Professional Documents
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ASSEMBLY INSTRUCTION
HV GIS and Transformer Cable Connector
5-S / 040 510 001 (2010-04-23)
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Table of Contents
Introduction page | 4 I
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Introduction
1 Introduction
I _
With the HV CONNEX cable termination system you have a modern connecting
system at your disposal. The socket already might be integrated into the
switchgear or transformer. The assembly of the separable connector is explained
and illustrated step by step in the following installation instruction. Kindly observe
the order of assembly steps. The assembly must be carried out by cable fitters
which hold a valid PFISTERER certificate for installation.
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General Remarks
2. General Remarks
_ II
2.1 Scope of Delivery
Check the scope of delivery for completeness on the basis of the packing list.
Contact the manufacturer immediately if parts are missing.
This installation instruction describes the safe and proper handling of the product.
The safety notes and directions specified as well as the local accident prevention
regulations and general safety rules applicable to the area of operation must be
observed.
The installation instruction, especially the chapter on safety and the respective
safety notes, must be studied completely before starting the work process. The
material read must have been understood.
The installation instruction is part of the product. It must be stored in the immediate
vicinity of the product (e.g. control room, switchboard station) accessible at any
time.
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General Remarks
II _
2.5 Spare Parts
Shelf life is not limited in general, but consumables like tapes, greases, and silver
varnish must be replaced two years after production date.
2.7 Disposal
2.8 Safety
The product has been manufactured at the time of its development and production
according to accepted engineering standards and is deemed safe to operate.
However, this product may present dangers if not used properly or according to its
intended purpose by professionally trained personnel.
Any use of the product exceeding the intended use and/or any different
use is prohibited and deemed as not in accordance with the intended
use. Any claims against the manufacturer and/or his authorized agents
because of damages resulting from unintended use of the product are
excluded.
The operator is solely liable for all damages resulting from unintended
use. The intended use also includes proper compliance with the
operating conditions as well as specifications and directions of these
installation instruction. The product may only be operated together with
the parts listed in the scope of delivery.
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General Remarks
_ II
2.10 Content of the Installation Instruction
Any person ordered to work on or with the product must have read and understood
the installation instruction prior to begin working with the product. This also applies
if the respective person has already worked with such or a similar product or has
been trained by the manufacturer. Knowledge of the content of the installation
instruction is the basis protecting persons against dangers, avoiding errors and
thereby operating the product in a safe and trouble-free manner. It is
recommended for the operator to request tangible proof by the personnel of having
taken notice of the installation instruction’s content.
The product may only be operated in a technically flawless and operationally safe
condition. The directions of the installation instruction must be followed completely
and without restrictions.
Apart from the safety notes and directions specified in this installation instruction,
the applicable local accident prevention regulations and general safety rules as
well as the applicable environmental protection regulations must be observed and
complied with. The operator and his authorized personnel are responsible for the
trouble-free operation of the product as well as for clear determinations regarding
the responsibility for installation and repair of the product.
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General Remarks
II _
2.13 Requirements on the Personnel
Only professional personnel authorized and trained by the manufacturer may work
on and with the product. The manufacturer will issue a training certificate to the
personnel. The certificate is valid for 3 years.
Professional personnel is anyone able to judge the work assigned to him and
recognize possible dangers because of this professional training, know-how,
experience and knowledge of the relevant regulations.
The responsibilities for work on and with the product (installation, repair) must be
clearly defined and observed to prevent ambiguous assignment of competencies
for the sake of safety.
Only persons may work on and with the product that can be expected that they will
perform their activities in a reliable manner. Any manner of work compromising the
safety of persons, the environment or product must be refrained from.
Persons under the influence of drugs, alcohol or medication affecting reaction time
must never work on or with the product.
The regulations regarding age and occupation applicable at the product location
must be observed when selecting the personnel.
The personnel is obligated to immediately report product changes affecting safety
to the operator.
