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ACCESSORIES FOR ELECTRICAL CABLES

ELCOTERM GLS - 1275/EZ 3675/EZ

Installation instruction

HEAT SHRINKABLE
STRAIGHT JOINT

for
three core
plastic or rubber insulated cables
with armour

Highest voltage 12 kV to 36 kV

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Copyonlyfornoncommercialand/ortechnicaluse.Documentandrelatedtechnicaldataarereleasedforpresentationandindicativepurposesaboutrelated
productsonly,andarebaseduponinformationbelievedbyElconMegaradtobecurrentlyaccurate.However,theyarenotbindingonElconMegaradtowards
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Code
DRAWING N MP9096
Drawed Rev. Approved

Issue 18/02/00 31/10/05


ELCON MEGARAD S.p.A.
HEADQUARTER and FACTORY: ARCELLA (AV) ITALY 834/EZ
Tel. +39 0825/6077 - Fax +39 0825/607782
Web site:www.elconmegarad.com e-mail: elcon@elconmegarad.com Signature C.I. G.D. M.M.

ELCOTERM GLS - 1275/EZ 3675/EZ Page 1/8 Drawing N 834/EZ


Ogni diritto sui presenti testi, disegni, prodotti e su ogni singola parte di essi di esclusiva propriet di Elcon Megarad S.p.A. Ogni riproduzione e/o distribuzione, anche parziale o tradotta, strettamente proibita.
All the rights on texts, drawings, products and each single part of them is exclusive property of Elcon Megarad S.p.A. All reproduction and/or distribution, even partial or translated of this document is strictly prohibited.
GENERAL INFORMATION
--- READ CAREFULLY THE INSTRUCTIONS BEFORE STARTING CABLE PREPARATION.
--- CHECK IF ALL THE COMPONENTS LISTED ON THE BILL OF MATERIAL ARE IN THE KIT.
--- HEAT SHRINK THE TUBES USING A SOFT FLAME OF A BUTAN OR PROPANE GAS TORCH, STARTING FROM THE
CENTER AND SLOWLY UP TOWARD THE END, HEATING IT UNIFORMELY ALONG THE CIRCUMFERENCE MOVING IT
ALL AROUND. DO NOT INSIST ON THE SAME PARTS, AND STOP WHEN COMPLETELY SHRUNK.

1. CABLES PREPARATION

CABLE WITH TAPE SHIELD


1.1 Overlap the cable to be jointed by 300 mm, at
least. Sign the reference line (middle of
overlap) on to the cables, then cut and remove
the surplus part in correspondence of the
reference line.

1.2 Cut and remove the outer jacket according to the dimension "A" shown on the bill of material enclosed from one cable (shortest
side) and to the dimension "B" shown on the bill of material enclosed from the other cable (longest side).
1.3 Cut and remove the armour so far the outer jacket edge. Then cut and remove the outer jacket for 100 mm again and fix the armour
edge by some layer of copper wire.

1.4 Clean up the outer-jacket with a suitable solvent for 1,5 m at least to avoid dirtiness is transferred to the internal surface of the
heat shrinkable tube. Spread the cores and remove the exposed filler.

--- each core operation ---


1.5 Fix the tape shield of each core to the
dimension "C shown on the bill of material
enclosed + 50 mm" from the cable edge by
some layers of adhesive copper tape.
1.6 Cut and remove the tape shield from the cores
end on the adhesive copper tape edge.

ELCOTERM GLS - 1275/EZ 3675/EZ Page 2/8 Drawing N 834/EZ


Ogni diritto sui presenti testi, disegni, prodotti e su ogni singola parte di essi di esclusiva propriet di Elcon Megarad S.p.A. Ogni riproduzione e/o distribuzione, anche parziale o tradotta, strettamente proibita.
All the rights on texts, drawings, products and each single part of them is exclusive property of Elcon Megarad S.p.A. All reproduction and/or distribution, even partial or translated of this document is strictly prohibited.
CABLE WITH WIRE SHIELD
1.1a Train the cables to overlap both ends for 1 m at
least; mark on to the cables a reference line in
a center of joint. Cut only one cable on the
reference line, and the other cable (longest
side) at 500 mm toward the end from the
reference line so to remove the surplus part.

