Siemens Energy DigiTRON TC3A-107 User manual

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DigiTRON
Installation, Operation and
Maintenance Manual
IOM-007 - Rev03
siemens-energy.com
Disconnectable Junction Boxes type TC3A-107 and similar
Electrical Distribution Units
Protection, Storage, Shipment, Unpacking, Deployment and
Maintenance Instructions

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Siemens Energy is a registered trademark licensed by Siemens AG
Disconnectable Junction Boxes type TC3A-107
and similar Electrical Distribution Units
Installation, Operations and Maintenance Manual
Protection, Storage, Shipment, Unpacking, Deployment
& Maintenance Instructions
Document No: IOM-007

Document No:
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Issue Date:
16/11/2020
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Foreword
Thank you for purchasing a Siemens Energy Subsea product. The information contained in this
document is an overview including the protection, storage, shipment, unpacking, deployment and
maintenance for DigiTRON disconnectable Junction Box type TC3A-107 and similar Electrical
Distribution Units.
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP FOR FUTURE REFERENCE
Revision Summary
This page records the revision status of the entire document and its authorisation for issue.
Copyright © 2020 Siemens Energy Subsea Connectors, (a division of Siemens Energy plc),
Subsea Excellence Centre, Ulverston, Cumbria, LA12 9EE, England.
Rev
Compiled
by
Date
Approved
by
Issue Date
Page(s) Affected/Remarks
3
R Wyatt
16/11/2020
Eric Chaize
16/11/2020
Updated onto new IOM template with product
safety advice clearly identified. Replaced
information regarding associated EFLs with
reference to IOM-001.
2
P. Westwell
Updated for use with similar EDUs.
1
First issue

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Contents
1PRODUCTS COVERED BY THIS MANUAL....................................................6
2BASIC INFORMATION & QUICK REFERENCE..............................................7
2.1 Product overview.....................................................................................7
2.2 Product specification and certification .................................................8
2.3 Contact details and feedback.................................................................9
2.4 Product advice label................................................................................9
2.5 Product marking ....................................................................................10
2.6 CE label/marking....................................................................................10
2.7 Product examples..................................................................................11
3PRODUCT SAFETY........................................................................................12
3.1 Action-related warnings........................................................................12
3.2 Intended use...........................................................................................12
3.3 General safety information...................................................................13
3.4Related documents................................................................................16
3.5 Control of substances hazardous to health (COSHH) .......................16
4ABBREVIATIONS...........................................................................................17
5SPECIFICATIONS...........................................................................................18
5.1 Connector Specification –Diver Mate type.........................................18
6PREPARING PRODUCT FOR USE OR STORAGE......................................19
6.1 Product protection and packaging ......................................................19
6.2 Lifting......................................................................................................19
6.3 Unpacking...............................................................................................19
6.4 Storage, protection and end of life ......................................................19
7INSTALLATION AND ASSEMBLY ................................................................22
7.1 Cathodic protection...............................................................................22
7.2 Junction Box installation......................................................................22
7.3 Installation of Junction Box and mounting brackets.........................23
7.4 Installation of EFLs onto the Junction Box.........................................27
8USER INFORMATION DURING NORMAL OPERATION AND FAULT
CONDITIONS..................................................................................................28
8.1 Visible/audible signals ..........................................................................28
8.2 Normal and faulty/dangerous operation..............................................28
8.3 Troubleshooting.....................................................................................28

