11kV Manual For Jointing - Section+1+and+2

UK Power Networks
11kV Jointing Manual

2011
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UK POWER NETWORKS 11KV JOINTING MANUAL I 2011 Section Index I Page 1
CONTENTS
1
INTRODUCTION
2
JOINTING INSTRUCTIONS
2.1 Single Core Polymeric Straight Joints 4
2.1.1 EPN/LPN/SPN Single Core Straight Joints (Copper Wire Screen Cables) 4
2.1.2 EPN Single Core Straight Joints (Copper Wire Screen to Polylam Cables) 4
2.1.3 EPN Single Core Straight Joints (Polylam to Polylam Cables) 4
2.1.4 Cable Preparation 4
2.1.5 Installing Heatshrink Materials and Components 5
2.2 Triplex Polymeric Straight Joints 11
2.2.1 EPN/LPN/SPN Triplex Straight Joints (Copper Wire Screen Cables) 11
2.2.2 EPN Triplex Straight Joints (Copper Wire Screen to Polylam Cables) 11
2.2.3 EPN Triplex Core Straight Joints (Polylam to Polylam Cables) 11
2.3 Single Core/Triplex Polymeric Branch Joints 18
2.3.1 EPN/LPN/SPN Single Core/Triplex Branch Joints (Copper Wire Screen Cables) 18
2.3.2 EPN Single Core/Triplex Branch (Copper Wire Screen to Polylam Cables) 18
2.3.3 EPN Single Core (Three Polylam Cables) 18
2.4 Three-Core Transition Straight Joints (Polymeric to Paper) 26
2.4.1 EPN Triplex or Single Core Polymeric (CWS) to PILC Straight Joints 26
2.4.2 EPN Polylam to PILC Straight Joints 26
2.4.3 LPN/SPN Triplex or Single Core Polymeric (CWS) to PILC Straight Joints 27
2.4.4 SPN Triplex to PICAS Straight Joints 27
1.1 Safety, Health, Environment and Quality Statement 1
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2.4.5 EPN/LPN/SPN Triplex to Three-Core Polymeric Cable Joints 27
2.5 Three-Core Paper Cable Straight Joints (PICAS and PILC) 38
2.5.1 EPN PILC to PILC Straight Joints 38
2.5.2 LPN PILC to PILC Straight Joints 38
2.5.3 SPN PILC to PILC Straight Joints 39
2.6 Three-Core Paper Cable Vertical Straight Joints (PILC) 48
2.6.1 EPN/LPN/SPN Vertical Straight Joints (PILC) 48
2.7 Three-Core Transition Branch Joints (Polymeric to Paper) 60
2.7.1 EPN PILC Main with Triplex or Single Core Polymeric (CWS) Branch Joints 60
2.7.2 EPN PILC Main to Polylam Branch Joints 60
2.7.3 LPN/SPN PILC Main with Triplex or Single Core
Polymeric (CWS) Branch Joints 61
2.7.4 SPN PICAS Main with Triplex Branch Joints 61
2.7.5 EPN Triplex or Single Core Polymeric (CWS) Main PILC Branch Joints 62
2.7.6 EPN Polylam Main PILC Branch Joints 62
2.7.7 LPN/SPN Triplex or Single Core Polymeric (CWS) Main PILC Branch Joints 63
2.7.8 SPN Triplex Polymeric Main PICAS Branch Joints 64
2.7.9 Triplex or Single Core Polymeric Main with a Triplex or Single Core
Polymeric Branch Joints 64
2.7.10 EPN Polylam Main with a Polylam Branch Joints 65
2.7.11 EPN Polylam Main with Triplex or Single Core Polymeric Branch Joints 65
2.7.12 EPN Triplex or Single Core Polymeric Main with a Polylam Branch Joints 66
2.8 Single Core Polymeric Pot Ends 77
2.8.1 EPN/LPN/SPN Triplex or Three Single Core Pot End Joints (CWS Cables) 77
2.8.2 EPN Polylam Pot End Joints 77
2.9 Three-Core Paper Cable Pot Ends (PICAS and PILC) 83
2.9.1 EPN/LPN/SPN Three-Core PILC/PICAS Pot End Joints 83
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2.10 New Single Core Polymeric Indoor Terminations 91
2.10.1 EPN/LPN/SPN Triplex or Three Single Core Termination Kits (CWS Cables) 91
2.10.2 EPN Polylam Termination Kits 91
2.11 Single Core Polymeric Terminations in to Existing Compound End Boxes 96
2.11.1 Kit Selection Tables 96
2.11.2 EPN/LPN/SPN Triplex or Three Single Core Termination Kits (CWS Cables) 96
2.11.3 EPN Polylam Termination Kits 97
2.12 T1 Transformer End Box Terminations 102
2.12.1 EPN/LPN/SPN Triplex or Three Single Core Terminations
into T1 Transformer End Box 102
2.13 Single Core Polymeric Pole Terminations 108
2.13.1 EPN/SPN Triplex Pole Termination Kits (CWS Cables) 108
2.13.2 EPN Polylam Pole Termination Kits 108
2.14 13kA PILC Cable Earth Kit 113
2.14.1 LPN and SPN 13kA PILC Cable Earth Kit 113
2.15 Three-Core Loop and Transitional Loop Joints 120
2.15.1 EPN Transitional Loop Joint PILC to Triplex or Single Core Polymeric (CWS) 120
2.15.2 EPN Transitional Loop Joint PILC to Polylam 120
2.15.3 LPN/SPN Transitional Loop Joint PILC to Triplex or Single Core
Polymeric (CWS) 121
2.15.4 SPN Transitional Loop Joint PICAS Main to Triplex 121
2.15.5 EPN Polylam to Polylam Loop Joint 122
2.15.6 EPN PILC to PILC Loop Joint 122
2.15.7 LPN/SPN PILC to PILC Loop Joint 123
2.16 Polymeric Single Core Cable Sheath Repair Kit 133
2.16.1 EPN/LPN/SPN Polymeric Single Core Cable Sheath Repair Kit 133
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3.1 Single Core Copper Wire Screened Polymeric Cables 1
3.1.1 Removing the Outer Sheath 1
3.1.2 Removing the Bonded Polymeric Screen 3
3.1.3 Removing the Easy Strip Insulation Screen 6
3.1.4 Removing the Polymeric Insulation 8
3.2 Single Core Polylam Cables 9
3.2.1 Removing the Outer Sheath and Aluminium Foil Layer 9
3.2.2 Installing Cheese-Grater Earth Connection 10
3.2.3 Removing the Easy-Strip Insulation Screen 13
3.3 Three-Core Polymeric Cables 16
3.3.1 Removing the Outer Sheath 16
3.3.2 Preparation of Plastic Cable Sheath 17
3.3.3 Preparation of Steel Wire Armour (Steel Wire Armour Cables) 18
3.3.4 Preparation of Copper Wire Screen (Copper Wire Screened Cables) 21
3.3.5 Removing the Inner Bedding Layer 26
3.3.6 Removing the Fillers 27
3.3.7 Removing the Insulation Screen 27
3.4 PICAS Paper Insulated Corrugated Aluminium Sheathed Cables 30
3.4.1 Removing the Outer PVC Sheath 30
3.4.2 Removing the Bitumen Layer 32
3.4.3 Removing the Corrugated Aluminium Sheath 32
3.4.4 Preparation of PVC Sheath 33
3.4.5 Removing the Copper Woven Tapes (CWT) and Core Fillers 34
3.4.6 Removing the Insulation Screen (Screened Cables Only) 35
3.4.7 Removing the Conducting and Belt Papers 36
3.4.8 Removing the Insulation Papers 38
3.5 PILC Paper Insulated Lead Sheathed Cables 40
3.5.1 Removing the Outer Serving or Sheath 40
3.5.2 Preparation of Plastic Cable Sheath 41
3.5.3 Removing the Steel Wire Armour 41
3.5.4 Removing the Steel Tape Armour 43
3.5.5 Removing the Inner Bitumen Layer 44
3
STANDARD PROCEDURES FOR PREPARING
11KV AND 6.6KV MAINS CABLES
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3.5.6 Removing the Lead Sheath 46
3.5.7 Removing the Conducting and Belt Papers 47
3.5.8 Removing the Core Fillers from Belted Cables 49
3.5.9 Removing the Copper Woven Tapes (CWT) (Screened Cables Only) 50
3.5.10 Removing the Insulation Screen (Screened Cables Only) 50
3.5.11 Removing the Insulation Papers 52
3.6 Moisture Testing on Paper Insulated Cables 54
4
STANDARD PROCEDURES FOR INSTALLING
MATERIALS AND COMPONENTS
4.1 Installing Stress Control and Insulation Materials 1
4.1.1 Belted Paper Cables 1
4.1.2 Build-Up Kit for Small Section Paper Cables 5
4.1.3 Screened Paper Cables 6
4.1.4 Single Core Polymeric Cables in Single and Triplex Straight/Branch Joints 9
4.1.5 Single Core Polymeric Cables in Transitional Straight or Branch Joints 11
4.1.6 Single Core Polymeric Cable Terminations 15
4.1.7 Three-Core Polymeric Cables 20
4.2 Installing Mechanical Connectors and Lugs 22
4.2.1 Single Core and Triplex Straight Joints 22
4.2.2 Three-Core Transition and Three-Core PICAS/PILC Joints 24
4.2.3 Single Core Branch Joints 26
4.2.4 Three-Core Transition Branch Joints 30
4.2.5 Mechanical Lugs for Indoor and Outdoor Terminations 33
4.2.6 Mechanical Thimbles for use in T1 Transformer End Boxes 35
4.3 Installing Connector Stress Control and Heatshrink Insulation 36
4.3.1 Single Core and Triplex Straight/Branch Joints 36
4.3.2 Transition and Paper to Paper Straight Joints 39
4.3.4 3-Core Transition Branch Joints 46
4.3.5 Polymeric and Paper Pot End Joints 50
4.4 Installing Bushing Boots 55
4.4.1 Cold Applied Switchgear Boots 55
4.4.2 Heat Shrink Boots 58
4.5 Installing Mechanical Earth Bonds and Associated Components 60
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4.5.1 Single Core Straight Joints 60
4.5.2 Triplex Straight Joints 62
4.5.4 Triplex Cables into Transition Joints Using a Support Ring 66
4.5.5 Standard PILC Earth Steel Wire Armour Cables (EPN and Pot Ends Only) 69
4.5.6 PICAS Earth (SPN Only) 70
4.5.7 13kA PILC Earth Kit Steel Wire Armoured Cables (LPN and SPN Areas Only) 71
4.5.8 13kA PILC Earth Kit Steel Tape Armoured Cables (LPN and SPN Areas Only) 76
4.5.9 Installing Aluminium Cages 79
4.5.10 Connections of Earth Screens on Indoor and Outdoor Terminations 81
4.6 Fitting Plastic Joint Boxes 83
4.7 Mixing and Installing Polyurethane Resin 85
4.8 Mixing and Installing Gurufex 88
4.9 Removing Gurufex 88
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UK POWER NETWORKS 11KV CABLE J OINTING MANUAL I 2011 Section 1 I Page 1
This 11kV J ointing Manual covers the approved methods and associated jointing kits for use on
11kV and 6.6kV mains cables within UK Power Networks.
This 11kV J ointing Manual is split into four sections:
Section 1 Introduction and Safety, Health, Environment and Quality Statement
Section 2 J ointing Instructions
Section 3 Standard Procedures for Preparing 11kV and 6.6kV Mains Cables
Section 4 Standard Procedures for Installing Materials and Components
Every attempt has been made to cover all the types of joint required. If the joint that you are
required to make is not covered, refer either to the Craft Training Centres at Bury St Edmunds and
Sundridge or to Asset Management.
1.1 Safety, Health, Environment and Quality Statement
It is paramount that all jointing activities are carried out in strict compliance with all Safety, Health,
Environmental and Quality policies and procedures. It is not intended to list all the detailed
procedures and guidance that apply to jointing as they would quickly become out of date. This
is intended to highlight the overall requirements, details of which can be found in the UK Power
Networks Central Document Library (CDL).
The requirements of the Distribution Safety Rules and associated approved procedures
and codes of practice shall be followed at all times.
Appropriate Personal Protective Equipment shall be worn.
An on-site risk assessment shall be carried out using the UK Power Networks standard
on-site risk assessment sheet at the start of every job and reviewed at the start of every
subsequent day of the job.
Only approved materials shall be used. Materials and substances which have not been
assessed by UK Power Networks under its COSHH procedure shall not be used without
assessment.
Only approved tools designed for the type of cable shall be used, and the condition of these
shall be checked each day before use.
Only persons who have been trained and assessed to a level acceptable to UK Power
Networks may carry out jointing on the network owned by UK Power Networks. People
shall only carry out work for which they have the necessary skills and training.
Work may only be carried out in accordance with network procedures and, where
appropriate, the agreement of network control.
Work may only be carried out if an appropriate task or job instruction has been issued for
that work, unless the person concerned is specically authorised to issue such instructions
to them.
Only competent or authorised persons specically appointed to do so may carry out jointing
work, receive Permits to Work and carry out the operational activities associated with
jointing such as linking and fusing.
The work site shall be kept tidy. Environmental risks created by the work and disposal of
waste shall be managed in accordance with UK Power Networks Environmental procedures.
1 I NTRODUCTI ON
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All jointing works shall be carried out in accordance with this manual and other guidance
issued by UK Power Networks.
All work carried out shall be recorded in the approved manner and details returned for
inclusion on the records management system.
Any incidents or near misses that occur, and any hazards that come to light shall be
reported to the AIRline reporting system.
This section is intended only as a summary of HSS requirements. Persons carrying out jointing
works on the network, shall ensure they are up to date with all relevant HSS procedures and
guidance before carrying out work. If in doubt, ask.
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This section contains a complete list of jointing instructions and kit selection tables for all 6.6kV and
11kV joints.
Only joints contained within this section are to be used in UK Power Networks. No other
joint kits or combinations of joint kit shall be used without the approval of UK Power
Networks Asset Management.
To simplify the kit selection tables only metric cable sizes are used. To convert from imperial to
metric conductor sizes refer to the comparison table below:
All sizes apply to both copper and aluminium conductor sizes.
2 J OI NTI NG I NSTRUCTI ONS
Imperial Conductor
Size (sq. in)
Metric Equivalent
Conductor
Size (sq. mm)
0.007 4
0.0225 16
0.04 25
0.06 35
0.1 70
0.15 95
0.2 120
0.25 150
0.3 185
0.4 240
0.5 300
For advice on the jointing of equivalent cable sizes, refer to your supervisor or engineer and
the contents of EDS 02-0027 11kV Triplex Cables.
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2.1 Single Core Polymeric Straight Joints
The tables below detail the joint kits required to complete this joint for the cable sizes listed. Any
jointing requirements for cable sizes not shown here shall be referred to one of the UK Power
Networks J ointing Schools.
2.1.1 EPN/LPN/SPN Single Core Straight J oints (Copper Wire Screen Cables)
2.1.2 EPN Single Core Straight J oints (Copper Wire Screen to Polylam Cables)
2.1.3 EPN Single Core Straight J oints (Polylam to Polylam Cables)
2.1.4 Cable Preparation
Refer to the following sections of this manual for details of the preparation of each type of cable:
3.1 Single Core Copper Wire Screened Polymeric Cables.
3.2 Single Core Polylam Cables.
Cable Sizes
mm
2
J oint Kit Description and Part Numbers
Single Core Straight J oint
35 to 95mm
2
150 to 300mm
2
Tyco Part No. SMOE 63401 SMOE 63402
Stores Code 04100A 04101K
70 95 70 95 1 per Phase
150 300 150 300 1 per Phase
Cable Sizes
mm
2
150-300mm
2
Polylam Earth Kit
Stores Code 04101K 04108D
Triplex Polylam
95 300 150 240 1 per Phase 1 for 3 Phases
Cable Sizes
mm
2
150-300mm
2
Polylam Earth
Kit
Stores Code 04101K 04108D
150 240 150 240 1 per Phase 2 for 3 Phases
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2.1.5 Installing Heatshrink Materials and Components
Refer to the following sections of this manual for the installation of heatshrink materials and other
components:
4.1 Installing Stress Control and Insulation Materials.
4.1.4 Single Core Polymeric Cables in Single and Triplex Straight/Branch J oints.
4.2 Installing Mechanical Connectors and Lugs.
4.2.1 Single Core and Triplex Straight J oints.
4.3 Installing Connector Stress Control and Heatshrink Insulation.
4.3.1 Single Core and Triplex Straight/Branch J oints.
4.5 Installing Mechanical Earth Bonds and Associated Components.
4.5.1 Single Core Straight J oints.
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Installation Instruction

11kV Single Core XLPE Straight Joint

For Cable Sizes: 35-95mm
2

SMOE 63401
UK Power Networks Stores Code 04100A
2

SMOE 63402
UK Power Networks Stores Code 04101K

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Cable Overlap
Overlap the cables as shown in Figure 1.
Mark the reference line.
1
Cable Preparation
Remove the oversheath to dimension shown in Table 1.
Clean the remaining oversheath for about 1m.
Bend back the shield wires onto the oversheath.
Fix the ends of the shield wires temporarily in place.
2
Core Preparation
Cut the cores at the reference line using a hacksaw
(refer to Table 1).
Thoroughly remove the core screen to the dimensions given
in the drawing, so that the insulation surface is free from all
traces of conductive material.
Clean and degrease the insulation.
Note: Do not nick the insulation
reference line
reference line
a
a
500
Measure the conductor bore depth of the connector and
remove the insulation on both cores equal to the insert depth
l (refer to Table 1).

