APECB 245 - 300 Instructions NKT 4280,0122,0C
APECB 245 - 300 Instructions NKT 4280,0122,0C
APECB 245 - 300 Instructions NKT 4280,0122,0C
Content
1.4 Control.................................................................... 4
1.6 Disposal.................................................................. 5
1.8 Checking................................................................. 6
1.11 Solvents................................................................ 6
1.15 Grease................................................................... 6
2. General tapes.................................................... 7
3. Assembly tools................................................. 8
2
Content
4. Cable positioning........................................... 10
5. Cable straightening........................................ 11
6. Cable pre-preparation..................................... 12
8. Cable preparation........................................... 15
9. Assembly ....................................................... 18
3
es
1.4 Control
Parts contained in the accessory kit should be visually inspected for
possible damage and installed in accordance with the following instruction.
Also a good personal judgment for safe working practices must be adopted.
4
GEnERAL FoR NKT CABLE ACCESSoRiES
1.6 Disposal
A lot of the materials can be recycled. Some articles are hazardous and
need special treatment. Sort the waste in accordance to local regulations.
Below you find information about common materials that can guide you.
• Metals
• Metals with surface treatment
• Corrugated paper
• Paper
• Wood packaging
• Plastic
Examples of materials to send to landfill:
• Porcelain insulators
• Polymeric insulator made of silicone rubber and fiber glass
reinforced epoxy.
5
es
1.8 Checking RS 1
Check that the diameter of the cable insulation corresponds to the marking
on the package of the relevant accessory, e.g. joint, adapters or stress relief
cone.
1.11 Solvents
Use methylated spirits when cleaning cable and accessory components.
Make sure to follow the manufacturer´s handling instructions. After cleaning,
any surface must be dry.
When separate instructions (e.g. for earthing kit) are provided, always read
these instructions before starting the work. Make sure to understand when
during the installation process these separate instructions shall be used.
1.15 Grease
Use grease on all screw joints. Available in the conductor clamp kit.
6
general tapes
2. General tapes
All tapes must be wound with 50 % overlap unless otherwise stated.
ET
RULLE
Rubber tape, shall be stretched until the oval markings become circular.
ST
Protective tape.
IV
HL
SG
FT
Filler tape.
7
assembly tools
3. Assembly tools
These special tools are needed for assembly and can be ordered from NKT:
SV 190
Tools for installation of stress relief cone.
SRT
Sheath removing tool to split the oversheath.
MB 1
Tool for opening cable sheaths.
RKM 130
Torque wrench for bolt connectors, bolt cable lugs, overhead line clamps,
etc. Torque wrench can be used with standard 1/2” sockets. Torque range
25-130 Nm.
Socket, 16 (long), 18 (long) and 24 mm.
24
18
16
730R
Torque wrench for bolt connectors, bolt cable lugs, overhead line clamps,
etc. Supplied with 7 mm socket head, extension arm and 8 mm internal
hexagon head. Torque range 6-50 Nm.
Socket, 10 and 13 mm.
13
10
8
Standard tools
Glass
For removing the insulation screen.
Hammer
Useful when beating the insulation back.
Knife
Useful when slice cable clamp gasket.
Scissors
Useful when cutting the sliding cone.
pliers
Useful for bending screen wires.
Screwdriver
Useful when installing the sealing on top cover.
wire brush
Useful for cleaning the conductor.
cable cutter
Useful for cutting the screen wires.
reciprocating saw
Useful for cutting the cable.
9
cable positioning
4. Cable positioning
1 Lift the cable into the correct position. Mark (I) the over sheath which
simulate the position of the lower edge of the box body, 43 mm from beam
surface. Also make a lengthwise mark (II) on the over sheath at the posi-
tion of the screen wire outlet centered as picture.
The work is carried out more easily on the ground with the cable lying hori-
zontally.
If the installation is made with cable vertically, then secure the cable and
place the box body as in point 7.6, page 14.
