Quality Certificate is not filled out completely and/or signed and returned to the Brug AG
immediately after installation.
• Different or incorrect installation deviant to the defined intended use in this mounting instructio
Scope of Delivery
• Check the completeness of the material with the packing and the parts list.
• Make sure that you have all the tools for installation.
• According to the first mounting step beginn to fill out the Quality Certificate in the appendix of this docume
Place of Installation
• The place must be plane, dry and dust free.
• The use of a statically stable framework is recommended.
• Cleanliness must be ensured throughout the entire installation. If necessary, protect the place of installation
with a roof.
Conditions of Installation
• The temperature conditions must be between 0°C and 45°C.
At actions steps with the brugg academy symbol

Here it is obligatory to fill out the Quality Certificat at the end of this document. You can send the complete filled
out document digital or printed out by postal mailing to:
Brugg Kabel AG, Industriestrasse 19, CH-5200 Brugg
5
Safety |
3 Safety
Target Group
Only trained specialists are allowed to install Brugg Cables products!
Minimal knowledge which must be proven is:
• successfully completed Training with Brugg Certificat in how to install and maintain Brugg products,
• have read and understood these mounting instruction before starting to mount,
• can realize und prevent dangers and risks while working on high voltage products,
• must fil out the Quality Certificat in this instruction to ensure professional mounting as well as quality
control of the assembly of the products of Brugg Kabel AG.
Personal Protective Equipment

Wear your personal safety equipment while mounting Brugg products!
Wear for all work:

Symbol Meaning Description
Protective Close fitting, tear-resistant cloth to protect from heat,
clothing flying sparks and small flying part
Safety Stable shoes to protect the feet from crushing,

shoes falling parts and slipping in slippery surfaces.
Wear for specifi actions steps:
Safety To protect fingers and skin of hot surfaces, sharp
gloves parts, irritating oder carcinogenic liquids.
Safety To protect the eyes from small flying parts, dang -

glasses rous radiation and irritating liquids.
Before starting to work

On eletrical equipment it is necessary to observe the fiv safety rules of electrical engineering:
1. Disconnect.
2. Secure against switching on again.
3. Determine zero-potential.
4. Earthing and short-circuiting.
5. Protect from neighboring live parts by covering them.
Warning Messages
Warning messages can be part of actions steps or can be valid for the whole document.
A warning message consists of
• the warning symbol,
• a signal word,
• the consequences caused by ignoring
• and the description how to avoid the risk.
6
Safety |
Signal Words Indicating the Degree of Danger
DANGER
• Is used for the higher level.
WARNING
• Is used for the lower level.
NOTICE Material Damage:
Symbol Description
NOTICE is used to adress practices not related to physical injury, but related to
possible damage of the product.
Additional Information:
Symbol Description
INFORMATION is used to adress practices with additional helpful, neccessary or simplifying

information.
General Safety Messages

Flamed surfaces
WARNING
Hot Surfaces.
• Do not touch hot surfaces with bare hands.
Cleaning agents
WARNING
Cleaning agents are harmful to health if swallowed, by inhalation and by contact to skin and
eyes.
• Product can be irritating to eyes and skin.
• Evidence of a carcinogenic effect
→→ Use your safety gloves, protective clothing and safety glasses.

→→ Use only in well-ventilated spaces.
→→ Do not eat, drink or smoke during cleaning.
→→ For further safety information and in case of a necessary medical consultation, see the
safety data sheets.
7
High Voltage Tools |
4 High Voltage Tools

For further details please visit our E-Catalog at http://brugg.nubosys.com/.
♦ Waterproof pen (white)

For local procurement
♦ Toolboxes
Type Application area Part no
A Hand workshop and measuring tools 88927
B Soldering tool set 88928
C Socket set 64350
♦ Peeling and stripping tools type SH

Cable diameter in mm Type Part no
15-50 SH50 65030
40-80 SH80 65031
70-130 SH130 65032
100-160 SH160 79066
♦ Cutting and peeling device type EH 150
Part no
88468
♦ Peeling tool type S

cable diameter in mm type part no
18-50 S50 65503
30-80 S80 65504
70-125 S125 65505
90-150 S150 65506
110-180 S180 77861
♦ Cable sheath dismantling fork
Part no
76631
♦ 3-arm puller type 12-2
Part no
88468
♦ Pressure disks for 3-arm puller