4
l
l
3
40
a
reference line
insulation
core screen
50
Table 1 Dimensions in mm
Cable Size mm
2
a I
35 to 95 140 30
150 to 300 170 60
5
20 10
Take the yellow void filling strip from the aluminium foil
packet. Remove the release papers from the strip with the
pointed ends.
Wrap the void filler around the core screen starting 20mm
from the end of the screen and continue onto the insulation
for 10mm.
Stretch the strip to half of its original width and apply under
tension to achieve a fine thin edge.
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Completion of Joint

Slide a combined tubing set over one XLPE cable core.
1 - Black and red screened insulation sleeve.
2 - Black outer sleeve.
Slide the black stress control tubing over the XLPE cable
core level with the end of the insulation cut back. Shrink
down starting from the insulation cut back before working
towards the oversheath as shown in drawing.
Fit the conductors into the connector. There should be no
gap left between the connector and the insulation.
Take up the tension equally on all bolts (do not shear bolt
heads at this stage).
Starting at the connector ends, tighten the bolts until the
heads shear off.
In the case of a proud edge showing after removal of the
bolts, this edge should be removed with a suited tool.
Re-align cables if necessary.
Note: If required (small cross sections) use a connector
holding tool avoiding conductor bending.
9
6
Installation of Mechanical Connector
The connector is supplied with insert half shells or
centralising rings, which have to be used on small
cross sections.
Check before installation if the conductor fits the
centralising ring or if it is insertable into the connector with
the half shells installed. The fit of the centralising rings is tight
and requires complete insertion.
8
insert shells
7
2 1
10
Clean and degrease the cable cores and the connector.
Fill the bolt holes with Raychem clay to obtain a smooth
finish.
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Remove the release paper from the black stress grading
patch. Position the patch centrally over the connector area.
Note: In the case of a rectangular patch apply the long side
across the connector.
Wrap the patch over the connector area starting at the
connector bolts.
Note: Do not stretch the patch.
Position the black and red screened insulating sleeve
centrally over the connector area.
a. Start shrinking the sleeve in the centre (1).
b. Continue shrinking by working towards one side (2),
stopping 50mm from the end.
Shrink the other half in the same way (3).
c. Shrink down the first end (4) and finally the second (5).
The sleeve should be fully shrunk without leaving
ridges.
Cable side with long shield wires:
Bend the shield wires back over the joint area. Form the
shield wires into two equal groups.
Cable side with the short shield wires:
Bend the shield wires back over the joint area close to the
copper mesh.

Gather the wires together and cut them centrally above the
50mm copper mesh overlap on the cable oversheath.
11
Starting with a 50mm overlap onto the oversheath of the ca-
ble side with the short shield wires, wrap one layer of copper
mesh round the joint with a 50% overlap.
13
50
Copper mesh
14
50
cut
b
50
2 3 4 5
c
12
a
1
15
Form two earth leads of the shield wires and insert into the
mechanical shield connectors supplied.
Tighten the bolts until the heads shear off.

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J oint completed.
Allow the joint to cool before applying any mechanical strain.
18
Clean and degrease the ends of the oversheath for a length
of about 150mm.
Centre the black outer sleeve over the copper mesh area.
Start shrinking in the centre, working towards the ends.
17
2
Wrap a second layer of copper mesh round the joint with a
50% overlap. Cover the complete joint area including the
mechanical shield connector.

16
Copper mesh
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2.2 Triplex Polymeric Straight Joints
jointing requirements for cable sizes not shown on this table shall be referred to one of the UK
Power Networks J ointing Schools.
2.2.1 EPN/LPN/SPN Triplex Straight J oints (Copper Wire Screen Cables)
Cable Sizes
mm
2
Triplex Straight J oint
35-95mm
2
150-300mm
2
Stores Code 04102U 04103E
70 95 70 95 1 per J oint
150 300 150 300 1 per J oint
Resin Volume 6.0 Litres
2.2.2 EPN Triplex Straight J oints (Copper Wire Screen to Polylam Cables)
Cable Sizes
mm
2
35-95mm
2
150-300mm
2
Polylam Earth Kit
Tyco Part No. SMOE 63403 SMOE 63404 SMOE 63409
Stores Code 04102U 04103E 04108D
Triplex Polylam
70 300 150 240* 1 per J oint 1 for 3 phases
Resin Volume 6.0 Litres 6.0 Litres
2.2.3 EPN Triplex Core Straight J oints (Polylam to Polylam Cables)
Cable Sizes
mm
2
35-95mm
2
150-300mm
2
Polylam Earth
Kit
Stores Code 04102U 04103E 04108D
150 240 150 240 1 per J oint 2 for 3 phases
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Refer to the following sections of this manual for the cable preparation details:
components:
4.3.1 Single Core and Triplex Straight/Branch J oints.
4.5.2 Triplex Straight J oints.
4.6 Fitting Plastic J oint Boxes.
4.7 Mixing and Installing Polyurethane Resin.
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11kV Triplex XLPE Straight Joint

2

SMOE 63403
UK Power Networks Stores Code 04102A
2

SMOE 63404
UK Power Network Stores Code 04103E

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Cable Overlap
Overlap the cables to be jointed by 200mm.
Mark the reference line.
Core Preparation
Cut the cores at the reference line using a hacksaw (refer to
Table 1).
Thoroughly remove the core screen to the dimensions given
in the Figure 3, so that the insulation surface is free from all
traces of conductive material.
Note: Do not nick the insulation!
3
Remove the insulation from both cores equal to the insert
depth l (refer to Table 1).

4
l
l
40
a
reference line
insulation
core screen
1
reference line 200
200
a
a
2
Stripping Dimensions
Carefully remove the cable oversheath to the dimension a shown in the Table 1 below. Degrease the outer cable sheaths for
a distance of 200mm.
Table 1 Dimensions in mm
Cable size mm
2
a I
35 to 95 140 30
150 to 300 170 60
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5
Completion of Joint

Slide the black and red screened insulation sleeve over one
of the XLPE cable core.

Check that these tubes are in place before fitting the
mechanical connector.

7
Slide the black stress control tubing over the XLPE cable
core level with the end of the insulation cut back. Shrink
down starting from the insulation cut back before working
towards the oversheath as shown in drawing.
6
9
Take the yellow void filling strip from the aluminium foil
packet. Remove the release papers from the strip with the
pointed ends.
Wrap the void filler around the core screen starting 20mm
from the end of the screen and continue onto the insulation
for 10mm.
Stretch the strip to half of its original width and apply under
20 10
The connector is supplied with insert half shells or
centralising rings, which have to be used on small
cross sections.
Check before installation if the conductor fits the
centralising ring or if it is insertable into the connector with
the half shells installed. The fit of the centralising rings is tight
and requires complete insertion.
8
insert shells
Fit the conductors into the connector. There should be no
gap left between the connector and the insulation.
Take up the tension equally on all bolts (do not shear bolt
heads at this stage).
Starting at the connector ends, tighten the bolts until the
heads shear off.
In the case of a proud edge showing after removal of the
bolts, this edge should be removed with a suited tool.
Note: If required (small cross sections) use a connector
holding tool avoiding conductor bending.
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b
50
2 3 4 5
c
11
12

13
Form the copper wire screens into two groups and connect
them together using the mechanical connector. Position the
connector in the gap between two insulating sleeves.
a
Bring all three cables together in trefoil formation. Wrap two
layers of tinned copper mesh around all three cores.
1
10
14
Clean and degrease the cable cores and the connector.
Fill the bolt holes with Raychem clay to obtain a smooth
finish.
Remove the release paper from the black stress grading
patch. Position the patch centrally over the connector area.
Note: In the case of a rectangular patch apply the long side
across the connector.
Wrap the patch over the connector area starting at the
connector bolts.
Note: Do not stretch the patch.
centrally over the connector area.
a. Start shrinking the sleeve in the centre (1).
b. Continue shrinking by working towards one side (2),
c. Shrink down the first end (4) and finally the second (5).
The sleeve should be fully shrunk without leaving
ridges.
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Fit and support the plastic shell, seal the ends using the
mastic provided with the kit.

Mix the resin following the manufacturers instructions and
fill the joint.

16
Degrease the cable oversheaths and wrap the centre of the
joint with the rubber sheet at the shell stand off position,
adhesive side outwards.
Flame brush the cable oversheaths for a distance of
100mm.

15
50
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2.3 Single Core Polymeric Branch Joints
The tables below detail the joint kits required to complete this joint for the cable sizes listed. This
joint is primarily to be used as a single core repair joint. Any jointing requirements for cable sizes
not shown on this table shall be referred to one of the UK Power Networks J ointing Schools.
2.3.1 EPN/LPN/SPN Single Core Branch J oints (Copper Wire Screen Cables)
2.3.2 EPN Single Core Branch (Copper Wire Screen to Polylam Cables)
2.3.3 EPN Single Core (Three Polylam Cables)
Cable Sizes
mm
2
Single Core Branch J oint
95-150mm
2
185-300mm
2
Stores Code 04104P 04105Y
95 150 95 150 1 per Phase
95 185 300 1 per Phase
150 300 185 185 1 per Phase
Cable Sizes
mm
2
95-150mm
2
Single Core Branch
J oint
185-300mm
2
Polylam Earth Kit
Stores Code 04104P 04105Y 04108D
Triplex Polylam
95 150 150 1 per Phase 1 for 3 Polylam
ends
185 300 150 240 1 per Phase 1 per Phase 1 for 3 Polylam
ends
Cable Sizes
mm
2
95-150mm
2
Single Core Branch
J oint
185-300mm
2
Polylam Earth Kit
Stores Code 04104P 04105Y 04108D
150* 150* 1 per Phase 1 per J oint
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Refer to the following sections of this manual for the preparation of each cable type:
components:
4.2.3 Single Core Branch J oints.
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11kV Single Core XLPE Branch Joint

2

SMOE 63405
UK Power Networks Stores Code 04104P
2

SMOE 63406
UK Power Networks Stores Code 04105Y

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Cable Overlap
Overlap the branch cable by about 300mm.
Mark the reference line on the cable.
Cut the main cable at the reference line.

1
300
reference line
2
dimensions in mm
reference line
60
60
160
160 60 60
core screen
oversheath
shield wires
All Cable Ends
Remove the release paper from the short lengths of yellow
void filling mastic with the pointed end, wrap it around the
core starting 20mm from the end of the screen and
continuing onto the insulation for 10mm. Stretch the
mastic to half of its original width and apply under tension to
achieve a thin edge on the insulation.
3
10 20
Cable Preparation
Remove the oversheaths to the dimensions given in the Figure 2, measured from the reference line.
Clean all the remaining oversheaths for about 800mm on both cable sides.
Fold back the copper wires and hold the ends in place with PVC tape.
Cut the branch cable at the reference line. Remove the core screen to the dimensions given in the Figure 2, so that the insu-
lation surface is free from all traces of conductive material. Remove the insulation to the dimension given in Figure 2.
Note: Do not nick the insulation.
STRESSCONTROL
Position the black stress control tubing level with the
insulation cutback. Shrink the tubing into position starting at
the insulation cutback before working towards the
oversheath as shown in Figure 4.
4
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Single Cable Side Only
Position the red insulation build up sleeve level with the end
of stress control tubing. Shrink the tubing into position,
starting at the insulation cutback before working towards the
oversheath as shown in Figure 5.
5
Completion of Joint

Slide the combined tubing set and the outer sleeve over the
single cable end.
The plastic bag of the tubing set can be used as additional
protection by placing it under the tubing set.

1. Black stress control tubing.
2. Black and red screened insulating sleeve.

Check that these tubes are in place before fitting the
mechanical connector.

6
Insert the black rubber profile (1) and the red mastic profile
(2) between the cores. Position the red mastic profile so that
it is level with the insulation cutback as shown in Figure 7.
The black rubber profile must butt up against the red mastic
profile.
7
2 1
1 2

Install the conductors in to the mechanical connector. The
insulation cutback must butt on the connector body. Tighten
the bolt set alternatively in several steps, starting with the
outer bolts, until the heads shear off.

Note: In the event of a proud edge showing after removal
of the bolt heads, this edge should be removed.
9
The connector is supplied with a centralising insert for use
on smaller cross sections on the single cable side. Check if
the conductor will fit through the hole in the plastic insert
provided with the connector.
If the conductor fits through the hole in the insert place it into
the single cable bore of the connector. The insert is not
required if it does not fit the conductor. The fitting is tight and
requires complete insertion.
8
insert
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Remove one release paper from the long yellow void filling
mastic strip and roll it up. Starting from the single core side,
wrap it around the core with a 50% overlap. The mastic
should be stretched to about half of its original width and
applied under tension.
Carefully fill all gaps. Continue across the connector.
11
Apply a total of two thin layers of yellow void filling mastic
over the connector, forming a smooth profile between the
end of the stress control tubing on the single core side and
the red mastic profile on the other side. Overlap the stress
control tubing and the red mastic profile for 5mm.
Lubricate the void filling mastic with the silicone tissue
provided.
12
Fill each of the remaining holes with clay to obtain a smooth
finish.
10
clay
150
a b
c
d
1
2
3 4
Pull the black stress control tubing from inside the tubing set
and position it with 10mm overlap of the rubber profile.
Start shrinking from the branch cable side working towards
the single core side.
The tubing should be fully shrunk and wrinkle free.
13
centrally over the stress control tube.
a. Start shrinking the sleeve in the centre over the
connector (1). Shrink carefully and slowly.
b. Check if fully shrunk down, preferably by looking
inside from the single core end. No gap should be
visible around the connector.
c. Continue slowly shrinking by working towards the
single core end (2) stopping 150mm from the end.
Then slowly shrink the other side completely (3).
d. Finally shrink down the second end (4). The sleeve
should be fully shrunk without leaving ridges.
14
Check
Attention! It is important to shrink slowly and to use
plenty of heat whilst following the steps below.
10
1
2
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Starting from the branch side, apply the tinned copper mesh
with a 50% overlap. around the previously installed tube, so
that the whole joint is covered.
15
Bend the copper wires back over the joint area and cut the
wires of the main cable to the required length.
On the single core side insert the shielding wires into the
mechanical connector and tighten the bolts finger tight.

For small section branches, check that the size of long
length of copper wire screen, matches the size of the copper
wire screen on the main.
16
On the branch side insert main and branch wires into the
second mechanical connector.
The copper wires of the branch cable should extend beyond
the first connector.
Tighten the bolts finger tight.
17
Cut the copper wires of the branch cable to the required
length and insert them in the first connector.
Tighten the bolts on both connectors until the heads shear
off to provide the earth connection.

18
Degrease the cable oversheaths.
Flame brush the oversheaths until they have a shiny
appearance for a distance of 100mm.
19
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b
c c
a
b
Offer the bottom of the plastic joint shell up to the joint .
Mark on the tinned copper mesh the centre of the stand off
positions in the shell. Wrap the rubber strips around the joint
on top of the previously marked positions, sticky side out.

