ABB Kabeldon, Box 531, S-441 15 Alingsås, Sweden, Telephone +46 322 770 00, Telefax +46 322 770 01

APECB 84-170

4290.5211-05ABB Kabeldon

June 2004

1

Cable termination forXLPE-insulated cables 84-170 kV.Insulator of porcelain or composite.

(Engelsk)

5048

ABB Kabeldon

4290.5211-05

2

General:

Read the whole installation instruction carefully before starting work.

This product should be installed by competent and trained personnel familiar with cables,accessories and safe operating practices. Parts contained in this kit should be visuallyinspected for possible damage, and installed in accordance with the following instructions.These instructions are intended to be a guideline for proper installation and not a substitutefor adequate training and experience in good safety practices.

Check that the diameter of the XLPE-insulation corresponds with the marking on the stresscone packet.

A cut-away drawing of the termination is found in Appendix 1. Some important figures arealso found in the drawing.

The cables shall be straightened before starting work by e.g. straightening equipment, typeRKM 1000, see installation instruction No 4290.355.

This instruction is applicable for cables with an insulation screen that is vulcanized to theinsulation.

The use of a rotating stripping tool e.g. RKM 4595 is strongly recommended when preparingthe XLPE-insulation.

All tapes are to be wound with 50 % overlap.

The nuts shall be tightened crosswise and in sequence until the specified torque is reached.

Tape designations

ET = Electrical tape, PVC

IV = Insulating self-bonding tape, to be stretched so that the width reduces to about26 mm.

For cleaning, use for example ethylalcohol.For cables with metallic sheath, using ”JSA 1 Pb,Al”, see instruction No. 4290.261For cables with copper wire and Al-foil using ”SCK”, see instruction No. 4290.603

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1. Place the box body on the cable.

Place the box body in position. Lift the cable intothe correct position.

Mark the cable at the lower edge of the box body.Also mark the position for the shield wire openingon the periphery of the sheath and a mark on thebox body flange.

The work is carried out more easily on the groundwith the cable lying horizontally.

If the installation is made with cable vertically, thensecure the cable and place the box body as inpoint 6.

2. Measure the length of the insulator.Cut of the cable A mm from the marking.

Box bodyA

Marking

~90

345

A

50495050

B

Insulator length B = ......................... mm+ 345

A = ......................... mm

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4290.5211-05

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4. Mark a distance of A-385+C mm from the end of the cable and remove the sheathfrom this point to the end of the cable.Fold back the shield wires over the edge of the sheath.(For cables with other types of shieldings see page 2.)

6. Check that the top of aluminum is free from burrs and varnish.Place the box body onto the cable.

3. Measure and note the length C of the stress cone.

C = ..........mm

5. Knock back the insulation with a piece of wood and a hammer.

C

A-385 +C

Box bodyTop of aluminum

Marking 5052

5053

5054

5056

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400min 40

Plane or glass

Insulation100Marking

NB! It is important that the instructions in sections 7 -10 are followed correctly soa smooth surface is obtained where the stress cone will be placed.

7. Mark out the distance from theend of the cable

This point only when using a rotatingstripping tool e.g. RKM 4595.

8. Remove the insulation screen to100 mmfrom the marking. Do not remove moreinsulation than necessary, especiallywithin 400 mm of the marking.

In order to avoid a waist on the insulation.Taper of the edge of the insulation screenup to the marking. Use for example aplane*) and cut only towards the insulationscreen.

*) Ordered separately.

9. Remove the insulation screen up to themarking. A plane*), or a piece of glasscan be used. Make a smooth transitionbetween the insulation screen and theinsulation. At least 40 mm of theinsulation screen and 400 mm of theinsulation are to be even and free fromsteps.

Smooth-off the insulation in area (G) firstand then the insulation screen in area (H)so that all unevennes disappear,especially where the stress cone will beplaced 400 mm out from the insulationscreen. Start with the rough abrasivecloth and finish with the fine.

NOTE! Smooth transition betweenthe XLPE and the insulation screen.

