Pfisterer MV-CONNEX 3 User manual

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MV-CONNEX Size 3 + 3-S wire screen
INSTALLATION INSTRUCTIONS
Inner cone
Take note of any additional instructions
prior to installation!!!

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Content

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CONNEX products provide an all-purpose plug-in connection
system, which is fully insulated, metal-enclosed and touch-proof. It is also
maintenance-free, suitable for outdoor use and waterproof.
CONNEX can even be used under extreme conditions.
The MV-CONNEX range for medium voltage networks features a wealth of
variants. In addition to the classic plug - socket combination, the program
includes multiple sockets, busbar connectors, surge arresters, variants for
the production of branching points above or below ground, motor connec-
tions and test xtures.
With their simple installation, factory tested MV-CONNEX components
speak for themselves. Working in dicult oil and gas environments during
installation and commissioning of transformers and switchgear is no lon-
ger required.
MV-CONNEX. The dry pluggable connection
system for medium voltage networks.
Silicone – a key material in medium voltage engineering.
Water, dirt, grease and oil resistant, completely maintenance-free,
impact-resistant and durable: Silicone is the ideal material for cable termi-
nations and far superior to conventional materials. When used as a stress
relief device in sealed applications, silicone performs much better than
harder materials such as EPDM because it helps to even out temperature
variations and unevenness in the cable surface. Silicone helps to prevent air
gaps, and therefore dangerous partial discharges are avoided. PFISTERER
takes extensive advantage of advanced LSR (Liquid Silicone Rubber) desi-
gns and special variations are made using RTV (Room Temperature Vulca-
nizing silicone).
Introduction
I
1 Introduction
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With MV-CONNEX you have a modern cable connector system. The socket
is already built into the switchgear. In the following instructions, the instal-
lation of the pluggable connector is described and illustrated step by step.
Please observe the sequence of steps during the installation. Installation
should be carried out by tters who have been trained by PFISTERER.
2 General Information
2.1 Information regarding the installation instructions
These assembly instructions describe the safe and proper use of the pro-
duct described. The specied warnings and instructions, and the appli-
cable local accident prevention regulations must be observed together
with general safety regulations.
Before starting work on the product, read the installation instructions all
the way through, particularly the chapter on safety and specic safety pre-
cautions. It is vital that what is read is understood. The installation instruc-
tions are a part of the product. It must be kept available and accessible in
the immediate vicinity of the product (e.g. control room, switch room) at
all times.
2.2 Contents of the installation instructions
Any person who is tasked to perform work on or with the product must
have read and understood the installation instructions before commenci-
ng the work. This is the case even if the person has already worked with this
or a similar product or has been trained by the manufacturer. Knowing the
contents of the installation instructions is one of the requirements for the
protection of personnel from hazards and the avoidance of mistakes, and
to operate the product safely and in a trouble-free manner. The operator is
recommend to ensure that sta can demonstrate that they have taken note
of the contents of these installation instructions.
General Information
II
2.3 Additional installation instructions
Depending on the scope of delivery (e.g. special versions or additional op-
tions that may have been ordered) these instructions may be supplemen-
ted by additional installation instructions, which must be observed and
applied in the same way.
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2.5 Liability and warranty
All information and data contained in these instructions were compiled
taking account of the applicable standards and regulations, technological
state-of-the-art and long standing expertise and experience.
These installation instructions are to be kept in the immediate vici-
nity of the product (e.g. the control room, switch room) and be ac-
cessible at all times to all persons who work on or with the product.
These installation instructions are to be read carefully before starting work
on and with the product! The manufacturer accepts no liability for any da-
mage or malfunction resulting from non-compliance with these installati-
on instructions.
The text and illustrations do not necessarily represent the scope of deli-
very. The illustrations are not to scale. Due to fact that special versions or
additional options may have been ordered, or innovative technical modi-
cations may have been made, the actual scope of delivery can dier in
some circumstances from the information and instructions described here.
Pictorial representations may also dier. If you have any questions, please
contact the manufacturer. We reserve the right to make technical modica-
tions within the framework of improving performance characteristics and
further development.
2.6 Guarantee
The warranty provisions are contained in the purchase agreement and the
manufacturer‘s general terms and conditions.
The manufacturer shall make the nal decision with a warranty claim as to
whether the product or defective parts should be returned or a site visit is
made.
Only use original spare parts from the manufacturer.
Where unapproved replacement parts are used, all warranty, service, com-
pensation and liability claims against the manufacturer or its agents, distri-
butors and representatives are no longer valid.
