PFISTERER ios. THE POWER CONNECTION Fitti ESS/ESP 170 HV Silicone and Porcelain sheded termination PFISTERER Ixosil Ltd. Cable Systems Altdort / Switzerland 4,4 english - 131164 - ©PFISTERER lxosil Ltd. — revised 0809ESSIESP 170 page 2 of 30 Table of contents 1. Preparation Note ..... 2, ImportantNote Bieaaaseey 2. Termination Type Abbreviation... 4. General Instruetions «.........006 5% CablePositioning 2! 51 Positioning and clamping cable... 52. Table K and t dimensions in rel head armature connections. 6 -Preparingeable ,, 61 General 2.) 62 Cable quality check 63 Cable diameter check os. .240 3 64 Preparing of core insulation on all cable types 654 Preparation of cable with Cu laminated sheath and sereen wires 6.58 Preparation of cable with Alu laminated sheath and screen wires 6.C Preparation of cable with screen wires only é 65D Preparation of cable with corrugated sheath without plumbing cone 65E Preparation of cable with lead sheath without plumbing cone. 6.5F Preparation of cable with lead sheath and screen wires without plumbing cone. 6.56 Preparation of cable with corrugated sheath with plumbing cone... 63H Preparation of cable with lead sheath with plumbing cone 7, Mounting of sereen pot and stress cone TL Gena sissnwrxenanasscunwnwners 72 Protecteonductor so. esssse re 73 Apply silicone grease 74 Mounting of sereen pot a 7.8 Mounting of stress cone 2... sees 75A Preperation of stress cone 2.2... 7.5B.— Sliding on stress cone with bib... 7.SC Cleaning excess grease... : 78D Sliding stress cone further 5.5... 758 Final degreasing, TSF Slide into fi Fixing screen pot to base plate . 8.1” Mounting base plate ....... 8.2A Fixing screen pot without plumbing cone 8.28 Fixing screen pot with plumbing cone 9. Tape wraping of stress cone and screen pot 10. Mounting hollow core insulator ibaa 3 11, Filling with compound and’ mounting head armature = 12, Connecting conduetor om axes 12.1 by using Compression Connector 12.18 by mechanical torque connector 13. Connecting eable sereen to screen pot . z 13.1A Screen Connection without plumbing cone foe 13.1B__Sereen Connection with plumbing cone for corugated and lead sheathed cables... 14. Check Sheet SiGe pemencosne stteeenseaee PFISTERER | xosu lcaESS/ESP 170 page 3 of 30 6 A ESE PE SONS GE L Preparation Note ‘Check that the materials are complete and suitable for the cable to be fitted on. Check that all the relevant tools required for the following installation work are available on site. Check that the site conditions are adequate to provide a clean and sheltered working environment for the correct and proper fitting of this product. Important Note ‘The information contained in these instructions is to show the correct method of installing this product, The product is only to be installed by a certified trained and competent jointer aware of all product requirements and safety practices, ‘The jointer must have learnt the correctly intended installation procedure and is responsible to arrange the site conditions required to install this product, PFISTERER Ixosil Ltd. Cable Systems Gotthardstrasse 31 CH-6460 Altdorf Tel +41 41 / 87475 75 Fax +41 41/874.75 76 E-mail: power@ixosil.ch Website: www.ixosil.ch PFISTERER boos Ltd, Cable Systems. ‘Alto Switzerland PFISTERER | xosi vars ohESSIESP 170 page 4 of 30 Termination Type Abbreviation ES_170C _. | | | | Outer sheding type Creepage length Sensor Size of termnation S silicone shedded (1/10 m) TE: PD sensor P- porcelain shedded OP: Data and cable- temperature sensor Check the type and size of the termination to be installed according the packing list or the label of the packing and the sheathing type of the cable, General Instructions ~ Work area has to be dry, clean and dust free. ~The use