tyco Electronics Raychem Product Installation Instructions TFT-250R-SG 25kV Cold Applied Outdoor Termination for Copper Tape, Wire Shield, Lead Sheath and UniShield®* Cable Energy Division * Unishield is a trademark of BICC General Cable Industries, INC. Raychem PILS8005, Rev AF {Tyco Electronics-Energy Pen 418329.000 8000 Pury oes Efecive Date: May 3, 2001 Fuquay-Varina, NC 27526Cable Type Selections Note: There are separate instructions for each cable type eee one Tape Shield Cable (page 4) Wire Shield Cable (page 9) UniShield Cable (page 13) Lead Sheath Cable (page 17) en a= Effective Date: May 31, 2001General Instructions Kitcontents FT cc T TTT TTAT Instalation Instruction Scone housing on holdout ‘Stess control patch Ral spring ‘Solder blocked ground braid ‘Adhesive backed copper tape strips Cloth tape Sealant tape strips ‘Suggested installation Equipment (not supplied with kit) + Cable preparation tools + Electrician's tape * Clean, lint-free cloths + Connector(s) and installation tools Safety Instructions Warning: When installing electrical As Tyco Electronics has no control power system accessories, failure to over field conditions which {ollow applicable personal safety influence product installation, itis requirements and written installation understood that the user must take instructions could result in serious or this info account and apply his own fatal injuries. ‘experince and expertise when installing product. Cleaning the Cable Use an approved solvent, suchas Some newer solvents do not Please follow the manufacturer's the one supplied in the P63 Cable evaporate quickly and need to be _instructions carefully. Prep Kit, to clean the cable. Be removed with a clean, lint-free sure to follow the manufacturer's cloth. Failure to do so could instructions. Failure to follow these change the electrical characteristics, Instructions could lead to product of the cable or leave a residue on failure. ‘the surface. Installation Instructions 1. Select product Check kit selection with cable diameter dimensions in table 1 opposite. Table 1 Nominal Conductor ‘Minlmax Kit Size Insulation ODs (Seo Note) TFT25IRSG _H-3IOANG (0.64-1.09°(16-28mam) TFT252R-SG ——#2-500 kemil (0185-1.45"(22-37mm) TFT253R-SG 250-750 komil 4.08-1.70°(27-43mm) TFT254R-SG 750-1250 kemil 4.49.220°(38-86mm) Note: Insulation ODs and nominal conductor sizes are based on 100 compact and concentic strandad cable dimensions, PIFS5098, Rov AF 3 PCN 478326-000 Effective Date: May 91, 2001Installation Instructions For Tape Shielded Cable 2. Prepare cables: Detain ineiaten catback gre ee Figure 1: Insulation Cutback (2) ae SEE ~ Peon Note: Hrolig used, 2=2 (Sonn) TT wrototon = Lenthot + amy en ipa eane WE Feige Tanda ; drawing to prepare the cable 2s deck Culbeck + 2. ooo et aE Sy ee rz 1"(25mm) — be Remove the backing from a piece of “Adhesive Back Copper Foil Tapa ——~. ‘copper foil provided and tape over the ‘ond of the shield as shown, sim 55088, Rev 4 PEN 410329-000 tat Etfective Date: May 31, 2001Installation Instructions Install ground braid Flare the moisture blocked end of the ground braid and place it onto ‘the tape shield butted up to the cable jacket. Attach the braid to the shield by placing two wraps of the spring clamp over the braid 1/4” from the jacket cutback. Fold the braid back over the spring clamp wraps. Continue to wrap the remaining clamp over the braid. Tighten clamp by twisting itn the direction it is wrapped. Apply a smal piece of copper adhesive tape foll on top of the spring clamp as shown, Note: Wrap the copper adhesive tape fol in the same direction 25 ‘he spring clamp to tighten the wrap. se 5860 Copper Adhestve Tape eee a 4, Make Lug Connection Crimp the connector using proper die and tool, Clean tug barrel of Inhibitor and dirt and fle off any sharp edges. oe '. Abrade (sand) and clean insulation ‘Abrade and clean the surface of the primary insulation using the solvent supplied with the termination or any other approved solvent. Be sure to remove any conductive particles or ‘contamination. Note: Use aluminum oxide abrasive strip only. I-65008, Rev AF 5 PON 47637-000 Effective Date: May 31, 2001& Install sealant Start wrapping seatant at end of iug barrel. Continue wrapping (no *half laps") until sealant is same thickness 2a insulation (at least two wraps). Continue wrapping on to the cable insulation for 1/2". Snap off any additional mastic. Solvent clean and abrade (sand) jacket. Using light tension, wrap one layer of sealant onto the cable jacket, even with the jacket cutback as shown, Press the solder-blocked portion of the braid into the sealant. Wrap an ‘additional layer of sealant over the braid solder-block, sandwiching the solder-block between layers of sealant. Installation Instructions Sealant Same Thickness. {As Insulation so Note: Some Lug Barrel May Be Showing =| | overtep insulation 