2.7 Spare parts
General Information
II
2.4 Copyright protection
These installation instructions are to be treated condentially. It is exclusi-
vely intended for persons employed to use the product. All contents, text,
drawings, images and other representations are protected under the Copy-
right Act and are subject to other intellectual property rights. Any misuse
is punishable.
Any disclosure to third parties, including making copies of any type or in
any form - even extracts - as well as the use and / or communication of the
contents without written permission from the manufacturer is not allowed.
Any infringements will lead to a claim for compensation. We reserve the
right to assert further claims.
We reserve the right to exercise our intellectual property rights.
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3 Safety
3.1 Intended use
At the time of its development and manufacture, the product was built ac-
cording to current, accepted rules of engineering and is safe to operate.
However, the product can pose dangers if it is not used by professionally
trained sta, or in an improper or unauthorised manner.
Any use beyond the intended use and / or any other use of the
product is prohibited and is considered not to be as intended.
Any claims against the manufacturer and / or his authorised re-
presentative for damage resulting from improper use of the pro-
duct are excluded. The operator is solely liable for all damages
resulting from improper use.
Operational reliability can only be maintained if the product is used as intended.
It may only be installed when the ambient temperature is within the range
of 0 °C to 45 °C. This refers to the preparation, laying or moving of the cable.
3.2 Changes and modications to the product
To avoid hazards and to ensure optimum performance, no changes nor ex-
tensions or alterations may be made to the product that are not expressly
approved by the manufacturer.
The product may only be operated in a technically awless and operatio-
nally reliable condition. The information given in the installation instruc-
tions must be followed in its entirety!
In addition to the safety precautions and instructions given in this instal-
lation manual applicable to the area of use of the product, local accident
prevention regulations and general safety must be observed and followed
as well as regulations for the protection of the environment.
The operator and personnel authorised by him are responsible for trouble-
free operation of the product and for clear denitions of the responsibili-
ties for installation and repair of the product.
3.3 Responsibility of the operator
Safety
III
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3.4 Risks that may arise from the use of the product
The product has been subjected to a risk analysis. The construction and
design of the product resulting from this work is state of the art.
The product is operationally reliable when used for its intended purpose.
However, a residual risk remains! The product works with high voltages.
Risk of electrocution!
Electrical power can cause very serious injury.
If the insulating part or components are damaged, there is a risk
of fatal injury from the electrical current.
3.5 Safety in the workplace
Following the warnings and instructions given in this installation manu-
al can prevent personal injury and damage to property while working
with and on the product. Failure to follow these instructions may result
in danger to persons and damage to or destruction of the product.
Failure to follow the warnings and instructions given in this installation
manual or the accident prevention regulations applicable to the appli-
cation, together with general safety regulations, shall void any liability
and claims for damages against the manufacturer or his authorised re-
presentative.
3.6 Personnel requirements
Skilled personnel means those who, due to their technical training, know-
ledge, experience and understanding of the regulations that apply to the
work assigned to them, can identify possible hazards.
The responsibilities working on and with the product (installation, mainte-
nance) must be clearly dened and adhered to, so that there is no lack of
clarity as regards safety when it comes to the division of responsibilities.
Only persons may work on and with the product who can be expected to
do their job reliably. Do not perform any activity that may aect the safety
of persons, the environment or the product.
Only personnel that are authorised and trained by the manufac-
turer should operate the product. Sta will receive a certicate
of training from the manufacturer. The certicate has a validity
of 5 years.
Safety
Before starting work on electrical systems, note the following:
Isolate from the power supply.
Secure to prevent reconnection.
Check that the power is o.
Earth and short circuit.
Cover or make inaccessible adjacent live parts.
1 1
2 1
3 1
4 1
5 1
III
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Persons who are under the inuence of drugs, alcohol or medication that
aects their reactions are not allowed to work on and with the product
under any circumstances.
When selecting personnel, the age and profession-specic regulations in
force at the location where the product is used must be observed.
The personnel are obliged to immediately report any changes that occur in
the product that may aect the safety of the operator.
3.7 Personal protective equipment (PPE)
During work on and with the product, the following must always be worn:
Protective clothing, tight-tting work clothing (low tear resistance, no long
sleeves, no rings or other jewelry, etc.).
Safety shoes for protection against heavy falling objects and slipping on a
non-slip surface.
When working in high risk areas (depending on local conditions):
When carrying out cleaning and lubricating work, the following are to be worn:
Gloves to protect the skin against contact with hazardous substances.
