Energy Division

Tricks of the Trade

The Tyco Electronics Brand Raychem is one of the world leading
brands in the power cable accessories market. We pioneered
­heat-shrinkable terminations in the 1960’s, joints in the 1970’s and
transitions and insulated separable connectors in the 1980’s. Our aim
is to make your job as a jointer as safe and comfortable as a tough
job can possibly be. Every successful instal­lation depends on you.

Because you are so important to us, we have prepared this booklet to

share with you some of the best ideas we have received from jointers
all over the world. We include information on modern tools and
­techniques available for the stripping of bonded semicon and easy
strip cables as well as time-honoured practices for dealing with paper
cable.

If you need additional assistance, don’t hesitate to contact us.

http://energy.tycoelectronics.com

Tyco Electronics
Energy Division
 1

General

Setup
2 3

Cleanliness
4

Cable Jacket
5

Solderless Connection
6

Core Treatment
 7
Screen Removal
8

Conductor Connection
9

Application of Mastic

Shrinking
10
Note:
It is possible that components or work
steps have been improved since you
last installed this product!

Before starting a job and preparing the

cables, we recommend that you check
to ensure that the kit you are going to
use fits the cables. You can do this by
referring to the kit label and the title of
the installation instructions.
 1
CTION
INSTRU

It is essential to read carefully the

instructions included in the kit and to
follow the steps in the correct
sequence.
The cable should be supported or fixed
and allowed sufficient space for ­working.

In the ideal jointing set-up there is

­sufficient cable length to allow the cable
ends to overlap.

Instruction

Place a protective cover over loose dirt

or sand, especially under the working
area.
 2
nstruction

Make sure to protect the working area

from rain, wind, moisture and dust.

Use the recommended tool set, and lay

out the tools on a tray so that they are
kept clean and easy to reach.
The bags in which the tubings are supplied are well suited for use as
protective covering over the cable jacket. This prevents the parked
tubing from becoming soiled.

Make sure your hands are clean

before beginning work.
To ensure good bonding, clean and
degrease all parts that will come into
contact with adhesives or sealants. 3

Any materials that become soiled or

contaminated should not be used!

All tubings to be parked and

positioned must be kept away from
dirt, grease and all other foreign
substances.

P
SCRA
To ensure good bonding, after the
cable ends have been stripped and
cleaned the polymeric jackets must
be abraded for about 250 mm from
the cutback.
Use abrasive paper, a suitable file or
a hacksaw blade to do the abrading.
Be certain to clean off the cable jacket
again when you finish abrading!

4
Steel Wire Armour (SWA)
Support ring For SWA cables a
support ring is required
to maintain a constant
pressure from the hose
clamp on the armour
and on the joint case.
Wire binder
Hose clamp

Steel Tape Armour (STA) For STA cables, copper

mesh is required on top
of the lead sheath un-
derneath the roll­spring.
Tighten the rollsprings
on the lead sheath and
Lead sheath
the STA with a twisting
Wire binder action.
Rollspring

Corrugated Sheath (CS) For corrugated-sheath

cables, contact plates
on top of and under­
neath the earth lead are
also required.

Contact plate
 Good electrical contact is needed in the
event of a short circuit. For this reason,
armouring needs to be abraded with
a wire brush, a file or the blade of a
hacksaw and afterwards cleaned with
solvent in order to remove the oxide layer.

5
SOLVENT
Please observe local regulations for handling paper cables
at low temperatures.

On plastic cables, make sure the

sharp edge of the armour cut does
not damage or cut into the core
screen.

With paper cables, it is very

important not to overbend the cores.
There is a danger that the paper
layers will break if you bend‑the
cable too far.
 To support the sensitive crotch
area, it is necessary to apply a
temporary nylon tape on top of
the belt papers or the fabric tape
at the sheath cut.

To shape the phases use only

tools without sharp edges,
such as a wedge, a spacer or a
length of core!
 For round triple-extruded cables,
use stripping tools as recommend­
ed by the cable manufacturer. If
necessary, remove any remaining
conductive particles with abrasive
paper.