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9PRODUCT OPERATION AND MAINTENANCE............................................29
9.1 Safety precautions.................................................................................29
9.2 Product maintenance and servicing....................................................29
9.3 Subsea protection of receptacle contact pins....................................29
9.4 Product protection; caps and dummy connectors.............................29
9.5 Live Mate / De-mate ...............................................................................31
9.6 Removal of marine growth and calcareous deposits.........................31
10 CUSTOMER COMMENTS/FEEDBACK.........................................................33
Tables
Table 1 List of other Installation, Operation and Maintenance manuals related to
DigiTRON product range.................................................................................6
Table 2 DigiTRON TC3A-107 product specification and certification......................8
Table 3 DigiTRON product contact details.................................................................9
Table 4 DigiTRON Diver Mate connector specification...........................................18
Table 5 Troubleshooting product contact details....................................................28
Illustrations
Figure 1 Product advice label........................................................................................9
Figure 2 Product marking on DigiTRON product ......................................................10
Figure 3 Junction Box type TC3A-107........................................................................11
Figure 4 Example of a different product configuration.............................................11
Figure 5 Test connector for diver type connector.....................................................23
Figure 6 Highlighting length of earth straps for CP connection to structure.........24
Figure 7 Earth straps secured under bracket mounting screws .............................25
Figure 8 Mounting bracket assembly .........................................................................25
Figure 9 ISO view of Junction Box indicating mounting screw positions..............26
Figure 10 Earth straps to be secured to mating structure .........................................26
Figure 11 Junction Box installed on structure ............................................................27
Figure 12 Typical Transport Caps (left) and Topside protective caps ......................30
Figure 13 Diver operated Subsea Caps........................................................................30
Figure 14 Diver operated Subsea Environmental Cap and Dummy Connectors,
flying and flanged types................................................................................31

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1 PRODUCTS COVERED BY THIS MANUAL
This document is an overview of the protection, storage, shipment, unpacking, deployment, and
maintenance instructions for DigiTRON disconnectable Junction Box type TC3A-107 and similar
Electrical Distribution Units (EDU).
Products covered by this IOM can be readily identified visually, all looking very similar to the
examples given section 2.7.
Part numbers for these Junction Box / EDU products all begin with:
TC3A-xxx -where xxx are part numbers for specific variants of Junction Box / EDU, differences
mainly being quantity of connectors, and connector types.
Installation, Operation and Maintenance manuals for other DigiTRON products not covered by this
document can be found on Siemens Subsea website www.siemens-energy.com /search Subsea, as
follows:
DOC. No.
PRODUCT
IOM-001
DigiTRON electrical flying leads, Jumper and Sensor Harnesses
IOM-002
DigiTRON single connectors
IOM-003
Obsoleted, replaced by IOM-002.
IOM-004
Not used
IOM-005
Retrievable Electrical Distribution unit (REDU), 2nd generation
IOM-006
Retrievable Electrical Distribution unit (REDU), 1st generation
IOM-008
DigiTRONffiber optic flying leads and harness assemblies
IOM-009
DigiTRONffiber optic single connectors
00003075
Subsea PT/TT sensors
00007464
Differential pressure sensors SDP-6 / SDP-8
Table 1 List of other Installation, Operation and Maintenance manuals related to DigiTRON
product range

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2 BASIC INFORMATION & QUICK REFERENCE
2.1 Product overview
DigiTRON Junction Boxes and EDUs intended use is communication and distribution of low voltage
between pieces of electrical equipment that are submerged in water, e.g. subsea.
The product utilizes the DigiTRON range of connectors. The DigiTRON connectors have been
developed for long term reliable communications and low voltage power control system applications
associated with offshore installations. The underwater mating capacity of these connectors is
achieved using pressure compensated electrical inserts employing the CE principle.
Examples of TC3A-107 Junction Box and similar EDUs are shown in section 2.7.

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2.2 Product specification and certification
Basic specifications relating to all products covered by this manual are below in Table 2. Additional
specifications can be found in section 5.
Design Life:
30 years in subsea environment
Rated voltage
1,000Vac pin-ground, 2,000Vac pin-pin
Rated current
In water: 4-way 35-40A 7-way 22-32A 12-way 20-28A
In air: 4-way 18A 7-way 14A 12-way 11A
Over-current
100A for 5 seconds, no more than 2 per hour
Rated number of
operations
1000 (750dry/250wet) mate / de-mate cycles (Power off)
Water depth
3,000 m (9,843 ft)
Deployment and
retrieval rate
Max. 350m/min (1,150ft/min)
Storage temperature
-40°C +70°C (-40°F +158°F) (upper limit is surface temperature of the
product and includes solar gain from bright sunlight)
Operational temp
Subsea: -5°C +60°C (+23°F +140°F)
In air: -20°C +50°C (-4°F +122°F)
Weight
Approx. 35kg (77lb) for TC1A-107. Refer to product drawing for other
variants.
Product Certification:
Standard
Description
EU Directive
2001/95/EC
General Product Safety
EU Directive
2014/35/EU
Low Voltage Directive
IEC 61984
Connectors - Safety requirements and tests
API-17F
Standard for Subsea Production Control Systems
Note: Self-certified via in-house testing.
Table 2 DigiTRON TC3A-107 product specification and certification