A
43 Mark (I)
Mark (II)
A= 2940 mm 2940 mm
74 B = 2710 156
B= mm
+ 230 mm
A= mm
10
cable straightening
5. Cable straightening
The cable ends shall be heat straightened for a length of 3,5 m. For the RS 2
straightening procedure please refer to the guidelines from the cable
manufacturer.
11
Cable pre-preparation
6. Cable pre-preparation
If a cable with lead or corrugated sheath is used, use earthing kit JSA 1
Pb, Al. See instruction 4290.2617 and 4290.7961.
If a cable with aluminium laminate is used, use screen connection kit SCK.
See instruction 4290.6031.
A - 85
Mark
2 Beat the insulation back, e.g. using a pipe and a hammer. Be careful
not to bend or damage the conductor wires.
12
box body assembly
Sealing surfaces
Sealing surfaces
Inner flange
Flange
10 Nm
2 x M6
Inner flange
13
box body Assembly
Box body
14
Cable preparation
8. Cable preparation
X= mm
40 Glass
15
Cable preparation
4 Strip the insulation L = 155. Clean the conductor with a wire brush.
For milliken conductors, remove segment insulation. In order to avoid
damaging the conductor when chamfering, wrap on a few turns of ET on
the conductor. Measure the inner diameter of the sealing cone. Chamfer
the insulation according to the table and figure.
RS 8
~5 x T L = 155
øE*
Sealing cone ø E*
ø mm mm
44 40
54 50
70 65
5 Smooth the insulation and the insulation screen. Do not use a coarser
RS 9
emery cloth than 220. Always finish with 400 grade cloth. Avoid using the
coarse emery cloth close to the insulation screen edge. While smoothing
the insulation screen, make sure that the insulation is protected from
conducting particles.
Be extra careful where the stress relief cone is to be placed, i e up to 500
mm from the insulation screen. To achive a smooth transition, the insulation
screen edge is allowed to have a waveform of maximum 10 mm. RS 10
Emery cloth
(grade 220 and 400)
Max 10 mm
16
Cable preparation
X + 60
+10
60 -20
Mark
+10
60 -20
17
assembly
9. Assembly
1 Clean and grease the entire inside surface of the stress relief cone.
Clean the cable insulation with methylated spirits. Grease the cable insu-
lation down to about 100 mm from the insulation screen.
Brush
Silicone grease
100
2 Hold the sliding cone in the lower edge of the stress relief cone so
that the fingers of the sliding cone do not enter the stress relief cone
completely.
Pull the stress relief cone down to about 100 mm from the edge of the
insulation screen. Remove the sliding cone and then pull the stress relief
cone down to the mark.
The tool SV 190 simplifies the installation of the stress relief cone.
SV 190
Mark
If required
Sliding cone
18
Assembly
3 Wipe off grease near the stress relief cone with methylated spirits. RS 11
Mark the position of the stress relief cone with ET 50 mm from the upper
part of the stress relief cone.
Wrap copper net with 10 mm overlap from 50 mm on the folded screen
wires and up on the stress relief cone to 40 mm from the skirt edge.
50 40 50
Copper net ET
IV
ET
19
Assembly
6 Push the top of inner flange under the skirt edge of the stress relief
cone to a distance of 10 mm below the stress relief cone to the edge of
the inner flange sealing surface. Insert the earthing tab of the hose clamp
under the edge of the stress relief cone. Do not tighten the hose clamp.
A -73 ± 10
10 ± 10
50 ± 3
ET
Hose clamp
Stress relief cone
7 Place the box body so that its lower edge coincide with mark (I) and
mark (II) carried out in point 4.1, page 10. Mark (II) align to box body
marking (I).
Mark (I)
Mark (II)
Mark (I)
20
Assembly
8 Pre attach the earth clamp to one to the cable clamp without torque. RS 12
Earth clamp
Cable clamp
2 x M10
Grease, OKS 250
9 Bundle the screen wire using some of the wires. Align position with
(II) carried out in point 4.1, page 10, out take position 90 mm below box
body lower edge.
