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APECB 84-170

Cable termination for


XLPE-insulated cables 84-170 kV.
Insulator of porcelain or composite.

ABB Kabeldon
4290.5211-05
(Engelsk)

5048

June 2004

ABB Kabeldon, Box 531, S-441 15 Alingsås, Sweden, Telephone +46 322 770 00, Telefax +46 322 770 01

1
4290.5211-05

General:

Read the whole installation instruction carefully before starting work.

This product should be installed by competent and trained personnel familiar with cables,
accessories and safe operating practices. Parts contained in this kit should be visually
inspected for possible damage, and installed in accordance with the following instructions.
These instructions are intended to be a guideline for proper installation and not a substitute
for adequate training and experience in good safety practices.

Check that the diameter of the XLPE-insulation corresponds with the marking on the stress
cone packet.

A cut-away drawing of the termination is found in Appendix 1. Some important figures are
also found in the drawing.

The cables shall be straightened before starting work by e.g. straightening equipment, type
RKM 1000, see installation instruction No 4290.355.

This instruction is applicable for cables with an insulation screen that is vulcanized to the
insulation.

The use of a rotating stripping tool e.g. RKM 4595 is strongly recommended when preparing
the XLPE-insulation.

All tapes are to be wound with 50 % overlap.

The nuts shall be tightened crosswise and in sequence until the specified torque is reached.

Tape designations

ET = Electrical tape, PVC

IV = Insulating self-bonding tape, to be stretched so that the width reduces to about


26 mm.

For cleaning, use for example ethylalcohol.


For cables with metallic sheath, using ”JSA 1 Pb,Al”, see instruction No. 4290.261
For cables with copper wire and Al-foil using ”SCK”, see instruction No. 4290.603

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1. Place the box body on the cable.

Place the box body in position. Lift the cable into


the correct position.

Mark the cable at the lower edge of the box body.


Also mark the position for the shield wire opening
on the periphery of the sheath and a mark on the
box body flange.

The work is carried out more easily on the ground


with the cable lying horizontally.

If the installation is made with cable vertically, then


secure the cable and place the box body as in
point 6.

2. Measure the length of the insulator.


Cut of the cable A mm from the marking.

B 345 A
Box body

Insulator length B = ......................... mm


+ 345
~90

A = ......................... mm

Marking

5049
5050

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3. Measure and note the length C of the stress cone.

C
C = ..........mm

5056

4. Mark a distance of A-385+C mm from the end of the cable and remove the sheath
from this point to the end of the cable.
Fold back the shield wires over the edge of the sheath.
(For cables with other types of shieldings see page 2.)

A-385 +C

Marking 5052

5. Knock back the insulation with a piece of wood and a hammer.

5053

6. Check that the top of aluminum is free from burrs and varnish.
Place the box body onto the cable.

Box body
Top of aluminum

5054

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NB! It is important that the instructions in sections 7 -10 are followed correctly so
a smooth surface is obtained where the stress cone will be placed.
A - 475 + C
7. Mark out the distance from the Marking
end of the cable

This point only when using a rotating


Insulation screen
stripping tool e.g. RKM 4595. 5057

8. Remove the insulation screen to100 mm


from the marking. Do not remove more Marking 100
Insulation
insulation than necessary, especially
within 400 mm of the marking.

In order to avoid a waist on the insulation. 5058

Taper of the edge of the insulation screen


up to the marking. Use for example a
plane*) and cut only towards the insulation
screen. 5059

Plane or glass
*) Ordered separately.

9. Remove the insulation screen up to the


marking. A plane*), or a piece of glass
can be used. Make a smooth transition 400
between the insulation screen and the min 40 5060

insulation. At least 40 mm of the


insulation screen and 400 mm of the
insulation are to be even and free from H G
steps.