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2.3 Contact details and feedback
For additional information or questions regarding the products visit the Siemens website
www.siemens-energy.com /search Subsea, or contact the following:
Department
E-mail address
Product Safety Officer
subsea.connectors.productsafety.gb@siemens-
energy.com
Technical Support
[e-mail]
Service (Site Team)
[e-mail]
Sales
[e-mail]
Table 3 DigiTRON product contact details
Any information, records, or Health and Safety feedback that needs to be detailed can be recorded
in section 10 of this document and sent to the relevant department in Table 3.
2.4 Product advice label
The following product advice label is supplied with all Siemens Energy subsea products.
Figure 1 Product advice label

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2.5 Product marking
Siemens Energy Junction Box / EDU products are marked with the Siemens Energy part number
and unique serial number. Also, the voltage, temperature and water depth ratings are indicated.
Typically, these are etched on a yellow-coloured label permanently attached to the product, refer to
Figure 3.
Also, similar information relating to each connector is etched onto the connector metal body, refer
to Figure 2.
Figure 2 Product marking on DigiTRON product
2.6 CE label/marking
The CE label/marking where applicable shows that the products comply with the requirements of the
applicable directives as follows:
•2014/35/EU –Low Voltage Directive
Declaration of Conformity will be supplied with the goods.

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2.7 Product examples
Figure 3 Junction Box type TC3A-107
Figure 4 Example of a different product configuration
Product identification label

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3 PRODUCT SAFETY
Siemens Energy Subsea recommends that the termination of all equipment shall only be undertaken
by trained, suitably qualified and experienced personnel (SQEP) i.e. competent person.
Following installation, commissioning or deployment of product, if you have any feedback please
complete and return the Customer Comments/Feedback form (Section 10). Please e-mail completed
form to the Product Safety Officer at [e-mail]
3.1 Action-related warnings
Classification of action-related warnings
The action related warnings are classified in accordance with the severity of the possible danger
using the following warning signs and signal words:
Warning symbols and signal words
Danger!
Imminent danger to life or risk of severe personal injury
Danger!
Risk of death from electric shock
Warning.
Risk of minor personal injury
Caution.
Risk of material or environmental damage
3.2 Intended use
The product is intended as a Low Voltage electrical connection system for subsea use.
There is a risk of injury or death to the user or others, or of damage to the product and other property
in the event of improper use or use for which it is not intended.
Intended use includes the following:
- observance of the installation and operating instructions included for the product and any other
system components.
- compliance with all inspection and maintenance conditions listed in the instructions.
- use of all recommended tooling appropriate for specific tasks.
- all activities to be undertaken by a competent person (see 3.3.1 for definition).
Any other use that is not specified in this document or covered in installation and operating
instructions, or beyond that specified in this document shall be considered improper use.
Caution. Risk of material or environmental damage, improper use of any kind is prohibited.