2"(10mm) ste 18 st80 PI-55008, Rev AF PCN 418328-000 Effective Date: May 31, 2001Installation Instructions T. Apply Stress Patch Note: The stress patch easily ‘sticks to itself and loose particles. Note: The patch may be rectangular. Follow the direction of the arrow on the backing paper of the stress patch. Longer dimension ‘9008 around tho cable, Remove backing paper from the patch. Using light tension and. ‘overlapping the semi-con by 1"(25mm), wrap the entire patch ‘round the semi-con as shown, a ‘Overlap somi-con by 1"(26mm) Avoid wrinkles and creases. iit 3 Tapo over sharp edges Using oth tape provide, tape over all sharp edges of the ground camp assert sim 8, Loosening Termination This operation is vital to the ‘simple installation of the product. Hold the termination in one hand and the holdout in the other. Gripping firmly, twist the termination ‘and holdout in opposite directions. Repeat twisting the termination and holdout, moving the hand in short Increments up the termination until the entire termination is felt to move on the holdout. Slide the termination until it lines up with the end of the holdout tube as shown. Note: Take care not to slide the termination off the end of the holdout. Stop the termination about 1/4” from the end of the holdout. 1/4" Stop Here | or 7 7 PEN A16525.000 rane Effective Date: May 31, 2001Installation Instructions 10. Installing termination ‘Align the end of the holdout Position the holdout over the cable eer een Until it meets the jacket cutback. Twist de the termination and slowly push itto the end of the holdout Slide the termination off the holdout with 2 twisting motion holding the termination that is on the holdout in Wes cone hand and puling the holdout with the other. rie Hoe: bo NOT sesh he wy ee termination. Te SEA Do NOT hold the termination that is partally installed and attempt to pull the remaining termination off the holdout, as this wil stretch the termination and generate an improperly installed termination if not repositioned. Using the pull tabs, pul the flip-back portion away from the main termination, atthe same time working the frst two fingers of each hand between the fp back and main termination. Pull the strotchod out fip- back over the cable Jacket and sealant, 2000 Ifthe termination is not correctly positioned after installation, itis possible to gently slide it into place so that the final assembly is positioned ‘as chown in the drawing in step 11. se Wipe over the surface of the termination to remove any dirt or grease, ‘Tho finished length ofthe termination should be approximately 12.0"(306mm) as shown, |« 12.0" 06mm}. This completes the installation, oy PIV55088, Rev AF a PON 418329-000 Effective Date: May 91, 2001Installation Instructions For Wire Shield Cable 1, Prepare Determine insulation cutback: length 2. Figure 1: insulation Cuthack (2) Note: Ifno lug is used, Z " (50mm) aol Le mee} z ~” use ; lasulation = Length of + (6mm) i Cuttack toon) Lug Barrel os Refer to Figure 1 and adjacent drawing to prepare the cable as <— 11°(28000m}+2 —s shown. Pull back drain wires as i shown. Do not pigtail wires at this Hagiar| time. 2: sr 2, Make Lug Connection Crimp the connector using proper die and tool. Clean lug barrel of inhibitor and dirt and file off any sharp edges. Lug ‘Abrade (sand) and clean isulation ‘Abrade and clean the surface of the primary insulation using the solvent supplied with the termination or any other approved solvent. Be sure 10 remove any conductive patticles or contamination. Note: Use aluminum oxide =S——1 j| <— seus in65098, Rev AF 1 PCN 416929-000 Effective Date: May 31, 2001Installation Instructions stalling termination ‘Align the end of the holdout ‘with the edge of the sealant Position the holdout over the cable ~ until it meets the jacket cutback. Twist the termination and slowly push it to the end of the holdout. Slide the termination off the holdout with a twisting motion holding the termination that is on the holdout in ‘one hand and puling the holdout with the other. Note: Do NOT stretch the termination. Do NOT hold the termination that is partially installed and attempt to pull the remaining termination off the holdout, as this will stretch the termination and generate an improperly instalied termination if not repositioned. Using the pull tabs, pull the fip-back portion away from the main termination, at the same time working the first two fingers of each hand between the flip back and main termination. Pull the stretched out flp- ‘back over the cable Jacket and sealant. lf the termination is not correctly positioned after installation, itis possible to gently slide It nto place so that the final assembly is positioned ‘as shown in the drawing in step 9, 9, Clean termination Wipe over the surface of the termination to remove any dirt or grease. The finished tongth ofthe termination should be approximately 12.0°(306mm) as shown. se ty ———- ‘This completes the installation. oe F-85088, Rev AF 2 PON 478929-000 i Effective Date: May 31, 2001Installation Instructions For UniShield Cable 1. Prepare cal Determine insulation cutback: length 2. = Figure 1: Insulation Cutback (2) 3: Hno lug is used, 2 = 2* (50mm) zw “yn wae Insulation = Lengthof + (mm) Cutback Lug Barrel Refer to Figure 1 and adjacent rawing to prepare the cable as shown. Pull back drain wires a5 ‘showin before culting somi-con/jacket. 