Safety glasses to protect the eyes from liquids.
3.8 Warnings
In this installation manual, warnings are also indicated by warning symbols.
Safety
III
Helmet for protection from falling and ying parts and materials.
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4 Transport / Storage
Check the package contents against the packing list to ensure it is com-
plete. If anything is missing, contact the manufacturer immediately. Please
refer to the Terms and Conditions of Sale and Delivery.
After the product has been delivered, immediately report any damage due
to faulty packaging or transport to the carrier, the insurer and the supply-
ing factory. Take steps to mitigate any damage that has already occurred
and prevent any further damage.
4.1 Scope of delivery
4.2 Packaging
The predominant packaging materials are wood, cardboard and plastics
(lms, foams). Packing materials include materials which are included in the
package to protect from moisture (e.g. silica gel bags).
If no agreement to the contrary has been made regarding the return of the
packaging material, the packaging material remains with the customer.
Disposal must be environmentally sound and in accordance with the re-
levant waste disposal regulations. If necessary, hire a waste management
company to dispose of the packaging material.
4.3 Storage
After unloading, the packages must be stored until installation.
The product must not be unpacked!
The following rules apply for storage:
Store in dry conditions. Maximum relative humidity: 60 %.
Ensure that the packages are not stored outdoors.
In addition, ensure that the oor of the storage area is dry during the
storage period.
Protect from direct sunlight.
Storage temperature -5 to 50 °C.
Store in dust-free conditions.
Avoid mechanical shock and damage.
Transport / Storage
IV
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For longer storage periods of over about 3 months check the
measures taken to preserve the product. If aggressive weather
conditions prevail, the protective materials may need to be re-
placed.
The storage time is generally not limited. However, consumables
such as tapes, specialty lubricants and silver for the replication
of a semi-conductive layer should be replaced two years after
production date.
4.4 Storage Time
4.5 Disposal
If no return or disposal agreement has been made, disassembled compo-
nents should be dispossed of as below:
Scrap the metallic materials.
Send plastic elements to plastic recycling.
Sort and dispose of remaining components according to material type.
Lubricants and other additives are subject to special waste treat-
ment and may only be disposed of by authorised companies!
Transport / Storage
IV
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Insulation removal pliers
Replacement blades
Peeling tools and outer
jacket cutter - set
XLPE - area
15 - 49 mm
Assembly socket
Size 3
For longitudinal and radial
cutting of the insulation to
expose the conductor
Ø 15 – 45 mm.
For removal of the outer
jacket, bonded semi-
conductive layer and to
chamfer the insulation.
For pre-assembly of CONNEX
cable terminal heads (e.g.
in the workshop).
305 051 051
305 063 063
827 951 001
827 174 004
Mounting Accessories
5 Installation Accessories
5.1 Tools required
Special tools are required for assembly and disassembly.
Name Item No. Description
Hydraulic
compression tool
Compression head
Size 3
Impact head
Size 3
T-handle screwdriver
SW 6
5.2 Recommended tools and accessories
Name Item No. Description
V
For axially pressing or
pulling of the
contact ring.
Including pull out in-
sert for hydraulic hand-
held crimping pliers.
For pre-assembly of the
contact ring.
To tighten or
loosening the screws
of the CONNEX
separable connector.
827 017 002
305 675 003
559 214 003
563 376 002
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Protection cap
Size 3 (metal)
Blind cap
Size 3
Transport case
(empty)
Pull o aid
For protection of
unplugged CONNEX
cable terminal heads
against damage and dirt
(not voltage proof).
Contact protection
for live CONNEX cable
terminal heads.
For keeping tools.
For easy unplugging
of CONNEX cable
terminal heads.
827 134 003
827 131 003
305 768 001
827 229 001
Mounting Accessories
5.3 Recommended tools and accessories as a complete set
5.4 Round crimp tool and compression sleeves
Item No. Code Ø(mm) Description
Crimping tool Crimping tool Outside diameter
of compression sleeve
V
Name Item No. Description
Assembly tool for
CONNEX cable
terminal heads in case
Size 3
Size 2-3
Size 1-3
Consisting of hydraulic
handheld crimping pliers,
press head, impact head,
T-handle screwdriver,
insulation removal pliers,
replacement blade, chain,
assembly lever, hole bar.
305 768 003
305 768 006
305 768 004
Name Item No. Description
300 632 632
300 632 635
300 632 637
300 632 639
300 632 640
300 641 641
300 641 001
For round crimping the
sleeves onto the ne wire
conductors of the cable.