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3.3 General safety information
Installation by competent persons only
The installation, inspection, maintenance, and repair of the product shall be undertaken by trained,
suitably qualified and experienced personnel (SQEP) i.e. competent person, to carry out a specified
activity. Installation, inspection, maintenance, and repair of products by untrained and deemed non-
competent persons could invalidate the product warranty. For further information contact Siemens
Energy Lifecycle Management at [e-mail] (Site Team).
Personal protective equipment (PPE)
Personal Protective Equipment (PPE) is legally defined as ‘all equipment (including clothing affording
protection against the weather) which is intended to be worn or held by a person at work and which
protects the user against one or more risks to their health or safety’.
In the hierarchy of risk control, PPE is considered to rank lowest and represent the option of last
resort. PPE is only appropriate where the hazard in question cannot be totally removed or controlled
in such a way that harm is unlikely (for example by isolating the hazard or reducing the risk at source
to an acceptable level).
All company personnel and operators should wear appropriate Personal Protective Equipment (PPE)
defined as a result of relevant risk assessments in accordance with the Personal Protective
Equipment (PPE) Regulations.
Wear appropriate PPE according to the product safety advice given in this document
Danger caused by improper operation and foreseeable misuse
Improper operation and foreseeable misuse may present a danger to you and others and cause
material damage. Carefully read the enclosed instructions and all other applicable documents,
particularly the “Safety” section and the warnings.
Danger! Risk of death from electric shock if shuttle pins (on the plug connector) are
depressed e.g. with a screwdriver when plug is live (foreseeable misuse).
- Testing activities must only be carried out by a competent person.
- Correct test connector shall always be fitted for electrical testing.
Danger! Risk of imminent danger to life, risk of severe personal injury caused by a shuttle
pin projectile due to damage caused to shuttle pins e.g. with a screwdriver (foreseeable
misuse).
- Maintenance and testing activities must only be carried out by a competent person.
- Correct tools must always be used.
Risk of death due to electrocution
Danger! Risk of death from electric shock due to exposed live pins, e.g. factory or top-side
system test and unmated receptacle is energised.
- Never energise a receptacle connector when not mated to a plug.
- Ensure all test procedures are followed.
- Communication channels and protocols are observed.

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Danger! Risk of death from electric shock due to unscreened cables.
- Do not touch electrical wires while energised. Ensure all test procedures are followed.
Danger! Risk of death from electric shock from any exposed conductors due to stored
electrical energy, e.g. capacitance of cable or elsewhere in the system.
- Ground all electrical conductors after testing and do not touch conductors until
electrical system is fully discharged. Ensure all procedures are followed.
Danger! Risk of death from electric shock, if product is terminated incorrectly e.g. loose
conductor touching metal body or terminated to metal body in error.
- Installation/termination activities must be carried out by a competent person.
- Always electrically ground metal bodies prior to electrically energising a connector.
- Never hold the product when live.
Danger! Risk of death from electric shock or severe personal injury through burning from
de-mating live conductors by hand.
- Do not de-mate the product while live
- Never hold the product while live
- Ensure all procedures are followed for mating/de-mating connectors.
Risk of injury and material damage due to testing, maintenance and
repairs carried out incorrectly or not at all
The products are non-serviceable by the user. In case of suspected faults with the product (refer to
section 8.2), do not use the product and contact Siemens Technical Support or Siemens Product
Safety for advice. Never attempt to carry out maintenance work or repairs on the product yourself.
Danger! Risk of death from electric shock if user dismantles / incorrectly re-assembles /
incorrectly terminates product (foreseeable misuse).
- There are no parts of the product that require maintenance or inspection. The product
should not be disassembled.
- Termination of electrical wires to the product must only be carried out by a competent
person.
Danger! Risk of death from electric shock from improper use of test connector
(foreseeable misuse). In particular, removal of the rubber termination sleeves placed over
the joint between the cable and the test connector is prohibited, as this will expose live
parts to the user.
- Never disassemble a test connector
Warning. Risk of minor personal injury from high temperature of the product due to ohmic
heating in short-circuit condition or high over-currents.
- In the event of a high over-current, allow the connectors to cool before touching.
- Ensure all testing of products both factory and deployed in-field have been completed
by competent persons.
Danger! Risk of severe personal eye injury due to pressurised oil squirting out of damaged
hose or removal of fill/vent screw.

