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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
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.
General Instructions
Use a propane (preferred) or butane gas torch.
Adjust the torch to obtain a soft blue flame with a yellow tip.
Keep the torch aimed in the shrink direction to preheat the material.
Clean and degrease all parts that will come into contact with adhesive.
Tubing should be cut smoothly with a sharp knife leaving no jagged edges.
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.
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
A
insulation reference line insulation
bedding bedding
earth lead oversheath
20 20
c
a b
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
B
insulation reference line insulation
bedding bedding
earth lead oversheath
20
20
c 40
a b
I I
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
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.
Joint completed. 11
Allow the joint to cool before applying any mechanical
strain.