41"(280mm)+ 2 ——>} lx 2*—»j oom) az) nmaes [eae net sonic 2. Make Lug Connection Crimp the connector using proper die and tool. Clean lug barrel of Inhibitor and dirt and file off any sharp edges. Leg 180 ‘Abrade (eand) and clean Insulation Abrade and clean the surface of the primary insulation using the solvent supplied with the termination or any ‘other approved solvent, Be sure to remove any conductive particles or contamination Note: Use aluminum oxide abrasive strip only 4 B10 Abrade = ste P1-65098, Rev AF 3 PON 418329-000 Effective Date: May 31, 2001Installation Instructions & Install sealant Start wrapping sealant at end of lug barrel. Continue wrapping (no “half laps”) unt! sealant is same thickness as insulation (atleast two wraps). Continue wrapping on tothe cable insuiation for 1/2". Snap off any additional mastic. [Start Here 190] Tape Sealant 006 ‘Same Thickness ‘As Ingulation 719 Insulation soe Note: Some Lug Barrol May Be Showing +1 | overt insutation 112"(10mm) sie 5. Apply tape sealant Lift the drain wires away from the cable jacket. Solvent clean and abrade Jacket. Using light tension, wrap one layer of sealant onto the jacket as shown, Lay the drain wires evenly back ‘over the jacket and press them into the sealant ‘Wrap an additional layer of sealant ‘over the drain wires and previously applied sealant. rs —— To [Tape sealant su [Press wires into sealant sme PI-85098, Rev AF 4 PCN 418329-000 Efiective Date: May 91, 2001Installation Instructions 6. Apply Str Note: The stress patch easily slicks to itself and loose particles. Patch Note: The patch may be rectangular. Follow the direction of the arrow on the backing paper of the stress patch. Longer dimension {goes around the cable. Remove backing paper from the patch, Using light tension and Overlapping the semi-con by 1"(25mm), wrap the entire patch around the semi-con jacket as shown. Avoid wrinkles and creases, a (400mm), Stress Relief Patch —+| | -1"(25:m) Onto Semicontdacket 7. Loosening Termination This operation is vital to the ‘simple installation of the product. Hold the termination in one hand and the holdout in the other. Gripping firmly, twist the termination ‘and holdout in opposite directions. Repeat tuisting the termination and holdout, moving the hand in short increments up the termination until the entire termination is felt to move fon the holdout. Slide the termination until it ines up with the ‘end of the holdout tube as shown. Note: Take care not to slide the termination off the end of the holdout, Stop the termination about 4/4” from the ond of the holdout. [Lug symbol band 114" Stop Here —| 185098, Rov AF 18 BON 416320-000 Effective Date: Mey 91, 2001Installation Instructions stalling termination Align the end of the holdout with the edge of the sealant Position the holdout over the cable until it meets the jacket cutback. Twist the termination and slowly push it to the end of the holdout. szeea Slide the termination off the holdout with a twisting motion holding the termination that is on the holdout in fone hand and puling the holdout with the other. Note: Do NOT stretch the termination. Do NOT hold the termination that is partially installed and attempt to pull the remaining termination off the holdout, as this wil stretch the termination and generate an improperly installed termination if not repositioned. Using the pull tabs, pull the flp-back portion away from the mai termination, at the same time working the first two fingers of each hand ‘between the flip-back and main termination. Pull the stretched out flip-back over the cable jacket and sealant szece LO If the termination is not correctly positioned after instalation, itis possible to gently slide it into place so that the final assembly is positioned as shown in the drawing in step 9. @ Clean termination aa ‘Wipe over the surface of the termination to remove any dirt or grease. The finished length of the termination should be approximately 12.0°(306mm) 1s shown. ; a ICO |+———120" let This completes the installation. oY, PI-65088, Rev AF 16 PON 418320-000 Effective Date: May 31, 20011. Prepare c Installation Instructions For Lead Sheath Cable Determine insulation cutback: length Z. Figure 1: Insulation Cutback (2) Note: if no lug is used, 2 = 2" (60mm) 1 (6mm) ee was Insulation = Lengthof + (mm) Cutback Lug Barrel ra Refer to Figure 1 and adjacent drawing to prepare the cable as |< 11"(260mm)+ 2 ——»| shown. a ‘edmm) >| 4"(25mm) +z sre |SemiCon Lead Sheath I-S5098, Rov AF 7 PCN 418328-000 Effective Date: May 31, 2001Installation instructions cr ‘ground braid Flare the moisture blocked end of the ground braid and place it onto the lead sheath butted up to the Cable jacket and solder to the lead sheath, ‘6 3. Make Lug Connection Crimp the connector using proper die and tool, Clean lug barre! of inhibitor and dirt and file off any sharp edges. 