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- Ensure all testing of products both factory and deployed in-field have been completed
by competent persons.
Warning. Risk of eye/bodily injury caused by released pressure during product
disassembly, in the event of retrieval from subsea with a fault that causes depth pressure
to be trapped inside the product.
- Ensure all product disassembly activities are completed by competent persons in
accordance with relevant procedures and using relevant personal protective
equipment (PPE).
Warning. Risk of bodily injury caused by pressure retaining parts becoming projectile due
to user over-pressurising the system, e.g. during Site Installation Test (SIT).
- Ensure all product SIT activities are completed by competent persons in accordance
with relevant procedures.
Risk of injury and material damage due to manual handling
Manual handling, lifting and carrying are known to be one of the largest contributors to occupational
ill-health. Ensure mechanical handling aids are used wherever possible to avoid manual handling.
Where manual handling is considered appropriate for the task, safe lifting guidelines must be
followed, e.g. adopt correct posture, consider team lifting, employ safe lifting technique, etc. Only
competent persons are permitted to perform tasks without supervision, if in doubt ask.
Warning. Risk of musculoskeletal injury from mating or de-mating connectors by hand.
- Referring to the mate / de-mate forces specified herein, ensure suitable manual
handling precautions are taken.
- Ensure all product testing activities are completed by competent persons in
accordance with relevant procedures.
Warning. Risk of musculoskeletal injury from manual handling of heavy products. Refer to
shipping information or product datasheet for weights of the product.
- Ensure mechanical handling aids are used wherever possible to avoid manual
handling.
- Where manual handling is considered appropriate for the task, safe lifting guidelines
must be followed, e.g. adopt correct posture, consider team lifting, employ safe lifting
technique, etc.
- Only competent persons are permitted to perform tasks without supervision, if in doubt
ask.
Warning. Risk of bodily injury from heavy product falling during lift with machinery.
- Ensure machinery/slings used have been tested and are within their expiry date.
- Safe lifting guidelines must be followed, e.g. lifting plan, banksman, etc.
- Correct lifting points must be identified and used.
- Only competent persons are permitted to perform tasks without supervision, if in doubt
ask.
Warning. Risk of minor personal injury to persons with sensitivities to silicone or mineral
based oils.
- There is a small risk that oil could leak from the product if faulty. Wear appropriate hand
protection when handling products or mineral or synthetic based oils in case oils leak
from the connector due to a fault.

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Warning. Risk of minor personal injury and material damage due to slips, trips and falls.
-Good housekeeping avoids slips, trips and falls, keep all work areas clean and tidy.
3.4 Related documents
Installers shall carry out a full site risk assessment and put into place all necessary steps and
procedures to comply with applicable area, regional, national or international health and safety
legislation, e.g. The Health and Safety at Work Act (HASAWA) in the United Kingdom (UK) and
ensure safety of themselves and others regarding manual handling and working at height
requirements.
During the product installation (and any subsequent work) it will be necessary to employ caution. All
installers and operatives involved from unloading the product until it is deployed in its final installed
location must exercise a full duty of care for themselves and others regarding safety. When lifting
and handling this product, operatives should employ assistance if required. In certain situations, it
may be necessary to use mechanical handling aids. Take care to avoid trip hazards, slippery or wet
surfaces.
Employers and installers should refer to the Health and Safety Executive (HSE) web site in the UK
for full advice and manual handling assessment charts (MAC) tool.
In addition, where no specific instructions are given then reference shall be made, but not restricted
to, where applicable, British Standards and codes of practice such as the following:
- The Health and Safety at Work Act.
- COSHH Control of substances hazardous to health.
- BS 7671 Requirements for electrical installations. IEE Wiring Regulations.
- The Electricity at Work Regulations.
It is the operator’s and installers responsibility to comply with current Company, area, regional,
national or international health and safety legislation.
3.5 Control of substances hazardous to health (COSHH)
Hazardous substances, Control of substances hazardous to health (COSHH) Assessments regards
to materials such as elastomers and oils, etc. used in DigiTRON products are available on request
from the Product Safety Officer at [e-mail].