20
a. Assemble the joint half shells around the joint and clip
together.
b. Fill any gaps around the cable entry holes as required.
c. Fill the joint with the approved resin following the
manufacturers instructions and safety data sheet.
The joint is now complete. Allow the resin to set before
applying any mechanical strain.
21
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Cable Sizes
mm
2
J oint Description and Part Numbers
Three Core Transition
Straight J oint
95-185mm
2
Straight J oint
240-300mm
2
PILC Build Up Kit
16-70mm
2
Stores Code 04120S 04121C 04125R
PILC POLY
16 70 95 1 per J oint 1 per J oint
95 185 95 185 1 per J oint
240 300 240 300 1 per J oint
Cable Sizes
mm
2
Three Core
Transition
Straight J oint
95-185mm
2
Three Core
Transition
Straight J oint
240-300mm
2
PILC Build Up Kit
16-70mm
2
Polylam Earth
Kit
Tyco Part No. SMOE 63410 SMOE 63411 SMOE 63429 SMOE 63409
Stores Code 04120S 04121C 04125R 04108D
PILC POLY
16 70 150 1 per J oint 1 per J oint 1 per J oint
2.4 Three Core Transition Straight Joints (Polymeric to Paper)
2.4.1 EPN Triplex or Single Core Polymeric CWS to PILC Straight J oints
2.4.2 EPN Polylam to PILC Straight J oints
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2.4.3 LPN/SPN Triplex or Single Core Polymeric CWS to PILC Straight J oints
Cable Sizes
mm
2
Three Core
Transition
Straight J oint
95-185mm
2
Three Core
Transition
Straight J oint
240-300mm
2
13.1kA Earth Kit PILC Build Up
Kit
16-70mm
2
Stores Code 04120S 04121C 04124G 04125R
PILC POLY
95 95 1 per J oint
240 300 240 300 1 per J oint 1 per J oint
Cable Sizes
mm
2
Three Core
Transition
Straight J oint
95-185mm
2
Three Core
Transition
Straight J oint
240-300mm
2
Stores Code 04120S 01421C
PICAS POLY
95 185 95 185 1 per J oint
300 300 1 per J oint
Cable Sizes
mm
2
Straight J oint
95-185mm
2
Straight J oint
240-300mm
2
Three Core Poly
Conversion Kit
Stores Code 04120S 01421C 04134Q
Triplex POLY
2.4.4 SPN Triplex or PICAS Straight J oints
2.4.5 EPN/LPN/SPN Triplex to Three Core Polymeric Cable J oints
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3.3 Three Core Polymeric Cables.
3.4 PICAS Paper Insulated Corrugated Aluminium Sheathed Cables.
3.5 PILC Paper Insulated Lead Sheathed Cables.
components:
4.1.1 Belted Paper Cables.
4.1.2 Build Up Kits for Small Section Paper Cables.
4.1.3 Screened Paper Cables.
4.1.5 Single Core Polymeric Cables in Transitional Straight/Branch J oints.
4.1.7 Three Core Polymeric Cables.
4.2.2 Three Core Transition and Three Core PICAS/PILC.
4.3.2 Transition and Paper to Paper Straight J oints.
4.5 Installing Mechanical Earth Bonds and Associated Components
4.5.4 Triplex Cables into Transition J oints Using a Support Ring.
4.5.5 Standard PILC Steel Wire Armour Cables.
4.5.6 PICAS Earth.
4.5.7 13kA PILC Earth Kit Steel Wire Armoured Cables.
4.5.8 13kA PILC Earth Kit Steel Tape Armoured Cables.
4.5.9 Installing Aluminium Cages.
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Instal lati on Instruction

11kV Three Core Transition Straight Joint

2

SMOE 63410
UK Power Networks Stores Code 04120S
2

SMOE 63411
UK Power Networks Stores Code 04121C

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belt papers/fabric tape
Cable Overlap

Plastic Cable with Copper Wire Screen
Overlap the cables to be jointed by about 200 mm. Mark the
reference line.

Strip the cables to the dimensions given below.
reference line
200
Pol ymeri c
Pl astic
lead sheath
wire amour
reference line
core screen
wire screen
60 140
20
200
b
220
40
PICAS Cabl e, screened
belt paper / fabric tape
Paper
Pol ymeri c
Pl astic
metal sheath
oversheath
140
20
c
220
40
PILC Cable, Steel Wire or Tape Armoured
a
b
Table 1
Conductor size Cut-back dimensi ons given below
mm a b c
95 - 500 300 450
- 300 550 350 490
Paper
oversheath
For three core pol ymeri c cabl es use the 185 to 300mm joint and
the paper cable dimensions below.
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The 13A earth clip may need to be installed at thi s
stage of the joint

Paper Cables

Remove the armours according to the dimensions shown in
the drawing on the previous page. Stand the armour wires
upright and remove all traces of compound from them and
the cable lead sheath. Thoroughly clean and abrade the lead
sheath for 200mm from the cable armour.
1
Wrap the short length of tinned copper mesh around the lead
sheath so that its edge just protrudes beyond the armour
wires when they are laid back down.
2
Relay the armour wires over the mesh and secure with a
worm drive clip.
3
4B
Belted Paper Cables
Tie a twine binder around the carbon paper 5mm from the
end of the lead sheath and tear the layers of paper off
against. Tie a second twine binder around the belt papers
20mm from the end of the metal sheath and tear off the belt
papers against it. Remove the fillers level with the belt
papers. Secure the paper insulation at the end of each core
using PVC tape. Using a clean, dry cloth, remove any excess
cable compound from the cores.
4A
Screened Paper Cables
Unwind the copper woven fabric tape and remove the fillers.
Rewind the tape around the crutch of the cable and tie it off
20mm from the end of the metal sheath.
Tie a twine binder around the screen papers at the
dimension given in the Figure 4B. Tear off the screen papers
level with the twine binder. Remove the top two paper tapes
to the same position as the screen papers. Using a clean, dry
cloth, remove any excess cable compound from around the
cores.

tape binder
5
20
20
reference line
180
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Three Core Pol ymeric Cables
Remove the semi conducting screen layer from the insulation
to the dimension shown in Figure 4C using approved tools
and jointing techniques. Do not nick the insulation layer.

4C
reference line
180
7
6
8
40 20
20 10
50
5
Push the yellow mastic wedge carefully into the crutch until
the tip is just below the belt paper or fabric tape. The wedge
will deform and partly extrude between the cores.

Slide the red insulating tubes over the cores on each cable
end, pushing then well down into the crutch.

Shrink the tubes, starting from the crutch and working
towards the core ends. Ensure that the tubes are shrunk
down evenly and are free from air or grease pockets.

For cable sizes below those shown in Table 1, the core tubes
should be substituted for those in the build up kit.

Remove the release paper from a 400mm yellow mastic tape
strip. Wrap the tape around the crutch, overlapping onto the
lead sheath by 20 mm and continue onto the red insulating
tubes for 20mm. Wrap a second strip of the yellow mastic
over the first layer. The mastic tape should be stretched to
half its original width and applied under tension.

Screened Paper Cables Onl y
Cut a 50mm long piece from the yellow void filling mastic
tape as shown in Figure 5.
Wrap the yellow mastic around the screen papers starting
20mm from the end of the screen and continuing onto the
insulation for 10mm.
Stretch the mastic to half its original width and apply under
Note: The yellow mastic should be applied in the same
direction as the lay of the screen papers.
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Position the red crutch sealing sleeve centrally over the
yellow void filling mastic tape and shrink into position.

Note: For cable sizes below 95mm
2
,the crutch sealing sleeve
should be substituted for that in the PILC cable build up kit.
9
Seal ant Tape
Wrap one layer of red sealant tape around the cable
oversheath for 60mm from the sheath cut with slight tension
and a one third overlap.
Screen Wires
Bend the screen wires back onto the red sealant tape
ensuring the wires are straight and do not cross. Use a wire
binder to keep them tight against the red sealant tape.

Semi Conducting Layer
to the dimension shown in Figure 13 using approved tools
and jointing techniques. Do not nick the insulation layer.

Insulation
Remove the insulation to the internal depth of the connector,
dimension L in the drawing.

Single Core XLPE Sheath Removal
Lay the single core XLPE cables in to their final jointing
position.
Mark the reference line and cut to length. Slide the large
support ring over all three single core cables. Carefully
remove the oversheaths.
Thoroughly degrease the outer cable sheath for a distance of
200mm from the sheath cut.

11
60
10
200
Moisture Seal
Wrap one layer of red sealant tape over the previously
applied 60mm red tape to sandwich the screen wires to form
a moisture seal. Continue onto the semi-conducting layer for
15mm. Degrease the insulation.

13
60 15
12
40
L
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14
30
Stress Relieving Tape
Remove one release paper from the short pointed yellow
void filling mastic strips. Starting 20mm on the semi-con
layer, continue taping on to the insulation for 10mm to form a
smooth taper. Stretch the tape to approx. half its original
width and apply under tension to ensure a smooth fine edge.
Remove the second release paper during this taping
operation.

Connector Installation
Reset the cores into their final jointing position.
Ensure that conductors have been cut to allow for the
moisture block in the centre of the connector.
Screw the shear head bolts into the connector body until the
tip is level with the inside surface of the connector

Note: The bolts should not be removed once they have been
screwed into the connector.
Position the connector on the short side of the joint and
tighten the shear head bolts, until they are finger tight.
The connectors should be positioned with the bolt heads
facing away from the centre of the joint.

Note: Do not remove the centre fixing bolt at this time.

Hold the connector with the recommended holding tool and
tighten the two shear head bolts sequentially until they shear
off.
16 reference line
shear head bolts
shear head bolts
holding tool
17
Remove the centre fixing bolt and position the other half of
the connector onto the corresponding core on the long side
of the joint.

At this time do not tighten the shear head bolts.
18
Core Tubing
Position the red core tubing over the cable core so it is level
with the end of the insulation cutback. Shrink down starting
from the cutback before moving towards the oversheath.

Using plastic tape or poly bags, cover the single core cables
beyond the red BPTM tubes and park the black and red
insulation tubes over them. Cover the tubes to protect them
from dust or moisture splashes.

Note: If the insulating tubes are a tight fit over the red BPTM
tubing, lubricate the tubing with a smear of silicone grease
from the sachet provided.

15
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19
holding tool
Bring the two halves of the connector together and insert the
centre fixing bolt.
Finger tighten the centre fixing bolt to join two V shapes
together.
Hold the connector with the recommended connector holding
tool and tighten the two shear head bolts sequentially until
they shear off.
Hold the connector with the recommended connector holding
tool and tighten the centre fixing bolt until it shears off.

Repeat this procedure for all connectors.
holding tool
20
Clean and degrease the ends of the red insulating tubing and
the connector. Remove one release paper from the yellow
mastic patch and wrap it around the connector. Apply the
patch centrally over the connector, taking care to exclude air
voids as it is applied.
Ensure the patch seam is located over the bolts of the
mechanical connector. Repeat the procedure on the
remaining connectors.
Leave the release papers in position until all three patches
are in place.
22
Remove the release paper from all three connectors.
The surplus yellow patch material extending over the
connector ends should be folded back and used to fill up the
steps between the core and connector body.
21
yellow mastic
Position the red and back screened insulation sleeves
centrally over the connectors.
Start shrinking the sleeves in the centre.
23
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50
check
a
b
c
d
1
2 3
4 5
24
a. Shrink the sleeves in the centre (1).
b. Check if fully shrunk by twisting the sleeve ends. The
sleeves should not move from its position. If the sleeve
rotates continue shrinking until it locks in place.
c. Continue shrinking by working towards one side (2),
stopping 50mm from the end. Shrink the other half in the
same way (3).
d. Shrink down the first end (4) and finally the second (5).
The sleeves should be fully shrunk without leaving ridges.
Fold the 1050mm length of tinned copper mesh in half for its
full length, so that its width is reduced to 30mm.
Wrap two layers of the copper mesh around the edge of the
support ring. Lay all the copper wires of the single core
cables on to the copper mesh. Continue to wrap the copper
mesh over the copper wires, clamp the copper mesh and
wire down on to the support ring, tap and tighten as the worm
drive is tightened, and trim off the excess copper wires.
Clean and degrease the space between the cage fingers and
the copper mesh. Using the red mastic tape, wrap it in the
space on the support ring.
28
Pol ymeric Cables
Form the 300mm length of the serrated contact strip into a
circle and position it on to the support ring edge, nearest to
the body of the joint. Slide the support ring along the cables
until the screen fingers cover the full width of the contact
strip. Use one worm drive clip only and clamp down the
fingers of the screen on to the contact strip. Remove any
excess clip length once fully tightened.

Note: Lightly tap the fingers of the aluminium cage while
tightening.
27
Metallic Earth Screen Connections
Fold the length of tinned copper mesh in half along its length.
Wrap the mesh around the lead sheath behind the black
cable breakout. Trim the length of contact strip to fit around
the sheath and secure. Fit the metallic cage centrally around
the joint, apply a temporary tape binder around the centre,
ensuring the overlap along the cage length remains equal.
Position the cage fingers over the contact strop and secure
with the worm drive clip.

Alumi nium Sheaths
Discard the tinned copper mesh. Position the serrated strip
over two adjacent crests.
26
Pull the cores together so that the black and red screened
insulation sleeves are in close contact with each other.
Wrap the length of tinned copper mesh around all three
sleeves and secure.

Post heat the joint at the crutch positions.
25
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29
Paper Cable Moisture Seal
Clean and degrease the metallic sheath.
Wrap the remaining space, approximately 60mm, between
the armours and the cage with two half lap layers of red
mastic sealant tape.
This is an important moisture seal do not leave it out.

c c b b
a
30
31
rubber patches
Degrease and flamebrush the MDPE oversheaths for a
distance of 100mm.
Trim the ends of the joint shell halves to accommodate the
cable being used. Place the bottom half of the joint shell
under the joint and mark the position of the two stand-off
mouldings on the earth cage.
Wrap a rubber patch around the cage centrally over these
marks and secure. The patch should be wrapped with the
white adhesive side facing outwards.
a. Assemble the joint shells around the joint and clip
together.
Support the joint before filling with resin.
manufacturers instructions and safety data sheet.

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2.5 Three Core Paper Cable Straight Joints (PICAS and PILC)
2.5.1 EPN PILC to PILC Straight J oints
2.5.2 LPN/SPN PILC to PILC Straight J oints
Cable Sizes
mm
2
PILC/PICAS
Straight J oint
95-185mm
2
PILC/PICAS
Straight J oint
240-300mm
2
PILC Build Up Kit
16-70mm
2
Stores Code 04131L 04132V 04125R
16 70 16 70 1 2
70 95 1 1
95 185 95 185 1
185 300 240 300 1
Cable Sizes
mm
2
PILC/PICAS
Straight J oint
95-185mm
2
PILC/PICAS
Straight J oint
240-300mm
2
13.1kA Earth Kit PILC Build Up
Kit
16-70mm
2
Stores Code 04131L 04132V 04124G 04125R
70 70 1 2
70 95 1 1
95 95 1
95 120 1 1
120 185 120 185 1 2
185 300 240 300 1 2
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2.5.3 SPN PICAS to PICAS Straight J oints
components:
4.1.2 Build-Up Kits for Small Section Paper Cables.
4.2.2 Three Core Transition and Three Core PICAS/PILC.
4.5.6 PICAS Earth.
Cable Sizes
mm
2
PILC/PICAS
Straight J oint
95-185mm
2
PILC/PICAS
Straight J oint
240-300mm
2
Stores Code 04131L 04132V
95 95 185 1
95 300 1
185 185 1
185 300 300 1
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11kV PILC / PICAS Strai ght Joint

For Cable Sizes 95-185mm
SMOE 63417
UK Power Networks Stores Code = 04131L
SMOE 63418
UK Power Networks Stores Code = 04132V

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Cable Preparation

Overlap the cables to be jointed by approximately 300mm.
Mark the centre of the overlap as a reference line.

Remove the oversheath and armour to the dimensions shown in Tables 1-3 depending on the cable types.

Clean, degrease and abrade the metal sheaths before the cores are exposed.

Corrugated aluminium sheaths should be cut at the top of a corrugation.

13kA Earth Clips wi ll be required for PILC cables in the LPN and SPN Areas - SMOE 63425 (SAP Code 04124G)
300
reference line
Paper Cable with Armour
metal sheath
wire armour
oversheath
reference line
c
a
180
20 60
d
b
180
20 60 120 120
Table 1
Conductor Size Stripping Dimensi ons (mm)
(mm
2
) a b c d
95 - 185 630 480 450 300
185 - 300 780 530 600 350
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Paper Cable without Armour
reference line
Armoured to Unarmoured Paper Cable
reference line
metal sheath
oversheath
metal sheath
wire armour
oversheath
120
e
c
b
180
20 60
20
120
d
metal sheath
oversheath
c
e
120
f
d
20
20
120
The 13kA earth clip must be install ed at this point before proceeding with the joint install ation.
Table 2
(mm
2
) c d e f
95 - 185 450 300 570 420
185 - 300 600 350 620 470
Table 3
(mm
2
) c d e f
95 - 185 450 300 570 420
185 - 300 600 350 620 470
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1b
180
reference line
20
20 10
2
50
3
4
formed yellow wedge
1a
20
tape binder
5
Belted Cables
end of the lead sheath and tear the layers of paper off
against. Tie a second twine binder around the belt papers
papers against it. Remove the fillers level with the belt
papers. Secure the paper insulation at the end of each core
using PVC tape. Using a clean, dry cloth, remove any excess
cable compound from the cores.
Screened Cables
Unwind the copper woven fabric tape and remove the fillers.
Rewind the tape around the crutch of the cable and tie it off
20mm from the end of the metal sheath.
dimension given in the Figure 1B. Tear off the screen papers
cores.