of damaged or unclean materials is grounds for a void in product guarantee. ~ Use eye and hand protection when using cleaning fluids. = Use gloves when greasing. ~ This instruction has to be followed exactly during the installation process, ~ Check the surface of the silicone stress cone. DO NOT USE if there are any cuts or deep abrasions, ~ Do not use any form of knife when handling silicone parts, ~ Apply tapes No. 13, No. 50 and copper fabric tape with 50% overlap. — Other acceptable cleaning fluids are: Toluol, Sieder benzin, White benzin, O-Xylol and Aceton. 25 ER PAGS SDE HCO OER PFISTERER bos! Lis, Cable Sysoms ‘Alte 1 Switerand PFISTERER | wos boatESS/ESP 170 page 5 of 30 $0 Ze RENEE I SEES SEE 5. Cable Positioning 5.1 Positioning and clamping of cable Fix the cable into position using at least two cable cleats. Using heating mats and alignment rails, heat and straighten the cable. ‘The 200 mm extra will be cut off after the heating and alignment process. K+t+200 min. 800 Legend 27 Base plate 28. Post insulator 42. Steel structure 43. Cable cleats all dimensions in mm PFISTERER bos Ls. Cable Systems PFISTERER | wos etESSIESP 170 page 6 of 30 0 tenes S F SER RTT 52 Table K and t dimensions in retation to creepage distance, termination type and head armature connections Dimension K Creepagelength Height Dimension K for termination type [hom] H ESS. ESP car 1810 1782 C38 1810 1782 cn 2200 2172 C58 2200 2172 cB 2200 2172 Dimension ¢ (for Hexagonal compression dies) Crosssection Conductor material Conductor material [mm] Copperstrandd —Alustranded Alu solid 240 170 200 22 | 300 176, 200 m2 = 400 200 2a 22 3| 500, 200 24 g 630, 200 286, EA 3 800 22 284 mm 3| 1000 222 284 : 7 9 a 5 5 1600 237 281 2000 27 Working Table Creepagelength Height Dimension Dimension [om] H K t Before cable preparation proceeds Please fillin working table using dimension table K and, Inthe case the working table has been filled out, use these dimensions provided. 2 eSNG SAC 20 IRI PFISTERER bos Lis Cable Systems PFISTERER | wos. ne oeaea chESS/ESP 170 page 7 of 30 RRR a a SESE 6. Preparing cable 61 General Use the following crossection drawings to cut cable to length. All measurements must be made from the cable end with cross checking from base plate, Do not use the outer sheath edge as a measuring point. ATTENTION: 1, ‘The overlap between core insulation and extruded semiconductor must not exceed 6” chamfer slope. 2, Insulation prepared as per PFISTERER Ixosil specifications with no longitudinel ‘markings or cuts, 3. The final position of the stress cone must have the core insulation and overlap onto te semi-conductor sanded smooth with sand paper 180 grit first and then polished with sandpaper 320 grit, The overlap between core insulation and semi-conductor must haves finished prepared slope of max.6°. 4, Peeling dimension is in the following table. 5. Any semi conductive material on the outer sheath must be removed for a distance of 150 mm from the outer sheath edge. 6. Fill in required dimension from cable preparations in check sheet. PFISTERER nos! Lic. Cable Systems. PFISTERER | xosi. a walkESS/ESP 170 page 8 of 30 (0 SS NN TERT CSS SRSA 6.2 Cable quality check ‘Check that the prepared cable insulation is not flat sided and the ovality and excentricity is within the acceptable limits according drawings below. In case this is not the result the cable must be prepared more in order to reach the acceptable limits or when not possible the manufacturer must be contacted for further checks, Ovality Excentricity Flatsiding oe © © ¥v v Vv 2 © x x Tolerances [>| seormaxo | O;EE"| | 6.3. Cable diameter check Check that the diameter of the peeled insulation is with in the limits according the table below, Fill in