Conductor diameter in mm Part no Conductor diameter in mm Part no
21.0 ≤ Øconductor ≤ 24.5 66416 42.0 ≤ Øconductor ≤ 45.5 66421
8

♦ Heating tube type 150
Length Part no
1m 88279
♦ Insulation pushing devices

Conductor diameter Tool Part no
basic tool 88957
pressure disc see tool cat.
adapter sleeve see tool cat.
Øconductor < 38.5 mm
sliding disc 78179
handlebar 78183
lubricant of type Molikote 62604
basic tool 88958
pressure disc see tool cat.
adapter sleeve see tool cat.
Øconductor ≥ 38.5 mm
sliding disc 78180
handlebar 78183
lubricant of type Molikote 62604
♦ AL-Angle
Length Part no
1m 77741
2m 78198
♦ Hot air gun 50°C - 600°C
Part no
62465
♦ Cable band saw
Part no
64912
♦ Cable sanding machine
Part no
88964
♦ BAND-IT® clamping tool
Part no
65799
9
♦ Sheath cutter for corrugated sheath
Part no
65502 (220 V / 50 Hz) 78026 (110 V / 60 Hz)
♦ Pulling device set

Tool Part no
Set Insulation diameter 50 - 126 mm 88299
♦ Torque wrench type 60
Part no
76149
♦ High-pressure pumps (with hose)

Conductor diameter Type Part no
65416
Øconductor ≤ 38.5 mm 35t
(pump with hose)
76691 (pump)
Øconductor ≥ 38.5 mm 60t
76693 (hose)
♦ Press heads
Conductor diameter Type Part no
Øconductor ≤ 38.5 mm 35t 65417
Øconductor ≥ 38.5 mm 60t 76692
♦ Press dies (hexagonal)

Type for Øbolt Description Part no
20 mm KZ 20 66025
25 mm KZ 25 66026
28 mm KZ 28 66027
32 mm KZ 32 66028
35 t
38 mm KZ 38 65418
≤ 1000 mm2
42 mm KZ 42 62270
44 mm KZ 44 62271
52 mm KZ 52 62272
58 mm KZ 58 76148
10

Type for Øbolt Description Part no
25 mm SK 25 65975
28 mm SK 28 65976
32 mm SK 32 65977
38 mm SK 38 65978
42 mm SK 42 65979
44 mm SK 44 62188
60 t for
52 mm SK 52 62364
> 240 mm2
58 mm SK 58 62016
60 mm SK 60 76698
65 mm SK 65 65980
70 mm SK 70 62017
75 mm SK 75 62608
80 mm SK 80 64413
♦ Oil pumps
Type Application Part no
D40 FR/TE ≤ 245 kV 88000
D50 FR/TE ≥ 245 kV 88010
♦ Vacuum pumps
Type Application Part no
D 2.5 Terminations ≤ 245 kV 88682
D 16 Terminations ≥ 245 kV 88662
Cleaning agents:
Silicon parts Cable insulation Cable sheath Metal parts
Cleaning set:
• Cold cleaner (UN1219)
X X X X
• Cleaning tissues (UN 1219)
Part no: 89031
For local procurement:

• Ethanol ≥ 96% alcohol or
X X X X
• min. 92% Ethanol with max.
4% Methanol
For local procurement:

X X X
• Cleaning petrol
→→ Never use cleaning petrols to clean silicon parts!
11
Product Overview |
5 Product Overview
The variables A, B, C, E, G and H serve as reference points for specifi assembly steps.
They are included in the technical drawing for orientation.
Variable Relevance
A Point to remove the sheath
Conductor B Point to remove cable jacket
C Point to remove the outer graphite
layer of the cable jacket
G E
G
Reference point, gland
Point to remove the cable insulation
H Soft transition from semiconductive
layer to the cable insulation
Cable insulation
Cable insulation
Semiconductive Iayer
E
Gland
B A
C
12 Illustrations not to scale - only for information
Cable & Casing Preparation | Cable cutting |

6 Cable & Casing Preparation
6.1 Cable cutting
CP1
Use Tool: Cutting and peeling device type EH 150
& Peeling and stripping tool type SH
base plate
B C
2445 mm 734 mm 280 mm
C 1.) Mark points B and C.