4, Abrade (sand) and clean insulation ‘Abrade and clean the surface of the primary insulation using the solvent ‘supplied with the termination or any ‘thier approved solvent. Be sure to ‘remove any conductive particles or contamination. 186 Note: Use aluminum oxide abrasive strip only. PI-S5098, Rev AF 18 GN 418329-000 Effective Date: May 31, 2001Installation Instructions install sealant i Start wrapping sealant at end of tug barrel. Continue wrapping (no *haif laps") until sealant is same thickness a insulation (at least two wraps). Tope. Sealant ‘Same Thickness AAS insulation aoe Continue wrapping on to the cable insulation for 1/2°. Snap off any adaitional mastic Note: Some Lug Barrel May Be Showing =] |--cvrap nen oan Solvent clean and abrade (sand) Jacket. Using light tension, wrap one layer of sealant onto the cable jacket, ‘even with the jacket cutback as shown, Press the solder-blocked portion of ‘tho braid into the sealant. Wrap an. additional layer of sealant over the braid solder-block, sandwiching the solder-block between layers of si sealant PIFSS098, Rev AF 9 PCN 418328-000 Effective Date: May 31, 2001Installation Instructions ‘Apply Stress Patch 4 (100mm) Note: The stress patch easily st sticks to itself and loose particles. Note: The patch may be Relief Patch rectangular. Follow the direction of the arrow on the backing paper of @a—To) the stress patch, Longer dimension goes around the cable. CEE at Remove backing paper from the aca patch. Using ight tension and Overlapping the semi-con by 1"(25mm), wrep the entire patch around the somi-con as shown. ‘Avoid wrinkles and creases. 7. Loosening Termination This operation Is vital to the simple installation of the product. Hold the termination in one hand and the holdout in the other. Gripping firmly, twist the termination ‘and holdout in opposite directions. Repeat twisting the termination and holdout, moving the hand in short inerements up the termination untit the entire termination is felt to move fon the holdout. Slide the termination until it lines up with the end of the holdout tube as shown. Note: Take caro not to slide the termination off the end of the holdout. Stop the termination about 1/4” from the end of the holdout, 114" Stop Here | PIV85088, Rev AF 20 BEN 416320-000 Effective Date: May 31, 2001Installation Instructions 8, Installing termination ‘Align the end of the holdout with the edge of the sealant Position the holdout over the cable Until it meets the jacket cutback. Twist the termination and stowiy push itto the end ofthe holdout. Slide the termination off the holdout with a twisting motion holding the termination that is on the holdout in tone hand and pulling the holdout with = relat ‘the other. oe Note: Do NOT stretch the termination. Do NOT hold the termination that is partially instalied and attempt to pull ‘the remaining termination off the holdout, as this wil stretch the termination and generate an improperly installed termination if not repositioned. Using the pull tabs, pull the flip-back portion away from the main termination, at the same time working the first two fingers of each hand ‘between the flip-back and main termination. Pull the stretched out flip-back over the cable jacket and sealant eet If the termination is not correctly positioned after installation, itis possible to gently side it nto place so that the final assembly is positioned fs shown in the drawing in step 9. IL85098, Rev AF 21 PCN 418329000 Effective Date: May 31, 2001Installation Instructions 9. Clean termination Wipe over the surface of the Clean ——_—____. ste termination to remove any dirt or grease. ‘The finished length ofthe termination should be approximately 12.0(308mm) as shown, }+——— 12.0" (306mm). ‘This completes the installation. g * Unishield is a trademark of BICC General Cable Industries, INC. we Correct athd offal fre osc Honeer. Thee Bacrance nat no como xt fl tanaon whic auence prodoxinsstaton. is he noe responsibty fo dtm ie subi the stalaton menage vars ol carson. Tye eso sry clgaione ao Dose eo. [Eocroie clandrd Condos af Sar lve peodut ane ne cae wl jo Elesroncs be nia ay er eel. iMWee consequat domages ‘rang rom no em or igoe a foci. Raychom'sa tae ath ol Teo Elecvones Corporeion PII-55098, Rov AF 22 {© 2001 Tyco Electronics Corporation PCN 418329-000 Printed USA 5Y3 1/2001 Effective Date: May 31, 2001