1.2a Cut and remove the outer jacket according to the dimension "A" shown on the bill of material enclosed from the shortest cable
side, and for the dimension "B shown on the bill of material enclosed + 500 mm from the longest cable side.
1.3a Cut and remove the armour so far the outer jacket edge. Then cut and remove the outer jacket for 100 mm again and fix the armour
edge by some layer of copper wire.

1.4a Clean up the outer-jacket with a suitable solvent for 1,5 m at least to avoid dirtiness is transferred to the internal surface of the
heat shrinkable tube. Spread the cores and remove the exposed filler.

--- each core operation ---


1.5a Remove the metallic tape, and don't cut the
wire shield but turn them downwards the armour
and fix them by copper wire at 10 mm from
outer jacket edge.
1.6a Fix the wires also on the outer jacket by some
layer of p.v.c tape ELCOPLAST 51.

1.7a Cut and remove only from the longest cable side the cores end for 500 mm.

ELCOTERM GLS - 1275/EZ 3675/EZ Page 3/8 Drawing N 834/EZ


Ogni diritto sui presenti testi, disegni, prodotti e su ogni singola parte di essi di esclusiva propriet di Elcon Megarad S.p.A. Ogni riproduzione e/o distribuzione, anche parziale o tradotta, strettamente proibita.
All the rights on texts, drawings, products and each single part of them is exclusive property of Elcon Megarad S.p.A. All reproduction and/or distribution, even partial or translated of this document is strictly prohibited.
2. CORES PREPARATION

2.1 Remove the cable semiconductor (if necessary use


appropriate tool), for the dimension "C" shown on the
bill of material enclosed from the edge.

2.2 Remove the cable primary insulation from the top of a


cable for HALF CONNECTOR DEPTH + 5 mm. Take
care to do not nick the conductor.

2.3 If necessary smooth the insulation surfaces, to be


sure that all semiconducting traces are removed,
using the supplied abrasive cloth without touching the
cable semiconductor.
Smooth the insulating cutting edge.
2.4 Clean up the exposed conductors and apply on the
edge some laps of p.v.c. tape.

We recommend during the assembling to protect by some paper or carton the tube from direct sun rays.
Furthemore we suggest not to remove the silicon paper supplied with the tube, and to slide the tubes on the cable with the silicon
paper positioned between the upper side of the cable or other tube and the tube's adhesive. In this way any sticking between the
tube and the cable sheath can be avoided, even in presence of high ambient temperature.

2.5 WARNING: Slip on the outer jacket, the two sealing MPS shrinkable tubes.
2.6 WARNING: Slip on each phase (joint longest side) n.1 insulating and semiconductive GIS tube, the insulating GMT tube (n.0
for voltage up to 12 kV or n.1 for voltage 17,5 kV and 24 kV or n.2 of a different size for voltage 36 kV) and n.1 stress control
MCC tube (if necessary slip the MCC tube on the joint shortest side). Protect them opportunely from dirtiness.

- follow the instructions for each core at a time -


2.7 Remove the p.v.c. tape on the conductors, connect
the conductors using a suitable M.V. CONNECTOR,
crimp it with a suitable tool and remove any sharp
point.
2.8 Clean the cable insulation by the cleaning tissue,
starting from the top end toward the semiconductor, if
necessary clean also the cable semiconductor without
touching the insulation previously cleaned.

NOTICE: the ELCOSEM 46 tape must be applied stretching it up to reduce the original width to the half, approximately.

