Fitting Instruction - · PDF fileThe jointer must have learnt the correctly intended...

Fitting Instruction

EST 123Dry and self supported High Voltage-Termination

0.1 English – 22725 – © PFISTERER Ixosil Ltd – 0311

PFISTERER Ixosil Ltd.Cable SystemsAltdorf / Switzerland

Table of contents1. Preparation Note ��32. Installation Note ��33. Termination Type Abbreviation ��44. General Instructions ��45. Cable Positioning ��5

5�1 Table K and t dimensions ��55�2 Positioning and clamping of cable��6

6. Cable preperation ��76�1 General��76�2 Cable quality check ��86�2�1 Cable diameter check (F) �� 86�3 Preparing of core insulation on all cable XLPE types ��96�4 Preparation of cable with laminated sheath and screen wires ��10

7. Mounting of the termination ��117�1 General��117�2 Check stress cone��117�3 Apply silicone grease ��117�4 Mounting termination ��127�5 Mounting of Shed set ��137�6 Gluing of Shed set ��14

8. Fitting of Drip seal and contact bolt ��158�1 Preparation for mounting Drip seal ��158�2 Fitting of contact bolt and Drip seal ��168�3 Mounting sealing cap��168�4 Fitting of Creepage current arrester ��168�5 Final point ��168�6 Drying ��16

9. Check Sheet EST ��1710. Mounting base plate ��18

10�1 General��1811. Fitting head armature brace ��1912. Tightening anchor clamp ��2013. Release head armature spring ��21

EST_ _ _ page 2

PFISTERER Ixosil Ltd.Cable Systems

Altdorf / Switzerlandwww.ixosil.ch

1. Preparation NoteCheck that the materials are complete and suitable for the cable to be fitted on.

Check that all the relevant tools required for the following installation work are available on site�

Check that the site conditions are adequate to provide a clean and sheltered working environment for the correct and proper fitting of this product.

2. Installation NoteThe information contained in these instructions is to show the correct method of installing this product. The product is only to be installed by a certified trained and competent jointer aware of all product requirements and safety practices�

The jointer must have learnt the correctly intended installation procedure and is responsible to arrange the site conditions required to install this product�

PFISTERER Ixosil LtdCable SystemsGotthardstrasse 31CH-6460 AltdorfTel +41 41 / 874 75 75Fax +41 41 / 874 75 76E-mail: [email protected]: www.ixosil.ch

EST_ _ _ page 3



3. Termination Type AbbreviationESF 72 - C23 L TE - 01

ESF Flexible, dry termination(Without self supporting propertys)

EST Flexible, dry termination (with self supporting propertys)

72 Voltage range (72-170 kV)

C23 Creepage length (15 - 53 1/10 m)

L LSR-silicone

TE PD-sensorOP Data and temperature-sensor

OPTE PD-CensorData and temperature-sensor

01 Size (01-14)

Check the type and size of the termination to be installed according the packing list or the label of the packing and the sheathing type of the cable�

4. General Instructions – Work area has to be dry, clean and dust free�

– The use of damaged or unclean materials is grounds for a void in product guarantee�

– Use eye and hand protection when using cleaning fluids.

– Use gloves when greasing�

– This instruction has to be followed exactly during the installation process�

– Unpack and check silicone parts just before installation.

– Do not use any form of knife when handling silicone parts�

– Apply tapes No� 13, No� 50 and copper fabric tape with 50% overlap�

– Acceptable cleaning fluids are: Toluol, Sieder benzin, Alcohol, O-Xylol and Aceton.

EST_ _ _ page 4



Dimension K (for ESF 123)Creepage length

[1/10 m]Shed sets Height H Dimension K

C31L 1 x 4 sheds 1297 mm 1362 mmC39L 1 x 8 sheds 1529 mm 1594 mm

Dimension t (for stress cone 170)CrosssectionConductor

Cu-Conductor

pressed

Al-Conductor

pressed

Al or Cu Conductor

screwedmm² mm mm mm95 136 121 136120 136 121 134150 136 119 134185 134 119 134240 134 113 134300 134 113 128400 128 118 128500 128 118 135630 128 171 135800 178 171 1831000 178 171 1351200 178 171 1841400 178 - 1831600 178 171 1832000 178 171 1852500 185 - 185

Working tableCreepage Height Dimension Dimension

[1/10 m] H K t

Attention:Please fill in the working table using the above information given before starting the cable preparation. When the wor-king table has been filled out, use these dimensions provided.

