Nexans Euromold K489TB/G User manual

This product should be installed only by competent personnel trained in good safety practices involving
high voltage electrical equipment. These instructions are not intended as a substitute for adequate
training or experience in such safety practices. These instructions do not attempt to provide for every
possible contingency. Failure to follow these instructions could result in damage to the product and
serious or fatal injury. IMPORTANT : Cable and associated apparatus must be de-energised, locked
out, and tagged prior to product installation.
a Nexans company
CAUTION : Read instructions thoroughly and completely prior to beginning installation.
Required components for the connector installation :
Only to be used on copper wire screened cable with
extruded easy strip or bonded semi-conductive screen and stranded circular conductors of
copper or aluminium.
3 x Cable reducer
911CA-W
Installation
instructions
Roll adhesive
tape
3 x 489TB/G
tee connector
Installation instructions for separable tee connector - type C interface
(K),(M),(P)489TB/G
Up to 42 kV
Water sealing
mastic, type MWS
(outdoor applications)
Silicone grease
+ wipers
+
Gloves
Field control
mastic, type
MFC-RLT
3 x Basic
insulating plug +
cap - 800BIPA
3 x Threaded
stud M16, spring
washer & nut
3 x Conductor
contact - TBC-X
or TMBC-X
+
or
Installation
instructions
Water sealing
mastic, type NGAF
(outdoor applications)
1 x Nylon vent rod
Sand paper
Page 1 of 9
IS91374-ENG - 489TB/G-45/S
22 October 2012 - Revision 1 - Supersedes edition of 4 May 2012
IS91374-ENG - 489TB/G-45/S - Revision 1
!
FOR INFORMATION ONLY Please always use the instructions supplied in the kit
!

M
375
50 55
325
approx.
500
equipment
bushing
(type C interface )
FOR OUTDOOR
APPLICATIONS :
apply water
sealing mastic
CUT
HERE
outer cable
sheath
tape
marker
edge of the
outer sheath
copper
wires
outer cable
sheath
adhesive
tape
sand outer
sheath
1Train the cable into the approximate finished
position next to the equipment bushing.
2Mark the centre line « M » of the bushing.
3Remove the outer cable sheath to a point 375 mm
from the centre line « M » of the bushing.
4 Sand the outer sheath over a distance of 50 mm.
5Apply a tape marker around the outer sheath
55 mm from the edge. For indoor applications,
bend the screen wires back over the outer sheath
and proceed to step no. 6.
For outdoor applications :
- Wrap one layer of water sealing mastic (type
MWS) around the outer sheath, flush with the end
(25 mm minimum width). Completely encircle the
cable.
- Bend the screen wires back over the mastic and
along the outer sheath, pressing them into the
mastic.
IMPORTANT : screen wires should not touch each
other when pressed into the mastic to prevent
water ingress.
6Using adhesive tape, fix the screen wires at a distance
of min 150 mm from the edge of the outer sheath.
7Cut the cable to a point 325 mm from the outer
sheath.
EQUIPMENT
min
150
NB : Only one phase is shown in these instructions. Make off all three phases
the same way. Use a cable conversion kit for 3-core cables.
CABLE PREPARATION
IS91374-ENG - 489TB/G-45/S - Revision 1
Page 2 of 9
!
FOR INFORMATION ONLY Please always use the instructions supplied in the kit
!

core insulation
easy strip
semi-conductive screen
1Check distance of 325 mm.
2Remove the easy strip semi-conductive screen to a point 40 mm from the outer sheath.
Cut squarely taking care not to cut the core insulation.
40
325
bonded
semi-conductive screen
1Check distance of 325 mm.
2Remove the bonded semi-conductive screen to a point 40 mm from the outer sheath.
Use an appropriate pencilling tool. Make a smooth transition between core insulation and semi-conductive screen.
3Remove any traces of conductive residue from the core insulation.
325
40
core insulation
outer sheath
outer sheath
For extruded easy strip semi-conductive screen
For bonded extruded semi-conductive screen
Page 3 of 9
IS91374-ENG - 489TB/G-45/S - Revision 1
!
FOR INFORMATION ONLY Please always use the instructions supplied in the kit
!