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4 ABBREVIATIONS
°C Degree Celsius
A Ampere
ac Alternating Current
API American Petroleum Institute
CE Community European
COSHH Control of substances hazardous to health
CP Cathodic Protection
dc Direct Current
DWG Drawing
EDU Electrical Distribution Unit
EFL Electrical Flying Leads
EMF Electrical Magnetic Field
M Metres
Max. Maximum
Min. Minimum
No. Number
PPE Personal Protective Equipment
REDU Retrievable Electrical Distribution Unit
ROV Remotely Operated Vehicle
SIT Site Installation Test
UNS Unified Numbering System for Metals and Alloys
V Volt

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5 SPECIFICATIONS
The following is a basic specification for DigiTRON diver-operated connectors utilized in the
products. Actual product may vary. Please refer to product specific data sheet(s), website
www.siemens-energy.com /search Subsea, or contact Siemens Energy Technical Support at
[e-mail] for more detailed information.
General specification of the product is listed in section 2.2, with the following additional specification
for Diver Mate connectors.
5.1 Connector Specification –Diver Mate type
Mate force
N/A: Integral clamp ring, max torque 20Nm (11lbf.ft)
Max misalignments
N/A: diver alignment by hand
Maximum mate and
de-mate speeds
1 m/s
Limit of exposure of male pins to seawater 28 days cumulative over lifetime
Table 4 DigiTRON Diver Mate connector specification
Caution. Risk of material damage. Maximum cumulative exposure of the male pins to
seawater is 28 days to prevent corrosion of the pins. If the connectors are to be left
unmated, in seawater, for any length of time Subsea Environment Cap or Dummy Plug
must be fitted to protect the pin contacts in the receptacle connectors. Over exposure will
increase the risk of corrosion damage or marine growth on the contact surfaces of the
receptacle contact pins. This could lead to damage to the seals and insulation within the
plug socket contacts. Plug connectors do not require full dummy connectors for
protection. Siemens Subsea advise the fitting of acetal caps to protect plugs against
marine growth. It is good practice to always fit the protective cap when a connector is
unmated topside prior to deployment to provide mechanical protection.
Caution. Risk of material damage. Unmated receptacles (exposed male pins) should
never be electrically energised subsea (even a small residual voltage). This will very
quickly corrode the pins or cause complete electrical failure of the product.

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6 PREPARING PRODUCT FOR USE OR STORAGE
6.1 Product protection and packaging
The Junction Box will be supplied with a dedicated transit box.
Caution. Risk of material damage. The Junction Box must be secured in a dedicated
transit box and always remain in a horizontal position to prevent risk of damage to the
diaphragms.
The Junction Box is designed to withstand vibration that occurs during transportation.
The Junction Box body is manufactured from subsea resistant plastic, with 316L stainless steel
connectors and as such is designed to withstand harsh environments. However, the connector
inserts and exposed parts are susceptible to mechanical damage if not adequately protected.
Transport caps are fitted to all DigiTRON connectors before transport, but topside protective caps
will be fitted if specified by the customer. Care should be taken to protect the connectors with bubble
wrap or similar wrapping materials to avoid surface damage during transit
Caution. Risk of material damage. Transport caps or protection caps must always be fitted
to an unmated connector during transport, and should remain in place while topside before
deployment
For information related to transportation of DigiTRON connectors and ELFs associated with the
Junction Box, please refer to Siemens documents IOM-001 and IOM-002, available on Siemens
Energy website.
6.2 Lifting
The Junction Box is too heavy for a one-person lift. Consider using a crane or other suitably rated
lifting device.
Sling around the plastic body. Do not use the connectors as a sling point.
The Junction Box must be kept in a horizontal position.
6.3 Unpacking
Remove wrapping material taking care to inspect for any surface damage or items that may have
become separated from the unit.
For parts supplied individually and wrapped in materials, do not use a knife to cut the wrapping
material, as this may cause damage to any elastomeric parts or painting of the product.
Do not remove transport or topside protection caps until the Junction Box is ready for installation.
Connectors/Equipment supplied in boxes must be stored in the box.
6.4 Storage, protection and end of life
All connectors come supplied with a transport cap. It is recommended to leave the caps on whenever
possible. The caps must be removed before subsea deployment.