PCN LR5237-000

Effective Date: August 8, 2013

PII 56394
Revision AC
1
Suggested Installation Equipment (not supplied with kit)
Cable preparation tools
TE P63 cable preparation kit or cable manufacturer approved
solvent
Clean, lint-free cloths
Non-conducting abrasive cloth, 120 grit or finer
Electricians tape
Connector(s) and installation tools
TE recommended torch
Recommended TE Torches
Install heat-shrinkable cable accessories with a clean burning torch,
i.e., a propane torch that does not deposit conductive contaminants
on the product.
Clean burning torches include the TE FH-2629, FH-2649 (uses
refillable propane cylinders) and FH-2618A (uses disposable
cylinder).
Adjusting the Torch
Adjust regulator and torch as required to provide an overall 12- inch
bushy flame. The FH-2629 will be all blue, the other torches will
have a 3- to 4-inch yellow tip. Use the yellow tip for shrinking.
Regulator Pressure
FH-2618A Full pressure
FH-2649 25 psig
FH-2629 15 psig
General Shrinking Instructions
Apply outer 3- to 4-inch tip of the flame to heat-shrinkable material
with a rapid brushing motion
Keep flame moving to avoid scorching
Unless otherwise instructed, start shrinking tube at center,
working flame around all sides of the tube to apply uniform heat
To determine if a tube has completely recovered, look for the follow-
ing, especially on the back and underside of the tube:
1. Uniform wall thickness
2. Conformance to substrate
3. No flat spots or chill marks
4. Visible sealant flow if the tube is coated
When installing multiple tubes, make sure that the
surface of the last tube is still warm before positioning
and shrinking the next tube. If installed tube has cooled, re-heat the
entire surface.
Customer Service
For 24 hour customer service, call 800-327-6996.
EHVT/GHVT-690-SG-LC
Series
69kV Class Outdoor High Voltage Termination for Al/Cu
Corrugated Sheath (ACS/CCS) Cable
Safety Instructions
When installing electrical power system accessories,
failure to follow applicable personal safety
requirements and written installation instructions could result in fire
or explosion and serious or fatal injuries.
To avoid risk of accidental fire or explosion when
using gas torches, always check all connections for
leaks before igniting the torch and follow the torch manufacturers
safety instructions.
To minimize any effect of fumes produced during
installation, always provide good ventilation of
confined work spaces.
As TE has no control over field conditions which
influence product installation, it is understood that the
user must take this into account and apply his own experience and
expertise when installing product.
Working around energized high-voltage systems may
cause serious injury or death. Installation should
be performed by personnel familiar with good safety practice in
handling high-voltage electrical equipment. De-energize and ground
all electrical systems before installing product.
Power distribution and transmission products must
be properly selected for the intended application. It
must be installed and serviced by competent personnel who have
been trained and understand proper safety procedures. These
instructions are written for such personnel and are not a substitute
for adequate training and experience in safety procedures.
Read and understand the contents of these
instructions before installation and follow all locally
approved procedures and safety practices before installing or
operating this equipment
These instructions cannot cover all details or variations
in the equipment, procedures, or processes described,
nor provide directions for meeting every possible contingency during
installation, operation, or maintenance. When additional information
is desired to satisfy a problem not covered sufficiently for the
users purpose, please contact your TE sales representative. These
instructions are not intended to supersede or replace existing safety
and operating procedures.
Upon receipt of a product, inspect it thoroughly for
damage and loss of parts incurred during shipment.
If damage or loss is discovered, file a claim with the carrier
immediately or contact your TE representative.
Product Installation Instructions
PCN LR5237-000
Effective Date: August 8, 2013
PII 56394
Revision AC
2
1. Product selection
Check kit selection with cable diameter dimensions in Table 1.
Installation Instructions
Table 1
"Y"
Depth of
Lug Barrel
+ =
"Z"
Insulation
Cutback
1/2"
(10mm)
(10mm)
1/2"
Y
Z
481
Insulation Cutback (Z)
"Y"
Depth of
Lug Barrel
Minus =
"Z"
Insulation
Cutback
1/4"(5mm)
Y
Z
(5mm) 1/4"
Crimped Lug
Mechanical Lug
481a
2. Prepare cables
Refer to illustrations to prepare the cables.
Use a round file at termination of semi-conductive
layer.
Clean and abrade insulation. Ensure insulation is free of all
conductive particles.