2.) Make a 1 mm groove at point B with cutting device.
B 3.) Peel the complete semi conductor from B to C.
4.) Grind the peeled surface with sandpaper 80.
If the cable jacket has an outer graphite-layer:

Clean both cables using cleaning agent up to 100 mm behind C.
CP2
1.) Slide the heat shrink tube over the
cable into a temporary position.
Illustrations not to scale - only for information 13

Cable & Casing Preparation | Screen Preparation |
6.2 Screen Preparation

6.2 XDRAL-ALT
SP5 50 mm Use kevlar cord
A
B
1.) Mark point A 50 mm from B.

2.) Heat with soft flame
3.) Cut in with cord and remove sheath.
1.)
2.)
3.)
Do not damage the Al/Cu-foil!
SP6 Use Tool: Cable sheath dismantling fork B

A
1.) Remove sheath including Al/Cu-foil up to A.
2.) Cut the screen wires.
1.)
2.)
280-300 mm
SP7 1.) Clean with cleaning agent.

2.) Brush with steel sponge. 1.) - 3.)
3.) If Al-foil: apply Metalon HT 1.5 on it.
4.) Bend screen wires back for next actions steps.
(Aldrey with bigger radius)

Conductor & Insulation Preparation | Screen Preparation |

7 Conductor & Insulation Preparation
1.) Mark point E 724 mm before A. CIP1
2.) Remove swelling up to 160 mm before point E.
B
A
3.) Fix the remaining swelling tape at the end with tape No. 228. m
724 m
1.)
3.)
2.)
mm
160
E
If the cable is not straight between end of jacket and swelling tape fixation
→→ Unwind the swelling tape and wind back after straightening.
Use Tool: Heating tube CIP2
1.) Place heating tubes over the cable up to the swelling tapes and ensure no inner contact to the cable.
2.) Heat up to the swelling tape.
3.) Consider the heating time in the table.
thIns in mm = insulation thickness

Øcond = diameter of conductor
If the Brugg heating tube is not used:

→→ Surface temperature of the insulation during heating must be about 80 - 100 °C.
HEATING TIME
thIns in mm Øcond≤21 mm 21<Øcond≤35 mm 35<Øcond≤45.5 mm 45.5<Øcond≤59.5 mm 59.5<Øcond
thIns≤15 6h 8h 9h 11 h 12 h
15<thIns≤20 7h 9h 10 h 12 h 13 h
20<thIns≤25 10 h 11 h 12 h 13 h
25<thIns≤30 12 h 12 h 13 h 14 h
30<thIns≤35 12 h 12 h 13 h 14 h

CIP3 Use Tool: Al-Angle
Straighten the cable by fixing on Al-Angle with belts.
Al-Angle
Before removing the Al- angle, the insulation must be cooled to the ambient temperature.
CIP4
1.) Measure the diameter of the conductor ØCond and choose length a according to the table.
Shear bolt top connector:
ØCond length a in mm
8.5 mm - 65.5 mm 2937
a = _________mm
ØConductor


Use Tools: cutting and peeling device CIP5
EH 150 & peeling knifes & 3-arm puller
A
1.) Mark a point with distance a from point A.

2.) Make a conical cut with cutting device and peeling knifes.
2.)
3.)
a
1.)
3.) Remove min. 5 mm of the insulation.
min. 5 mm
Only if conductor has swelling tape or powder: CIP6

→→ Remove all the swelling tape and powder (between segments and
between the wire layers).
→→ Form the conductor again.
→→ Fix the conductor-form with a copper-wire wrapping.