Screened Cables Onl y
Cut a 50mm long piece from the yellow void filling mastic
tape as shown in Figure 5.
Remove the twine binder from the end of the screen papers.
direction as the lay of the screen papers.


For cable sizes below those shown in Table 1, the core tubes
should be substituted for those in the build-up kit.

Cut a 50mm long piece of the yellow void filling mastic,
remove the release paper and roll it up to form a wedge.
Push the formed mastic wedge carefully into the crutch until
the tip is just below the belt paper or fabric tape.
The wedge will deform and partly extrude between the cores.
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5
20 20
6
7
red/black insulation sleeve
I
reference line
8
reference line
shear head bolts
shear head bolts
holding tool
9
Clean and degrease the exposed metal sheath.
Remove one release paper from the yellow mastic strip.
Wrap the mastic strip around the crutch of the cable
overlapping the metal sheath by 20mm and continue onto the
red insulating tubings for 20mm.
Wrap the remaining strip of yellow mastic over the first.
Position the red crutch sealing sleeve centrally over the
yellow mastic strips. Shrink the sleeve starting from the metal
sheath.
Completion of Joint
Set the cores into their final jointing position, cores should
only be crossed on the long side of the joint.
Cut the cores to length allowing for the length of the centre
block in the mechanical connectors.
Remove the insulation for the depth of the connector barrel I.
Slide one red/black screened insulating sleeve over each
core on the long side of the joint.
Connector Installation
Reset the cores into their final jointing position.
Check that conductors have been cut to allow for the

Screw the shear head bolts into the connector body until the
tip is level with the inside surface of the connector.

Note: The bolts should not be removed once they have
been screwed into the connector.
Position the connector on short side of the joint and tighten
the Shear Head Bolts finger tight.
The connectors should be positioned with the bolt heads
facing away from the centre of the joint.

Note: Do not remove the centre fixing bolt at this time.

tighten the two Shear Head Bolts sequentially until they
shear off.
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10
holding tool
holding tool
11
12
13
14
yellow mastic patch
Remove the centre fixing bolt and position the other half of
the connector onto the corresponding core on the long side
of the joint.
At this time do not tighten the Shear Head Bolts.
Bring the two halves of the connector together and insert the
centre fixing bolt.
Finger tighten the centre fixing bolt allowing the two V
shapes to nest together.
tighten the two Shear Head Bolts sequentially until they
shear off.
tighten the centre fixing bolt until it shears off.

Repeat this procedure for all connectors.
Clean and degrease the ends of the red insulating tubing in
the connector area and the connector. Remove one release
paper from the yellow mastic patch and wrap it around the
connector. Apply the patch centrally over the connector,
taking care to exclude air voids as it is wrapped. Check that
the patch seam is located over the bolts of the mechanical
connector. Repeat the procedure on the remaining
connectors.
Leave the release paper in position until all three are
completed.
Remove the release paper from over all three connectors.
The surplus yellow patch material extending over the
connector ends should be folded back and used to fill up the
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16
17
18
contact strip
19
red mastic tape
10mm
edge of contact strip
Position the red and black screened insulation sleeves
centrally over the connectors.
Start shrinking the sleeves in the centre.
b. Check if fully shrunk by twisting the sleeve ends.
The sleeve should not move from its position.
If the sleeve rotates continue shrinking until it locks
in place.
Pull the cores together so that the red/black screened
insulation sleeves are in close contact with each other.
Wrap the length of tinned copper mesh around all three
sleeves and secure.

Post heat the joint at the crutch positions.
Earth Cage Installation

Alumi nium Sheathed Cables
Cut the serrated contact strip into two and form piece into a
circle.
Place each piece around the aluminium sheath bridging the
crests of two of the sheath corrugations.
Note: Ensure the contact strip ends do not overlap. Check
that a 10mm gap is maintained between edges.

Armoured Cables
The contact strip should be positioned over the ends of the
wraparound copper sheet.
Clean and degrease the exposed aluminium sheath.
Starting 10mm over the end of the outer cable sheath apply
one half lapped layer of the red mastic tape over the end of
the cable sheath and the exposed aluminium sheath, up to
the edge of the contact strip.

Note: Do not tape over the contact strip.
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rubber patches
20
worm drive clips
tape binder
tape binder
Worm drive drive clips
21
red mastic sealant strip
24
23
Clean, degrease and abrade the outer cable sheath for a
distance of 100mm on each side of the joint.
Position the earth cage around the joint, taking care to space
the fingers equally over the previously installed contact strips.
Apply a temporary tape binder around the cage to hold it in
position and clamp the earth cage at each end with worm
drive clips provided.
Armoured Cables
Wrap the remaining space between the ends of the
rmours and the fingers of the earthing cage with two
half lapped layers of the red mastic sealant strip.

Note: This is an important moisture seal do not leave it out.
Trim the ends of the joint half shells to accommodate the
cable being used. Place the bottom half of the joint shell
under the joint and mark the position of the two joint shell
stand-off mouldings on the earth cage.
white adhesive side facing outwards.
. Assemble the joint shells around the joint and clip
Together (a).
. Fill any gaps around the cable entry holes as required.
Support the joint before filling with resin (b).
. Fill the joint with the approved resin following the
manufacturers instructions and safety data sheet (c).
The joint is now complete. Allow the resin to set before
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2.6 Three Core Paper Cable Vertical Straight Joints (PILC)
The table below details the joint kits required to complete this joint for the cable sizes listed. Any
2.6.1 EPN/LPN/SPN Vertical Straight J oints (PILC)
2.6.3 Installing Heatshrink Materials and Components.
components:
4.1.2 Build-Up Kits for Small Section Paper Cables.
Cable Sizes
mm
2
Vertical Transition
Straight J oint
120-300mm
2
PILC Build-Up Kit
70mm
2
PILC Build-Up Kit
95mm
2
Stores Code 04126B 04127L 04128V
PILC POLY
120 300 185 300 1 per J oint
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Vertical Transition Joint for -Core PILC to 3 x 1 Core Flame
Retardant Pol ymeric 11kV Cables

For Cable sizes 120-300mm
2

SMOE-62667
UK Power Networks Stores Code 04126B
For smaller PILC Cables use the following additional ki ts:
70mm
2
SMOE 62900
UK Power Networks Stores Code 04127L
95mm
2
SMOE 62901
UK Power Networks Stores 04128V
BEFORE JOINTING CHECK THAT YOU HAVE THE
CORRECT KIT OR KITS REQUIRED FOR THE SIZE OF THE
CABLES TO BE JOINTED
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wire binder
Preparation of Cables

Cut the paper cable to length, allowing an extra 50mm for core setting.

Overlap the cables as shown in the drawing, ensuring the polymeric cables overlap the paper cable by 100mm.
Paper Cable Preparation

Remove the oversheath, armour and bedding according to the dimensions shown in the drawing.

Pol ymeric Cable Paper Cabl e
Wrap a wire binder around the armour wires level with end of
the oversheath.

Mark a line on the lead sheath 200mm from the wire binder.

Note: The lead sheath will be removed at this mark.

Clean the wire armours and lift them vertically. Thoroughly
clean the metal sheath.

100
5
80
20
120 380 50
550
oversheath
SWA armour
lead sheath
carbon paper
bel t paper
Insulation papers
reference l ine
200
1
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IMPORTANT Separate the cores carefull y so as not to
damage the bel t or core i nsulation papers.
Slide the oil barrier tubing over the cores and position them
50mm from the end of the belt papers. Shrink down the oil
barrier tubing starting at the crutch. Shrink down the first
30mm of the tubing, twisting the tubing around the core to
ensure the tubing is fully shrunk. When all three tubes are fully
shrunk, push the tubes into the crutch butting them as close to
the belt papers as possible.
Continue to shrink all three tubes working towards the core
ends.
Wrap the second roll of tinned copper mesh (EPPA-009-1050)
over the three copper earth braids inline with the end of the
wire armour.

Fill the gap between the lifted armours and the mesh with
layer of black mastic.
Mark a line on the lead sheath 80mm from the end of the
cable sheath (inline with the end of the wire armour).
Wrap one of the rolls of tinned copper mesh (EPPA-009-1050)
around the lead sheath level with the mark.
Lay the three earth braids over the tinned copper mesh.
Position them at 9, 12 and 3 clock.

Note: Check that the solder blocks in the earth braids sit over
the lead sheath close to the armours.
Lay the wire armours back over the lead sheath, earth braids
and copper mesh and black mastic.
Secure the armours with the wire drive clip.

For PILC Cable sizes of 70mm
2
use SMOE 62900 (SAP
Code 04127L) and for 95mm
2
use SMOE 62901 (SAP Code
04128V)
Substitute the armour clamp provided in the main joint kit with
the smaller clamp provided in the build up kit.
Fold the three copper earth braids back over the cable and
temporarily secure with tape. Remove the metal sheath at the
position marked in step 1, in such a way that a slight bell is
formed. Tie a twine binder around the carbon paper (if any)
5mm from the end of the lead sheath. Tear off the carbon
paper level with the twine binder. Tie a twine binder around the
belt papers 20mm from the end of the lead sheath. Tear off the
belt papers level with the twine binder. Remove the fillers level
with belt papers.
Protect the belt papers with PVC tape before setting the cores.
Start taping 20mm onto the lead sheath and continue over the
belt papers. Apply the tape under tension.
6
copper mesh (EPPA-009-1050)
3
2
80
copper earth braids
copper mesh (EPPA-009-1050)
4
Worm drive clip
5
end of lead sheath
20
5
protection tape
oil barrier tubing
black mastic tape
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Slide the conductive tubes (CNTM) over the cores and position
them 150mm in from the reference line.
Shrink the tubes starting from the reference line working,
before working towards the cable crutch.

2
use SMOE 62900 (SAP
Code 04127L)
Substitute the conductive tubes provided in the main joint kit
with the smaller conductive tubes provided in the build up kit.
Insert the yellow void filling wedge into the crutch of the cable.
Push the wedge into the crutch until the tip is level with end of
the belt papers.

Note: Remove the protection tape after inserting the yellow
void filling wedge.
Remove the release paper from the long yellow void filling
astic strip and roll up the mastic. Apply the void filling mastic
with a 50% overlap, stretching it to about half its original width
and applying it under tension. Overlap the lead sheath by
20mm and continue over the conductive tubing for a distance of
10mm. Apply the second and third strip over the first forming a
cone shape.
Clean and degrease the lead sheath and conductive tubing.
Pass the conductive cable breakout over the cores and pull it
well down into the cable crutch. Shrink the breakout into place
starting at the centre (1), work first towards the lead sheath (2),
then shrink the turrets onto the cores (3). The numbers in the
drawing indicate the shrink sequence.

Note: Post heat the breakout to ensure all expansion lines
have disappeared.

For PILC Cable sizes 70mm
2
04127L)
Substitute the conductive breakout provided in the main joint kit
with the small conductive breakout provided in the build up kit.
Set the cores into their final joint position. Cut the cores to
length allowing for the centre block in the mechanical
connector.
Remove the insulation papers and clear oil barrier tubing for a
distance of:
I = the depth of connector barrel plus 5mm.

CNTM
CNTM
CNTM
8
10
7
reference line
150 mm
CNTM
CNTM
CNTM
yellow void filling wedge
protection tape
9
10
20
Yellow void filling mastic
11
conductive cable breakout
1.
2.
3.
reference line.
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Remove the release paper from the short angled strips of
yellow void filling mastic. Wrap the mastic around the end of
the conductive tubing covering it by 10mm and 10mm of the
clear oil barrier tubing.
tension to achieve a fine thin edge onto the clear barrier
tubing.
Position the black stress control tubing (J SCR) over the cores
so that the end of the tube is approximately 2mm from the end
of the insulation cut.
Shrink the tube starting from the core end working towards the
cable crutch.
Clean and degrease the cable breakout turrets and conductive
tubing.
Position the short black sealing sleeves (MWTM) over the
cores and onto the turrets of the cable breakout. Shrink the
sleeves starting from the cable breakout working along the
cores.
Note: The sleeves are coated with an adhesive sealant. During
shrinking the sleeves will begin to slide along the turrets of the
breakout, so it is advised that a low flame is used during
installation of these tubes.
Preparation of paper cable complete.
2
use SMOE 62900 (SAP
Code 04127L) or for 95mm
2
04128V)
Install an additional stress control tube directly over the
previously installed stress control tube.
Shrink the tubes starting from the core end working towards
the crutch.
12
15
16
10 10
13
2mm
J SCR
J SCR
J SCR
MWTM
MW
TM
M
W
TM

sealing sleeves
yellow void filling mastic
14
2mm
J SCR
J SCR
J SCR
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Cut the cores to length allowing for the thickness of the

Remove the semi-con core screen up to the position marked in
the previous step.

Remove the insulation to the depth of the connector (I).
There should be no gap left between the connector and
the insulation.


Remove the release paper from the short angled strips of
yellow void filling mastic. Wrap the mastic around the end of
the semi-con, covering 10mm of the semi-con and 10mm of
the insulation.
Stretch the mastic to half its original width an apply under
tension to achieve a fine thin edge onto the insulation.
Mark a line on the semi-conductive screen 30mm from the
edge of the yellow void filling mastic.
Wrap one turn of the red (S1085) mastic sealant around the
cable screen level with this mark.
Position the stress control tubing (J SCR) over the polymeric
cables, so that the tube is 2mm from the end of the insulation
cut.
Shrink the tubes starting from the insulation cut.
Pol ymeric Cable Preparation
Fold the copper wires back over the cable jackets and
temporary secure with tape.

Mark the reference line (centre of joint) on the single-core
cables, 220mm from the end of the cable jacket.

Mark the semi-conductive core screen removal position
150mm from the reference line.
18
19
20
21
17
150
70
220
semi-con removal position
70 150
reference line
10 10

red sealant mastic
30
J SCR
2 mm
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Installation of the mechanical connector
The connector is supplied with insert half shells which have to
be used on small cross section cables.
Check before installation if the conductor can be inserted into
the connector with the half shells installed. Remove the inserts
from the connector if the conductor does not fit into the
connector.
Fit the conductors into the connector. There should be no gap
left between the connector and the insulation. Take up the
tension equally on all bolts (do not shear bolt heads at this
stage).
Starting at the connector ends, tighten the bolts until the heads
shear off.
In the case of a proud edge showing after removal of the bolts,
this edge should be removed with a suited tool.
Note: For small cross section cables use a connector holding
tool to support the connector as you shear off the bolts.
Remove any sharp edges from the connector.
Clean and degrease the connector.

From the centre of the connector, mark a line 180mm on the
stress control tubing (J SCR).
Wrap one turn of the red mastic sealant (S1085) around each
stress control tubing with the outside edge level with the mark.

Slide the large cable breakout over the three single core
polymeric cables.
Ensure the fingers of the cable breakout face away from joint.

Position the cable breakout away from the jointing area.
Slide the three black and red (ECIT) screened insulation
sleeves
over the single core cables and position them away from the
jointing area.
24
25
26
red sealant mastic (S1085)
180 180
centre of connector
JSCR
JSCR
insert shells
22
23
cable breakout
JSCR
JSCR
JSCR
JSCR
JSCR
JSCR
ECIT
ECIT
ECIT
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30
31
screened insulation tubes ECIT
Copper mesh EPPA 009-4000
50
end of cable breakout
mastic folded back
JSCR JSCR
27
Yellow stress control patch
Position the black and red screened (ECIT) insulation tubes
centrally over connectors.
Start shrinking the tubes in the centre.
a. Continue shrinking the tubes in the centre.
b. Before moving towards the ends, check that the tubes are
fully shrunk by twisting one end. If the tube rotates apply
more heat. When the tube is locked in place continue
shrinking towards one end.
c. Continue shrinking towards one of the ends, stopping
approximately 50mm from the end.
d. Shrink the other half of the tube in the same way, stopping
50mm from the end.
Move back to the first end and shrink the remaining 50mm.
Finally, shrink the remaining 50mm on the other end of the
joint.
The tubes should be fully shrunk, leaving no ridges.
Relay the cores and pull them together.
Starting 50mm in from the end of the cable breakout wrap one
layer of the tinned copper mesh (EPPA 009-4000) with a 50%
overlap over the joint continuing up to the ends of the cable
jackets of the single core cables.