40" (1000mm) Z
(135mm) 6"
Cable
Jacket
(50mm)
2"
Al/Cu
Corrugated
Shield (ACS/CCS)
3054
3. Clean cable jacket; apply red sealant
Solvent clean and abrade the exposed ACS/CCS. Apply red sealant
for 4 (100mm) over the cable jacket, overlapping the sealant onto
the ACS/CCS for 1/2 (15mm).
Red Sealant
4
101
Kit Conductor Size
Min/Max
Insulation OD Max Jacket OD
EHVT-690-G(SG) 1/0 - 4/0 1.18 - 1.77 (30 - 45 mm) 2.36 (60 mm)
EHVT-691-G(SG) 4/0 - 350 kcmil 1.50 - 2.05 (38 - 52 mm) 2.65 (67 mm)
EHVT-692-G(SG) 350 kcmil - 1000 kcmil 1.95 - 2.55 (50 - 65 mm) 3.25 (82 mm)
EHVT-693-G(SG) 1000 kcmil - 2000 kcmil 2.50 - 3.05 (63 - 77 mm) 3.95 (100 mm)
EHVT-694-G(SG) 2000 kcmil - 3000 kcmil 2.76 - 3.38 (70 - 86 mm) 4.33 (110 mm)
GHVT-691-G(SG) 1/0 - 350 kcmil 1.50 - 2.05 (38 - 52 mm) 2.65 (67 mm)
GHVT-692-G(SG) 350 kcmil - 1000 kcmil 1.95 - 2.55 (50 - 65 mm) 3.25 (82 mm)
GHVT-693-G(SG) 1000 kcmil - 2000 kcmil 2.50 - 3.05 (63 - 77 mm) 3.95 (100 mm)
PCN LR5237-000
Effective Date: August 8, 2013
PII 56394
Revision AC
3
5. Install ground braids, hose clamps, and binder wire
Lay the two ground braids over the contact strip as shown. Fix the
braids in place with hose clamps. Apply a tinned copper wire double
binder around the cable, leaving tails at least 2 long as shown.
Flare the moisture-blocked ends of the ground braids
and place them on the ACS/CCS.
Punched
Contact
Strip
102
4. Install punched contact strip
Form the punched contact strip into a circular shape and position it
centrally around the ACS/CCS.
Ground Braid
Hose Clamps Binder
2
103
6. Cover hose clamps with mesh
Cover the hose clamps with 2-3 layers of 2 (50m) wide copper mesh
and tie off with a half-hitch..
Copper
Mesh
104
7. Apply paint
Apply tape (adhesive side up) on insulation 3/4 (20mm) from semi-
con cutback. The tape makes a straight edge for the 3/4 (20mm) of
exposed insulation.
Shake bottle of conductive paint for 30 seconds. Apply conductive
paint over insulation as shown and overlap semi-con shield by 1/2
(10mm). Do not splash paint on insulation between masking tape
and connector.
Allow paint to dry about 5 minutes, remove tape.
1/2"(10mm)
Conductive paint
3/4" (20mm)
3062a
PCN LR5237-000
Effective Date: August 8, 2013
PII 56394
Revision AC
4
8. Apply grease
Apply silicone grease. Cover 1/4 (6mm) of the conductive paint and
16 (405mm) of the insulation.
Allow paint to completely dry before applying grease.
Grease
16"
(405mm)
3063a
9. Position long black stress control tube; shrink in place
Butt the long black stress control tube against the ACS/CCS cutback,
with the arrow pointing down toward the cable jacket. Begin
shrinking at the ground end and work to the top of the tube.
Post-heat tube for about 30 seconds.
Longer Black Stress Control Tube
3064a
10. Apply red sealant
Apply red sealant at the lug end of the stress control tube using
only slight tension and a small overlap. Cover 1/2 (15mm) of the
stress control tubing and 1/2 (15mm) of the insulation to achieve a
smooth profile. Less than one full strip is sufficient.
1/2"(13mm)
Insulation
Overlap
1/2"(13mm) Stress Control
Tube Overlap
3065
Small Tube
2"(51mm)
3066
12. Position short stress control tube; shrink in place
Butt the stress control tube against the ACS/CCS cutback. Begin
shrinking at the ground end and work to the top of the tube.
Post heat tube for about 30 seconds.