5. Cable Positioning

5.1 Table K and t dimensions

The drawing on top shows a representation, where the different dimensions are located� Drawing is not to scale�

EST_ _ _ page 5



5.2 Positioning and clamping of cableFix the cable into position using at least two cable cleats� Using heating mats and alignment rails, heat and straighten the cable� Note: by corrugated, lead or armor sheathed cables it may be necessary to remove these metalic sheaths before the above mentioned heating and straightening procedure can be carryed out�

The Reference line is approximatlyon the same level as the base plate�

Attention:This point is not the top of termination� Depending on how much the termination shrinks in legth on fitting, the cable will need to be pulled for a justment

Note:Slide on cable clamb, extension cageand base plate into park position�

ATTENTION:Cable cleats are not in Scope of surply�The completed termination shall have the first two cable cleats moun-ted as here indicated�

Legend29 Marking tape (lower edge is reference point)43 Cable clamp45 Base plate46 Post insulators57 Extension cage58 Creepage current arrester60 Anchoring clamp125 Cable cleats

all dimensions in mm

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6. Cable preperation

6.1 GeneralUse the following cross section drawings to cut cable to length� All measurements must be made from the cable end with cross checking from marking tape lower edge� Do not use the outer sheath edge as a measuring point.

ATTENTION:

1� The transition between core insulation and outher semiconductor screen shall not exceed 6° chamfer slope�

2� Insulation prepared as per PFISTERER Ixosil requirements� (Demostrated and practiced during training course)

3� The final position of the termination shall have the core insulation and transition to semi-conductor sanded smooth with sand paper 180 grit first and then polished with sandpaper 320 grit� The transition between core insulation and semi-conductive screen shall have a finished prepared slope of max. 6°.

4� For cable preparation dimensions see appropriate parts list and cross sectional drawing�

5� Any semi conductive material on the outer sheath must be removed for a min distance of 1000mm from the outer sheath edge�

6� Fill in required dimension from cable preparations in check sheet

EST_ _ _ page 7



6.2 Cable quality checkCheck that the prepared cable insulation is not flat sided and the excentricity is within the acceptable limits according to drawings below�

Excentricity Flatsiding

Maximum 15% difference between the thickest and thin-nest point in insulation. No Tolerance

Flat sidedness ist not accepted. The cable shall be round.

The user result range is min 0.85 to max. 1.15 Dimension a and b has to be messured at least at 6

points. Calculate with the biggest difference.

6.2.1 Cable diameter check (F)

Check that the diameter of the prepared insulation is with in the limits according to the appropriate parts list� Fill in dimension (F) in check sheet� (Position 1)

ATTENTION:DO NOT install if cable preperation is outside given limits stipulated�

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6.3 Preparing of core insulation on all cable XLPE types

Sand and polish smooth the core insulation and transition to extruded semi conductive outer screen with first 180grit and then 320 grit sand paper.

Remove the insulation for the contact bolt after the termination has been fitted.

Diameter Q has to be 5 mm larger than the inside diameter of the lower part of the stress cone�

Attention:The temporary cone on the end of the insulation will be cut off before peeling dimension t� (Tip, ensure the cable is longer than K + t)

Legend29 Marking tape (Lower edge is reference point)


Reference line for lower edge of termination

230mm

Sand w

ith 180gritP

olish with 320grit

In this area

Q

EST_ _ _ page 9



6.4 Preparation of cable with laminated sheath and screen wiresLegend3 Sealing tape6 Cu fabric tape (1 Layer)11 Tape No� 13 (1 Layer)14 Tape No� 50 (1 Layer)14a Tape No� 5015 Tape No� 6029 Marking tape Lower edge is reference point for lower edge of termination29a Tape No� 3531 Creepage current arrester59 Clip60 Shrink sleeve No�80 66 Flexible flat lead (Option, refer to part list)70 Compression sleeve71 Roll spring73 Bonding cable81 Outer sheath with semi-conductive layer82 Outer sheath without semi-conductive layer83 Semiconductive screen84 Insulation86 Screen wires92 Laminated sheath



Out

er s

heat

h ed

ge

1000

1000

As

shor

t as

poss

ible

31

31

ATTENTION:Legend No� 31 only for ESF and EST72

EST_ _ _ page 10



7. Mounting of the termination

7.1 GeneralReminder� Observe clean conditions

7.2 Check stress coneCheck the surface of the silicone stress cone� DO NOT USE if there are any cuts or deep abrasions�

7.3 Apply silicone grease Cover the indicated area with P4 grease�Use only a clean and smooth grease poll for greasing termination�Ensure the entire surface inside the termination and indicate area on cable is cover with P4 grease�

Attention:When applying grease always use gloves provided�

Legend29 Marking tape (Lower edge is reference point)32 Grease poll (For applying P4 sillicone grease) all dimensions in mm

Area to be covered evenly w

ith P4 grease


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7.4 Mounting terminationSlide on termination until the lower edge is flush with the lower reference edge of the marking tape�Twisting of the termination during mounting is permitted howeveron final positioning the twist was be removed. Use the molding form line in the silicone as reference

Legend29 Marking tape (Lower edge is reference point)

Reference line for lower edge

of termination

EST_ _ _ page 12



7.5 Mounting of Shed setSlide on Shed set until about 50-100 mm from the stress cone�Follow step 7�6 before continue with the secondShed set�

NOTE:The molding form line shall have an offset from about 90° between the different parts�


of termination

Mol

ding

form

line

(Fro

m p

rodu

ctio

n)ed

ge o

f ter

min

atio

n

EST_ _ _ page 13



7.6 Gluing of Shed setDegrease and clean the hole area� Apply silicone glue E4 on shed and cable� Slide Shed set down Squeese together the two sheds Starting from the center and squeesing out to the edge of the sheds�

The molding form line shall have an offset from about 90° between the different parts�

This area has to be cleaned well, before appling silicone glue E4


of termination

EST_ _ _ page 14



P2

8. Fitting of Drip seal and contact bolt

8.1 Preparation for mounting Drip seal

From top of termination shedsmark dimension 65mm + t�Cut cable off to this length�

Remove insulation and anyother layers above the conductor�

Wrap tape No. 50 flush with the insulation top edge to dimension P2�Dimension P2 has to be at least 4 mm bigger than the hole diameter (P1) of the drip seal�

Fill in dimension S into check sheet�


P1

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8.2 Fitting of contact bolt and Drip sealHead Contact bolt (Compression)Ensure the conductor is correctly prepared and clean before mounting the compression bolt� Compression sequence depends on space between contact bolt and insulation� If distance isshorter than 10mm from bottem to top,when distance is longer then 10mm from top to bottem�Head Contact bolt (Mechanical torque connector)Ensure the conductor is correctly prepared and clean before mounting the mechanical torque connector� (See instructions in packet for manufacturer fitting procedure)

8.3 Mounting sealing capClean areas indicated very well with cleaning fluid. Cover and evenly with E4 glue. Immediately after slide the sealing cap into position. Once sealing cap has reached final position twist to spread glue over sealing interface� Squeese together the two sheds Starting from the center and squeesing out to the edge of the sheds�

Fill in dimension LV into Check sheet

8.4 Fitting of Creepage current arresterFit creepage current arrester in grooveprovided at the base of the stress cone�Attention: Take care not to damage the Stress cone during the above mounting process�

8.5 Final pointEnsure the creepage current arrester lead and bonding cable are secured inplace with cable ties�

8.6 DryingThe Glue E4 needs 3 days to dry out�

Legend27 Sealing cap33 E4 silicone glue

Wrap edge withTape No. 35

and make a small cone

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Customer: Contract No:Project: Termination-Type:Circuit-Name: Serial-No.:

Phase:Group No.

Jointer name: Signature Date:Superviser name: Signature Date:

No. Description Measurement mm1 Dimension K

End of insulation<=> lower edge of marking tape2 Dimension t

Hole depth or head contact bolt3 Diameter of prepared insulation4 Lower edge of marking tape <=> top edge of semi

conductive layer5 Dimension Q6 Dimension P7 Dimension S (before compression)8 Dimension LV

Comments:

After installation, please sign and send back the orginal check sheets to the address below for final approval.Bitte

PFISTERER Ixosil LtdCable SystemsGotthardstrasse 31CH-6460 Altdorf

Fax: +41 41 874 75 76

9. Check Sheet EST

10. Mounting base plate

10.1 GeneralObserve clean conditionsGrease all bolts P4�Use P1 contact grease on all metalic interfaces

Fitting sequence:

General1/Mount extension cage to base plate�2/Mount support insulator to base plate, tighten bolts with 130Nm and position top of insulatorapproxamately for the fitting of head armature brace�3/Mount Anchor clamp (loose) on the cable so it can still slide along cable�

Legend27 Base plate55 Bolts M12 x 40mm (Allen key head) (Tighten to 78Nm)56 Ripple spring washer M12 56a Flat bearing washer 24/12 x 1�5mm56b Nut M1257 Extension cage58 Ripple spring washer M1059 Bolts M10 x 40mm (Allen key head tighten to 50Nm)60 Anchor clamp

EST_ _ _ page 18



11. Fitting head armature brace

Fitting sequence:

1/Fit Head armature brace to support insulator� Grease bolts with P4 and tighten down to 130Nm (Legend 50/51)2/Mount spring tension device over head armature� Ensure correct seating in head armature brace (Legend 53)3/Tighten locating grub screws in spring tension device� (Legend 52)

Legend50 Bolts M16 x 45mm (Allen key head tighten to 130Nm)51 Ripple spring washers M1652 Locating grub screw M10 x 20mm (Allen key head) 53 Spring tension device54 Head Armature brace

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12. Tightening anchor clamp

Fitting sequence1/Pull cable (with care) in the opposite directionto the head armature brace to remove any bend obseved in termination�2/Tighten anchor clamp evenly to 30Nm�3/ Secure surface current arrester lead to base plate�4/ Mount bonding cable lug and fit to Anchoring clamp as indicated�

Legend27a Bolts M16 x 70mm (tighten to 110Nm)57 Base plate extension60 Cable Anchor60a Bolts M10 x 40mm (Allen key head tighten to 30Nm)61 Surface current arrester lead62 Bonding cable connection M12 (tighten to 50Nm) and M16 (tighten to 60Nm)

EST_ _ _ page 20



13. Release head armature spring

Fitting sequence1/ Release Tension spring device, by releasing bolts M10 x 80mm with M10 nut and remove�

Legend52 Locating grub screw M10 x 20mm (Allen key head)61 Release bolts M10 x 80mm

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