Note: Ensure the tinned copper mesh is wrapped around the
exposed semi-conductive layer of the single core polymeric
cables.
The surplus patch material extending over the stress control
tubing ends should be folded back and used to fill up the
28
Remove the release paper from the yellow stress control patch
and wrap it around the connector.
Apply the patch centrally over the connector, ensuring the
patch overlap is located over the bolt heads.

2
use SMOE 62900 (SAP
Code 04127L) or for 95mm
2
use SMOE 62901(SAP Code
04128V)
Using the yellow void filling strips taken from the build up kit,
apply the tape around the paper core forming a smooth profile
up onto the end of the connector.
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Lay the three earth braids back over the joint and connect them
to the three conductors formed from the wire shields with the
mechanical tunnel connectors.
Secure the three copper earth braids to the lead sheath with
the large constant force roll spring.
Secure the roll spring with four turns of PVC tape.

Form the copper wires of the single core cables into single
conductors and lay them back over the joint.

Wrap two to three turns of the tinned copper mesh
(EPPA 009-650) around the exposed lead sheath between the
end of the armours and cable breakout skirt.
33
34
35
tunnel connector
constant force roll spring
PVC tape
32
formed conductors
tinned copper mesh
EPPA 009-650
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Position the wraparound joint sleeve centrally over the joint.
Pass the retention clip over the rails of the wraparound to keep
it in place.
Push the metal channels over the rails of the wraparound.
The ends of the metal channels should butt up and equally
overlap the retention clips.
After all channels have been pushed on they should overlap
the ends of the wraparound equally.
retention clip
metal channel 39
Always wear suitable protective gloves to protect your
hands against loose glass fibres.
Position the coated fibre glass blanket centrally over the joint
with its long dimension along the cable axis and the grey
coating facing inwards (detail a).
Wrap the blanket tightly around the joint and secure it in place.
Starting in the centre section of the joint, using the tinned
copper mesh.
Work towards each end of the joint, folding the blanket to fit
closely to the joint shape and secure in place with tinned copper
mesh.
Wrap one layer of the tinned copper mesh (EPPA 009-4000)
with a 50% overlap across the joint, starting from the constant
force spring continuing up to the cable jackets of the single
core cables.

Wrap two layers of black mastic sealant around the armours
behind the worm drive clip over the previously installed black
mastic.
Clean, degrease and abrade the single core cable jackets for a
distance of 75mm from the ends of the cable jacket cut.

Position the cable breakout over the joint, pulling the skirt as far
as possible over the joint.

Shrink the breakout starting at the fingers, before working
towards the joint.
36
tinned copper mesh EPPA 009-4000
38
cable breakout
37 a
black mastic sealant
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Shrink the wraparound sleeve into place starting at the middle
of the joint. When the colour of the paint on the wraparound
has completely changed to black, progressively move towards
the ends of the sleeve.

Note: Extra heat is required on the metal channel. Heat until
the white marking line can be seen under the channels.
Joint complete.

Allow the joint to cool before applying any mechanical strain.

Note: If the joint is installed in any position other than
horizontal the cable should be supported by stand off brackets
and cable cleats.
On completion fix the fire resi stant information label onto
the joint wraparound.
42
40
41
White marking line
ire rest i at n klh al sdf
asl kfjlaj fj fsdfsdf sdfsdf ffffffff asdf ffffff fffff sdfasdf
asdfasdf asdfasd sd asdfasd
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2.7 Three Core Transition and Polymeric to Polymeric Branch Joints
2.7.1 EPN PILC Main with Triplex or Single Core Polymeric CWS Branch J oints
2.7.2 EPN PILC Main to Polylam Branch J oints
Cable Sizes
mm
2
Branch J oint
95-185mm
2
Branch J oint
240-300mm
2
PILC Build-Up Kit
16-70mm
2
Stores Code
04122M 04123W 04125R
Main Branch
95 120 95 1 per J oint
120 150 95 185 1 per J oint
150 240 300 1 per J oint
185 95 185 1 per J oint
185 300 95 300 1 per J oint
Cable Sizes
mm
2
Three Core
Transition
Branch J oint
95-185mm
2
Three Core
Transition
Branch J oint
240-300mm
2
PILC Build-Up Kit
16-70mm
2
Polylam Earth
Kit
Stores Code
04122M 04123W 04125R 04108D
Main Branch
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2.7.3 LPN/SPN PILC Main with Triplex or Single Core Polymeric CWS Branch J oints
2.7.4 SPN PICAS Main with Triplex Branch J oints
Cable Sizes
mm
2
Three Core
Transition
Branch J oint
95-185mm
2
Three Core
Transition
Branch J oint
240-300mm
2
13.1kA Earth Kit PILC
Build-Up Kit
16-70mm
2
Stores Code
04122M 04123W 04124G 04125R
Main Branch
16-70 95 1 per J oint 2 per J oint
95 95 1 per J oint
Cable Sizes
mm
2
Three Core
Transition Branch
J oint
95-185mm
2
Three Core
Transition Branch
J oint
240-300mm
2
Stores Code 04122M 04123W
PICAS Triplex
95 95 1 per J oint
95 185 1 per J oint
95 300 1 per J oint
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C
O
N
T
R
O
L
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D
2.7.5 EPN Triplex or Single Core Polymeric CWS Main PILC Branch J oint
2.7.6 EPN Polylam Main PILC Branch J oints
Cable Sizes
mm
2
Three Core
Transition
Branch J oint
95-185mm
2
Three Core
Transition
Branch J oint
240-300mm
2
PILC Build
Up Kit
16-70mm
2
Polymeric
Preparation
Kit 95-
150mm
2
Polymeric
Preparation
Kit 185-
300mm
2
Tyco Part No. SMOE 63412 SMOE 63413 SMOE 63429 SMOE 63415 SMOE
63416
Stores Code
04122M 04123W 04125R 04129F 01430B
Poly
Main
PILC
Branch
95 185 1 per J oint 1 per J oint
185 95 150 1 per J oint
Cable Sizes
mm
2
Three Core
Transition
Branch J oint
95-185mm
2
Three Core
Transition
Branch J oint
240-300mm
2
PILC Build
Up Kit
16-
70mm
2
Polylam
Earth Kit
Polymeric
Preparation
Kit 95-
150mm
2
Polymeric
Preparation
Kit 185-
300mm
2
Tyco Part No. SMOE
63412
SMOE
63413
SMOE
63429
SMOE
63409
SMOE
63415
SMOE
63416
Stores Code
04122M 04123W 04125R 04108D 04129F 01430B
Main Branch
150 16 70 1 per J oint 1 per J oint 2 per J oint 1 per J oint
U
N
C
O
N
T
R
O
L
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E
D
Cable Sizes
mm
2
Three Core
Transition
Branch J oint
95-185mm
2
Three Core
Transition
Branch J oint
240-300mm
2
PILC
Build
Up Kit
16-
70mm
2
13kA
Earth Clip
Polymeric
Preparation
Kit 95-
150mm
2
Polymeric
Preparation
Kit 185-
300mm
2
Tyco Part No. SMOE
63412
SMOE
63413
SMOE
63429
SMOE
63414
SMOE
63415
SMOE
63416
Stores Code
04122M 04123W 04125R 04124G 04129F 01430B
Main Branch
95 19 70 1 per J oint 1 per
J oint
1 per J oint
95 120 300 1 per J oint 1 per
J oint
1 per J oint
185 16 35 1 per J oint 1 per
J oint
1 per J oint 1 per J oint
185 70 1 per J oint 1 per
J oint
1 per J oint
185 120 185 1 per J oint 1 per
J oint
1 per J oint
185 240 300 1 per J oint 1 per
J oint
1 per J oint
240 16 70 1 per J oint 1 per
J oint
1 per J oint
240 120 300 1 per J oint 1 per
J oint
1 per J oint
300 120 300 1 per J oint 1 per
J oint
1 per J oint
2.7.7 LPN/SPN Triplex or Single Core Polymeric CWS Main PILC Branch J oint
U
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C
O
N
T
R
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D
2.7.8 SPN Triplex Polymeric Main PICAS Branch J oints
2.7.9 Triplex or Single Core Polymeric Main with a Triplex or Single Core Polymeric
Branch J oints
Cable Sizes
mm
2
Three Core
Transition
Branch J oint
95-185mm
2
Three Core
Transition
Branch J oint
240-300mm
2
Polymeric
Preparation Kit
95-150mm
2
Polymeric
Preparation Kit
185-300mm
2
Stores Code
04122M 04123W 04129F 04130B
Triplex
Main
PICAS
Branch
Cable Sizes
mm
2
Three Core
Transition
Branch J oint
95-185mm
2
Three Core
Transition
Branch J oint
240-300mm
2
Polymeric
Preparation Kit
95-150mm
2
Polymeric
Preparation Kit
185-300mm
2
Stores Code
04122M 04123W 04129F 04130B
Triplex
Main
PICAS
Branch
240 300 70 95 1 per J oint 1 per J oint 1 per J oint
U
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O
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2.7.10 EPN Polylam Main with a Polylam Branch J oints
2.7.11 EPN Polylam Main with Triplex or Single Core Polymeric Branch J oints
Cable Sizes
mm
2
Three Core
Transition
Branch J oint
95-185mm
2
Three Core
Transition
Branch J oint
240-300mm
2
Polylam
Earth Kit
Polymeric
Preparation
Kit 95-
150mm
2
Polymeric
Preparation
Kit 185-
300mm
2
Tyco Part No. SMOE 63412 SMOE 63413 SMOE
63409
SMOE
63415
SMOE 63416
Stores Code
04122M 04123W 04108D 04129F 01430B
Main Branch
150 150 1 per J oint 3 per J oint 2 per J oint
240 150 1 per J oint 3 per J oint 1 per J oint 1 per J oint
Cable Sizes
mm
2
Three Core
Transition
Branch J oint
95-185mm
2
Three Core
Transition
Branch J oint
240-300mm
2
Polylam
Earth Kit
Polymeric
Preparation
Kit 95-
150mm
2
Polymeric
Preparation
Kit 185-
300mm
2
63409
SMOE
63415
SMOE
63416
Stores Code
04122M 04123W 04108D 04129F 01430B
Main Branch
U
N
C
O
N
T
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O
L
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E
D
2.7.12 EPN Triplex or Single Core Polymeric Main with a Polylam Branch J oints
Cable Sizes
mm
2
Three Core
Transition
Branch J oint
95-185mm
2
Three Core
Transition
Branch J oint
240-300mm
2
Polylam
Earth Kit
Polymeric
Preparation
Kit 95-
150mm
2
Polymeric
Preparation
Kit 185-
300mm
2
63409
SMOE
63415
SMOE
63416
Stores Code
04122M 04123W 04108D 04129F 01430B
Main Branch
U
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O
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components:
4.2.4 Three Core Transition Branch J oints.
4.5.6 PICAS Earth.
U
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11kV Three-Core Transitional Branch Joint

95-185mm
Tyco El ectronics Part No: SMOE 63412
UK Power Networks Stores Code: 04122M
240-300 mm
Tyco El ectronics Part No: SMOE 63413
UK Power Networks Stores Code: 04123W

U
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O
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reference line
Stripping Dimensions Branch Joint with Paper Main with Polymeric Branch using standard kit.
Stripping Dimensions for Al ternative joint combinations These will requi re additional cable preparation
kits as detail ed in section 2.7 of the UK Power Networks 11kV Jointing Manual
belt papers
screen papers
wire armour
reference line
oversheath
metal sheath
100
350 600
60
140
PILC
PICAS
POLYMERIC
PILC
PICAS
350 600
100
POLYMERIC
140 60
overlap
overlap
180
POLYMERIC
PILC
180 180
For an all pol ymeric cable joint, replace the PILC cable
with a pol ymeric cable stripped to the dimensions below.
U
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O
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D
The 13KA earth clip may be requi red. If so omit
Steps 1 to 3.

PILC Cable Preparation

Remove the armours according to the dimensions shown on
page 68. Stand the armour wires upright and remove all
traces of compound from them. Thoroughly clean and abrade
the lead sheath for 200mm from the cable armour.
1
Wrap the short length of copper mesh (EPPA-009-850)
around the lead sheath so that its edge just protrudes beyond
the armour wires when they are laid back down.
2
Relay the wires over the mesh and secure with a worm drive
clip.
3
4B
IMPORTANT: Separate the cores carefull y so as not to

Belted Cables Onl y
end of the metal sheath and tear off the carbon paper against
the twine binder. Tie a twine binder around the belt papers
papers level with the twine binder. Remove the fillers level
with the belt papers. Secure the paper insulation at the end
of each core using a tape binder. Using a clean, dry cloth,
remove any excess cable compound from around the cores.
Move on to step 5.
4A
Unwind the fabric tape and remove the fillers. Rewind the
tape around the crutch of the cable and tie off 20mm from the
end of the metal sheath.
dimension given in the drawing. Tear off the screen papers
cores.

tape binder
5
20
20
reference line
180
U
N
C
O
N
T
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E
D
Push the yellow mastic wedge carefully into the crutch until
the tip is just below the belt paper or fabric tape. The wedge
will deform and partly extrude between the cores.

6
end, pushing them well down into the crutch.


For cable sizes below 95mm
2
the core tubes should be
substituted for those in the appropriate build up kit.

4C
Remove the twine binder from the crutch on belted cables.
Remove the release paper from a 400mm yellow mastic void
filling tape strip. Wrap the tape around the crutch,
overlapping onto the lead sheath by 20mm and continue onto
the red insulating tubes for 20mm. Wrap a second strip of the
yellow mastic over the first layer.

7
40 20
180
reference li ne
20
5
20 10
50 4D
Tie a twine binder around the screen papers at the dimen-
sion given in the drawing. Tear off the screen papers level
with the twine binder.
Remove the top two paper tapes to the same position as the
screen papers.
Using a clean, dry cloth, remove any excess cable compound
from around the cores.

Cut a 50mm piece from the yellow mastic void filling tape as
shown in the drawing.
Stretch the mastic to half its original width and applied under
direction as the screen papers.
U
N
C
O
N
T
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L
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E
D
Position the crutch red sealing sleeve centrally covering the
yellow mastic tape. Shrink it into position.

2
the crutch sealing sleeve
should be substituted for one in the build up kit.
8
Seal ant Tape
Wrap one layer of red sealant tape for 60mm from the sheath
cut with slight tension and a one third overlap.
10
Screen Wires
Bend back the screen wires onto the red sealant tape
binder or cable tie to keep them tight against the red sealant
tape.

Semi-Conducting Layer
Remove the semi-conducting screen layer from the insulation
to the dimension as shown, using the approved tools and
methods as applicable.
Do not nick the insulation layer.

Moisture Block
applied 60mm red tape to sandwich the screen wires giving a
moisture block. Continue onto the semi-conducting layer for

mastic strips. Starting 20mm on the semi-con layer, continue
taping on to the insulation foil for 10mm to form a smooth
taper. Stretch the tape to half its original width and apply
under tension to ensure a fine neat edge. Remove the
second release paper during this taping operation.
Single-Core Cable Sheath Removal
Lay the single core plastic cables in their final jointing
position.
remove the outer jacket.
Thoroughly abrade and degrease the outer cable sheaths for
a distance of 200mm from the sheath cut.

IT IS IMPORTANT THAT THIS OPERATION IS CARRIED
OUT AT THIS STAGE. DO NOT LEAVE OUT.
9
60
200
11
180
12
60 15
Moisture block
Yellow void filling mastic tape
40
U
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Core Tubing
Position the red core tubing (BPTM-50/20) over the cable to
coincide with the red mastic tape. Shrink into place starting at
the oversheath end. Strip back the tubing and insulation to
suit the depth of the bore of the type of connectors used.
insulation tubes over them. Cover the tubes to protect
against dust or moisture splashes.

Note: If the insulating tubes are a tight fit over the red
BPTM tubing, lubricate the tubing with a smear of silicone
grease from the sachet provided.

13
Fitting Mechanical Connectors
Arrange the core of the branch cable to the core of the main
cable and cut to length. Remove the core insulation +5mm.
Use the cable ties to bind together each pair of cores on the
branch side as close to the crutch as possible. Slide the
mechanical connector over the core ends. Position the cable
core on the single side of the joint against the connector
mark and cut to length. Remove the core insulation +5mm.
Slide the connector collar over the core. Place the core end
into the open channel. Position the insert over the conductor
at the channel position. Slide the collar over the insert,
locking the insert to the connector body.
16
Cut each core to length. Remove the conductor insulation to
a length equal to the hole depth in the connector +5mm.
Note: Allow for the water block in the connector when cutting
the cores and insulation.
Use the cable ties to bind together each pair of cores on the
branch side as close to the crutch as possible.
Slide the black and red tubes (2) over each pair of cores on
the branch side, taking care not to scratch the inside of the
tubing on the exposed conductor.
Fit the appropriate bolts in the connector and tighten them up (hand tight) using a 19mm socket. Repeat the same method on
the other two connectors. The configuration of the cores and connector positions are shown in the drawing opposite. No other
arrangement is allowed. Tighten up each bolt one full turn each time before moving on to the next bolt. Repeat the operation
to ensure that all the bolts are evenly tightened. Shear off the bolts at the centre of the connector first and followed by the
bolts at each end last.
Check that you have all the bolt heads before continuing with the joint, so that none have gone inside any of the tubes.
Completion of Joint
Position the short (TWJ S) build up sleeves over each core on
the single side of the main cable as shown in the drawing.
Lay back away from the jointing area.