dimension (F) in check sheet (Position 1), In case the diameter is not within the given limits, DO NOT INSTALL THE TERMINATION. ‘Termination Stress cone ‘Min. prepared Max, prepared size size core O core O ot BL 46mm 55mm o Bz 52mm 2mm oe BS 60mm mm 04 B4 70mm 34mm. 05 BS 2mm 99mm 2 RE A Roi TT SS PFISTERER bosl Ld. Cable Systems PFISTERER | xosi. Me wisi. chESSI/ESP 170 page 9 of 30 64 Preparing of core insulation on all cable types Round off edges with 180 grit sand paper to improve mounting of seal and stress cone. Round off and smoothen out any area that could damage the seal and stress cone when being mounted. Polish smooth insulation and overlap to the __ 55 semicondutor with 180 and 320 grit sandpaper. Fill in dimensions (K and t) in SED os - check sheet (Positions 2 and 3). ay \ y \ SHOU oF BOY] Legend 9 Marking tape for positioning of stress cone all dimensions in mm PFISTERER bos Lie Cable Systems PFISTERER 1 osu. aot ennESSIESP 170 page 10 of 30 6.5A Preparation of cable with Cu laminated sheath and screen wires Legend Laminated sheath Tape No. 60 Cu fabric tape (1 layer) 1 2 3 4 Roll spring 9 to 30 mm 5 x 6 ‘Screen wires ~ Outer sheath without semiconductive layer Outer sheath with semiconductive layei Plat earth lead Marking tape for stress cone Marking tape for screen pot seal I Tape No. 13 (I layer) 12 Tape No. $0 (1 layer) 13 Shrink sleeve No.30 — all dimensions in mm Bottom of base plate i PFISTERER bool Ld. Cable Systems PFISTERER | xosi. ao enaESSIESP 170 page 11 of 30 en AP SRT i PS 6.5B Preparation of cable with Alu laminated sheath and screen wires Legend Laminated sheath Tape No. 60 Cu fabric tape (1 layer) Roll spring Screen wires Outer sheath without semiconductive layer 7 Outer sheath with semiconductive layer 9 Marking tape for stress cone 10. Marking tape for screen pot seal 11 Tape No. 13 (1 layer) 12 Tape No. 50 (1 layer) 13 Shrink sleeve No.30 up to 30 mm ~ all dimensions in mm Bottom of base plate PFISTERER beosl Lis ‘Cable Systems [Ntdor | Switzoriand PFISTERER i vosi potestESS/ESP 170 page 12 of 30 6.5C Preparation of cable with screen wires only up to 30 mm Legend 3 Cu fabric tape (1 layer) 4 Roll spring 5 Screen wires 6 Outer sheath without semiconduetive layer 7 Outer sheath with semiconductive layer 9. Marking tape for stress cone 10 Marking tape for screen pot seal IL Tape No. 13 (1 layer) 12 Tape No. 50 (I layer) 1B. Shrink sleeve No.3 all dimensions in mm Bottom of base plate SES SSS RRS PFISTERER os Li, Cable Systems PFISTERER | wos ot eas wo eos chESS/ESP 170 page 13 of 30 65D Preparation of cable with corrugated sheath without plumbing cone up to 30 mm Legend 3 Cu fabtic tape (1 layer) 6 Outer sheath without semiconductive layer 7 Outer sheath with semiconductive layer 8 Flatearth lead 9. Marking tape for stress cone 10 Marking tape for screen pot seal 11 Tape No. 13 (1 layer) 12 Tape No. 50 (1 layer) 13 Shrink sleeve No.30 15 Conrugated sheath. 16 Clamping bowl 17 Toro clamp @ all dimensions in mm ® ©: PFISTERER bosl Ls, Cable Systems PFISTERER | xsi. er eaoahekESS/ESP 170 page 14 of 30 6.5E Preparation of cable with lead sheath without plumbing cone Legend 3. Cu fabric tape (I layer) 6 Outer sheath without semiconductive layer 7 Outer sheath with mesa semiconductive layer “eB ; 8 Platearth lead 9) Marking tape for stress cone 10 Marking tape for sereen pot seal 1] Tape No, 13 (1 layer) 12. Tape No. 50 (I layer) 13 Shrink sleeve No.30 16 Clamping bowl 117 Toro clamp 18 Tape No, 50 or 13 @ 19 Support ring (must be fitted loose on the padding tape)~ 20 Lead sheath all dimensions in mm Bottom of base plate ad OL ost ‘5 SA SS A SG PFISTERER hos Ld Cable Systeme PFISTERER | wos. me rcosnchESS/ESP 170 page 15 of 30 ARENA RAMEE TA LE EE! 6.5F Preparation