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15kV Class
Transition Splice for 3/C PILC to
3/C Armored Extruded Dielectric (Poly/EPR) Power Cables
Suggested Installation Equipment (not supplied with kit) Recommended Tyco Electronics Torches
• Cable preparation tools Install heat-shrinkable cable accessories with a “clean burning” torch,
• Tyco Electronics P63 cable preparation kit or cable manufacturer i.e., a propane torch that does not deposit conductive contaminants
approved solvent on the product.
• Clean, lint-free cloths
• Non-conducting abrasive cloth, 120 grit or finer Clean burning torches include the Tyco Electronics FH-2629,
• Electrician’s tape FH-2649 (uses refillable propane cylinders) and FH-2618A (uses
• Connector(s) and installation tools disposable cylinder).
• Tyco Electronics recommended torch
Adjusting the Torch
Safety Instructions Adjust regulator and torch as required to provide an overall 12- inch
DANGER: When installing electrical power system accessories, bushy flame. The FH-2629 will be all blue, the other torches will have
failure to follow applicable personal safety requirements and written a 3- to 4-inch yellow tip. Use the yellow tip for shrinking.
installation instructions could result in fire or explosion and serious
or fatal injuries. Regulator Pressure
FH-2618A Full pressure
To avoid risk of accidental fire or explosion when using gas torches,
FH-2649 25 psig
always check all connections for leaks before igniting the torch and
FH-2629 15 psig
follow the torch manufacturer’s safety instructions.
Cleaning the Cable
To minimize any effect of fumes produced during installation, always
provide good ventilation of confined work spaces. Use an approved solvent, such as the one supplied in the P63 Cable
Prep Kit, to clean the cable. Be sure to follow the manufacturer’s
As Tyco Electronics has no control over field conditions which instructions. Failure to follow these instructions could lead to
influence product installation, it is understood that the user must product failure.
take this into account and apply his own experience and expertise
when installing product. Some newer solvents do not evaporate quickly and need to be
removed with a clean, lint-free cloth. Failure to do so could change
Customer Service the volume resistivity of the substrate or leave a residue on the
surface. Please follow the manufacturer’s instructions carefully.
For 24 hour customer service, call 800-327-6996.
General Shrinking Instructions
• Apply outer 3- to 4-inch tip of the flame to heat-shrinkable material
with a rapid brushing motion
• Keep flame moving to avoid scorching
• Unless otherwise instructed, start shrinking tube at center,
working flame around all sides of the tube to apply uniform heat
Note: When installing multiple tubes, make sure that the surface of
the last tube is still warm before positioning and shrinking the next
tube. If installed tube has cooled, re-heat the entire surface.
1. Product selection
Note: Table is for 100% insulated Poly cable. For 133% insulated
cable, check actual cable dimensions.
3. Prepare cables
Choose the cable type (Choice 1-3) and use the dimensions shown in
Table 2 to prepare the cables.
Choice 1
CL
If Metallic Tape Shield Cable
A1 A2
Refer to Table 2 and prepare the cables as shown. Remove any fillers B
to the armor cutback. Bend back the grounding conductors(s) over C
4"
the jacket as shown. (102mm)
PO
L PILC
Go to Step 4, page 3. Y
Grounding 176
Conductor(s)
Grounding
Go to Step 4 below. Conductor(s) Tape over ends
of drain wires 177
CL
Choice 3
A1 A2
If UniShield* Cable
B
C
Refer to Table 2 and prepare the cables as shown. Remove any 4"
(102mm)
fillers to the armor cutback. Pull drain wires back to Dimension B
PO
and temporarily tape over ends as shown. Bend back the grounding L PILC
Y
conductors(s) over the jacket as shown.
Grounding Tape over ends
Conductor(s) of drain wires 178
Go to Step 4.
*UniShield is a trademark of General Cable Technologies Corporation
Choose the cable type (choice 1 or 2) and follow the directions given.
Choice 1
Tack solder metal tape shields to prevent unwrapping and tape over PILC
sharp edges with one wrap of electrician’s tape.
Lead
Go to Step 7 page 4. Paper Sheath
Insulation 102
Place an Oil Barrier Tube (OBT) over each phase, butted to the
lead sheath (or belt paper) cutback. Shrink the three OBTs in place
starting at the lead sheath cutback.
PILC
Note: To achieve a smooth, wrinkle-free installation, use a reduced
flame to install the thin-walled OBT. Lead
OBTs Sheath 394
The installed OBTs should have a smooth, wrinkle-free surface after PILC
shrinking. Reheat to smooth any wrinkled areas.
395
Lead Sheath
If Belted PILC Cable...Discard 1” wide copper mesh. Go to Step 12.
