Abtech HVJB Series Guide

ABTQ-50 rev 13
Last review: 5th Sept 16
INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS FOR
ABTECH ‘HVJB’ series – CML16ATEX3324 and IECEx CML 16.0100
1/4
Abtech Ltd.
Newhall Road, Lower Don Valley, Sheffield S9 2QJ
Marking (standard temperature)
The maximum power dissipation and voltage
permitted in this terminal box are marked on the
label and identified as W and __kV. The ambient
temperature range for which this product is suitable
is either–20oC to +40oC or –50oC to +55oC. Where
the narrower ambient range (shown left) is applicable
it need not be included.
The IP66 rating is an example and may read IP66,
IP67 or IP68
Marking (high operating temperature)
The maximum power dissipation and voltage
permitted in this terminal box are marked on the
label and identified as ***W and __kV. The ambient
temperature range for which this product is suitable
is –50oC to +55oC.
The IP66 rating is an example and may read IP66,
IP67 or IP68
Installation
Note When this product is to be used in high operating temperature mode the cable insulation material must be
suitable for that operating temperature.
1) Using the mounting dimensions provided, either in the product catalogue data sheets or on the drawings
supplied (as part of the project documentation) mark out the positions for the mounting holes on the surface
where installation is required.
2) Drill the mounting holes for either M10 fixing studs.
3) Insert the top two studs leaving 8 to 10mm protruding and lift the enclosure into position using such
assistance as may be necessary to avoid injury and hang the top fixing brackets of the box onto the studs.
Note: When lifting eye-bolts are provided note the limits given on the instruction document ABTQ-231
Ensuring that the box is secure, insert and tighten the bottom two studs. Now complete tightening the top
two studs.
4) Unfasten the lid securing screws and remove the enclosure lid. Put the lid in a safe place.
5) Install and secure the cable glands in accordance with the manufacturer’s instructions.
Main Power Cable Connections
6) Remove the top half on each power core cable clamp and put safely aside.
7) Remove the terminal post lock nuts, washers and the upper current bars and put safely aside.
8) Pull the cables into the box leaving trailing leads long enough to reach their respective crimp lugs after
routing through the cable clamps.
9) Trim each cable core so that the conductor end will reach the inside stop of the crimp lug on which it is to be
terminated.
10) Strip the insulation of each cable core by the length of the crimping barrel plus 2mm.
11) Remove each crimping lug in turn from the terminal post and place the securing nuts to one side.
12) Insert the conductor into the crimp lug barrel, ensuring that all strands of the conductor enter the barrel. This
will ensure that minimum clearance distances are not compromised by stray strands.
13) Crimp each lug onto the respective conductor using Cembre die sets or equivalent. Ensure that the crimp
die set used is suitable for the conductor size and is not damaged or excessively worn. The crimp die set
may produce either a hexagon type crimp or an indent type crimp. With hexagon die sets execute at least
two crimps on each lug.
14) Route the cable core through the appropriate cable clamp and place the hole in the palm of the now
attached cable lug on to its respective terminal post, on top of the lower current bar.

ABTQ-50 rev 13
Last review: 5th Sept 16
INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS FOR
ABTECH ‘HVJB’ series – CML16ATEX3324 and IECEx CML 16.0100
2/4
Abtech Ltd.
Newhall Road, Lower Don Valley, Sheffield S9 2QJ
15) Where the conductors to be connected are of different sizes the lugs will be of different thickness. Bring the
thinner lug to the same thickness as the thicker lug buy using tinned or freshly cleaned copper washers.
16) Replace the upper current bar.
17) Apply a small amount of high temperature grease to the stud thread, just sufficient to wet the surface then
secure the current bar and cable clamp assembly in place with the flat washer, spring washer and two
locknuts provided. Ensure that the spring washer is fully compressed by the first lock nut then, using a
spanner* to secure the locknut under the lower current bar, apply a further 1/8 to ¼ turn. If using installation
equipment with torque settings, for M10 securing nuts apply 35 Nm or for M20 securing nuts apply 55 Nm.
Secure the fitting with the second lock nut. (* The spanner is to prevent the tightening torque being
transmitted through the insulating pillar).
18) Check each cable lug to ensure that there are no stray strands from the conductor which might compromise
the minimum clearance distances. If any are identified they must be cut off back to the conductor insulation.
19) When all the cable lugs have been attached and correctly tightened replace the top halves of the power
core cable clamps and tighten each one to secure the cables. Finger tight + 1/8 to ¼ turn is usually
adequate.
20) Replace the flat acrylic cover and secure in position using the nylon studs and washers provided.
21) If no field terminals are used proceed to point 34.
22) If spare conductors are installed refer to Spare Conductor Earthing.
23) If conductor screen terminals are installed refer to Conductor Screen Terminals.
Field Terminal Cable Connections (where fitted)
Note: Consideration must be given to any use limitations or special conditions detailed on the certificates for
the terminals fitted.
24) Remove the top half on each field core cable clamp and put safely aside.
25) Remove the terminal covers and put safely aside.
26) Remove the terminal current bar connection studs and put safely aside.
27) Pull the cable(s) into the box leaving trailing leads long enough to reach their respective crimp lugs after
routing through the cable clamps.
28) Trim each cable core so that the conductor end will reach the inside stop of the crimp lug on which it is to be
terminated.
29) Using the crimp lugs provided, If the field cables are 10 mm2or larger crimp each lug onto the respective
conductor using Cembre die sets or equivalent. Ensure that the crimp die set used is suitable for the
conductor size and is not damaged or excessively worn. The crimp die set may produce either a hexagon
type crimp, (2 crimps per lug), or an indent type crimp.
30) If the field cables are smaller than 10 mm2crimp each lug using a Newey and Eyre Crimpstar crimping
tool or equivalent. Ensure that the crimping tool is not damaged or excessively worn.
NOTE: If the crimp lug is damaged during installation a replacement should be purchased from either
ABTECH, Cembre ([phone], or one of their stockists). If the site engineer requires to source from a
local supplier, then that engineer will be responsible for ensuring that the crimp lug and its associated crimping
tool comply with BS EN 31238-1:2003.
31) Route the cable core through the appropriate cable clamp and place the hole in the palm of the now
attached cable lug above the hole on its respective terminal current bar.
32) Retrieve the current bar connection stud and use it to secure the lug in place.
33) When all the cable lugs have been attached and correctly tightened replace the terminal covers.
34) Replace the top halves of the field core cable clamps and tighten each one to secure the cables.
35) Replace the lid and secure it by closing the lid and tightening the lid fixing screws. Ensure that all gland
plate securing screws are tightened.
36) Test the installation.
Earthing/Grounding
The HVJB unit is provided with an internal and external earthing/grounding facility. This must be connected to
the appropriate earth bonding circuit before electrical power is connected to the contents of the enclosure. Any