Note: Where the joints are designed for cables in excess of
185 mm there are two tubes per core. These tubes are of
different sizes and can be nested inside each other for easy
positioning.
14
1
15
2
2
2
U
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2 3 5 1 4
Pull the cores together and wrap the length of tinned copper
mesh around all three insulation sleeves in the centre and
secure.
Remove the cable ties holding the branch cores together.
21
Apply a thin smear of grease over the yellow mastic. Position
the three black and red screened insulating sleeves centrally
over the connector. Use cable ties to bind together each pair
of cores on the branch side. Shrink the tubes starting on the
branch side of the connector (1). Shrink to within 50mm of
the end (2) and then switch to the single side stopping 50mm
from the end (3). Then finish off the first end (4) and then the
second end (5).
20
The connectors should be covered with the yellow mastic
patches using the following procedure.
There are three patches per connector. The first patch is
located over the single end of the connector as shown with
the overlap located over the bolts area.
The two remaining patches should be formed into one long
patch by sticking them together, overlapping each other by
50mm. Wrap this long patch around the double end of the
connector, with the double 50mm thickness over the bolt
area of the connector.
19
Roll up lengthways the wide (S1251) red mastic strips and
insert them top and bottom between the parallel cores of the
branch side. Firmly press into place butting against the
connector edge. Now cut the 600mm piece of yellow void
filling mastic into 6x100mm pieces. Remove the release
paper from both sides of one piece, fold it in half lengthways
and roll up to form a rod shape 50mm long. Position one
piece at each end of the connector where the step is at its
largest, as shown in the drawing.
18
yellow mastic red mastic
patch 2+3
50
patch 1
Position the short (TWJ S) build up sleeve, up to the insulation
cut, and shrink down starting at the insulation cut end and
continuing towards the cable crutch.

For joints where two sleeves are used, the smaller of the two
should be shrunk first. The second sleeve should be then be
positioned over the first and shrunk down in a similar manner.
17
1
U
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D
Wrap one piece of the serrated metal contact strip around the
copper mesh. Do not overlap the ends of the contact strip.

Corrugated Aluminium Sheaths
Fit the serrated strip over two adjacent crests of the
aluminium sheath.

23
Using the short length of tinned copper mesh, fold it in half
and wrap it around the lead sheath.

Corrugated Aluminium Sheaths
Discard the tinned copper mesh.
22
50
Wrap two layers of the copper mesh around the edge of the
support ring, lay all the copper wires of the single core
cables on to the copper mesh, continue to wrap the copper
mesh over the copper wires. Clamp the copper mesh and
wire down on to the support ring, tap and tighten as you go,
and trim off the excess copper wires. Clean and degrease
the space between the cage fingers and the copper mesh.
Apply two half lap layers of red mastic tape to the space on
the support ring between the copper wires and the aluminium
age.
26
Pol ymeric Cables
circle and position it on to the support ring edge nearest the
joint. Slide the support ring along the cables until the screen
fingers cover the full width of the contact strip. Use one worm
drive clip only and clamp the fingers of the screen down on to
the contact strip. Remove any excess clip length once fully
tightened.
25
Position the earth cage around the joint, taking care to space
the fingers equally over the support ring ends and the cable
lead sheath. Apply a temporary tape binder around the cage
to hold it in position. On the branch side of the joint, divide
the cage fingers equally and shape them so that they lie flat
on top of the serrated strip. Clamp the earth cage at each
end using the worm drive clips, over the serrated strips.
Remove any excess clip length after fully tightening.
Note: Lightly tap the fingers of the aluminium cage while
tightening.
24
U
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C
O
N
T
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E
D
Clean and degrease the lead sheath. Using the thin red
mastic tape, wrap the remaining space approximately 30mm,
between the armours and the cage with two half lap layers.
Note: This tape is important as it provides a major moisture
seal. DO NOT LEAVE IT OUT.
27
red mastic
c c
b
b
a
Degrease and abrade the plastic cable outer sheath where
applicable, for a distance of 100mm. Trim the ends of the
joint half shells to accommodate the cables used. Place the
bottom half of the joint shell under the joint and mark the
position of the shell stand-off mouldings on the earth cage.
adhesive side outwards.
28
together.


29
C. Fill the joint with the approved resin following the
manufacturer's instructions and safety data sheet.

The joint is now complete.

Allow the resin to set before applying any mechanical strain.

30
rubber patches
U
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2.8 Single Core Polymeric Pot Ends
2.8.1 EPN/LPN/SPN Triplex or Three x Single Core Pot End J oints (CWS Cables)
2.8.2 EPN Polylam Pot End J oints
components:
4.3.5 Polymeric and Paper Pot End J oints.
Cable Sizes
mm
2
Triplex Pot End J oint
95-150mm
2
185-300mm
2
Stores Code 04106J 04107T
95 185 1 per J oint
240 -300 1 per J oint
Cable Sizes
mm
2
95-150mm
2
185-300mm
2
Polylam Earth Kit
Stores Code 04106J 04107T 04108D
150 1 per J oint 1 per J oint
240 1 per J oint 1 per J oint
U
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InstaIIation Instruction

11kV SingIe Core or TripIex CabIe Pot End

For cabIe sizes 95-185mm
SMOE 63407
UK Power Networks Stores Code = 04106J
For cabIe sizes 240-300mm
SMOE 63408
UK Power Networks Stores Code = 04107T

U
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1
2
60
200
CabIe Preparation
Slide the support ring over the three single cables. Lay the
cables in to their final position and mark the reference line.
Cut the cables to length and remove the outer sheath.
SeaIant Tape

Screen Wires
Bend the screen wires back onto the red sealant tape
binder or cable tie to keep them tight against the red sealant
tape.
Semi-Conducting Layer
Remove the semi-conducting screen layer from the insulation
to the dimension shown using the approved tools and
methods as applicable. Do not nick the insulation layer.

3
40
Moisture BIock
applied 60mm red tape to sandwich the screen wires giving a
moisture block. Continue onto the semi-conducting layer for

4
Stress ReIieving Tape
mastic void filling tape. Starting from 20mm on the semi-con
layer and continue taping onto the insulation for 10mm to
form a smooth taper. Stretch the tape to half its original width
and apply under tension to ensure a fine neat edge. Remove
the second release paper during this taping operation.
5
15 60
30
75
220
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Core Tubing
Position the red core tubing over the cable onto the end of
the red mastic tape. Shrink down starting from the
oversheath end. Trim the red core tubing level with the cable
end.

6
30
yellow mastic star
40
end caps
ECIC
7
8
9
10
Cut one of the 150mm yellow void filling mastic strips into
three equal pieces.
Arrange the strips in the shape of a star.
Position the centre of the star against the core end as
Apply a 150mm strip of the yellow void filling mastic around
the last 40mm of the core end securing the previously
installed yellow star.
Position over each core end a small black heatshrink end
cap. Shrink down each cap, using a hammer shaft pressing
against the end of the cap to ensure the cap does not slide
off the core end.
Slide onto each core a black and red screened insulation
tube (ECIC).
Position the tubes so that they overlap the ends of the cable
caps by 30mm.
U
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C
O
N
T
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D
Degrease and abrade the plastic cable sheath for a distance
of 100mm. Trim the ends of the joint half shells to
accommodate the cables used. Place the bottom half of the
joint shell under the joint and mark the position of the two
shell stand-off mouldings on the earth cage.
white adhesive outwards.
Wrap two layers of the tinned copper mesh around the end of
the support ring, lay all the copper wires of the single core
cables on to the copper mesh, continue to wrap the tinned
copper mesh over the copper wires, clamp the copper mesh
and wires down on to the support ring, tap and tighten, and
trim off the excess copper wires. Clean and degrease the
space between the cage fingers and the copper mesh. Using
the red mastic tape, wrap it in the space on the support ring.

13
14
15
Rubber Patches
Position the support ring 250mm from the cable end of the
black and red insulating tubes.
Wrap and secure the serrated strip around the support ring.
Wrap the cage around the joint and temporary secure. Space
the cage fingers equally around the support ring and the cage
using the worm drive clip.
50
check
a
b
c
d
1
2 3
4 5
The sleeves should not move from their position.
If the sleeves rotate continue shrinking until they lock in
place.
11
12
CompIetion of Joint

Wrap the roll of tinned copper mesh around the centre of the
black and red tubes.
U
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O
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D
c
a
b
J oint complete. Allow the resin to set before applying any
mechanical strain.
together.
b. Fill any gaps around the cable entry hole as required.
manufacturer's instructions and data sheet.
16
17
U
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O
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2.9 Three Core Paper Cable Pot Ends (PICAS and PILC)
The table below details the joint kits required to complete this joint for the cable sizes listed. Any
2.9.1 EPN/LPN/SPN Three Core PILC/PICAS Pot End J oints
Refer to the following sections of this manual for the preparation of each cable type.
components:
4.3.5 Polymeric and Paper Pot End J oints.
Cable Sizes
mm
2
Three Core PILC/PICAS
Pot End J oint
95-300mm
2
PILC Build-Up Kit
16-70mm
2
Stores Code 04133F 04125R
95 300 1 per J oint
U
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11kV Three-Core PILC/PICAS Pot End

For cable sizes 95-300mm
SMOE 61757
UK Power Networks Stores Code = 04133F

U
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D
belt papers/fabric tape
wire or tape armour
reference line
60 140
20
360
aluminum sheath
oversheath
140
20
Paper Cable with Armour
360
oversheath
Cable Preparation

Paper Cable with Alumini um Sheath
reference line
lead sheath
U
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O
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Paper Cables

Remove the armours according to the dimensions shown
on page 84. Stand the armour wires upright and remove all
1
Wrap the short length of tinned copper mesh (EPPA-009-
850) around the lead sheath so that its edge just protrudes
beyond the armour wires when they are laid back down.
2
clip.
3
4 B
Belted Cables Onl y
end of the lead sheath and tear off the carbon paper against
20mm from the end of the lead sheath and tear off the belt
of each core using a PVC tape binder. Using a clean, dry
cores.
4 A
Screened Cables
cores.

tape binder
5
20
20
reference line
180
U
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O
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Push the mastic wedge carefully into the crutch until the tip is
just below the belt paper or fabric tape. The wedge will
deform and partly extrude between the cores.

7
IMPORTANT - Separate the cores carefull y so as not to
end, pushing them well down into the crutch.


2
, the core tubes should be
substituted for those in the build up kit.

6
Position the red crutch sealing sleeve centrally covering the

9
Remove the release paper from a 400mm length of yellow
void filling mastic tape. Wrap the tape around the crutch,
overlapping onto the lead sheath by 20mm and continue onto
the red insulating tubes for 20mm. Stretch the mastic to half
its original width and apply under tension to achieve a fine
thin edge. Wrap a second strip of the yellow mastic over the
first layer.

8
40 20
Cut a 50mm piece from the yellow void filling mastic tape as
shown in the figure 5.
20 10
50
5
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30
yellow mastic star
40
end caps
ERIC
10
11
12
13
Set the cores into their final jointing position. Cut the cores to
the dimensions given in the drawing.

Cut one of the 150mm yellow void filling strips into three
equal pieces.
Arrange the strips in the shape of a star.
Position the centre of the star against the core end as shown
in the drawing.
Apply a 150mm strip of the yellow void filling mastic around
the last 40mm of the core end securing the previously
installed yellow star.
Position over each core end a small black end cap.
Shrink down each cap, using a hammer shaft pressing
against the end of the cap to ensure the cap does not slide
off the core end.
Slide onto each core a red and black screened insulation
tube (ERIC).
Position the tubes so that they overlap the ends of the cable
caps by 30mm.
50
check
a
b
c
d
1
2 3
4 5
14
The sleeves should not move from their positions.
If a sleeve rotates continue shrinking it, until it locks in
place.
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Compl etion of Joint

Wrap the roll of tinned copper mesh around the centre of the
black and red tubes.
15
Earthing Cage Instal lation

Cut the serrated contact strip into two and form each of them
into circles.
Place each piece around the aluminium sheath bridging the
crests of two of the sheath corrugations.
Note: Ensure the contact strip does not overlap. Check that a
10mm gap is maintained between edges.

Clean and degrease the exposed aluminium sheath.
Starting 10mm over the end of the outer cable sheath, apply
one half lapped layer of the red mastic tape over the end of
the cable sheath and the exposed aluminium sheath, up to
the edge of the contact strip.

Note: Do not tape over the contact strip.
red mastic tape
10
edge of contact strip
17
contact strip
16
Lead Sheathed cables
Fold the length of tinned copper mesh in half along its length.
Wrap the mesh around the lead sheath behind the red crutch
sealing sleeve. Trim the length of contact strip to fit around
the sheath and secure.

Metallic Earth Screen Connections
Fit the metallic cage centrally around the joint, apply a
temporary tape binder around the centre, ensuring the
overlap along the cage length remains equal. Position the
cage fingers over the contact strip and secure with the worm
drive clip.

18
19
rubber patches
Clean, degrease and abrade the plastic cable sheath as
applicable for a distance of 100mm. Trim the ends of the joint
half shells to accommodate the cables used. Place the
bottom half of the joint shell under the joint and mark the
position of the two shell stand-off positions on the earth cage.
white adhesive side outwards.
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J oint complete. Allow the resin to set before applying any
mechanical strain.
together.
b. Fill any gaps around the cable entry hole as required.
manufacturer's instructions and data sheet.
c
a
b
20
21
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2.10 New Single Core Polymeric Indoor Terminations
The tables below detail the termination kits required to complete this termination for the cable sizes
listed. Any jointing requirements for cable sizes not shown on this table shall be referred to one of
the UK Power Networks J ointing Schools.
2.10.1 EPN/LPN/SPN Triplex or Three Single Core Termination Kits (CWS Cables)
2.10.2 EPN Polylam Termination Kits
components:
4.1.6 Single Core Polymeric Cable Terminations.
4.2.5 Mechanical Lugs for Indoor and Outdoor Terminations.
4.4 Installing Bushing Boots.
4.4.1 Cold Applied Switchgear Boots.
4.5.10 Connection of Earth Screens on Indoor and Outdoor Terminations.
Cable Sizes
mm
2
Joint Kit Description and Part Numbers
Single Core
Indoor
Termination Kit
95-185mm
2
Single Core
Indoor
Termination Kit
240-300mm
2
Polylam Earth
Kit
Right Angle/In-Line
Boot Kit
95-300mm
2
Stores Code 04150T 04151D 04108D 04155S
150 1 per End Box 1 per End Box 1 Set per End Box
240 1 per End Box 1 per End Box 1 Set per End Box
Cable Sizes
mm
2
Single Core Indoor
Termination Kit
95-185mm
2
Single Core Indoor
Termination Kit
240-300mm
2
Right Angle/In-Line
Boot Kit
95-300mm
2
Stores Code 04150T 04151D 04155S
95 185 1 per End Box 1 Set per End Box
240 300 1 per End Box 1 Set per End Box
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11KV Single-Core XLPE Indoor Termination

2

SMOE 63419
UK Power Networks Stores Code 04150T
2

SMOE 63420
UK Power Networks Stores Code 04151D

When Bushing Boots are required use:
For Cable sizes 95-300 mm
2
SMOE 62803
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Cut back the insulation according to
dimension K = depth of cable lug
barrel hole.
Install the cable lug.
Degrease and clean the core insulation
and the lug.

Thoroughly remove the core screen
to within 40mm of the oversheath
cut. The surface of the insulation
should be free from all traces of
conductive material.
Smooth out any irregularities.
Fit the cable lug onto the bushing and
mark on each single cable the end of
the conductor position inside the
barrel of the lug.
Cut the cable to the required length.
Remove the oversheath according to
the dimension given in the Figure 2.
Degrease and clean the end of the
oversheath for about 100mm.
Wrap the red sealant tape around the
end of the oversheath.

Bend the shielding wires back onto
the oversheath. Avoid crossing the
individual wires.
Fix the shielding wires with a wire
binder 60mm from the end of the
oversheath.
Gather the shielding wires together to
form an earth lead.
Remove the release paper and wrap
the void filling strip around the end of
the core screen.
Cover 20mm of the core screen and
10mm of the insulation, stretching it
to about half its original width and
applying it under tension.