Solder copper mesh to the lead sheath. Cut off excess mesh close to
lead sheath.
Shrink in place starting at the end nearest to the center of the splice.
PILC
Black
I Conductive Tubes 221
OBT/Insulation 222
SRM Insert
PILC
225
Note: To ensure SRM to OBT adhesion, gently heat the SRM insert
and adjacent OBT before moving on to the next step.
PILC
Note: Do not over apply. The finished SRM diameter should not
exceed that of the breakout installed in the next step.
358
Position the conductive breakout over the SRM so that the inside
butts up hard against the SRM.
Shrink in place starting at the fingers and working toward the other
PILC
end.
Conductive
Breakout 359
After the breakout has shrunk, continue to apply heat until the PILC
breakout has a smooth, uniform surface.
360
Place one set of nested tubes over each clean Poly cable.
208
306
29. Apply Discharge Control Compound (DCC) Apply thin film of DCC over installed SRM
DCC DCC DCC
Snip open the end of the DCC ampule and apply a thin film of
compound over the three applications of SRM.
1847
Center the tubes over the splice. Begin shrinking at the center (1)
of the tubes, working the torch around all sides of the tubes. After
3 2
the center portion shrinks, work towards one end (2), then to the 1
opposite end (3).
Note: Do not point the flame at the cable semi-con. Black Stress Control Tube
Visible wrap
The rings from the SRM wraps may be visible as the tubing shrinks. lines
Post heat the connector area until the tube surface is smooth and the
underlying SRM wraps are no longer visible.
310
Center tubes over the black stress control tubes. Shrink in place
using the same method as in Step 31.
311
Remove backing from red sealant. Using light tension, wrap sealant
over the cable, butted against the red insulating tube as shown.
Build the sealant to the level of the red insulating tube.
312
Center tubes over the red insulating tubes. Shrink in place using the
same method as in Step 31.
313
Center tubes over the black/red dual layer tubes. Shrink in place
using the same method as in Step 31.
314
Choose the appropriate cable type (Choice 1-3) and follow the
directions given to ground each phase.
Pigtail the shield wires and crimp on to the ground braid using the
connectors provided.
315
Lay the braids across the splice tubes and solder ground braids to the
lead sheath of the PILC cable. Deburr the connection, cut off excess
braid and trim pigtailed wires.
Go to Step 37.
316
Choice 2 Ground
Braid Spring
Clamp
If Metallic Tape or LC Shield Cable
(1) Flare one end of the ground braid and place it onto the metallic
tape, butted up to the red sealant.
(2) Attach the braid to the shield by placing two wraps of the spring
clamp over the braid. 3) Fold the braid back over the spring clamp 317
wraps. Continue to wrap the remaining clamp over the braid.
Tighten clamp by twisting it in the direction it is wrapped and secure
with copper foil tape provided.
1 2 3
Lay the braids across the splice tubes and solder ground braids to the
lead sheath of the PILC cable. Deburr the connection, cut off excess
braid and trim pigtailed wires. Copper Foil Tape
Go to Step 37.
318
Bend the grounding conductor(s) back over the tubes and solder to
the lead sheath. (It may be necessary to splice in an extension to the PO
L PILC
ground conductor(s) in order to reach the lead sheath. Y
Grounding 712
Conductor(s)
Bind the ends of the armorwrap to the cable armor and lead sheath 693
with the tape provided. Tape Wrap
693a
2578
Preheat evenly along both sides of the rail/channel area until this
area begins to shrink. To achieve uniform heating, move the flame
back and forth from one side of the channel to the other as shown
in illustration “A” while moving flame along the entire length of the
channel as shown in illustration “B” until the sleeve starts to shrink.
This technique will assure a properly preheated rail and channel area.
A B
Begin shrinking at the center of the sleeve and work toward each
end.
White indicator
Apply heat until the sleeve is fully shrunk and the heat-sensitive
green paint is completely converted to black. Continue heating the
rail/channel area for another 5 seconds per foot. A white line should
be visible in the channel gaps indicating sufficient heating.
The Information contained in these installation instructions is for use only by installers trained to make electrical power installations and is intended to describe the correct method
of installation for this product. However, Tyco Electronics Corporation has no control over the field conditions which influence product installation. It is the user’s responsibility to
determine the suitability of the installation method in the user’s field conditions. Tyco Electronics’ only obligations are those in Tyco Electronics’ standard Conditions of Sale for this
product and in no case will Tyco Electronics be liable for any other incidental, indirect or consequential damages arising from the use or misuse of the products.
TE (logo) and Tyco Electronics are trademarks. Copyright 1998, 2010 Tyco Electronics Corporation. All Rights Reserved.