Smooth-off the insulation in area (G) first


and then the insulation screen in area (H)
so that all unevennes disappear,
especially where the stress cone will be
placed 400 mm out from the insulation 5061

screen. Start with the rough abrasive


cloth and finish with the fine. Right Smooth tapered surface

NOTE! Smooth transition between Conductive


the XLPE and the insulation screen. Insulation
layer
5062

Wrong
10. Wind 10 layers of ET-tape A-435+C ET-tape
from the edge of the conductor end. A-435+C
Check that the edge of the insulation
screen is within 40, +0/-5 mm from the
ET-tape marking. +0
-5 6725

40
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11. Strip the insulation L mm. Measure the inner diameter of the sealing cone.
Chamfer the XLPE according to the table below. In order to avoid damaging the
conductor when chamfering and the inside of the stress cone, cover the conductor
with ET-tape. Smooth-off the chamfer to remove any unevenness.
∼ 5xT L = 155

ØE
Sealing cone ØE
Ø mm mm

44 40
54 50

T
5063

12. Clean the insulation using solvent for example ethylalcohol. Grease the XLPE
insulation with the grease supplied down to 100 mm from the edge of the insulation
screen. Wipe the stress cone clean inside. Then grease the inside from both ends.

5064

13. Hold the sliding cone in the lower edge of the stress cone so that the fingers of the
sliding cone do not enter the stress cone completely.

Pull the stress cone down to about 100 mm from the edge of the insulation screen.
Remove the sliding cone and then pull the cone down to the ET-tape.

Stress cone tool SV 140* makes it easier to fit the cone.

* Ordered separately

SV 140*
Sliding cone
ET-tape

ET-tape

If required
5065
5067

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14. Clean away grease near the stress cone with solvent.
Mark the position of the stress cone with ET-tape 50 mm from the upper part of
the stress cone.

Wrap on copper net with 10 mm overlap from 50 mm on the shield wires and up on
the stress cone to 40 mm from the skirt edge.

Wrap IV-tape five times with overlap over the copper net.
Cover the IV-tape with one layer of ET-tape.

Copper net
50 50

IV-tape 20 20 ET-tape

5055
ET-tape 5068

15. Push the Top of aluminum under the skirt edge of the stress cone to a distance of
10 mm below the stress cone.
Insert the the metal contact of the hose clamp under the edge of the stress cone.
Do not tighten the hose clamp.

Box body
10±10 mm
(A-190 ±10 mm)

50 ±3 mm

Stress cone
Hose clamp
Metal contact
5069

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16. Place the box body so that its lower edge and shield wire opening coincide with the
marking carried out in point 1.
Fold out the shield wires through the opening in the lower edge of the box body. The
opening can be enlarged by removing the knockouts.

Wind bitumenized paper hard around the cable at the lower edge of the box body to a
diameter of approx 125 mm. Mount the cable clamps so that the guiding nob
coincides with the groove in the box housing. Screw the cable clamps together to
secure the cable.

Check that the distance between the stress cone and the Top of aluminium is within
10±10 mm. Also check the distance 50±3, and the distance A-190 ± 10 mm,
see point 15.

Tighten the hose clamp on the stress cone. Install the other hose clamp in contact
with the metal contact and tighten. The locks of the two hose clamps shall be
displaced at least 50mm. Fold back the metal contact.

Remove the ET-tape at the upper edge of the stress cone and on the conductor end.

Connect the shield wires to the earthing clamp on the box body.

Bitumenized paper
10 ±10 mm

Earthing clamp
Cable clamp
5070

17. Clean the insulator with a dry cloth to remove dirt and damp.

Place the O-ring in the box body flange in position.

Fasten the self-adhesive insert gaskets on the insulator clamps or on the porcelain.

Place the insulator over the end of the cable down to the box body. Check that the
cable goes straight into the insulator. Centre the box body in the porcelain insulator
by means of the four holes in the box body. Composite insulator is centred by the
screws.

Secure the insulator onto the box body with the insulator clamps for the porcelain
insulator or with the bolts directly in the flange for the composite insulator.
Tighten the insulator clamp nuts or the bolts in succession to a torque of 45 Nm.

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18. Appendix 2 shows the assembling of the cover.