Wind one layer of IV around the cable for better grip for bitumized paper.
Wind bitumized paper hard around the cable. Starting 130 mm from the
lower edge of the box body to a diameter of approximately 180 mm.
130
Screen wires
Bitumized paper
ø ~180
90
21
Assembly
10 Cut a cross in the gasket membrane on the cable clamp with earth
clamp attached. Insert the screen wires through the opening of the gas-
ket. The opening can be enlarged by removing the knockout to from Ø 40
mm to Ø 60 mm. Preferable using a screwdriver and a hammer, grind if
sharp edges.
ø 40
ø 60
11 Mount the cable clamps so that the lip coincides with the groove in
the box body, check alignment to mark (II). Set rotation of clamp by align
cable clamp marking and box body marking. Screw the cable clamps
together to secure the cable and rotation of the cable clamp. Tighten the
bolts 6 x M12. Torque 45 Nm. Tighten the bolts 2 x M10. Torque 45 Nm.
45 Nm
2 x M10
22
Assembly
12 Connect the screen wires to the earthing clamp on the cable clamp to RS 13
which the station earth may also be connected. Tighten the bolts 4 x M10.
Torque 45 Nm.
Earthing clamp lid could be turned for different range of the screen
wires. In the range of 55-650 mm2 the same clamp marking shall
be visible after assembly.
In the range of 350-1050 mm2 the same clamp marking shall be
visible after assembly
45 Nm
4 x M10 Grease, OKS 250
Earthing clamp
13 Check that the distance between the stress relief cone to the edge of
the inner flange sealing surface is within 10 ±10 mm. Also check the dis-
tance 50 ±3 mm and the distance A - 73 ± 10 mm.
Tighten the first hose clamp on the stress relief cone ~3 Nm. Install the
second hose clamp in contact with the earthing tab and tighten. The locks
of the two hose clamps shall be displaced at least 50 mm. Bend the earth-
ing tab so it´s end is pointing towards the flange. Remove the ET at the
upper edge of the stress cone and on the conductor end.
A -73 ± 10
Earthing tab
10 ± 10
50 ± 3 ET
ET
Hose clamps
23
Assembly
14 Wipe the insulator (polymeric or porcelain) dry and clean with methyl-
ated spirits, use a clean cloth.
Polymeric
Porcelain
15 Clean the O-ring track in the box body with methylated spirit. Apply a RS 14
thin layer of silicone grease on the O-ring with your fingers. Place the
O-ring in position in the box body track by lock it on three places first and
with a following sweep over the places in between.
Silicone grease
24
Assembly
Place the insulator over the end of the cable down to the box body. Check
that the cable goes straight into the insulator. Centered by the threaded
pin. Secure the insulator onto the box body with the insulator clamps for
the insulator.
Tighten the nut 8 x M10 crosswise and in succession to 33 Nm tightening RS 15
torque.
Insulator clamps
33 Nm
8 x M10
Insulator clamps
25
Assembly
17 For polymeric insulator. Place the insulator over the end of the cable
down to the box body. Check that the cable goes straight into the insula-
tor. Centered by the screw.
Secure the insulator with the bolts directly in the flange for the composite
insulator. Tighten the bolts 8 x M10 crosswise and in succession to 45 Nm RS 15
tightening torque.
45 Nm
8 x M10
18 Assemble the flange clamp kit including flange clamps and support
insulators to the box body with M16 bolt and washer. Unscrew a few turns
and insert to flange. Make sure that the edge for the top flange clamp is
positioned in the box body track. Use X4 marking and align flange clamps
to box body. Pre torque with ~10 Nm.
Flange clamp
Support insulators
~10 Nm
Box body
X3 X3
X4 X4
26
Assembly
19 Place the clamp on the top cover, mount the 2 x M8 bolts with the RS 16
sealing washers and tighten to 20 Nm.