For “easy strip” cables, use a round

file to cut radially through the core
screen until the dielectric just
be­comes visible. Use a scoring tool
as recommended in the tool list to
do longitudinal stripping. To prevent
cuts in the cable dielectric, never
PVC tape to guide the cut
use a knife.

On graphite screened cables, pro­

tect the remaining screen with PVC
tape (sticky side on the outside!)
and wash off the unwanted graphite
screen with a cable cleaner or
solvent recommended by the cable
manufacturer following any handling
precautions given by the cleaner or
solvent manufacturer.

For paper cables, tear off the screen

or belt papers against a twine
­binder, leaving an even straight
edge. For screened cables also
remove the first two paper layers
exposed after removal of the
screen. Always secure the core
papers at the end with PVC tape.
 W D OI T
HO TRAIGH
E T A S CUT?
G EN
SCRE For screen removal, it is
very important to make
certain that no conduc-
tive material is left on the
exposed cable dielectric,
and that the remaining
screen cut (including con-
ductive paint) is straight
7
with no jagged edges.
Note: Crimping sequence for lugs
When crimping connections it
is absolutely necessary to use
only those dies, crimping tools
and the corresponding lugs and
ferrules recommended by the
crimp manufacturer.

On cable lugs the insulation

cutback should be the internal
length of the tubing plus 5 mm
to allow for expansion. Start
crimping at the top and proceed
down the tube towards the
bottom end of the lug.

Make sure to park the

tubing before crimping!
 Crimping sequence Shear-off sequence
for ferrules for mechanical connectors

For connectors using more

than one shear bolt per entry
side, tighten them alternately
The same procedure is required and shear them off starting
for ferrules: here you start in the with outer bolts.
middle and work on alternate
sides towards the ends. To Note:
ensure uniform length on 3-core When a cordless impact wrench
cables, complete the first indents is in use the tightning intervalls
on each core before finishing should be in the range of
each ferrule. Use a file to remove 2 seconds.
any rough edges which may
result from the crimping.

Do not remove grease from inside of

ferrules or lugs before installing.
On paper cables and tape screens,
the yellow void filler should be
applied in the same direction (turn)
as the last paper layer or metal foil.

Special tip:
Always make sure your hands are
clean before applying yellow void
filler at screen cuts, crotch areas
and on the ferrules.

Any materials that become soiled

or contaminated should not be
used!

You can make things easier by

removing the tape from the release
paper a little at a time.

After the yellow void filler is control tubing over it.

applied to an individual ferrule, This prevents contact
centrally position the stress with other mastics.
When applying mastic tape,
always stretch it to about half its
original width and apply each turn
slightly overlapping the previous
one.

A good way to avoid mastic sticking

to your fingers is to coat your hands
with a very thin film of silicone grease
after you’ve cleaned them.
Lastly…
After the shrinking procedure is completed as shown in the kit
instruction, allow the accessory to cool down before subjecting it
to mechanical strain.

Use a propane gas torch as recommended in the tool list

for shrinking heat-shrinkable components. Adjust the torch
to obtain a soft blue flame with a yellow tip. Pencil-like blue
flames should be avoided.
For terminations:
If readjusting the core position, it is necessary to postheat. Additional
components, such as conductive paint or PVC tape, must not be
used for identification marking of track resistant outer tubings. There
should be no clamping or other materials on the termination itself.

Keep the torch aimed in In particular check

the shrinking direction to underneath tubings or in
preheat the material. other areas where the heat
cannot be applied evenly.
Keep the flame moving
continuously to prevent
scorching.

10

After shrinking, each tubing and molded part should be

smooth and free of wrinkles and “cold spots”.
Metric, British, British Standards
US Conductor C.S.A. of Number and
Conversion Chart Conductor Diameter of
sq. inch Strands inch

  .001    3/.020
   ó
   1/.036
  .0015    1/.044

  .0020    3/.029

   3/.036
  .003    ó
   1/.046

  .0045    7/.029
  .0050    1/.083

  .007    7/.036
  .008    1/.103
  .01    7/.044
  .013    1/.128
  .0145    7/.052

  .20    1/.160
  .0225    7/.064
  .03   19/.044
   ó
  .04    1/.192
  19/.052
  .06   19/.064

