Energy Division http://energy.tycoelectronics.com Power Cable Accessories Catalogue 2003/2004 tt Introduction 3 nn ee tt Terminations – Low and Medium Voltage 15 nn oo CC Connection Systems for gas-insulated Switchgear up to 24 kV 37 Joints – Low Voltage 47 Joints – Medium Voltage 67 Sealing Systems 85 Repair Sleeves and Tubings 93 Tools and Accessories 101 Connection Boxes 109 1 2 nn Introduction oo General 4 ii Low Voltage Jointing System 7 tt cc Medium Voltage Terminations System 8 uu Medium Voltage Jointing System 9 dd Electrical Stress Control in Cable Accessories 10 oo Weathering and Ageing Resistivity 11 rr tt Technology of Heat-Shrinkable Products 12 nn II Advantages of Raychem Heat-Shrinkable Products 13 3 Tyco Electronics Energy Division We develop, manufacture and market innovative products which benefit from its advanced know-how in the field of material science. All products are designed to help our customers to improve the reliability and economy of their electrical networks and equipment. Our broad portfolio of products offered for the electrical power industry include cable accessories, surge arresters, insulators, insulation enhancement products, components for electrical equipment as well as connectors and fittings for up to 800 kV. This catalogue contains terminations, joints, connection boxes and accessories for cable types most commonly used in the electrical distribution and industrial networks of Central & Eastern Europe / CIS (change to your country!). As one of the largest suppliers of cable accessories in the world, Raychem products are offered for nearly all special and foreign cable constructions. Please contact the Raychem products representative for technical support and additional information about cable accessories or the other product lines. Raychem cable accessories As a result of sustained and extensive research and long experience in technical support work, Raychem products are developed during the last 3 decades to become a complete system of cable accessories up to 170 kV. The long-term performance of Raychem heat-shrinkable materials has been demonstrated by the well-proven Raychem accessory system. Millions of installations in some of the most severe service conditions have confirmed the reliability of the Raychem heat-shrinkable technique under high electrical, thermal and environmental stress. The technology that is common to all Raychem heat-shrinkable cable accessories is based on radiation crosslinked polymers with an elastomeric shape memory. They provide a significantly improved mechanical, chemical and thermal resistance compared to non-crosslinked products. Raychem cable accessories are distinguished by their good insulating and sealing characteristics, high mechanical toughness and resistance to weathering and chemicals, such as UV radiation and alkaline soils. Because of the large shrink area of the individual parts, it is possible to use a few standard accessories to cover a large range of different cable types and cross sections. This means that warehousing is simple and economical. In addition, Raychem cable accessories can be stored for an unlimited length of time under normal conditions. The product line includes indoor and outdoor terminations, inline and transition joints as well as universal insulation, sealing and repair systems for use in the cable network. All medium voltage accessories include a stress control system either as separate stress control tubing or integrated as stress control coating in an insulating tubing. In terminations, the insulating tubing ensures a non-tracking and erosion resistant surface and provides an environmental seal to the cable lug and the oversheath. The connection area of joints is covered by an elastomeric dual-wall tubing which provides an interface free insulation and an outer screening. 4 Installation No special tools are required for the cable preparation. The installation of the heat- shrinkable parts is performed with a propane gas torch which is usually also used for the preparation of paper and plastic cables. When delivered, all individual parts are stretched so far that they can easily be slid over the prepared cable end. When sufficiently heated, they shrink and firmly enclose the cable and protect it against moisture, while the adhesive melts and fills all grooves and voids. Raychem cable accessories are constructed in a similar way to the cables themselves and can, like these, be bent in narrow spaces. Upside-down installations of terminations are possible simply by turning the heat-shrinkable sheds. The accessories can immediately put into operation after installation. Test process and qualification Raychem cable accessories are designed and fully tested to meet Raychem specification PPS 3013 which encompasses the requirements of major national and international standards, e.g.: IEC, CENELEC, GOST, BS