core insulation
field control mastic,
type MFC-RLT conductor
conductor
contact
protective
adhesive tape
conductor
1 A. For compression type contacts : remove the core insulation from the conductor for a distance « C » mm
(C= depth of contact bore + 10 mm).
1 B. For mechanical type contacts : remove the core insulation from the conductor for a distance « C » mm
(C= depth of contact bore + 10 mm).
2Slightly bevel the edge of the core insulation. Do not sharpen in cone-shape.
3Thoroughly clean core insulation. Always wipe towards the screen wires.
4As a protection, wrap a few turns of adhesive tape around the conductor end.
5Remove field control mastic strip, type MFC, from coated paper. Apply the mastic on the cutback edge of the
semi-conductive screen, covering approximately 5mm of the extruded semi-conductive screen and 5mm of the
core insulation. Push the mastic in place while stretching it progressively until both ends overlap and tear-off the
excess mastic. Using the coated side of the paper, squeeze the mastic tightly in place on the step of the
semi-conductive screen.
6For outdoor applications: Wrap another layer of water sealing mastic (type NGAF). Start taping 25 mm from
the end of the outer sheath over the first mastic layer and the screen wires and continue up to a point 10 mm on
the semi-conductive screen. Make a cone-shape.
1Lubricate* the indicated area : core insulation, mastic, semi-conductive screen and inner surface of the reducer.
2Slide the reducer down the cable.
3Remove the protective adhesive tape from the conductor.
REMOVAL OF THE CORE INSULATION
INSTALLATION OF THE CABLE REDUCER
A. Compression type contacts (Type TBC-X) B. Mechanical type contacts (Type TMBC-X)
10
C
10
10
core insulation
cable reducer
cable reducer
protective
adhesive tape
lubricate
bevel
core insulation conductor
contact
conductor
10
C
* USE ONLY THE SILICONE LUBRICANT SUPPLIED
25
edge of the outer sheath
water sealing mastic (type NGAF)
IS91374-ENG - 489TB/G-45/S - Revision 1
Page 4 of 9
!
FOR INFORMATION ONLY Please always use the instructions supplied in the kit
!

adhesive
tape
equipment
bushing
1For aluminium conductors : before installing the conductor contact, wire brush the conductor.
2Fit the contact on to the conductor.
3Position the crimp contact taking care that the contact hole aligns with the bushing hole.
4Prior to crimping, distance « Z » must be between 225 and 230 mm.
5Crimp the contact. Please refer to the crimp chart for crimp sequence.
6After crimping distance « Z » must be between 225 and 235 mm.
If necessary, adjust the position of the cable reducer until distance « Z » is within the tolerance range.
Using adhesive tape, secure the cable reducer.
7Remove any burrs left after crimping and wipe-off excess inhibitor.
CRIMPING/TIGHTENING OF THE CONTACT
Compression type contacts (Type TBC-X)
A
Z
conductor
contact
deep indent
crimping DIN crimping
contact
palm
Page 5 of 9
IS91374-ENG - 489TB/G-45/S - Revision 1
!
FOR INFORMATION ONLY Please always use the instructions supplied in the kit
!

holding tool
contact
palm
equipment
bushing
1For aluminium conductors : before installing the conductor contact, wire brush the conductor.
2Insert, if necessary, the centre ring into the contact barrel according to the table in the contact installation
instruction.
3Position the contact taking care that the contact hole aligns with the bushing hole.
4Before tightening, distance « Z » must be between 225 and 230 mm.
5Tighten the contact. Please refer to the installation instruction included with the contact.
6After tightening, distance « Z » must be between 225 and 235 mm.
If necessary, adjust the position of the cable reducer until distance « Z » is within the tolerance range.
Using adhesive tape, secure the cable reducer.
Mechanical type contacts (Type TMBC-X)
B
cable reducer
Before tightening
After tightening
conductor
contact
Z = 225 - 230
Z = 225 - 235
adhesive
tape
IS91374-ENG - 489TB/G-45/S - Revision 1
Page 6 of 9
!
FOR INFORMATION ONLY Please always use the instructions supplied in the kit
!