Assembly | Preparing an Edgeless Transition from Semiconductive Layer to Cable Insulation |
8 Assembly
8.1 Preparing an Edgeless Transition from Semiconductive Layer to Cable Insulation
A1 Use Tool: Peeling and stripping tool type SH
A
1.)
mm
H 9944
2.)
remove semiconductive layer
1.) Mark point H 944 mm to point A.

2.) Peel off the semiconductive layer from point G up to point H ± 5 mm with peeling tool SH.
→→ When polishing, make sure to reduce the diameter as little as possible.

→→ If the insulation is not exactly round after the peeling, scratch and finish the surface with a
piece of glass.


A2
2.) H 30 mm roughen
polish
SC-Iayer
Cable insulation
no groove! SC-Iayer
Cable insulation
no edge!
SC-Iayer
Cable insulation
5.)
Cable insulation
1.)
H
stress cone length
1.) Polish the Cable insulation from point H to the left along the length of the stress cone with
rough sandpaper (at least always with 320 grit sandpaper) and be careful to remove as little as
possible material.
→→ If Øinsulation exceeds the specified application range of the stress cone contact
Brugg Cables AG for the further mounting steps.
2.) Take another piece of sandpaper and roughen the firs 30 mm of the outer semi-conductor
from point H to the right with first 150, then 220 and last 320 grit sandpaper and reach a slight
gradient shown in the detail graphic on the top.
Don‘t pollute the insulation with polished material of the semi-conductor!
(Use absolutely two pieces of sandpaper. One for the insulation and one for the semi-
conducting layer)
3.) Inspect the polished insulation for scratches, using a mirror, bare hands, and an inspection lamp
4.) measure the diameters defined in the quality certificate (section QC4) and fill in the tab
5.) Cover the insulation with a plastic foil to prevent damages and impurities.

A3
1.) Wrap 2 layers copper braid No.63 from B 160 mm beyond E.
2.) Wrap 2 layers B 40 tape from the sheath end A 160 mm beyond point E.
3.) Measure Øcable above the cable jacket.
1.)
Øcable = _________mm 774 mm B

160 mm
E
3.)
2.)
774 mm
Øcable
160 mm
A B
A4 Use Tool: Iron saw
1.) Saw conical part of the insulated gland at Øcable + 10 mm 1.)

with iron saw and grind the edges.
2.) Shift insulated gland over cable until jacket.
Øcable + 10 mm
2.)
insulated gland

Assembly | Mounting Gland and Stress Cone |

8.2 Mounting insulated Gland and Stress Cone
A5
1.)
1.) Shift insulated gland to the right.
2.) Wrap rubber tape up to the inner
E Ø of the sealing adapter.
insulated gland
2.) rubber tape
3.) Install greased o-rings.

4.) sealing adapter 4.) Shift the sealing adapter to the
point E.
4.)
E
3.)
5.) Fix sealing adapter by a layer B50-

EPR tape.
Images of the gland in the

instruction is not the same as on
the drawing but the mounting steps
5.) B50 tape
stay the same.

A6
1.) Shift insulated gland back on the sealing adapter.
1.)
2.) Make a mark at the end of the insulated gland.
gland
3.) Shift insulates gland to the right.
mark
4.) Wrap rubber tape under tension up to

the Øcable +5 mm.
5.) Shift insulated gland back to final position.


Use Tool: Hot air gun A7
1.) Heat surface with hot air gun (no flame)

2.) Finish when it is absolutely smooth and a color change
begins with silky sheen.
stress cone
end position
lengthstress cone
A8
1.)
1.) Cover stress cone inside with silicone grease.

2.) Wrap PVC-tape No. 228 on conductor to cover sharp edges.
1.)
2.)
Do only use the supplied silicone grease!
A9
1.) Put a mark 40 mm behind semicon edge H. 1.)

semicon edge
2.) Install slide-on tube.
H
3.) Slide on the stress cone up to the mark by
hand or use slide-on device.
40 mm
2.) slide-on-tube
3.) stress cone

A10
1.) Connect stresscone-lip to semicon of the cable.
2.) Wrap 4 layers tape No. B40 beside the lip.
tape No. B40
20 mm
stresscone-lip