2 3
240
wire binder
60
sealant tape
clean
100 mm
K
5 6 4
40
insulation
20
10
void filler
(yellow)
core screen
1
Pass the gland sealing sleeve over the
three single core cables and position
away from the jointing area. Secure
the cable gland to the base plate.
Slide the base plate over the single
cables and set each cable to the
relevant bushing stem.
Check that the copper wire shields will
reach the base plate mechanical
connector.
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Note: After installation the termination
must be post-heated as well as the
palm of the cable lug until a bead of
sealant (green) appears around the
top of the tubing.
Allow the termination to cool before
Preheat the cable lug slightly before
placing the tubing over the core.
The bottom end of the tubing should
be level with the wire binder.

Clean and degrease the termination
and bushing.
Slide the boots over the completed
terminations.
Fasten the connectors to the
bushings.
Shrink the tubing down starting at the
screen cut using a soft yellow flame.
Heat the area well but avoid
scorching of surface. Continue
shrinking towards the cable lug.
Finally shrink down the bottom end of
the tubing.
The numbers in the drawing indicate
the shrink sequence.

Diameter of cable lug barrel:
Use additional red sealant tape to
build up the diameter of the cable lug
barrel for small cross section cable
sizes.

7
Completion of Termination
8 9
2
1
3
10 11
Apply a thin layer of silicone grease
50mm onto the termination as shown
and slide the insulating boot down
over the termination.
12
50
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18
r
D
Min. 15 mm
Note: Clean the bushing before the
installation of the bushing boot.
onto the bushing.
Connect the cable lug to the bushing.
Push the boot upwards over the
bushing as far as possible.
Installation of the RCAB is now
complete.

13 14
Terminations complete.
Check that the minimum spacing
between the terminations and
terminations to any earthed metal
work are maintained:

b. phase to earth =15mm
c. phase to phase =20mm

Degrease the terminations and the
boots. Fit the front cover of the box
and secure.

Position the sealing sleeve over the
cable gland and shrink down the
sleeve, starting from the top of the
gland, before working down towards
the cables.
Termination completed.
16 17
15
Secure the base plate and gather the
copper wire shields from each cable
together. Connect them to the plate
using the provided mechanical
connector.
Minimum bending radius
Minimum bending radius (r) = 15 x D
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2.11 Single Core Polymeric Terminations into Existing Compound End Boxes
In most cases, it is possible to install single core polymeric cables into existing bitumen or oil
lled end boxes. The only issue is whether standard cold applied bushing boots can be used. The
table below details the minimum clearance dimensions that can be used for this type of bushing
protection.
If the above clearances cannot be achieved within the end box, it shall be sealed and lled with
Guruex.
2.11.1 Kit Selection Tables
The tables below and overleaf detail the termination kits required to complete this termination for
the cable sizes listed. Any jointing requirements for cable sizes not shown on this table shall be
referred to one of the UK Power Networks J ointing Schools.
2.11.2 EPN/LPN/SPN Triplex or Three Single Core Termination Kits (CWS Cables)
x y
y
y
Operating Voltage (kV) 6.6 11
Minimum clearance between bushing centre (x) mm 100 100
Minimum clearance between bushing centre and ground (y) mm 60 60
Minimum clearance between cold applied bushing boots mm 12 12
Cable Sizes
mm
2
Single Core Indoor
Termination Kit
95-185mm
2
Single Core Indoor
Termination Kit
240-300mm
2
Stores Code 04150T 04151D
95 185 1 per End Box
240 300 1 per End Box
Guruflex Supplied in 10 litre kits (Stores Code =02204N)
use sufficient to fill box to the existing compound level
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2.11.3 EPN Polylam Termination Kits
components:
4.8 Mixing and Installing Guruex.
Cable Sizes
mm
2
Single Core Indoor
Termination Kit
95-185mm
2
Single Core Indoor
Termination Kit
240-300mm
2
Polylam Earth Kit
Stores Code 04150T 04151D 04108D
150 1 per End Box 1 per End Box
240 1 per End Box 1 per End Box
Guruflex Supplied in 10 litre kits use sufficient to fill box to existing compound level
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11KV Single-Core XLPE Indoor Termination

2

SMOE 63419
UK Power Networks Stores Code 04150T
2

SMOE 63420
UK Power Networks Stores Code 04151D

When Bushing Boots are required use:
For Cable sizes 95-300 mm
2
SMOE 62803
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barrel hole.
and the lug.

Fit the cable lug onto the bushing and
mark on each single cable the end of
the conductor position inside the
barrel of the lug.
the dimension given in the Figure 2.
Wrap the red sealant tape around the
end of the oversheath.

individual wires.
oversheath.
Gather the shielding wires together to
form an earth lead.
the void filling strip around the end of
the core screen.

2 3
240
wire binder
60
sealant tape
clean
100 mm
K
5 6 4
40
insulation
20
10
void filler
(yellow)
core screen
1
Pass the gland sealing sleeve over the
three single core cables and position
away from the jointing area. Secure
the cable gland to the base plate.
Slide the base plate over the single
cables and set each cable to the
relevant bushing stem.
Check that the copper wire shields will
reach the base plate mechanical
connector.
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Note: After installation the termination
must be post-heated as well as the
palm of the cable lug until a bead of
sealant (green) appears around the
top of the tubing.
Allow the termination to cool before

Clean and degrease the termination
and bushing.
Slide the boots over the completed
terminations.
Fasten the connectors to the
bushings.
screen cut using a soft yellow flame.
Heat the area well but avoid
the tubing.

Diameter of cable lug barrel:
Use additional red sealant tape to
build up the diameter of the cable lug
barrel for small cross section cable
sizes.

7
8 9
2
1
3
10 11
50mm onto the termination as shown
and slide the insulating boot down
over the termination.
12
50
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18
r
D
Min. 15 mm
Note: Clean the bushing before the
installation of the bushing boot.
onto the bushing.
Connect the cable lug to the bushing.
Push the boot upwards over the
bushing as far as possible.
Installation of the RCAB is now
complete.

13 14
Terminations complete.
Check that the minimum spacing
between the terminations and
terminations to any earthed metal
work are maintained:

b. phase to earth =15mm
c. phase to phase =20mm

Degrease the terminations and the
boots. Fit the front cover of the box
and secure.

Position the sealing sleeve over the
cable gland and shrink down the
sleeve, starting from the top of the
gland, before working down towards
the cables.
Termination completed.
16 17
15
Secure the base plate and gather the
copper wire shields from each cable
together. Connect them to the plate
using the provided mechanical
connector.
Minimum bending radius
Minimum bending radius (r) = 15 x D
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2.12 T1 Transformer End Box Terminations
The table below details the termination kits required to complete this termination for the cable sizes
2.12.1 EPN/LPN/SPN Triplex or Three Single Core Terminations into T1 Transformer End Box
components:
4.2.6 Mechanical Thimbles for use in T1 Transformer End Boxes.
4.4 Installing Bushing Boots.
4.4.2 Heat Shrink Boots.
Cable Sizes
mm
2
Single Core Indoor Terminations TX End Box
95mm
2
Tyco Part No. SMOE 62831
Stores Code 04154H
95 1 Set per End Box
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11V Si ngle-Core XLPE Indoor Termination for T1 Transformer End Box

For 95mm
2
Single-core XLPE or Triplex
SMOE 62831
UK Power Networks Stores Code 04154H
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Transformer oop 95mm
2
Termi nations
Cable Preparation

Pass the low voltage sealing sleeve over the three single core cables and position it away from the jointing area.

Fix the cable gland to the gland plate.

Carefully position the three single-core cables through the cable gland and gland plate.

Position one of the Thimble Connectors centrally into the bushing half shells. Mark a line on the cable sheaths
165mm from the bottom of the connector. This line will be the sheath removal position.

Note: On completion of the terminations the wire shields from each single core cable will be passed through the
cable gland and clamped to the outside surface of the gland. To ensure a sufficient length of wire shield is
maintained the cables should be cut to a length of 650mm.
T1 Transformer End Box
sealing sleeve
650

165
All dimension in mm
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1 2 3
L
K
60
sealant tape
wire bi nder
40
Remove the oversheath to dimension
shown in drawing.
Cut the core to dimension L + K, where
L=160mm and K =the depth of cable
thimble +5mm.

Clean and degrease the end of the
oversheath for approximately 100mm.

Wrap one layer of red sealant tape with a
small overlap and tension around the end
of the oversheath for 60mm.
Bend the copper wires back onto the
oversheath. Avoid crossing the
individual wires. Fix the wires to the
surface o f the sealant tape on the over-
sheath with a wire binder.
Temporarily secure the copper wires
along the cable oversheath.
Thoroughly remove the core screen to
within 40mm of the oversheath cut.
The surface of the insulation should be
free from all traces of conductive material
and any irregularities should be smoothed
out.
20
10
5 4 6
K
Dimension: K = depth of cable lug barrel
hol e + 5mm.
Note: Ensure a holding tool is used to
support the cable lug while the bolts are
sheared off.
Clean and degrease the core insulation and
the lug.
Note: Fill any remaining gap between the
lug and insulation with red sealant tape.
Remove the release paper and wrap the
yellow void filling strip around the end of
the core screen.
continue onto the insulation for 10mm.
Stretch the strip to half of its original width
and apply under tension to achieve a fine,
thin edge onto the insulation.
The bottom end of the tubing should be
level with the wire binder.
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11
7 9
Clean and degrease the termination and
bushings.
Slide the right angle boots over the
completed terminations.
Fasten the connectors to the bushings.

Note: At this stage of the installation
check the correct core spacing are as
specified in step 13.
10
Drawing A
Cut the tubing back onto the cable lug
barrel if necessary. Post heat the cable
lug until a bead of green sealant appears
around the top of the tubing.

Drawing B
Cut the tubing level with the end of the
cable insulation. Clean the surface of the
mechanical Connector. Allow the
termination to cool before applying any
mechanical strain.
8
Shrink the tubing starting at the bottom,
before working towards the cable lug.

Remove the release paper from the black
mastic tape. Wrap the strips of mastic
around the bushing nut and the exposed
parts of the connector, covering all sharp
edges.
To ease the installation of the right angle
boots, one layer of PVC tape can be
applied over the black mastic tape.
The PVC tape must not be applied over
the bushing or termination.

Position the right angle boots over the
bushing as shown.
A
B
Shrink the boots in place starting at the
inside angle of the boot.
Shrink the top of the boot onto the
bushing first and continue downwards
over the core.
12
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a a b b
14 13
Bend the individual wire shields over the
outside of the cable gland and secure
with the two worm drive clips provided.
The shielding wires should overlap the
cable gland by at least 75mm.
Cover the screw clamps with strips of the
black sealant mastic and position the
sealing sleeve over the cable gland.
Shrink the sealing sleeve starting from the
top of the cable gland before working
towards the cables.
Termination complete.
Check that the minimum spacing between
terminations and to any earth plane
are maintained.

a. between phase and ground =15mm
b. between phases =20mm

Transformer end box complete.
75mm
sealing
sleeve
shi eld wi res
15
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2.13 Single Core Polymeric Pole Terminations
The tables below detail the termination kits required to complete this termination for the cable sizes
2.13.1 EPN/SPN Triplex Pole Termination Kits (CWS Cables)
2.13.2 EPN Polylam Pole Termination Kits
components:
Cable Sizes
mm
2
Single Core Outdoor
Termination Kit
95-185mm
2
Stand Off Insulators
(set of 3)
Surge Arresters
(set of 3)
Tyco Part No. SMOE 63421 EPBI 1000 OCP2-12S-NFF
Stores Code 04152N 04153X 09436E
95 185 1 kit per Termination 1 set per Termination
(if required)
1 set per Termination
(if required)
Cable Sizes
mm
2
Single Core
Outdoor
Termination Kit
95-185mm
2
Polylam Earth Kit Stand Off
Insulators
(set of 3)
Surge Arresters
(set of 3)
Tyco Part No. SMOE 63421 SMOE 63409 EPBI 1000 OCP2-12S-NFF
Stores Code 04152N 04108D 04153X 09436E
150 240 1 per Pole
Termination
1 per Pole
Termination
1 set per
Termination
(if required)
1 set per
Termination
(if required)
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11V Single-Core Outdoor Termination

SMOE 63421
UK Power Networks Stores Code = 04152N

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Cable Preparation

the dimension given in the drawing.
Wrap the red sealant tape around
the end of the oversheath.

individual wires.
oversheath.
Gather the shielding wires together
to form an earth lead.
3 4
240
wire binder
60
sealant tape
clean
100
1 2
Secure the metal crucifix onto the pole
at a convenient working height. Fix the
insulators to the crucifix, positioning
the central insulator in the centre of the
fixing cut away.

Secure the copper wire shield
connector to the crucifix.
Fix the mechanical lugs to the
insulators. Secure the cables in the
cleat on the crucifix. Overlap the
cables 400mm beyond the lug fixing
bolts. This will allow the copper wire
shields to be connected to the crucifix
later in the installation.
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barrel hole.
and the lug.
Note: Do not use cable lugs with barrel
holes deeper than 110mm.
the yellow void filling mastic strip
around the end of the core screen.

K
6 7 5
40
insulation
20
10
Yellow void
filler
core screen

Shrink one heatshrink shed into
place at the position shown in the
drawing below.
screen cut using a soft yellow
flame. Heat the area well but avoid
the tubing.

8
9
2
1
3
10
180
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11 12
Bolt the cable lugs onto the
insulators. Gather the copper wire
shields into three groups.
Secure the wire shields into the
connector on the crucifix.
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2.14 13kA PILC Cable Earth Kit
The table below details the sizes of cable which shall have a 13kA Earth Clip tted, in conjunction
with all the relevant joint kits in the LPN and SPN areas. They are not required for pot end joints.
Any jointing requirements for cable sizes not shown on this table shall be referred to one of the UK
2.14.1 LPN and SPN 13kA PILC Cable Earth Kit
To install these clips further details for the preparation of each cable type can be found in the
following sections of this manual:
To complete these joints further details for the installation of components can be found in the
following sections of this manual:
Cable Sizes
mm
2
Three Core PILC/PICAS
Pot End J oint
95-185mm
2
Tyco Part No. SMOE 63414
Stores Code 04124G
16 95 Not Required
120 300 1 per PILC Cable in J oint
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11kV PILC 13A Earth Kit for Steel Wire and Steel Tape Armoured Cables

For cable Sizes 95-400mm
SMOE 63414
UK Power Networks Stores Code = 04124G

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Steel Wire Armour Cables

Working from the base kit instruction, strip the cable down to
the lead sheath leaving 60mm of cleaned lifted armours.

Abrade and degrease the lead sheath for a distance of 20mm
from the lifted armours.
A1
Apply two layers of the red sealing mastic around the lead
sheath starting 100mm from the lifted armours covering
40mm of sheath working back towards the armours.
A2
Position the black sealing sleeve onto the lead sheath up to
the lifted wire armours. Shrink down the sleeve.
A3
A4
Apply two layers of the red sealing mastic around the
insulating sleeve for a distance of 40mm, starting at the end
furthest away from the armours, before working back towards
the lifted armours.

60
40
red sealing mastic
black sealing sleeve
red sealing mastic
lifted armours
A5
copper mesh
Unwrap and fold in half lengthways one of the tinned copper
mesh rolls. Wrap it around the lead sheath at the end of the
insulating sleeve.
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Apply a double 18 gauge wire binder around the centre of the
clip and dress down the clip to suit the lead sheath profile.
Wrap the earth clip around the cable, ensuring the ends of
the clip are over the copper mesh fitted on the lead sheath,
and the red sealing mastic on the clip is positioned over the
sealing mastic previously installed on the insulating sleeve.
Remove the release papers from one of the red sealing
mastic strips and stick the strip down the centre of the solid
earth clip.
Note: This is an important moisture seal. Do not leave it out.
A8
A7
A6
red sealing mastic
wire binder
A9
A10
copper mesh
worm drive clip
Unwrap and fold in half length ways the remaining two rolls of
tinned copper mesh, wrap a roll around each end of the clip
over the tinned copper petals.
Lay down the armours onto the copper mesh and secure with
the worm drive clip.
Note: Do not cross the armour wires.
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Prior to the fitting of the metallic earth cage, wrap a contact
strip around the copper mesh at the end of the earth clip.
If the wire binder comes loose remove it. Apply two layers of
the red sealing mastic around the exposed earth clip
between the ends of both armours and earth cage.
A11
A12
40 30 60
contact strip
red sealing mastic
worm drive clipclip
B1
B2
B3
60
50
lead sheath steel tape armour
red sealing mastic
copper mesh
10
Steel Tape Armour Cables

Working from the base kit instruction, strip the cable down
to the lead sheath leaving 60mm of cleaned armours.