Personal injuries and property damages when working with and on the product
can be prevented by following the safety notes and directions specified in these
installation instruction.
Neglecting these notes can lead to endangering persons and damaging or
destroying the product.
Any liability and damage compensation claims against the manufacturer or his
representative are void in case of non-compliance with the safety notes and
directions specified in these installation instruction as well as with the accident
prevention regulations and general safety rules applicable to the operation area.
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General Remarks
_ II
2.15 Personal Safety Equipment (PSE)
Always wear the following when working on and with the product:
Protective work clothing
Closely fitting work clothes (low tear strength, no wide sleeves, no rings and
other jewelry, etc.)
Safety shoes
to protect against heavy parts being dropped and slipping on slippery surfaces
The product has been subjected to a danger analysis. The resulting construction
and design of the product correspond to the state-of-the-art.
The product is safe to operate when used as intended. Nonetheless, a residual risk
remains! The product operates with high electrical voltage.
2.
2 Secure against power restoration
3.
3 Check for absence of voltage
4.
4 Ground and short-circuit
5.
5 Cover or block off adjacent live parts
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Assembly Accessories
3 Assembly Accessories
III _
3.1 Required PFISTERER special tools
Hooked Wrench
for tightening of the bell flange’s threaded counter ring.
No. 827 087 001 – size 5-S
Impact Device
for pre-assembly of contact part.
No. 559 214 004 – size 4, 5-S
No. 559 214 006 – size 6, 6-S
The following tools may useful as they are designed especially for
PFISTERER cable systems:
Push-on Device
for assembly of insulating part.
No. 827 103 002
Strap Wrench
for turning of the threaded counter ring.
No. 002 306 001 – size 5-S
Heating mat
for heating before straightening.
No. 880 265 564 – 1 m
No. 880 165 181 – 2 m
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Assembly Accessories
III
HV Cable Stripper
for cable preparation (peeling, removing and bevelling the insulation).
Stop rings for various stripping lengths available on request.
No. 827 976 001 – range Ø 35 - 90 mm
Fitting Clamp
for fixing block and tackles during assembly.
No. 827 153 010 – Cable diameter 50-100mm
No. 827 153 011 – Cable diameter 75-150mm
POM-bar
for greasing of the insulating part’s inner surface
No. 620 018 019
Alignment Rails
for straightening of the cable (2 items).
(Two screw clamps needed for assembly.)
No. 880 164 185 – 1 m
No. 880 165 185 – 2 m
Pipe Cutter
for cutting of corrugated sheath.
No. 827 972 001
Chain Cutter
for cut around the outer jacket.
No. 827 980 001
Hexagonal Screwdriver
for screwing on the bell flange.
No. 546 004 018 – size 4 – SW8
No. 546 004 010 – size 5-S, 6, 6-S – SW10
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Assembly Accessories
III
Unicut
for cable preparation (peeling, removing and bevelling the insulation).
Unicut 30 –
No. 880 265 214 – for Ø 30 - 85 mm over insulation
Unicut 40 –
No. 880 265 215 – for Ø 70 - 125 mm over insulation
Feed Jaws
for Unicut.
No. 880 265 415 – for Unicut 30
No. 880 265 721 – for Unicut 40
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Positioning
apcpar
o. x8.080
00
80
640
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Cable Preparation
5 Cable Preparation
V _
130
4 Measure a length of 535 mm from the “jacket cut” and saw the
conductor off accordingly with a metal saw – do not cut!
535
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Cable Preparation
5 Strip the conductor over a length of 120 mm and break the end of
the insulation edge to create a slightly bevelled edge (10 mm).
535
10 120
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Cable Preparation
13 Wrap crepe paper half overlapping from the “jacket cut” up to 200 mm
over the silver varnish and the insulation.
ca. 200
50
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Cable Preparation
17 After the heat-shrink tubing cooled down, place the helical spring on
the heat-shrink tubing.