Assembly | Mounting Connector |

8.3 Mounting Connector
1.) Remove PVC-tape No. 228 from the conductor. C1

2.) Cut the conductor with distance g to end of insulation.
3.) Clean with cleaning agent.
4.) Brush with steel sponge.
5.) If Al-conductor: brush with steel brush and apply Metalon HT 1.5 on the conductor.
6.) Cover insulation with plastic protection foil.
6.)
Connector type g
FR 1.) - 5.)
comp. 1-pc 2-pcs
g in mm 100 100 91.5

Assembly | Mounting Connector |
8.3.a Shear Bolt Connector - One Piece
C2b
1.) Slide the bolt on the cable.

2.) Tighten the shear bolts in several steps crosswise
(from handtight to the shear point).
connection bolt
Remove all metallic splints from the screwing area!

→→ If the shear bolt connector is used the extension = 0 has to be written down
in the quality certificate, section QC3.

Assembly | Insulating Gland and Connector |

8.4 Insulating Gland and Connector
A11 lreal
1.) Measure the real length of the Insulator lreal with a measuring tape.
2.) Calculate the difference ∆ between real and lInsulator (see drawing).
3.) Add ∆ to lenght e mm. e = 2615 mm e + ∆ = _________mm
A12
1.) Check length e to the top of the bolt again. Align gland if necessary. E
m+∆
2615 m
2.)
2.) Wrap10-12 layer tape B50.
3.)
3.) Wrap oil silk tape over tape B50.
Always wrap the tapes with equal force to achieve a symmetrical round wrapping on the gland!

A13
Form a conus of EPR tape B50

(30% extended, 50% overlapped).


round with R5 1.) 2.) 3.) A14
1.) Polish with sandpaper grit 220.

2.) polish with sandpaper grit 320.
3.) Clean the insulation using cleaning agent.
→→ Do not smudge any traces of the outer semi-conductor on the insulation.
→→ Do not touch the cleaned insulation with bare hands.
→→ Clean with direction from insulator to outer semi-conductor.
4.)
4.) Use hot air gun (no flame) at th
insulation until surface is completely
smooth. (starts to change color, acquire
silky luster)
5.) 120 mm 5.) Wrap 2 layers B40 tape
(wrap large radius).
6.) Wrap B50 tape up to a thickness

of 8 mm.
6.)
8 mm

8.4.a Assembly XDRAL-ALT

Use Tool: BAND-IT® clamping tool A15
1.) Apply Metalon HT 1.5 on the first 100 mm of the cylindric part of the gland.
2.) Bend sceen wires on gland.
3.) Use 2x BAND-IT® metal bands to fix
4.) Cover all screen wires and the sheath with 4 layers of tinned copper braid
No.63.
100 mm
1.)
B
2.) 4.)
3.)
be aware of the earthing connection eye! see drawing!

Assembly | Mounting Insulator und Baseplate |

8.5 Mounting Insulator und Baseplate
Use Tool: Hot air gun A17
290 mm
1.) Wrap 1 layer B50 tape. (30% extended, 50% overlapped).
1.)
2.) Wrap 3-4 layers preimpregnated reinforcing tape:

- drop the tape into water and squeeze it, B
- wrap 3-4 layers, 2.)
- after 10-15 minutes dry the tape using hot air gun.
240 mm
3.)
3.) Cover with HV sealing tape 20x1x900.

(1 layer, 2-3 mm overlapped)
100 mm
1.) Clean with cleaning agent. A18

2.) Slide heat shrink tube on insulated gland.
3.) Use soft flame to shrink the sleeve. 2.)
1.) & 3.)

A19
1.) Clean carefully with cleaning agent.
A20 1.) 1.) Slide on baseplate.

2.) Tighten screws crosswise (16x)
2.) with tightening torque 30Nm.
3.) Install plug.
4.) Install valve.


A21
Preparing & Mounting the sliding ring:
→→ If necessary, adjust the sliding ring for the groove in the bolt so that
it retains a round shape as in the left-hand graphic.
→→ Prepare the sliding ring so that it presses itself into the groove on
its own.
1.) Insert greased o-ring into baseplate.