  .10   19/.083

  .15   37/.072

  .2   37/.083
  .25   37/.093
  .3   37/.103

  .4   61/.093

  .5   61/.103
  .6   91/.103
  .75   91/.103

1.0 127/.103
 Metric American Wire Gauge
Equivalent Cross-sectional Metric C.S.A. AWG
Metric C.S.A. Area mm2 or MCM
mm2 mm2

   0.65    0.653    19 AWG

   0.75
   0.823    18
   0.97    1.04    17

   1.29    1.31    16
   1.5
   1.65    15
   1.94
   2.08    14
   2.5
   2.62    13
   2.90    3.31    12
   3.23
   4.0
   4.17    11
   4.52    5.26    10
   5.16
   6.0
   6.63     9
   6.45
   8.37     8
   8.39
   9.35   10.0   10.55     7

  13.30     6
  12.90
  14.52   16.0   16.70     5
  19.35   21.15     4
  26.67     3
  25.81   25.0
  33.63     2
  35.0
  38.71   42.41     1
  53.48     1/0
  50.0
  67.43     2/0
  64.52   70.0
  85.03     3/0
  95.0
  96.77 107.20     4/0
120.0 126.64   250 MCM
129.03 152.00   300
150.0
161.25
185.0 202.71   400
193.55
240.0 253.35   500
258.06 304.00   600
300.0
354.71   700
322.58
400.0 405.35   800
387.00
483.87 500.0 506.71 1000
625.0
645.00
IT 1000-005 IT 1000-006

IT 1000-007 IT 1000-008

IT 1000-009 IT 1000-010 IT 1000-011

IT 1000-019 FH-1630-S-TS 1

IT 1000-023
Recommended Tools for Cable Preparation

Set Content Product
Description

  1   1x Hammer 300 g
  2   1x Screwdriver 3.5 mm
  3   1x Screwdriver 6.5 mm IT 1000-005
  4   1x Hacksaw
  5   1x Hacksaw junior
  6   1x Pipe Wrench, size 250
  7   1x Side cutter, size 160
  8   1x Pincers, size 180 IT 1000-006
  9   1x Combination Pliers, size 180
10   1x Scissors, size 200
11   1x Folding ruler, size 2
12   1x Wirebrush, size 4
13   1x Hook knife IT 1000-007
14   1x Cable knife – B
15   1x Sharpening stone, 125 x 50 mm
16   1x File set, medium size
17   1x Control mirror, 100 x 100 mm + Cover
18   1x Spreader 3-way
19   2x Core separator IT 1000-008
20 54x Cleaning tissue
21   1x Refillable AI-Container 0.41
22   1x Stripping tool for bonded screens,
round conductor
23   1x Tool set with knife, allan key set IT 1000-009
packed in a tool box
24   1x Gas torch set FH-1630-S-TS 1
25   1x Scoring tool for easy strip screens IT 1000-011
26   1x Diameter tape IT 1000-010
27   1x Leather tool case IT 1000-012
28   1x Cordless impact wrench IT 1000-023
29   1x Installation tool for mech. connectors IT 1000-019
Energy Division – innovative and economical solutions for the
electrical power industry: cable accessories, connectors & fittings,
insulators & insulation, surge arresters, switching equipment, lighting
controls, Power Measurement and Control.

All of the above information, including drawings, illustrations and

graphic designs, reflects our present understanding and is to the best
of our knowledge and belief correct andreliable. Users, however, should
independently evaluate the suitability of each product for the desired
application. Under no circumstances does this constitute an assurance
of anyparticular quality or performance. Such an assurance is only
provided in the context of our product specifications or explicit
contractual arrangements. Our liability for these products is set forth
in our standard terms and conditions of sale. Raychem, TE Logo and
Tyco Electronics are trademarks.
Energy Division – innovative and economical solutions for the
­electrical power industry: cable accessories, connectors & fittings,
­insulators & insulation, surge arresters, switching equipment,
lighting controls, power measurement and control.

© Tyco Electronics EPP 0377 11/07

Tyco Electronics Raychem GmbH

Energy Division
Finsinger Feld 1
85521 Ottobrunn/Munich, Germany

Phone: +49-89-6089-0
Fax: +49-89-6096345

http://energy.tycoelectronics.com