Abrade and degrease the lead sheath for a distance of
150mm from the armours.
Apply two layers of the red sealing mastic around the lead
sheath for 50mm working from the armour cut.
Fold two of the tinned copper mesh rolls in half lengthways
and wrap one around the lead sheath 10mm from the end
of the red mastic. Wrap the second around the armours
10mm from the end.
U
N
C
O
N
T
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O
L
L
E
D
Slightly raise the petals of one side of the clip, which will
cater for the armours. Wrap the clip around the cable,
ensuring the ends of the clip are over the fitted copper mesh
on the lead sheath. Check the red mastic sealing tapes are
pressed together. Dress down the clip petals onto the sheath
armours.

Using one of the red sealing strips, remove one of the
release papers and stick the strip down the centre of the solid
tinned copper strip, one side only.
Note: This is an important moisture seal. Do not leave it out.
B5
B4
red sealing mastic
B6
B8
B7
wire binder
worm drive clip copper mesh
worm drive clip
Apply a double wire binder around the centre of the clip.

Fold in half lengthways the remaining tinned copper mesh
roll. Wrap it around the end of the clip over the petals which
are on the lead sheath.

Fit the worm drive clip around the petals on the armours
and secure.
Before fitting the cage, wrap the serrated strip around the
copper mesh at the end of the clip. Secure the cage with
the worm drive clip.
U
N
C
O
N
T
R
O
L
L
E
D
Apply two layers of the red sealing tape, using a slight
overlap around the exposed earth clip between the armours
and the cage.
B9
red sealing mastic
U
N
C
O
N
T
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O
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E
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2.15 Three-Core Loop and Transitional Loop
The tables below details the joint kits required to complete this joint for the cable sizes listed. Any
2.15.1 EPN Transitional Loop J oint PILC to Triplex or Single Core Polymeric CWS
2.15.2 EPN Transitional Loop J oint PILC to Polylam
Cable Sizes
mm
2
Loop J oint
95-185mm
2
Three Core
Transition
Loop J oint
240-300mm
2
PILC Build-Up Kit
16-70mm
2
Stores Code
04137U 04138E 04125R
Paper XLPE
95 150 95- 185 1 per J oint
150 240 300 1 per J oint
185 95 185 1 per J oint
185 300 95 300 1 per J oint
Cable Sizes
mm
2
Three Core
Transition
Loop J oint
95-185mm
2
Three Core
Transition
Loop J oint
240-300mm
2
PILC Build Up Kit
16-70mm
2
Polylam Earth Kit
Stores Code
04137U 04138E 04125R 04108D
Paper XLPE
U
N
C
O
N
T
R
O
L
L
E
D
2.15.3 LPN and SPN Transitional Loop J oint PILC to Triplex or Single Core Polymeric CWS
2.15.4 SPN Transitional Loop J oint PICAS Main to Triplex
Cable Sizes
mm
2
Three Core
Transition
Loop J oint
95-185mm
2
Three Core
Transition
Loop J oint
240-300mm
2
Polymeric
Preparation
Kit
95-150mm
2
Polymeric
Preparation
Kit 185-
300mm
2
Tyco Part No. SMOE 63440 SMOE 63441 SMOE 63415 SMOE
63416
Stores Code
04137U 04138E 04129F 01430B
Poly
Main
Poly
Branch
Cable Sizes
mm
2
Three Core
Transition
Loop J oint
95-185mm
2
Three Core
Transition
Loop J oint
240-300mm
2
Polylam
Earth Kit
Polymeric
Preparation
Kit
95-150mm
2
Polymeric
Preparation
Kit
185-300mm
2
Tyco Part No. SMOE
63440
SMOE
63441
SMOE
63409
SMOE
63415
SMOE
63416
Stores Code
04137U 04138E 04108D 04129F 01430B
Triplex Polylam
U
N
C
O
N
T
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2.15.5 EPN Polylam to Polylam Loop J oint
2.15.6 EPN PILC to PILC Loop J oint
Cable Sizes
mm
2
Three Core
Transition
Loop J oint
95-185mm
2
Three Core
Transition
Loop J oint
240-300mm
2
PILC Build
Up Kit
16-70mm
2
PILC Cable
Preparation
KIt
95-185mm
2
PILC Cable
Preparation
KIt
240-300mm
2
Tyco Part No. SMOE
63440
SMOE 63441 SMOE
63429
SHSM-
12AL(2)
SHSM-
12BL(10
Stores Code
04137U 04138E 04125R 04140K 04141U
Paper Paper
16 70 16 70 1 per J oint 2 per J oint 1 per J oint
Cable Sizes
mm
2
Three Core
Transition
Loop J oint
95-185mm
2
Three Core
Transition
Loop J oint
240-300mm
2
Polylam
Earth Kit
Polymeric
Preparation
Kit
95-150mm
2
Polymeric
Preparation
Kit
185-300mm
2
Tyco Part No. SMOE
63440
SMOE
63441
SMOE
63409
SMOE
63415
SMOE
63416
Stores Code
04137U 04138E 04108D 04129F 01430B
Polylam Polylam
U
N
C
O
N
T
R
O
L
L
E
D
2.15.7 LPN/SPN PILC to PILC Loop J oint
Cable Sizes
mm
2
Three
Core
Transition
Loop J oint
95-
185mm
2
Three Core
Transition
Loop J oint
240-
300mm
2
PILC
Build Up
Kit
16-
70mm
2
PILC Cable
Preparation
Kit
95-
185mm
2
PILC Cable
Preparation
Kit
240-
300mm
2
13.1kA
Earth Kit
Tyco Part No. SMOE
63440
SMOE
63441
SMOE
63429
SHSM-
12AL(2)
SHSM-
12BL(10
SMOE
63414
Stores Code
04137U 04138E 04125R 04140K 04141U 04124G
Paper Paper
16 70 16 70 1 per J oint 2 per
J oint
1 per J oint
16 70 95 1 per J oint 1 per
J oint
2 per J oint
95 120 185 1 per J oint 1 per J oint 1 per
J oint
185 185 1 per J oint 1 per J oint 2 per
J oint
240 300 185 1 per J oint 1 per J oint 2 per
J oint
240 300 240 300 1 per J oint 1 per J oint 2 per
J oint
U
N
C
O
N
T
R
O
L
L
E
D
components:
4.5.6 PICAS Earth.
U
N
C
O
N
T
R
O
L
L
E
D

11kV Three-Core Transitional Loop Joint

95-185mm
SMOE 63440
UK Power Networks Stores Code = 04137U
240-300mm
SMOE 63441
UK Power Networks Stores Code = 04138E

This base ki ts makes one complete joint for one three core PILC/PICAS
cable to three singl e-core pol ymeric cables. Other cable combi nations can
be made using cable preparation ki ts.

U
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O
N
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reference line
100
a
60
140
PILC
PICAS
POLYMERIC
40
PILC Cable Preparation

Remove the armours according to the dimensions shown in
Table 1. Stand the armour wires upright and remove all
1
Wrap the short length of tinned copper mesh (EPPA-009-
850) around the lead sheath so that its edge just protrudes
beyond the armour wires when they are laid back down.
2
If a 13KA earth clip is required install it now and then proceed to step 4.
Table 1
Conductor size Cut-back dimensi ons given below
mm a
95 - 185 500
240 - 300 600
180
Pol ymeric
U
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O
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clip.
3
4 B
Belted Cables Paper Cables Onl y
end of the lead sheath and tear off the carbon paper against
20mm from the end of the lead sheath and tear off the belt
of each core using a tape binder. Using a clean, dry cloth,
remove any excess cable compound from around the cores.
4 A
5
Screened Paper Cables Onl y
cores.

tape binder
5
20
20
reference line
180
Unwind the fabric tape and remove the fillers. Rewind the tape
around the crutch of the cable and tie off 20mm from the end
of the metal sheath.
Tie a twine binder around the screen papers at
level with the twine binder.
Remove the top two paper tapes to the same position as the
screen papers.
Using a clean, dry cloth, remove any excess cable compound
from around the cores.
180
reference li ne
20
Cut a 50mm piece from the yellow mastic void filling tape as
20 10
50 6
U
N
C
O
N
T
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D
Push the mastic wedge carefully into the crutch until the tip is
just below the belt paper or fabric tape. The wedge will
deform and partly extrude between the cores.

8
IMPORTANT - Separate the cores carefull y so as not to

towards the core ends. Check that the tubes are shrunk

2
, the core tubes should be
substituted for those in the build up kit.

Position the red crutch sealing sleeve centrally covering the

2
, the crutch sealing
sleeve should be substituted for that in the build up kit.
10
Remove the release paper from a 400mm yellow mastic tape
strip. Wrap the tape around the crutch, overlapping onto the
lead sheath by 20mm and continue onto the red insulating
tubes for 20mm. Apply the void filling mastic with a 50%
overlap, stretching it to about half its original width and
applying it under tension. Wrap a second strip of the yellow
mastic over the first layer.

9
40 20
7
11
200
Single-Core Pol ymeric Cable Sheath Removal
Lay the single core plastic cables in their final jointing
position.
remove the outer jackets.
Thoroughly abrade and degrease the outer cable sheath for
a distance of 200mm from the sheath cut.

Note: It is important that this operation is carried out at this
stage. Do not leave it out.
U
N
C
O
N
T
R
O
L
L
E
D
Seal ant Tape
Screen Wires
Bend the screen wires back onto the red sealant tape,
binder or PVC tape to keep them tight against the red sealant
tape.

Semi Conducting Layer
to the dimension shown using the approved tools and
methods as applicable. Do not nick the insulation l ayer.

Core Tubing
Position the red core tubing (BPTM-50/20) over the cable to
level with the red mastic tape. Shrink into place starting at the
oversheath end. Strip back the tubings and insulation to suite
the type of connectors used. Check that the cores are
correctly identified.
insulation tubes over the cables onto this protection. Cover
the tubes against dust or moisture splash.

Note: If the insulating tubes are a tight fit over the red BPTM
tubing, lubricate the tubing with a smear of silicone grease
from the sachet provided.
Moisture Block
applied 60mm of red tape to sandwich the screen wires to
provide a moisture block. Continue onto the semi-conducting
layer for 15mm. Degrease the insulation.

void filling mastic strips. Starting 20mm from on the semi-con
layer, continue taping on to the insulation for 10mm to form a
smooth taper. Stretch the tape to half its original width and
apply under tension to ensure a fine neat edge. Remove the
second release paper during this taping operation.

12
13
14
15
60
40
40
60 15
moisture block
stress relieving tape
17
Set the cores in to their final joint position.
Secure the cores close to the crutch using the cable ties
provided.
Arrange the cables as shown in the drawing.
U
N
C
O
N
T
R
O
L
L
E
D
21
20
Roll up a length of the yellow void filling mastic tape and
push it into the single entry hole of the connector.
There are three patches per connector. The first patch is
located over the single end of the connector as shown with
the overlap located over the bolts area.
The two remaining patches should be formed into one long
patch by sticking them together, overlapping each other by
50mm. Wrap this long patch around the double end of the
connector, with the double 50mm thickness over the bolts.
19
red mastic
18
Fitting the Mechanical Connectors
Cut the cores to length.
Remove the insulation from each core and fit the mechanical
connectors.
Remember to install and shear off the bolts in the empty
single end of the connector.
yellow mastic
patch 2 +3
Roll up lengthways the wide (S1251) red mastic strips and
insert them top and bottom between the parallel cores of the
branch side. Firmly press into place butting against the
connector edge. Now cut the 600mm piece of yellow void
filling mastic into 6 x 100mm pieces. Fold it in half
lengthways and roll up to form a rod shape 50mm long.
Position one piece next to the connector where the step is at
its largest, as shown in the drawing.
Position the black heatshrink cap over the single end of the
connector and shrink down. Hold the cap in position using
the shaft of a hammer.
Repeat this process for all three cores.
black cap
yellow mastic
2 3 5 1 4
22
50
Apply a thin smear of grease over the yellow mastic. Position
the three black and red screened insulating sleeves centrally
over the connector. Use cable ties to bind together each pair
cores on the branch side. Shrink the tubes starting on the
branch side of the connector. Shrink to within 50mm of the
end and then switch to the single side stopping 50mm from
the end. Finish off the first then the second ends.
U
N
C
O
N
T
R
O
L
L
E
D
Pull the cores together and wrap the length of tinned copper
mesh around all three insulation sleeves in the centre and
secure.
Remove the cable ties holding the branch cores together.
Wrap one piece of the serrated metal contact strip around the
copper mesh. Do not overlap the contact strip ends.

For cables with aluminium sheaths
Fit the serrated strip over two adjacent crests of the
aluminium sheath.

24
Using the short length of tinned copper mesh, fold it in half
along its length and wrap it around the lead sheath.

For cables with aluminium sheaths
Do not apply the tinned copper mesh.
23
50
26
Wrap the aluminium earth cage around the joint. Secure the
cage using cable ties or a PVC tape binder.
Divide the petals of the cage equally between the two cables.
Secure the cage down onto the serrated strips of each cable
or the support ring using the worm drive clips.
25
27
Pol ymeric Cables
circle and position it on to the support ring edge nearest the
joint. Slide the support ring along the cables until the screen
fingers cover the full width of the contact strip. Use one worm
drive clip only and clamp down the fingers of the screen on to
the contact strip. Remove any excess clip length once fully
tightened.
U
N
C
O
N
T
R
O
L
L
E
D
c
a
b
Wrap two layers of the tinned copper mesh around the edge
of the support, lay all the copper wires of the single core
cables on to the copper mesh, continue to wrap the copper
mesh over the copper wires, clamp the copper mesh and
wires down on to the support ring, (tap and tighten), and trim
off the excess copper wires. Clean and degrease the space
between the cage fingers and the copper mesh. Using the
red mastic tape, wrap it in the space on the support ring.
together.
manufacturer's instructions and safety data sheet.

The joint is now complete.
Allow the resin to set before applying any mechanical strain.
28
Fold the petals of the cage down on the open side of the
joint. This will now close the cage and fully shield the internal
part of the joint.
Degrease and abrade the cable sheaths for a distance of
100mm.
Trim the ends of the joint half shells to accommodate the
cable used. Place the bottom half of the joint shell under the
joint and mark the position of the two shell stand-off
mouldings on the earth cage.
marks and secure.
The patch should be wrapped with the adhesive (white) side
outwards.
29
30
31
rubber patches
U
N
C
O
N
T
R
O
L
L
E
D
2.16 Polymeric Single Core Cable Sheath Repair Kit
The tables below details the materials required to complete this sheath repair for the cable sizes
2.16.1 EPN/LPN and SPN Polymeric Single Core Cable Sheath Repair Kit
Cable Sizes
mm
2
Polymeric Single Core Cable Sheath Repair Kit
Tyco Part No. CRSM 84/20-250/239
Stores Code 02305F
95 300 1 per single core
U
N
C
O
N
T
R
O
L
L
E
D

CRSM Wraparound Repair System for Triplex Cable Sheaths

CRSM 84/20-250/239
UK Power Networks Stores Code = 02305F

U
N
C
O
N
T
R
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D
1
2
3
4
General Instructions
Only use an approved propane gas torch.
Adjust the torch until it has a soft blue flame with a yellow tip. Pencil-like blue flames should be not be used.

Cable nspection (before installation)
Carefully remove the cable jacket to a maximum length of 75mm either side of the damaged section.
Check that the cable layers beneath the oversheath for signs of further damage.
If there is no damage to either the copper wires or the insulation, replace the oversheath.
If there is damage to the other layers an appropriate repair must be carried out (i.e. straight joints and a new section of cable).

The wrap-around should extend for at least 50mm at each end beyond the area to be protected.

Clean, degrease (using an approved degreasing solvent)
and abrade the oversheath, where it comes into contact with
the heatshrink wrap-around sleeve.
Remove the foil from the adhesive side of the heatshrink
wrap-around sleeve.
Position the heatshrink wrap-around sleeve centrally around
the area of damage oversheath.
Slide the steel channel onto the rail (the use of the
Raychem pulling tool AD 1608 is recommended for
channels above a length of 500mm).
U
N
C
O
N
T
R
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D
Installation complete. Allow the wrap-around sleeve to
cool before applying any mechanical strain.
7
6
5
Start shrinking in the centre of the heatshrink wrap-around
sleeve opposite the channel, before working towards the
ends.
Continue heating the channel area until adhesive flows out
on both ends of the heatshrink wrap-around sleeve and the
channel.
U
N
C
O
N
T
R
O
L
L
E
D

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