2.) Mount the lower locking ring, the
greased o-rings and the sliding ring.
3.) Put insulator carefully on the baseplate.
3.) 4.) Tighten crosswise (24x) with
tightening torque 30 Nm
insulator
3.)
2.)
greased O-rings
1.)
4.)
Outdoor sealing end without support Insulators!

A22
1.) Tighten crosswise (6x),

tightening torque 25 Nm.
3.)
2.) Mount adapter.
3.) Insert greased O ring.
2.)
1.)


A23
3.)
2.) 1.) Insert greased O ring.

2.) Mount valve with tightening
torque 15 Nm.
1.) 3.) Mount the upper locking ring

Filling and Fixing | Mounting Insulator und Baseplate |
9 Filling and Fixing Filling and mounting up to 45 ° inclination angle

FF1 Use Tool: Oil & vaccum pump
vacuum gauge
oil display
2.)
2.)
vacuum pump
1.)
length z
oil level 2.) Z

point
(after drain)
1.) Connect pump for silicone oil to the valve at the gland.
2.) Connect vaccum pump to the vacum gauge and connect
them to the upper valve.
3.) Evacuate until 0.9 mBar.
4.) Now during the evacuation process fill 175 l oil (insulator in
vertical position) into the termination.
5.) Remove the vacuum equipment and fill in oil up to point Z
(according to table). Check with measuring stick.
1.)
°
45
1.)
oil pump


FF1
length Z in mm oil weight

in dependence to the temperature of oil at fillin in kg
stresscone Øins_min Øins_max -10 °C 0 °C 10 °C 20 °C 25 °C 30 °C 40 °C 50 °C
58 60 329 305 280 255 243 230 206 181 210.3
60 62 329 305 280 255 243 230 206 181 209.9
62 64 329 305 280 255 243 230 206 181 209.5
64 66 329 305 280 255 243 230 206 181 209.0
245/50/172 66 68 329 305 280 255 243 230 206 181 208.6
68 70 329 305 280 255 243 230 206 181 208.1
70 72 329 305 280 255 243 230 206 181 207.6
72 74 329 305 280 255 243 230 206 181 207.1
74 76 329 305 280 255 243 230 206 181 206.6
76 78 329 304 279 255 242 230 205 181 205.5
78 80 329 304 279 255 242 230 205 181 204.9
80 82 329 304 279 255 242 230 205 181 204.4
245/65/187 82 84 329 304 279 255 242 230 205 181 203.8
84 86 329 304 279 255 242 230 205 181 203.3
86 88 329 304 279 255 242 230 205 181 202.7
88 90 329 304 279 255 242 230 205 181 202.1
90 92 328 304 279 254 242 230 205 180 200.9
92 94 328 304 279 254 242 230 205 180 200.3
94 96 328 304 279 254 242 230 205 180 199.6
96 98 328 304 279 254 242 230 205 180 199.0
98 100 328 304 279 254 242 230 205 181 198.3
100 102 328 304 279 254 242 230 205 181 197.6
245/78/200 102 104 328 304 279 254 242 230 205 181 196.9
104 106 328 304 279 254 242 230 205 181 196.2
106 108 328 304 279 254 242 230 205 181 195.5
108 110 328 304 279 254 242 230 205 181 194.8
110 112 328 304 279 255 242 230 205 181 194.0
112 114 328 304 279 255 242 230 205 181 193.3
114 115 329 304 279 255 242 230 205 181 192.7

FF2
(Filling mounted below 45° angle of inclination)
expansion tank
vacuum gauge
oil pump
vacuum pump
oil display
valve
Follow the separate mounting instruction of the used expansion tank (ET 2).
FF3
1.) Mark 12 mm below the top end of the insulator.

2.) Fill the mixed compound WG 900 (mixing instruction included) up the mark only. Don‘t overfill
3.) Await hardening of the compound, then mount the silicon cap.
12 mm


FF4
1.) Put on silicone cape.
Mounting the silicon cap:

The slot (round) in the cap should match the
valve on top of the insulator.