A - 475 + C

Insulation screen

Marking

5057

5058

5059

5060

5061

5062

H G

40

+0- 5

A-435+C

6725

10. Wind 10 layers of ET-tape A-435+Cfrom the edge of the conductor end.Check that the edge of the insulationscreen is within 40, +0/-5 mm from theET-tape marking.

InsulationConductivelayer

Right

Wrong

Smooth tapered surface

ET-tape

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12. Clean the insulation using solvent for example ethylalcohol. Grease the XLPEinsulation with the grease supplied down to 100 mm from the edge of the insulationscreen. Wipe the stress cone clean inside. Then grease the inside from both ends.

∼ 5xT L = 155

Ø E

T

Sealing cone Ø EØ mm mm

44 4054 50

5063

5064

ET-tape

Sliding cone

If required

SV 140*

ET-tape

50655067

13. Hold the sliding cone in the lower edge of the stress cone so that the fingers of thesliding cone do not enter the stress cone completely.

Pull the stress cone down to about 100 mm from the edge of the insulation screen.Remove the sliding cone and then pull the cone down to the ET-tape.

Stress cone tool SV 140* makes it easier to fit the cone.

* Ordered separately

11. Strip the insulation L mm. Measure the inner diameter of the sealing cone.Chamfer the XLPE according to the table below. In order to avoid damaging theconductor when chamfering and the inside of the stress cone, cover the conductorwith ET-tape. Smooth-off the chamfer to remove any unevenness.

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15. Push the Top of aluminum under the skirt edge of the stress cone to a distance of10 mm below the stress cone.Insert the the metal contact of the hose clamp under the edge of the stress cone.Do not tighten the hose clamp.

Stress cone

Metal contactHose clamp

Box body

(A-190 ±10 mm)

50 ±3 mm

ET-tape

50 50

ET-tape

Copper net

20 20IV-tape

50555068

5069

14. Clean away grease near the stress cone with solvent.Mark the position of the stress cone with ET-tape 50 mm from the upper part ofthe stress cone.

Wrap on copper net with 10 mm overlap from 50 mm on the shield wires and up onthe stress cone to 40 mm from the skirt edge.

Wrap IV-tape five times with overlap over the copper net.Cover the IV-tape with one layer of ET-tape.

10±10 mm

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16. Place the box body so that its lower edge and shield wire opening coincide with themarking carried out in point 1.Fold out the shield wires through the opening in the lower edge of the box body. Theopening can be enlarged by removing the knockouts.

Wind bitumenized paper hard around the cable at the lower edge of the box body to adiameter of approx 125 mm. Mount the cable clamps so that the guiding nobcoincides with the groove in the box housing. Screw the cable clamps together tosecure the cable.

Check that the distance between the stress cone and the Top of aluminium is within10±10 mm. Also check the distance 50±3, and the distance A-190 ± 10 mm,see point 15.

Tighten the hose clamp on the stress cone. Install the other hose clamp in contactwith the metal contact and tighten. The locks of the two hose clamps shall bedisplaced at least 50mm. Fold back the metal contact.

Remove the ET-tape at the upper edge of the stress cone and on the conductor end.

Connect the shield wires to the earthing clamp on the box body.

17. Clean the insulator with a dry cloth to remove dirt and damp.

Place the O-ring in the box body flange in position.

Fasten the self-adhesive insert gaskets on the insulator clamps or on the porcelain.

Place the insulator over the end of the cable down to the box body. Check that thecable goes straight into the insulator. Centre the box body in the porcelain insulatorby means of the four holes in the box body. Composite insulator is centred by thescrews.

Secure the insulator onto the box body with the insulator clamps for the porcelaininsulator or with the bolts directly in the flange for the composite insulator.Tighten the insulator clamp nuts or the bolts in succession to a torque of 45 Nm.

Bitumenized paper

Cable clampEarthing clamp

10 ±10 mm

5070

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18. Appendix 2 shows the assembling of the cover.Place the clamp on the top cover, mount the M8 bolts with the sealing washers andtighten with 20 Nm.