Black Stress Control Tube
3067
11. Position short red or gray tube; shrink in place
Position tube 2 (50mm) from ACS/CCS cutback as shown. Begin
shrinking at the ground end and work to the top of the tube.
Post heat tube for about 30 seconds.
Any tube overlap at the conductor will be trimmed
later.
PCN LR5237-000
Effective Date: August 8, 2013
PII 56394
Revision AC
5
13. Apply red sealant
Apply red sealant at the lug end of the stress control tube using only
slight tension and a small overlap. Cover 1/2 (15mm) of the stress
control tubing and 1/2 (15mm) of the red tube to achieve a smooth
profile.
3/4"(19mm)
Red or gray
tube overlap 1/2"(13mm)
Stress control tube overlap
10a
14. Apply black mastic profile
Wrap two layers of black mastic profile one on top of the other, as
shown. Cut off excess profile material.
Two layers black
mastic profile
3-1/2"
(80mm)
3069
Two layers red sealant
6"
(152mm)
3070
15. Apply red sealant
Starting at the bottom edge of the stress control tube, apply two
layers of the red sealant over the previously applied sealant and
shield wires (or ground braid).
16. Position long red or gray tube; shrink in place
Position the long red or gray tube over the previously applied red
sealant.
Begin shrinking at the ground end and work to the top of the tube.
Preheat tube for two minutes.
Red or gray Tube
3071
17. Install connector
Choose the termination lug type (crimped or mechanical) to be
installed. For a crimped lug, continue with Step 18. For a mechanical
lug, go to step 22.
18. Crimped lug cut back tubing; install lug
When cool, trim excess red tube to insulation cutback to expose
conductor. Install, clean, and degrease cable lug.
3072
19. Chamfer tube and insulation
Chamfer the insulation to the diameter of the cable lug to achieve a
smooth transition.
Chamfer
3073
CHOICE 1
PCN LR5237-000
Effective Date: August 8, 2013
PII 56394
Revision AC
6
21. Position sealing boot; shrink in place
Position the sealing boot so that it covers the core and connector
equally and shrink it into place, starting at the lug end.
Go to step 26.
Sealing
boot
3075
Cut back
to insulation
Sealing sleeve
13
1 3
2 4
14
CHOICE 2
22. Mechanical lug cut back tubing, install lug
Cut back the tubing to match the cable insulation cutback.
Position the short sealing sleeve over the cable.
23. Insert conductor
Insert the conductor completely into the lug barrel hole. Tighten all
screws by hand. Tighten all screws with the right tool, according to
the sequence given in the drawing, until the screw heads shear off.
Apply supplied filler over the sheared bolts to obtain smooth finish.
Clean and degrease the cable lug.
20. Apply red sealant
Wrap red sealant around the insulation and cable lug. Fill up any
gaps between insulation and cable lug. Apply two layers of sealant
over the lug body.
Fill gaps
Red sealant
3074
24. For connections with cable lug diameter smaller than
cable core only
Wrap red mastic with slight tension around the insulation and
connector to achieve a smooth transition.
Red mastic
19
20
25. Preheat cable lug
Preheat the cable lug. Position the sealing sleeve so that it covers the
connector barrel. Shrink it into place, starting at the top.
PCN LR5237-000
Effective Date: August 8, 2013
PII 56394
Revision AC
7
27. Position skirts; shrink in place
Shrink the skirts into place according to the dimensions shown at
right.
This completes the termination.
(450mm)
17-3/4"
(90mm)
3-1/2"
Equispaced
3077
26. Apply spring clamp at end of outer red or gray tube
Remove copper wire binder.
At the edge of the red or gray tube wrap the spring clamp over the
tube similar to the figure at right. Attach the small copper braid as
shown. Fix in place with the metallic tie wrap. Attach both braids to
main grounding system.
1 2 3
3076a
The Information contained in these installation instructions is for use only by installers trained to make electrical power installations and is intended
to describe the correct method of installation for this product. However, TE has no control over the field conditions which influence product
installation. It is the users responsibility to determine the suitability of the installation method in the users field conditions. TEs only obligations
are those in TEs standard Conditions of Sale for this product and in no case will TE be liable for any other incidental, indirect or consequential
damages arising from the use or misuse of the products.
Raychem, TE Connectivity and TE connectivity (logo) are trademarks.
Copyright 2007, 2011, 2013 Tyco Electronics Corporation, a TE Connectivity Ltd. Company. All Rights Reserved.