CSN, MSZ, PN, STN, STR, VDE, etc. Test reports are available which document the tests performed in test institutes and in Raychem laboratories on the long-term electrical and environmental behaviour of cable accessories and materials. The currently relevant CENELEC standards tested to are: HD623.S1:1995 – Specifications for joints, stop ends and outdoor terminations for distribution cables of rated voltage 0,6/1,0 (1.2) kV HD629.1.S1:1996 –Test requirements on accessories for use on power cables of rated voltages from 3,6/6 (7,2) kV up to 20,8/36 (42) kV. Part 1: Cables with extruded insulation. HD629.2.S1:1997 –Test requirements on accessories for use on power cables of rated voltages from 3,6/6 (7,2) kV up to 20,8/36 (42) kV. Part 2: Cables with impregnated paper insulation. For product testing and selection we follow the classifications for rated voltages Uo/U(Um) as referred to in IEC and Cenelec standards: Uo is the rated power-frequency voltage between phase conductor and earth or metallic screen for which the cable accessory is designed. U is the rated power-frequency voltage between phase conductors for which the cable accessory is designed. Um is the maximum value of the ‘highest system voltage’ for which the cable accessory may be used. To cover all typical voltages in distribution networks, Tyco Electronics Energy Division tests cable accessories to the highest sets of rated voltages: 3,8/6,6 (7,2) kV 6,35/11(12) kV, 8,7/15 (17,5) kV, 12,7/22 (24) kV, 19/33 (36) kV and 20,8/36 (42). The quality standards of all materials throughout the entire manufacturing process beginning with the raw materials and continuing through to the packaged product are continuously monitored and documented. Materials as well as complete accessories are regularly requalified. As a result of our well established Quality Management System including quality assurance, Tyco Electronics Energy Division was one of the first in the industry to achieve a certification according to ISO 9001. Service Even the best technology can be applied in the wrong way. To avoid such situations, we have established a technical support service to provide technical information and application guidelines for our customers, such as cable fitters, project and maintenance engineers, constructors, equipment manufacturers and specification and purchasing engineers. A sound and practice oriented range of services is provided: (cid:1)Presentations and Seminars (cid:1)Technical papers focusing on new industry trends and products (cid:1)Training in cable preparation, installation techniques and product selection for engineers and installers (cid:1)Practical demonstrations and field installations (cid:1)Solutions to specific customer problems 5 Quality Standards, Environment, Health and Safety The quality standards of all materials throughout the entire manufacturing process beginning with the raw materials and continuing through to the packaged product are continuously monitored and documented. Materials as well as complete accessories are regularly requalified. As a result of our well established Quality Management System including quality assurance, Tyco Electronics Energy Division continuously achieves re- certification according to ISO 9001. Regular installations of Raychem heat-shrinkable cable accessories are considered to present no risk to health based on investigations by independent test institutes and customer evaluations. Moreover, hazards typically associated with cable accessory installations can be eliminated by avoiding any soldering or handling of conventional 2component or bitumen fillers. No messy or harmful residues requiring special or costly disposal are left over after installation. Only ecologically sound and recyclable components are used and packaging materials are continuously reduced. Our efforts and investments over the years in improving the environment led not only to the elimination of ozone-depleting materials and substantial reductions of waste materials and water consumption but also to new processes allowing crosslinked materials to be recycled. As a result of these efforts, we have successfully completed the environmental assessment in accordance with ISO 14001 and received a certification as one of the first companies in the industry. Ordering and delivery All cable accessories come complete with the necessary electrical insulation materials, installation instructions (in local language) and a bill of material. Solderless earth connections are either included in the kits or can be ordered separately. Cable lugs and connectors are only included if specifically stated. Medium voltage termination kits and joint kits for 3-core cables include materials for all 3 phases, joint kits for single core cables only material for one phase. We continuously monitor delivery performance and lead times, look for opportunities toshorten cycle times and improve service. We also analyse our responsiveness throughout our distribution network to customers. This is not static, but rather a constantly improving process directed towards our goal: complete customer satisfaction. 