13.0
18.5
22.5
25.0
28.5
32.0
36.5
HR 11
HR 16
HR 20
HR 22
HR 25
HR 28
HR 32
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6 Technical Data / Conguration
6.1 Dimensions and weight(s)
6.2 Cable data
Technical Data / Conguration
approx. 270
approx. 460
D = 54.8
D = 130
D = 148
Size 3 | 3-S
Length, including heat-shrink tubing
Outer diameter, max.
Bolt circle
Weight / Piece
Contact ring
With voltage tap Size 3 | 3-S
Conductor diameter* min. / max.
CSA, min. / max.
Diameter over insulation, min./max.
VI
[mm] approx. 460
[mm] 148
[mm] 130
[kg] approx. 3.3
[mm] 55.8
[mm] 6.1 / 36.0
[mm2] 35 / 800
[mm] 15.5 / 46.0
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6.3 Characteristics
Technical Data / Conguration
Size 3 Size 3-S
Nominal current
Max. operating voltage
Rated Withstand voltage
Rated lightning impulse
Partial discharge
DC testing
Rated short time current
Rated impulse current
VI
In [A] 1250 1250
Um[kV] 42 52
50 Hz/5 min [kV] 95 117
1.2/50 μs [kV] 200 250
2 x U0[pC] ≤ 10 ≤ 10
15 min 6 x U0[kV] 125 156
0.5 sec [kA] 63 63
1 sec [kA] 50 50
[kA] 150 150
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6.4 Conguration
Contact ring
Tension cone
Thrust piece
Insulating part
Capacitive voltage tap (optional)
Screws M8 x45
Gasket
Bell ange
Capacitive voltage tap (optional)
Heat-shrink tubing
Technical Data / Conguration
VI
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Cable Quality
7 Cable Quality
Check the eccentricity and any attening of the cable using the following
table.
a b
Maximum 15 % dierence between
thickest and thinnest point.
0.85 ≤ − ≤ 1.15
The result must be within
the following limits:
Minimum: 0.85
Maximum: 1.15
a
b
No tolerance.
No attening allowed, the cable
must be round.
ab
Eccentricity Flattening
Installation of the product where the above limits are not com-
plied with may cause damage.
If limits are exceeded, the cable must be reworked until it con-
forms to the tolerances specied. If this is not possible, the pro-
duct should not be installed. In such cases, contact "PFISTERER
Kontaktsysteme GmbH".
VII
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8 Installation / Assembly
8.1 Positioning
235
1
x
45
min. 500
L
8.2 Cable preparation
L = 235 + x (min. 400)
1
110 160
1
110 160
Remove outer jacket to "jacket cut" (1).
1 1
Recommended tools (see chapter 5.2, page 12):
▪Peeling tool and outer jacket cutter set
If the outer jacket is conductive, the conductive layer must
be removed up to 500 mm behind the "jacket cut" (1) (e.g. by
peeling, grinding, washing, ...).
Installation / Assembly
VIII
The installation is to be carried out in a clean and dry environ-
ment. The cable must be straightened 500 mm in front and be-
hind the "jacket cut" (1).
Only peel cable when it is straight.
All dimensions in mm.
1 1 Mark the "jacket cut" (1) on the cable 45 mm below the socket.
In the case of cable with wire earth screen:
L = 235 mm + x mm; however min. 400 mm
x = required length of the earth screen
Roughen outer jacket over 110 mm in the shrinkage area with emery
grit 60.
2 1

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1
1
155
1
110 160
Installation / Assembly
VIII
1
110 160
Clean roughed area.
3 1
4 1 Flame the roughened area.
Slide the smaller heat-shrink tubing over the cable to line it and shrink it
on in the roughened area.
5 1
Only with cable < 38 mm outer diameter
Again roughen the heat-shrink tubing in the shrinkage area with grit 60
emery over 110 mm.
6 1

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1
45
1
45
1
160
Installation / Assembly
VIII
1
545 036 002
Remove outer jacket a further 45 mm behind the "jacket cut" (1).
7 1
Only for cables with outer diameter > 58 mm
Apply woven insulating tape from the outer jacket for 40 mm to the
"jacket cut" (1) with a 50 % overlap.
8 1
At the "jacket cut" (1), apply 2 – 3 more layers one on top of the other.
9 1
Apply the control mark 160 mm from the "jacket cut" (1).
10 1
Apply one layer of sealing tape 10 mm behind the control mark.
11 1
12 1 Remove balancing tape at the "jacket cut" (1).