ABTQ-50 rev 13
Last review: 5th Sept 16
INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS FOR
ABTECH ‘HVJB’ series – CML16ATEX3324 and IECEx CML 16.0100
3/4
Abtech Ltd.
Newhall Road, Lower Don Valley, Sheffield S9 2QJ
earth/ground conductor brought into the enclosure must be terminated onto the enclosure internal earth/ground
stud.
Spare Conductor earthing
When spare conductors are fed into the box, either for an alternative power supply or for a spare motor, earthing
points may be fitted for the parking of those spare conductors to ensure that they are maintained at earth
potential. Such earthing points are welded to the rear face of the enclosure. All spare conductors must be
threaded underneath the cable clamping rail (if the cable is stiff it might be necessary to temporarily remove this
rail) and the phase barrier support rail and be secured using the earthing point located in the appropriate phase
bay of the enclosure. A nut and vibration resistant washer are provided and must be used. Apply torque to a
minimum of 20Nm, maximum 25Nm.
Conductor Screen Terminals
Conductor screens are most often connected to local earth inside the enclosure. Where the intermediate
connection of monitoring equipment is required additional terminals, isolated from earth, may be made available
for the individual connection of cable screens. These terminals will be of the ABTECH MV type and be secured
to an additional framework of insulating rails, as shown below. The conductors used on these terminals whether
between these terminals and the cable screens or the connecting cable to the monitoring equipment, shall be
terminated on the appropriate MV terminal stud using Cembre single hole crimp lug with palm hole suitable for
stud size M8. Refer to the MV terminal instructions ABTECH reference ABTQ-206 for further detail. The method
of securing the other end to the cable screen shall be in accordance with site engineering practice and be
suitably insulated from earth.
The return cable from the monitoring equipment shall be terminated to an appropriate earth either on or local to
the HVJB enclosure to prevent circulating earth currents.
Operation
1. The lid must be secured using all the lid screws provided in order to maintain the IP rating.
2. No attempt must be made to remove the enclosure lid whilst electrical power is connected to the contents of
the enclosure.
The earthing/grounding facility must be connected to the earth bonding circuit at all times when electrical power
is connected to the enclosure.
Maintenance
The laws of the applicable country must be considered and maintenance checks carried out accordingly.
Additional checks that are advisable to ensure the efficiency of ABTECH ‘S’ range enclosures on which the
HVJB is based are: -
Activity
Frequency
1
Check that the lid seal is not damaged and is in place
Each time the enclosure is
opened
2
Check that all lid fixing screws are in place and secured
Each time the enclosure is
opened
3
Check that all gland plate fixing screws are in place and secured
Each time the enclosure is
opened
4
Check that the mounting bolts are tight and free of corrosion
Annually
5
Check the security of all cable glands
Annually
6
Check the enclosure for damage
Annually
Chemical Attack
The ABTECH HVJB is manufactured from 316 stainless steel. The following additional materials are also used:
Silicone rubber,
Copper,
Brass,
Cast epoxy resin,
Glass reinforced polyester,
Nylon (polyamide),
Acrylic (polymethylmethacrylate).

ABTQ-50 rev 13
Last review: 5th Sept 16
INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS FOR
ABTECH ‘HVJB’ series – CML16ATEX3324 and IECEx CML 16.0100
4/4
Abtech Ltd.
Newhall Road, Lower Don Valley, Sheffield S9 2QJ
Consideration should be given to the environment in which these enclosures are to be used to determine the
suitability of these materials to withstand any corrosive agents that may be present.
Static Hazard
The HVJB does not present a hazard from static electricity.
Vibration
The HVJB is designed for use in areas subject to normal industrial levels of vibration. They are not designed for
use in areas subject to intentional or extreme conditions of vibration.
Protection From Foreseeable Faults
Circuits connected in the enclosure must be externally protected using suitable circuit interruption devices to
prevent overloading. Provided the enclosure is correctly installed, there should be no foreseeable faults.