Top cover
20 Nm
2 x M8
20 Place the two O-rings in position in the top cover. Grease the inside RS 17
of the sealing cone and the chamfer of the cable insulation with the supplied
grease. Mount the sealing cone on the top cover.
O-ring
O-ring
Sealing cone
Silicone grease
27
Assembly
21 Place the top cover on the insulator and orient the top cover to a wanted position for the top bolt. e.g.
orient the mark on the top cover so that it lies in line with the box body opening. See point 4.1, page 10.
The top cover can be placed with the top bolt in any position for porcelain insulator and in eight positions
for polymeric insulator.
Centre the top cover. Check that the sealing cone is correctly mounted and seals against the top cover and
the cable insulation.
For polymeric insulator, tighten the bolt 8 x M10 crosswise and in succession to 45 Nm tightening torque.
For porcelain insulator, tighten the nut 8 x M10 crosswise and in succession to 33 Nm tightening torque.
45 Nm
8 x M10
33 Nm
8 x M10
28
Assembly
22 If the conductor clamp has nine bolts, the conductor of the cable
should end10 ± 10 mm above the clamp. Should the clamp have fifteen
bolts, the cable conductor end should be 0 ± 10 mm above the clamp.
Place the top bolt in the clamp. If the clamp has nine M12 bolts, tighten
the nine bolts in succession to a torque of 70 Nm, starting with the lowest
centre bolt, then the conductor bolts and finally the bolts for the top bolt.
If the clamp has fifteen M10 bolts, tighten the fifteen bolts in succession to
RS 19
a torque of 45 Nm, starting with the lowest centre bolt, then the conductor
bolts and finally the screws for the top bolt.
Clamp
11 12 5 6
9 10 3 4
7 8 1 2
Clamp
19 20 9 10
17 18 7 8
15 16 5 6
13 14 3 4
11 12 1 2
29
Assembly
45°
30
Assembly
24 Cover the filling holes during cooling 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 small screwdriver to make one turn under the
collar of each sealing. Check that it seals against the surface on the top
cover.
Sealing
25 Place the two O-rings for the top cover cap in position. Grease the RS 20
top bolt and the O-rings in the top cover cap with supplied grease, mount
the top cover cap and tighten the bolts 8 x M6 with approximately 10 Nm.
Mount the sealing on the top bolt and the top cover cap. RS 21
O-ring
31
Assembly
>1 GΩ
200
< 50
Copper wire
lashing
32
Assembly
27 When the termination is to be lifted into its final position, the lifting
slings is to be secured around the cable then inserted in separate slings
positioned at the top of insulator.
Tighten the bolts on top of flange clamp to a torque of 100 Nm. Tighten
the bolts for attachment to support at 100 Nm. Never more than 200 Nm. RS 23
Two soft sling around the cable. (Long enough to reach well above
termination)
100 Nm
4 x M16
100 Nm
(Max 200 Nm, not
included in the
NKT acessories kit)
33
Adjustment of the flange clamp
X4
X3
X3
X4
X3
X3
X4
X3
X3
X4
X4
X3
X4
X3
X4
X3
X3
Support position
X4
X4
100 Nm
4 x M16
100 Nm
(Max 200 Nm, not
included in the NKT
acessories kit)
34
adjustment of the cable clamp
45 Nm
6 x M12
Cable clamp
Cable clamp
35
Dimensional drawing
B (Insulator length)
A - 544
A - 85
36
dimensional drawing
A - 544
A - 85
B (Insulator length)
37
notes
38
Record sheet
13. Record sheet
Phase: Supervisor:
Temperature: °C Jointers:
4 Porcelain insulator. B= A=
6 Stripping dimensions. A - 85 =
39
4280,0122,0C
NKT HV CABLES
Box 531 | SE-441 15 Alingsås | Sweden
Tel +46 322 770 00
Email [email protected]
www.nkt.com