General
Components or work steps may have been changed since you last time
installed this product.
Only competent and trained personnel familiar with cables, accessories
and safe operating practices should install ABB accessories.
This instruction is intended to be a guideline for a proper
installation and is substitute for adequate training and
experience in good safety practices.
This instruction applies to cables with an insulation screen
that is strip-able or bonded to the insulation. To remove
strip-able insulation screens, use a round file. To remove
bonded screens use a rotating tool or a piece of glass.
Check that the diameter of the cable insulation corresponds
to the marking on the package of the relevant accessory, e.g.
joint, adapters or stress relief cone.
Cleanliness during the whole installation is of great importance.
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3151-3756CNTHB
Rev.b
3-core cable installation
一、 Install the cold shrink accessory
1、 Make the cable locate in the due location and cut off the cable according to bellow dimension,
polish the armoring tape and twine PVC tape around the end of copper tape and armoring tape as
in the picture.
（reference dimension is 800-1200mm)
PVC Tape
Unit: mm
Copper screen tape
800-1200 Inner sheath
10
Armoring tape
40
Over sheath
2. Fix the earthing line, firstly fix the 16mm2 copper braid on the armoring tape with constant
force spring, secondly fix the 25 mm2 copper braid around the three phase cooper tape of the
cable, and apply some filling mastic between the two earthing line(copper braid) to separate
them for insulation effect. And then twine the filling mastic around the constant force spring
which is on the copper tape, make the filling mastic to form a cone shape which is 30mm above
the over sheath of the cable. At lastÿtwine one layer of sealing mastic around the over sheath
to prevent moisture.
Copper screen tape
Constant force spring
Filling mastic
Copper braid
Sealing mastic
Over sheath
3. Install the cold shrink jacket and hose. Put the cold shrink jacket into the end of the cable
(pay attention to the pulling direction of the supporting strip), pull out the supporting strip
anticlockwise to make sure the cold shrink jacket cover the filling mastic. And then pull out the
supporting strip of the cold shrink hose in the same way. Then put the cold shrink hose on the
cable and make sure the hose can cover the jacket at least 20mm and pull out the supporting strip.
Supporting strip
Cold shrink hose
Cold shrink jacket
Copper braid
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3151-3756CNTHB
Rev.b
二 Install the connector and surge arrester
1、Cut and strip the cable.
Cut and strip the cable according to installation rule and make sure the surface of insulating
layer without scratch. If scratched, must polish the surface with emery paper. Chamfer the
fracture of semi-conductive layer and insulating layer to make semi-conductive layer and
insulating layer transit smoothly (Note: do not scratch the insulating layer).
Conductor length: 5mm + depth of lug; Length of insulating layer: 158mm
Length of semi-conductive layer: 30mm ; Length of copper screen: 5mm.
2. Twine semi-conductive tape.
Stretch the semi-conductive tape to 150%~200%. Twine semi-conductive step from the fracture of
copper screen and cold shrink hose. The step width is 25mm and the thickness is 3~5mm.
Note: Semi-conductive tape must be stretched to the length required and ensure the surface of
semi-conductive tape and cable clean.
PVC Tape
50
Conductor
158
10
Insulation
Semi-conductive layer
30
Semi-conductive step
Copper screen tape
Cold shrink hose
5
3. Clean insulating layer.
Wipe insulating layer from the fracture of insulating layer to semi-conductive tape with cleaning
paper and avoid that the conductive particle is on the insulating layer (do not wipe reversely or
back and forth.). If there is conductive particle on the insulating layer, must polish the
insulating layer and wipe the surface with cleaning paper.
4. Install stress cone.
Apply silicone grease on the surface of insulating layer and stress cone hole. Then push stress
cone into insulating layer until stress cone step is close to semi-conductive step.
Note: Avoid to use excessive force to push the semi-conductive step away.
Stress cone
Semi-conductive step
图 5
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3151-3756CNTHB
Rev.b
5. Install the cable lug.
Push the cable lug on conductor, protect the stress cone and use clamp to compress the lug by 3 times.
Polish cable lug if burrs exist.
Crimp the lug
Stress cone
Semi-conductive step
6、Install the connector 图 6
a. Clean inner surface of connector with cleaning cloth, adapter and cable lug. Make sure there is no
impurities conductive particles. Apply grease on adapter and inside the elbow. Push the connector
on cable until cable lug fully contact with inner surface of connector. Please notice that adapter
should be remain steady when push connector on cable.
b、Clean the bushing and elbow with cleaning cloth. Push the elbow onto the bushing. Tighten the
M16×M16 stud with 45N.m torque. Install plain cushion and nut in turn.
c、Clean the plug and elbow with cleaning cloth. Apply grease inside rear elbow and on insulation plug.
Screw in the plug with installation tool. Push on the cap.
⑧⑨ ⑩ ⑾
① ② ③ ⑿
④
① Bushing ⑤ ⑦ Earthing line
⑥
② Stud ⑧Flat gasket
③ Grease ⑦ ⑨ Spring washer
④ Cable lug ⑩ Nut
⑤ Connector ⑾ Plug
⑥ Stress cone ⑿ Cap
图7
7、Install the surge arrester
If surge arrester is required to install, tighten connecting rod with M16×M16 screw by wrench
with 45N.m torque.
Apply grease on rear surge arrester body and push into front connector. Install plain cushion
and nut in turn. tighten the nut with 45N.m torque.
8、Repeat procedure 6.c step.
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3151-3756CNTHB
Rev.b
9、Connect earthing lines of connector, cable and surge arrester to ground.