FF5
base plate
1.) Mount an anchoring clamp ~100 cm

below the base plate onto the steel
construction.
2.) Fix the cable in the anchoring clamp
and screw it together.
~100 cm
steel construction
2.)
1.)
anchoring clamp
Outdoor sealing end without support Insulators, directly mounted on steel structure!

Quality Certificate |
10 Quality Certificat
This quality certificate is an inherent part of the product. The jointer himself must fill it in. The document
must contain data and measured dimensions which can be essential for a proper and safe functioning of the
product. This document has to be submitted to Brugg Cables immediately after completed installation.
In case of incorrect data, incompleteness or deceit the warranty is excluded.
Product Type: _______________________ Document No.: _______________________

Project: _______________________ Project No.: _______________________
Drawing: _______________________ Revision: _______________________
Installation place: _______________________
Feeder: _______________________ Silicone oil type (if filled) _____ (Brugg No., not part No.!)
Voltage: ___________________ Oil level after drain (TF/TT): _______________________

Manufacturer of Cable: ___________________ Type of Cable: _______________________
Conductor: Cross Section: _______________________ mm2
Conductor Ø: _______________________ mm
Aluminium:
Copper:
Swelling tapes: Yes No
XLPE: Inner SC Ø: _______________________ mm
Insulation Ø: _______________________ mm
Outer SC Ø: _______________________ mm
Metal screen: Lead sheath and copper wires

Lead sheath
Aluminium/copper corrugated sheath
Aluminium/copper laminated sheath
Screen wires: Round Flat
Aldrey Aluminium Copper
Jointer, Assembler
Company: _______________________ Date of assembly: _______________________
First Name: _______________________ Certificate Number _______________________
Family Name: ________________________ Signature: ________________________
Supervisor
Company: _______________________ Date of assembly: _______________________
First Name: _______________________ Certificate Number _______________________
Family Name: ________________________ Signature: ________________________
41
Quality Certificate |
QC1. Cable insulation test and serial number of the stress cone
Phase Sheath DC test Stresscone No. Type STRC

Mounting Instruction TFD 2
QC1. Cable insulation-‐test and serial number of stress-‐cone
Epoxy-‐insulator
QC2. Heating time
Phaseand contraction
Sheath DC-‐test of insulation
Stresscone No. Type STRCD
No.
Phase Heating time in h Contraction in mm

table 2
QC2. Heating time and contraction of insulation
Heating time contraction

Phase
[h] [mm]
QC3. Extension of connector and distance from connector up to the semicon edge
table 3
Phase Extension in mm Length h in mm
QC3. Extension of connector after crimping and the distance from the connector end up to the
outer SC
extension h
Phase
[mm] [mm]
QC4. Diameter of the cable after peeling

table 4
QC4. Taking
Øconductor of 01
measurements
Øinsulationa02
t cable insulation
Øinsulation 03 Øinsulation 04 Øsemicon 05
Phase
[mm] [mm] [mm] [mm] [mm]
Øconductor -‐ Ø1 Øinsulation -‐ Ø2 Øinsulation -‐ Ø3 Øinsulation -‐ Ø4 Øsemicon -‐ Ø5
Phase
[mm] [mm] [mm] [mm] [mm]
table 5
figure 20
QC5. Position of the springs at the assembly temperature

Reset form Print form Send form per email
Position Temperature
Phase
42 [mm] [°C]
Brugg Kabel AG
Mounting Instruction
Drawings:
HE 4180-‐0 Rev. ac
Termination-‐type:TFD 245 kV
Cabletype:
Mounting I nstruction
Drawings:
All polymeric cable types HE 4180-‐0 Rev. ac
1 x 400-‐2500245
(DB) kV
mm 2
Cabletype:
Mounting
All polymeric cable Brugg
I Kabel AG
nstruction
types
1 x 400-‐2500 (DB) mm 2
Mounting IBrugg Kabel AG

nstruction
Drawings:
Brugg Kabel AG
Revision 00 01 02 03 HE 4180-‐0
04 Rev. ac05
Klosterzelgstrasse 28
Termination-‐type:TFD 245 kV Klosterzelgstrasse 28

nstruction
Written Sk,stb
2014-‐09-‐26 CH-5201
CH-5201 Brugg
Brugg
Verified
Cabletype:
Released Tel.: Drawings:
Tel.: +41
+41 (0)
(0) 56
56 460
460 33
33 33
33
Revision All polymeric