Place the clamp on the top cover, mount the M8 bolts with the sealing washers and
tighten with 20 Nm.

Place the O-rings in the top cover in position. Grease the sealing cone and the
chamfer of the cable insulation with the supplied grease. Mount the sealing cone on
the top cover.

Mark the top cover at the edge in line with the clamp. Place the top cover on the
insulator and orient the top cover to a wanted position for the top bolt. E.g. orient the
mark made on the top cover in line with the shield wire opening. The top cover can
be placed with the top bolt in any position for porcelain insulator and in eight
positions for composite insulator.

Center the top cover when porcelain insulator. Check that the sealing cone is
correctly mounted and seals against top cover and cable insulation.

NB! Make sure there are no dirt or metal particles on the top cover, cable end
or clamp, which might fall into the insulator during installation. If possible,
cover the filling holes.

Tighten the insulator clamp nuts or the bolts for composite insulation in succession to
a torque of 45 Nm.

Check that the conductor end is 10 ±10 mm above the clamps edge.

Place the top bolt in the clamp.


Tighten the 9 bolts in succession to a torque of 70 Nm, starting with the lowest centre
screw, then the conductor screws and finally the screws for the top bolt
( see picture).

10 ± 10 mm

5051

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19. Heat up the oil IG 1804 supplied to about 120°C.

The oil can be poured when the termination is in position or when it is on the ground.

If the oil is poured in on the ground incline the insulator approx. 45° and use a funnel.

Pour the oil and allow the oil to cool to about 30°C. Cover the filling holes during
cooling to prevent dirt and moisture to come into the insulator.

Mount the two sealings carefully in the top cover filling holes. Use e.g. a small
screwdriver to make one turn under the collar of each sealing. Check that it seals
against the surface on the top cover.

Place the two O-rings for the top cover cap in position.

Grease the top bolt and the hole in the top cover cap with supplied grease, mount the
top cover cap and tighten the M6-screws with approx. 10 Nm.

Mount the sealing on the top bolt and the top cover cap.

Clamp

Top cover

O-rings Sealing
Sealing cone 5822

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O-rings
Sealing

Nut and spring washer for


Sealing porcelain insulator.
Screw and spring washer for
composite insulator.
Clamp
Sealing cone

Insulator clamp and


insert gasket for
porcelain insulator

Insulator clamp and


insert gasket for
porcelain insulator

5071

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20. For cables with conducting layer on the outer sheath.

Remove the conducting layer on the


outer sheat for a distance of 200 mm.

200

5072

Check the insulation with an insulation tester.


The resistance must be more than 200 Mohm.

MΩ Lashings

Outer sheath
5073

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21. When the termination is to be lifted into position the rope is to be secured around the
cable below the cable clamps so that the lifting load will be taken by the cable and
not by the termination. Tie at least two support ropes around the insulator.

The lifting rope should be able to glide through the knots of the supporting ropes.

Lifting rope

Supporting rope

The lifiting rope should be able


to glide throug these knots.

22. Lift the temination in position, check that the


box body gets a level contact with the bracket,
if not, adjust with washers.
Tighten the bolts , Torque ~100 Nm.

23. Secure the cable to the support with three 6427

cable clamps within 1,5 m from the termination.

ABB Kabeldon 13
14
235 ~L

86,5 Insulator length


4290.5211-05

435

max Ø 120
Ø40/50/54

APECB 84-170
min 125

Type
A - 435 + C

APECB 841

APECB 1705
APECB 1704
APECB 1703
APECB 1452
A - 385 + C
The position for the edge of the sheath depens on dimension C. Can be below the insulator.

L
A - 190

2620
2120
1860
1620
1300
A
Appendix 1

6710

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Assembly of cover Appendix2


Sealing

Top cover cap O-rings

Top bolt

Clamp

Sealing

Top cover

O-rings

Sealing cone

Insert gasket

Insulator clamp Screw and


for porcelain sealing washer
insulator for clamp.
5076

ABB Kabeldon 15