50
18 Tear off the crepe paper at the edge of the heat-shrink tubing.
(160/30)
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Checking
6 Checking
VI _
6.1 Measurements
_
Check the measurements, measure the shown diameters and fill in the
check sheet (chapter 6.3) with the dimensions a (semi-conducting
layer), b (insulation) und c (conductor).
535
160 255 120
130
50
a b c
Ø
Ø of
of semi-conducting
semi-conducting layer (a) -– Ø
layer (a) Ø of
of insulation
insulation (b)
(b)<=
<=5
5 mm
mm
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Checking
VI
6.3 Check sheet
_
Warranty claims can only be granted if check sheet is beeing Address for reconsignment:
returned within 4 weeks after installation.
PFISTERER Kontaktsysteme GmbH
Productmanagement HV CONNEX
Customer: Rosenstr. 44
73650 Winterbach
Contract No.:
Germany
Project:
Phone: +49 (0) 7181 - 7005 - 0
Equipment type: GIS Transformer
Fax: +49 (0) 7181 - 7005 - 565
Equipment name:
E-mail: dialog@pfisterer.de
Phase:
Network set up: insulated solidly grounded/earthed
Product
CONNEX size: 4 5-S 6 6-S
Before assembly
Diameter over semi-conducting layer: (a) ______ mm
Diameter over insulation: (b) ______ mm
Diameter over conductor: (c) ______ mm
Serial No. insulation part: ___________________
Serial No. bushing: ___________________
After plug in
Reference mark measurement check: OK
Comments
Fitter:
-------&
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Assembly
7 Assembly
_ VII
160
PFISTERER
1× HV Special Grease
PFISTERER
1× HV Special Grease
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Assembly
VII
68
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Assembly
VII
14 Fix contact ring at the tension cone by using the impact device. The
contact ring may not be turnable.
Required tool (see chapter 3):
¡impact device
900
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Assembly
VII
PFISTERER
0,5 × HV Special Grease
21 Turn back the threaded counter ring by strap wrench to the cable
clamp until the insulating part touches the thrust piece.
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Assembly
VII
22 Apply a fitting clamp or rope (for block and tackles) at the cable.
Apply two block and tackles at the equipment.
Position separable connector by using the block and tackles in front
of the socket.
Optional tools (see chapter 3):
¡fitting clamp
¡distance pin with eyebolt
¡block and tackle
PFISTERER
2× HV Special Grease
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Assembly
VII
25 Clean surface of the insulating part and apply thin and even 1.5 bags
of PFISTERER HV special grease.
PFISTERER
1,5 × HV Special Grease
26 Plug in the separable connector by using the block and tackles, until
the distance between bell flange and flange is 15 mm.
Plug in straight! At plugging the contact system must not
touch the inside of the socket.
15
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Assembly
VII
28 Apply the first cable clamp at approx. 800 mm from the socket. The
cable clamp has to be applied in such a way that the cable leads
into the center of the bell flange.
29 Remove block and tackles and fitting clamp (or rope).
ca. 800
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Assembly
VII
320
Screw the threaded counter ring in place and thighten it with the
hooked wrench until the gasket ring touches the heat-shrink tubing.
Then complete another approx. two turns.
Required tool (see chapter 3):
¡hooked wrench
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Earthing
8 Earthing
_ VIII
8.1 Connecting lead alloy sheath
_
1 Remove outer jacket over a length of 60 mm at 200 mm behind the
heat-shrink tubing.
60 ca. 200
60 ca. 200
3 Apply a copper mesh tape in two halves around the lead alloy
sheath and solder it leak-proof at the range of the sealing tape.
ca. 50
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Earthing
VIII
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8.2 Earthing of bell flange & lead alloy sheath
_
1 Bell flange must be earthed!
2 Bundle the copper mesh tapes and press on a compression cable
lug.
If bushing includes a capacitive voltage tap it must be
connected with a voltage indicating system or earth.
ground connection
or
linkbox
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