2.9 (ONLY FOR VOLTAGE 24 kV AND 36 kV)


Apply, an half lapped layer of semiconductive tape
ELCOSEM 46 on the connector and on conductor
exposed parts.

ELCOTERM GLS - 1275/EZ 3675/EZ Page 4/8 Drawing N 834/EZ


Ogni diritto sui presenti testi, disegni, prodotti e su ogni singola parte di essi di esclusiva propriet di Elcon Megarad S.p.A. Ogni riproduzione e/o distribuzione, anche parziale o tradotta, strettamente proibita.
All the rights on texts, drawings, products and each single part of them is exclusive property of Elcon Megarad S.p.A. All reproduction and/or distribution, even partial or translated of this document is strictly prohibited.
NOTICE: the ELCOMASTIC 85 tape must be applied stretching it up to reduce the original width to the half, approximately.

2.10 Apply at least two half-lapped layers of ELCOMASTIC


85, on the connector area, filling uniformely the area
between connector ends and primary insulation, which
has to be overlapped for about 15 mm. Any way, after
wrapping, the final diameter in the connector area
should be slightly greater than one of the cable
insulation.

2.11 Apply two half lapped layers of ELCOMASTIC 85 on the cable semiconductor edges overlapping it for 10 mm and the insulation
for 20 mm.

2.12 Slide the stress control tube MCC (black colour) on the joint in such a way as to overlap fairly the cable semiconductor on both
sides. Heat shrink the tube starting from the center toward the ends. Pay attention to avoid heat shrink the other tubes on the
side of the cores.
WARNING: the stress control tubes MCC and the red insulating tubes GMT have to be cleaned by suitable solvent after the
heat shrinking.

2.13 Apply two half lapped layers of ELCOMASTIC 85, starting from MCC tube edges overlapping for 30 mm the cable semiconductor
on both sides.

2.14 Center on the MCC tube and then heat-shrink the insulating tubes GMT (red colour) supplied in the kit, beginning with the one
having the smaller diameter and then the other one, according to the instructions before mentioned.

ELCOTERM GLS - 1275/EZ 3675/EZ Page 5/8 Drawing N 834/EZ


Ogni diritto sui presenti testi, disegni, prodotti e su ogni singola parte di essi di esclusiva propriet di Elcon Megarad S.p.A. Ogni riproduzione e/o distribuzione, anche parziale o tradotta, strettamente proibita.
All the rights on texts, drawings, products and each single part of them is exclusive property of Elcon Megarad S.p.A. All reproduction and/or distribution, even partial or translated of this document is strictly prohibited.
2.15 Position the shrinkable insulating and semiconductive tube GIS (red/black colour) on the joint in such a way to center it on the
previously applied tube, heat shrink it as above.

3. SHIELDING OPERATION

CABLE WITH TAPE SHIELD


3.1 Wrap the ELCOSHIELD 49 tinned copper tape on each single core, start up to overlap the exposed tape shield for 20 mm, wrap
the core with an overlap 20 % until overlap the exposed tape shield for 20 mm at opposite side. Fix the extremity, at the end of
the taping, by a knot obtained by the same tape.

3.2 Position the ground copper braids (short pieces) on the two cores of the joint and fix them on the exposed tape shield, to the
two side of each core with the constant force spring.
3.3 Position the ground copper braid (longest piece and larger size) on the other core of the joint and fix it on the exposed tape
shield, to the two side with the constant force spring. Compact the cores.

1) Apply the ground copper braid on the tape shield;


fasten the constant force spring edge on the tape
shield.
2) Fix the ground copper braid by two laps of constant
force spring in such a way as the extremity comes out
for several mm, to make, successively, a lapel on the
same to be applied.
3) Refold the ground copper braid and wrap the rest of
the constant force spring on it. Twisting the costant
force spring so far tight definitively.