of cable with lead sheath and screen wires without plumbing cone Legend 3 Cu fabric tape (1 layer) 5 Screen wires 6 Outer sheath without + semiconductive layer 7 Outer sheath semiconductive layer 8 Flat earth lead 9. Marking tape for stress cone 10 Marking tape for screen pot seal 11 Tape No. 13 (1 layer) ——, | 12 Tape No. 50(1 layer) | |_ 13 Shrink sleeve No.30 16 Clamping bow! 17 Toro clamp 18 Tape No. 50 or 13 19 Support ring (must be fit loose on the padding tape) 20 Lead sheath @ © all dimensions in mm Bottom of base plate up to 30 mm. 00 Wy PFISTERER hos Lid. Cable Systems PFISTERER | wos. et alooESS/ESP 170 page 16 of 30 SEE 8 TR RRO 65G_ Preparation of cable with corrugated sheath with plumbing cone Legend 3 Cu fabric tape (I layer) 4 Roll spring ~ 6 Outer sheath without up to 30 mm semiconductive layer 7 Outer sheath with semiconductive layer 9 Marking tape for stress cone 10 Marking tape for screen pot seal 11 Tape No. 13 (I layer) 12 Tape No. 50 (I layer) 13 Shrink sleeve No.30 * 15 Corrugated sheath f u all dimensions in mm 007 Bottom of base plate 0% 0 PFISTERER hot Lic Cable Systems PFISTERER) ros. we oecvosehESS/ESP 170 page 17 of 30 SER SSS SE EN ELSES 6.5H_ Preparation of cable with lead sheath with plumbing cone Legend 3. Cu fabric tape (1 layer) ~ 4 Roll spring weston 6 Outer sheath without semiconductive layer 7 Outer sheath with semiconductive layer 9 Marking tape for stress cone 10 Marking tape for screen pot seal 1] Tape No. 13 (1 layer) _ 12 Tape No. $0 (I layer) 13 Shrink sleeve No.30 20 Lead sheath all dimensions in mm Bottom of base plate Oe 0% ‘oar PFISTERER basi Li, Cable Systems ‘Altdrt/ Suitzerand PFISTERER 1 1xosi ‘erosESS/ESP 170 page 18 of 30, 52 AEE 2 EI: Ts TA 72 13 Mounting of screen pot and stress cone General Reminder: Observe clean conditions. Slide shrink sleeve No. 70 into park position on cable (for plumbing cone version also the plumbing cone and ,O" ring). Protect conductor Wrap conductor using tape No. 35 Apply silicone grease Cover sereen pot and cable where indicated with P4 silicone grease, using gloves. Legend 9. Marking tape for stress cone 10 Marking tape for sereen pot seal 21 Screen pot seal 22 Screen pot 26 Silicone grease P4 44 Tape No. 35 all dimensions in mm. PFISTERER los Li, Cabla Systems PFISTERER i ixosi. moESSIESP 170 page 19 of 30 i RR EA RR RE 7.4 Mounting of screen pot When mounting the screen pot pull only on the silicone area. Note: Seal and screen pot can be mounted seperately, depending on expansion. Legend 9 Marking tape f \ } secon NY 10 Marking tape for NY screen pot seal 13 Shrink sleeve No. 30 22 Screen pot all dimensions in mm NS RR EES PFISTERER bos Lid Cable Systoms ‘Altdoct 1 Swiveriand PFISTERER | wos iso chESS/ESP 170 page 20 of 30 EN SESE NIT 7.5 Mounting of stress cone 7.54 Preperation of stress cone Check thoroughly and ifnecessary clean stress cone, Apply P4 silicone grease inside of stress cone as indicated. — ® © @ Legend 9 Marking tape for stress cone oy eae 7.5B_ Sliding on the stress cone with bib 24 Oa taaned Use the bib when mounting stress cone. 25 Bib 26 Silicone grease P4 45 Degrease this area 7,5C Cleaning excess grease Slide the stress cone to the top edge of the semiconductive edge. ® Degrease the area between the stress ‘cone and the marking tape. Wait for the cleaning agent to evaporate. PFISTERER ios Lis Cable Systems PFISTERER | wos. ot noahESSI/ESP 170 page 21 of 30 7.5D_ Sliding stress cone further Slide the stress cone down until the lower edge of the marking tape. 7.5E_ Final degreasing Degrease cable above the stress cone foradistance of 20mm and allow the cleaning agent to evaporate. 