Place the O-rings in the top cover in position. Grease the sealing cone and thechamfer of the cable insulation with the supplied grease. Mount the sealing cone onthe top cover.

Mark the top cover at the edge in line with the clamp. Place the top cover on theinsulator and orient the top cover to a wanted position for the top bolt. E.g. orient themark made on the top cover in line with the shield wire opening. The top cover canbe placed with the top bolt in any position for porcelain insulator and in eightpositions for composite insulator.

Center the top cover when porcelain insulator. Check that the sealing cone iscorrectly mounted and seals against top cover and cable insulation.

NB! Make sure there are no dirt or metal particles on the top cover, cable endor clamp, which might fall into the insulator during installation. If possible,cover the filling holes.

Tighten the insulator clamp nuts or the bolts for composite insulation in succession toa torque of 45 Nm.

Check that the conductor end is 10 ±10 mm above the clamps edge.

Place the top bolt in the clamp.Tighten the 9 bolts in succession to a torque of 70 Nm, starting with the lowest centrescrew, then the conductor screws and finally the screws for the top bolt( see picture).

5051

10 ± 10 mm

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19. Heat up the oil IG 1804 supplied to about 120°C.

The oil can be poured when the termination is in position or when it is on the ground.

If the oil is poured in on the ground incline the insulator approx. 45° and use a funnel.

Pour the oil and allow the oil to cool to about 30°C. Cover the filling holes duringcooling to prevent dirt and moisture to come into the insulator.

Mount the two sealings carefully in the top cover filling holes. Use e.g. a smallscrewdriver to make one turn under the collar of each sealing. Check that it sealsagainst the surface on the top cover.

Place the two O-rings for the top cover cap in position.

Grease the top bolt and the hole in the top cover cap with supplied grease, mount thetop cover cap and tighten the M6-screws with approx. 10 Nm.

Mount the sealing on the top bolt and the top cover cap.

5822

O-ringsSealing cone

Sealing

Top cover

Clamp

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Sealing

Insulator clamp andinsert gasket forporcelain insulator

ClampSealing cone

Sealing

5071

O-rings

Nut and spring washer forporcelain insulator.Screw and spring washer forcomposite insulator.

Insulator clamp andinsert gasket forporcelain insulator

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20. For cables with conducting layer on the outer sheath.

Remove the conducting layer on theouter sheat for a distance of 200 mm.

200

Outer sheath

LashingsMΩ

5072

5073

Check the insulation with an insulation tester.The resistance must be more than 200 Mohm.

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Lifting rope

Supporting rope

The lifiting rope should be ableto glide throug these knots.

22. Lift the temination in position, check that thebox body gets a level contact with the bracket,if not, adjust with washers.Tighten the bolts , Torque ~100 Nm.

6427

21. When the termination is to be lifted into position the rope is to be secured around thecable below the cable clamps so that the lifting load will be taken by the cable andnot by the termination. Tie at least two support ropes around the insulator.

The lifting rope should be able to glide through the knots of the supporting ropes.

23. Secure the cable to the support with threecable clamps within 1,5 m from the termination.

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Appendix 1

6710

Ø40/50/54

min

125

235

86,5

435

~ L

Insu

lato

r len

gth

C

A -

435

+ C

A -

385

+ C

The

posi

tion

for t

he e

dge

of th

e sh

eath

dep

ens

on d

imen

sion

C. C

an b

e be

low

the

insu

lato

r.

A -

190

A

max Ø 120

Type LAPECB 841 1300APECB 1452 1620APECB 1703 1860APECB 1704 2120APECB 1705 2620

APECB 84-170

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ABB Kabeldon 15

Appendix2Assembly of cover

Top cover

Top cover cap

Sealing

Top bolt

Clamp

Sealing cone

Insulator clampfor porcelaininsulator

Sealing

5076

O-rings

O-rings

Insert gasket

Screw andsealing washerfor clamp.