⑧⑨⑩ ⑾
① ② ③ ⑿
④ ②
⒃
① Bushing ⑤
⒀
② Stud ⑥
⑦ Earthing line
③Grease ⑦ ⒀ Surge arrester jacket
⑧Flat gasket
④ Cable lug ⒁ Surge arrester
⑨ Spring washer ⒂ Earthing line
⑤Connector
⑥ Stress cone ⑩ Nut ⒁ ⒃ Copper connecting rod
⑾ Plug ⑦
⑿ Cap ⒂
6
3151-3756CNTHB
Rev.b
1-core cable installation
一、Install 1-core cold(or heat) shrink cable accessory
1、 Cut and strip the cable.
Cut and strip the cable according to installation rule and make sure the surface of insulating
layer without scratch. If scratched, must polish the surface with emery paper. Chamfer the fracture
of semi-conductive layer and insulating layer to make semi-conductive layer and insulating layer
transit smoothly (Note: do not scratch the insulating layer).
Conductor length: 5mm + depth of lug; Length of insulating layer: 158mm
Length of semi-conductive layer: 30mm ; Length of copper screen: 5mm.
2、Twine semi-conductive tape.
Stretch the semi-conductive tape to 150%~200%. Twine semi-conductive step from the fracture of
copper screen. Make the semi-conductive tape cover the 5mm copper screen, and form a 3mm thick
cylinder step. Note: Semi-conductive tape must be stretched to the length required and ensure the
surface of semi-conductive tape and cable clean.
PVC Tape
50
Conductor
158
Insulation
10
Semi-conductive layer
30
Semi-conductive step
Copper screen tape
5
Cold shrink hose
3、Install the earthing line.
The distance between semi-conductive tape and cable over sheath is 80mm (keep 30mm armoring tape
and 10 mm inner sheath).Polish the armoring tape and fix the two earthing lines on the copper
screen and armoring tape, and separate the two earthing lines with filling mastic,( If the cable
has no armoring tape, only need to fix one earthing line on the copper screen), at last, twine
filling mastic around two constant force springs to make sure seal good enough at the 80mm area.
PVC tape
10
Copper screen tape
Constant force spring
Inner sheath
80
Copper braid Filling mastic
Armoring tape
30
Filling mastic
Over sheath
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3151-3756CNTHB
Rev.b
4、Install cold (or heat) shrink hose.
Put the cold (or heat) shrink hose on the cable over sheath. Shrink the hose begin at the
semi-conductive step until the hose cover the cable over sheath around 60mm, cut off extra hose.
Insulation
Starting point for shrinking the horse
Cold(or heat)shrink hose
Over sheath
图 3
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3151-3756CNTHB
Rev.b
二、Install the connector and surge arrester
1. Clean insulating layer.
Wipe insulating layer form the fracture of insulating layer to semi-conductive tape with cleaning
paper and avoid that the conductive particle is on the insulating layer (do not wipe reversely or
back and forth.). If there is conductive particle on the insulating layer, must polish the
insulating layer and wipe the surface with cleaning paper.
2. Install stress cone.
Apply silicone grease on the surface of insulating layer and stress cone hole. Then push stress
cone into insulating layer until stress cone step is close to semi-conductive step.
Note: Avoid excessive force that the semi-conductive step is pushed away.
Stress cone
Semi-conductive step
3. Install the cable lug.
Push the cable lug on conductor, protect adapter and use clamp to compress the lug by 3 times.
Polish cable lug if burrs exist.
Crimp the lug
Stress cone
Semi-conductive step
4、Install the connector
a. Use cleaning cloth clean inner surface of connector, adapter and cable lug. Make sure there is no
impurities conductive particles. Apply grease on adapter and inside the elbow. Push the connector
on cable until cable lug fully contact with inner surface of connector. Please notice that adapter
should be remain steady when push connector on cable.
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3151-3756CNTHB
Rev.b
b、Clean the bushing and elbow with cleaning cloth. Push the elbow onto the bushing. Tighten theM16×M16
stud with 45N.m torque. Install plain cushion and nut in turn.
c、Clean the plug and elbow with cleaning cloth. Apply grease inside rear elbow and on insulation plug.
Screw in the plug with installation tool. Push on the cap.
⑧⑨ ⑩ ⑾
① ② ③ ⑿
④
① Bushing ⑤ ⑦ Earthing line
⑥
② Stud ⑧Flat gasket
③ Grease ⑦ ⑨ Spring washer
④ Cable lug ⑩ Nut
⑤ Connector ⑾ Plug
⑥ Stress cone ⑿ Cap
5、Install the surge arrester
If surge arrester is required to install, tighten connecting rod with M16×M16 screw by wrench
with 45N.m torque. Apply grease on rear surge arrester body and push into front connector.
Install flat gasket,spring washer and nut in order.
6、Install the plug and repeat procedure 6.c step.
7、Connect earthing lines of connector, cable and surge arrester to ground.
⑧⑨⑩ ⑾
① ② ③ ⑿
④ ②
⒃
① Bushing ⑤
⒀
② Stud ⑥
⑦ Earthing line
③Grease ⑦ ⒀ Surge arrester jacket
⑧Flat gasket
④ Cable lug ⒁ Surge arrester
⑨ Spring washer ⒂ Earthing line
⑤Connector
⑥ Stress cone ⑩ Nut ⒁ ⒃ Copper connecting rod
⑾ Plug ⑦
⑿ Cap ⒂
10
3151-3756CNTHB
Rev.b