6 Raychem Low Voltage Jointing System With extensive application over the last decades, the Raychem jointing system for mechanical or crimp connectors is widely used and acknowledged as a highly dependable and easy-to-install jointing method for conventional and modern cable types. Theprinciple of the construction and the simple way of installation are described with a joint for 1 kV plastic insulated cables. Installation After preparation of the cable ends according to the installation instruction, the smaller inner tubings as well as the outer tubing are slipped over the cores. The conductors are now connected with mechanical or crimp connectors. All joints are designed to allow crossing of the cable cores. The inner tubings are positioned over the connectors and shrunk down to tightly fit the connectors and the core insulation ensuring an adequate wall thickness even around the more bulky mechanical connectors. At the same time the heat causes the adhesive, precoated on the inside of the tubings, to melt and flow. The resulting bond seals out moisture and corrosion and conforms to the thermal expansion of the cable. The outer tubing is positioned over the jointing area and shrunk. The mechanical and sealing functions of the oversheath are assured by this thick-walled tubing. A durable and repeatable seal is produced by means of a hot-melt adhesive pre-applied to the entire length of the tubing. The joint is complete and can be put into operation immediately. Construction 1 Outer tubing:Thick-wall protection 1 3 against mechanical stresses and against moisture by sealing onto the oversheath. 2 Inner tubings:Thick wall tubing providing electrical insulation and protection of the connection area against moisture inside the cable. 3 Hot-melt adhesive 3 2 7 Raychem Medium Voltage Termination System Raychem developed during the 60’s a series of new polymers for use at medium and high voltage. The resulting materials possess exceptional resistance to prolonged electrical stress and weathering, but are also capable of being shrunk down quickly to fit and seal a cable. Raychem accessories provide an universal system of indoor and outdoor terminations for paper or plastic insulated cables, for single or three core cables, for cables with round or sector shaped conductors and most types of screening or armouring. 1 The following describes the typical modules of a modern medium voltage termination: 1 Moisture sealing Durable sealing is achieved by special Raychem sealants on the inside of non-tracking, weather-resistant components. At the same time as the installer heats the tubings, the shrinking action causes the sealant to melt and flow into place. In case of three core cables, a sealant-lined heat-shrinkable breakout installed over the 2 cores and cable crutch provides a sealed and weather-resistant surface from the connecting lugs to the oversheath. 2 Compact and versatile stress control To meet the need for space-saving, flexible termination design, adaptable to different types of compact equipment, we developed a Raychem material with a carefully controlled non-linear impedance based on ceramic semiconductor technology (ZnO), which is applied in the form of a coating inside the tubing. When the tubing is shrunk, 3 the stress control coating is softened by the applied heat and conforms and bonds to even irregular insulation surfaces to ensure a void free contact. Details of electrical stress control in Raychem terminations can be found on page 10. 3 Non-tracking insulation tubing The superior non-tracking characteristics and long-term erosion resistance of Raychem terminations have been exhaustively demonstrated in comparative tests at major independent laboratories and Raychem’s own extensive development facilities. These 4 results are borne out by the continuing performance of over a million units installed in tropical, desert, arctic and industrially polluted climates, confirming that Raychem terminations do not track even in severe service conditions and verifying their exceptional erosion resistance and reliability. The phenomenon of tracking and erosion is explained on page 11. 4 Yellow void filler The semi-conducting void filler is easily applied in form of a short adhesive tape. It ensures that, independent of the type of semi-conductive screen or removal method, no air voids can cause discharges in the high stress area of the screen end. 5 Earthing Earthing wires or braids are imbedded in the sealing mastic to prevent any corrosion by moisture ingress. For cables with tape screen or metal sheaths with armour solderless earthing systems are either provided within the termination kit or can be ordered separately. 1 5 8