CABLE WITH WIRE SHIELD


3.1a Compact the cores and wrap the ELCOSHIELD 49 tinned copper tape around the 3 cores, start up to overlap the exposed cable
semiconductor, wrap the cores with an overlap 20 % until overlap the exposed cable semiconductor at opposite side. Fix the
extremity, at the end of the taping, by a knot obtained by the same tape.

ELCOTERM GLS - 1275/EZ 3675/EZ Page 6/8 Drawing N 834/EZ


Ogni diritto sui presenti testi, disegni, prodotti e su ogni singola parte di essi di esclusiva propriet di Elcon Megarad S.p.A. Ogni riproduzione e/o distribuzione, anche parziale o tradotta, strettamente proibita.
All the rights on texts, drawings, products and each single part of them is exclusive property of Elcon Megarad S.p.A. All reproduction and/or distribution, even partial or translated of this document is strictly prohibited.
3.2a Turn the wire shield on to the joint, joint and twist the wires together in order to obtain a strand shape conductor. After having
removed the exceeding length, connect the conductors by a connector contained in the kit, out of central area of joint. Fix the
connector to the joint by some layers of p.v.c. tape ELCOPLAST 51.

4. ARMOUR BUILD UP OPERATION

4.1 Position the metallic joint case around the joint and secure it by two layers of p.v.c. tape ELCOPLAST 51 in several point. Check,
before securing with pvc tape, that the diameter of the joint case does not exceed the internal diameter of tube MPS to be applied
successively.

CABLE WITH TAPE SHIELD

4.2 Turn the ground copper braid edge on the joint case.
4.3 Fix the joint case ends on the armour blocking also the ground copper braid edge using two screw clip for side.
4.4 Cover the sharp edges of the screw clip and the edge of joint case with some layers of p.v.c. tape ELCOPLAST 51.

CABLE WITH WIRE SHIELD

4.3a Fix the joint case ends on the armour blocking also the wire shield using two screw clip for side.
4.4a Cover the sharp edges of the screw clip and the edge of joint case with some layers of p.v.c. tape ELCOPLAST 51.

ELCOTERM GLS - 1275/EZ 3675/EZ Page 7/8 Drawing N 834/EZ


Ogni diritto sui presenti testi, disegni, prodotti e su ogni singola parte di essi di esclusiva propriet di Elcon Megarad S.p.A. Ogni riproduzione e/o distribuzione, anche parziale o tradotta, strettamente proibita.
All the rights on texts, drawings, products and each single part of them is exclusive property of Elcon Megarad S.p.A. All reproduction and/or distribution, even partial or translated of this document is strictly prohibited.
5. OUTER JACKET BUILD UP OPERATION

5.1 Roughen with abrasive cloth the outer jacket for 100 mm, both edges.
5.2 Slide on the joint one of the sealing MPS tubes overlapping the roughen outer jacket for 100 mm.
5.3 Heat shrink the tube, as before mentioned, until it perfectly stick to the cable. The adhesive that will come out from the ends of
tube shows that the heat shrinking has been sufficient.
5.4 Roughen the tube edge in a middle point of the joint for 100 mm at least.
5.5 Wrap the sealing mastic ELCOMASTIC 75 on to the tube edge (roughen zone).

5.6 Slide on the second sealing MPS tube to overlap for 100 mm, the outer jacket edge, and the MPS tube previously applied. Heat
shrink the tube until it perfectly stick to the cable.

5.7 The joint is ready to be energized.

ELCOTERM GLS - 1275/EZ 3675/EZ Page 8/8 Drawing N 834/EZ


Ogni diritto sui presenti testi, disegni, prodotti e su ogni singola parte di essi di esclusiva propriet di Elcon Megarad S.p.A. Ogni riproduzione e/o distribuzione, anche parziale o tradotta, strettamente proibita.
All the rights on texts, drawings, products and each single part of them is exclusive property of Elcon Megarad S.p.A. All reproduction and/or distribution, even partial or translated of this document is strictly prohibited.

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