1Train the cable into the approximate finished
position next to the equipment bushing.
2Mark the centre line « M » of the bushing.
3Remove the outer cable sheath to a point 375 mm
from the centre line « M » of the bushing.
4 Sand the outer sheath over a distance of 50 mm.
5Apply a tape marker around the outer sheath
55 mm from the edge. For indoor applications,
bend the screen wires back over the outer sheath
and proceed to step no. 6.
CONNECTOR INSTALLATION ON CABLE
CONNECTOR INSTALLATION ON BUSHING
cable reducer connector
housing
equipment
bushing
clean thoroughly
lubricate
connector
housing
lubricate
1Clean cable reducer, core insulation and contact.
2Lubricate* the inside of the connector housing and outer surface of the cable reducer.
3Check if the longer interface of the tee connector is pointed towards the bushing. Whilst preventing the
cable reducer from further movement down the cable, gently slide the housing on the cable. Its final position is
reached when the centre of the contact spade is along the axis of the interfaces of the connector. The cable
reducer must stay in place during installation.
* USE ONLY THE SILICONE LUBRICANT SUPPLIED
3Clean and lightly lubricate* both connector and
bushing interface.
4Push the connector on to the bushing.
equipment
bushing
1Install M16 threaded stud into the
bushing interface.
2Using a 13 mm wrench or a hex key of
8 mm, tighten the stud exerting
30 Nm (3 kgm or 22,1 foot-pounds).
M16 stud
Page 7 of 9
IS91374-ENG - 489TB/G-45/S - Revision 1
!
FOR INFORMATION ONLY Please always use the instructions supplied in the kit
!

* USE ONLY THE SILICONE LUBRICANT SUPPLIED
5Install the spring washer and M16 nut on to the threaded stud.
6Use torque wrench with a socket wrench 22 and tighten exerting 50 Nm (5 kgm or 36,9 foot-pounds) of torque.
In order to achieve the correct applied torque ensure that there is no lubricant on the threaded
parts.
22mm
22mm
22 mm
socket
1/2" - 12,7 mm
torque wrench
L ≥ 90 mm
extension
50 Nm
30 Nm
1/2" - 12,7 mm
torque wrench
22 mm
socket
basic
insulating
plug
lubricate
1Clean and lubricate* the insulating plug for the opposite side of the connector.
2Insert the plug in the connector and tighten assembly : use torque wrench with socket of 22 and tighten exerting
30 Nm (3 kgm or 22,1 foot-pounds) of torque.
In order to achieve the correct applied torque ensure that there is no lubricant on the threaded
parts.
M16 nut
spring
washer
INSTALLATION OF THE BASIC INSULATING PLUG
IS91374-ENG - 489TB/G-45/S - Revision 1
Page 8 of 9
!
FOR INFORMATION ONLY Please always use the instructions supplied in the kit
!

INSTALLATION OF THE CAP CONNECTOR EARTHING
AND CABLE CLAMPING
NOTE :
A connector/bushing mated combination should not be allowed to carry the full weight of the cable.
Therefore it is necessary to clamp the cable as close as possible to the connector.
IMPORTANT NOTES :
- Never disconnect the connector from energised equipment nor energise a disconnected connector
without previously installing on its appropriate corresponding mating part.
- Do not allow hydrocarbon oils or solvents to contaminate the E.P.D.M. rubber.
In the event of contamination, wipe the surface clean with a dry cloth.
a Nexans company
Nexans Network Solutions NV - div. EUROMOLD
Zuid III - Industrielaan 12
B-9320 EREMBODEGEM-AALST – BELGIUM
Tel: [phone] – Telefax: +32 (0)53/83 10 13
[email protected]
protective
cap
nylon vent
rod
Installation on insulating plug :
- Clean the inside of the cap and the outside surface of
the connector and insulating plug.
- Place the nylon vent rod along the insulating plug
(see fig.) to exhaust the air during assembly of the cap.
- Push the cap over the connector and on to the
insulating plug.
- Press the centre of the cap on to the locking point
until it snaps in place. Press the cap on all sides to
make sure it is well positioned over the connector.
Position the cap with the pulling tab pointing
downwards.
- Remove the nylon vent rod.
system
earth
cable
clamp
screen
wires
1Bend back the screen wires along the outer
sheath to form a pig tail.
2Connect the earthing lead and screen wires to
the system earth.
earthing
lead
Page 9 of 9
IS91374-ENG - 489TB/G-45/S - Revision 1
!
FOR INFORMATION ONLY Please always use the instructions supplied in the kit
!