00 01 cable
02 types
Fax:
Fax: +41
03 HE
+41 (0) 56
56 460
460 35
(0)4180-‐0 36
35 Rev.
04
36 ac05
1 x 400-‐2500245
Version: 2014-‐09-‐26 (DB) kV
mm2 www.bruggcables.com

www.bruggcables.com
nstruction
Written Sk,stb
2014-‐09-‐26 info@brugg.com
info@brugg.com
Verified
Cabletype:
Released Drawings:
Version: 2014-‐09-‐26 1 x 400-‐2500245
(DB) kV
Brugg Kabel AG
mm2
Cabletype: Drawings:
1 x 400-‐2500245
(DB) kV
mm2
Revision 00 01
Brugg Kabel AG
02 03 04 05
Cabletype:
Written Sk,stb
2014-‐09-‐26
Drawings:
Verified All polymeric cable types HE 4180-‐0 Rev. ac
Released 1 x 400-‐2500245
(DB) kV
mm2

Mounting Instruction: Termination Type: Cable Type: Drawing: Highest Voltage For The Equipment (Um)

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Mounting

Cabletype: Highest Voltage for Drawin

All polymeric cable types

READ THIS MANUAL BEFORE STARTING TO MOUNT!

2 Information on this Document

XLPE insulated cable with copper/aldrey screen wires

Information on this Document | ﻿

Liability and Restriction of Liability

At actions steps with the brugg academy symbol

Brugg Kabel AG, Industriestrasse 19, CH-5200 Brugg

Personal Protective Equipment

Wear for all work:

Safety Stable shoes to protect the feet from crushing,

Safety To protect the eyes from small flying parts, dang -

Before starting to work

INFORMATION is used to adress practices with additional helpful, neccessary or simplifying

General Safety Messages

• Do not touch hot surfaces with bare hands.

→→ Use your safety gloves, protective clothing and safety glasses.

4 High Voltage Tools

♦ Waterproof pen (white)

♦ Peeling and stripping tools type SH

♦ Cutting and peeling device type EH 150

♦ Peeling tool type S

♦ Cable sheath dismantling fork

♦ 3-arm puller type 12-2

♦ Pressure disks for 3-arm puller

High Voltage Tools | ﻿

♦ Insulation pushing devices

♦ Hot air gun 50°C - 600°C

♦ Cable band saw

♦ Cable sanding machine

♦ BAND-IT® clamping tool

♦ Sheath cutter for corrugated sheath

65502 (220 V / 50 Hz) 78026 (110 V / 60 Hz)

♦ Pulling device set

Set Insulation diameter 50 - 126 mm 88299

♦ Torque wrench type 60

♦ High-pressure pumps (with hose)

Øconductor ≤ 38.5 mm 35t 65417

Øconductor ≥ 38.5 mm 60t 76692

♦ Press dies (hexagonal)

High Voltage Tools | ﻿

D40 FR/TE ≤ 245 kV 88000

D50 FR/TE ≥ 245 kV 88010

D 2.5 Terminations ≤ 245 kV 88682

D 16 Terminations ≥ 245 kV 88662

For local procurement:

For local procurement:

→→ Never use cleaning petrols to clean silicon parts!

Cable & Casing Preparation | Cable cutting |

2445 mm 734 mm 280 mm

C 1.) Mark points B and C.

If the cable jacket has an outer graphite-layer:

Illustrations not to scale - only for information 13

6.2 Screen Preparation

1.) Mark point A 50 mm from B.

Do not damage the Al/Cu-foil!

SP6 Use Tool: Cable sheath dismantling fork B

SP7 1.) Clean with cleaning agent.

14 Illustrations not to scale - only for information

Conductor & Insulation Preparation | Screen Preparation |

Use Tool: Heating tube CIP2

Information on this Document |

High Voltage Tools |

High Voltage Tools |