7.5F Slide into final position Slide the stress cone up to the top edge of the marking tape. (twisting the stress cone left and right). This is its final position. ‘Check after 30 utes to see if it has slide away from marking tape Ifthe stress cone has moved then repeat procedure in point 7.5C (using a smaller distance) When after 2 hours no movement in the stress cone is observed then the next procedure can be carred out. ca PFISTERER | nos. 120) 8 Q Legend 9 Marking tape for stress cone 23 Stress cone 45 Degrease this area PFISTERER hos Lid Cable Systems Alor Switzoriana ‘warwxos chESS/ESP 170 page 22 of 30 ‘7: DRRRARUR RRS CREE SE REM YR ANRAEEE? 8. Fixing screen pot to base plate 8.1 Mounting base plate Attention: Check inside edge of the base plate, if sharp, sand smooth before fitting. (sealing edge) Tighten down base plate into position and grease all bolts with P4, 8.2A_ Fixing sereen pot without plumbing cone After fixing sereen pot to base plate use centralisation bolts to centralize cable. ‘Tighten just enough to centralize. DO NOT OVERTIGHTEN. Legend 5 Screen wires 10 Marking tape for sereen pot seal 21 Screen pot seal 22 Screen pot 26 Silicone grease P4 27 Base plate 28 Post insulator 29 Centralising bolts M8 30 Contralising backing ring 33 Bolt M16 34 Washer M16 35 Bolt M12 36 Washer M12 PISTERER tos Li, Cabo Systems PFISTERER 1 wosi. we eeeESSIESP 170 page 23 of 30 1. eNom aR RRR ee 8.2B Fixing screen pot with plumbing cone After fixing screen pot to base plate use centralisation bolts to centralize cable. Tighten just enough to centralize. DO NOT OVERTIGHTEN. Legend 10 Marking tape for sereen pot seal 15 Corrugated sheath 21 Seren pot seal 22 Screen pot 26 Silicone grease P4 27 Base plate. 28 Post insulator 29 Centralising bolts M8 30 Centralising backing ring 33 Bolt M16 34 Washer M16 35 Bolt M12 36 Washer M12 PFISTERER bosl Lis. Cable Systems PFISTERER | wos. Mot enalchESSIESP 170 page 24 of 30 SR RSE £9 SR SSM 9. Tape wraping of stress cone and screen pot Degrease stress cone, tape layer and screen pot seal. Wrap step onto stress cone and screen pot with sealing tape (making a slope). Wrap 3 layers of tape No. $0 as indicated in drawing. ‘Tape No. 50 end tied down by cable tie. Legend 9 Marking tape for stress cone 10. Marking tape for sereen pot seal 12 Tape No. 50 (3 layers) 14 Sealing tape 37 Cable tie PFISTERER tos Lt, Cable Systems ‘Aldor 1 Swizeriand PFISTERER | ixosi. wor ob.okESS/ESP 170 a ET ED RST TS 10. Mounting hollow core insulator Apply P8 grease to ,,O* ring and ensure correct seating. Apply PI greasebetween contacting surfaces. Apply PA grease to bolts andtighten bolts to 40 Nm torque. Legend 31 Insulator 32 ,O* Ring (grease with P8) 35. BoltM12 (grease with P4) 40 Pl grease PFISTERER wos Le, Cable Systems Aldor Switecand PFISTERER | wos. veohESS/ESP 170 page 26 of 30 FE | TAN LNT 11. Filling with compound and mounting head armature Heat compound to 120 °C and allow to cool to 70 °C, The filling operation ofthe termination must continue without large intervals, For the compound level directly after filling, see tables below. Fill in dimension E in check sheet (Position 4). Once filling has been completed remove the PVC protective tape from conductor and clean conductor plus sealing surface Apply PI grease between contacting surfaces before mounting head armature, Apply Pé grease to the head armature bolts and tighten to 20 Nm. Note: Final closing of the head armature must take place within a max. time of 4 hours of filling. ‘roase bots wih P& t 1a bots tein torque 20 Nm ‘Spring washer MB Grease 0" ngs wih PA \ roase contact surface wih Pt vel ecty ater ing For ESS only For ESP only Dimension E Dimension E ca7 200mm. C58 500mm C58 200mm C73 500mm 72 300mm PFISTERER os Ls Cable Systems ‘ltd Swizeriand PFISTERER 1 vos. ‘oneESS/ESP 170 page 27 of 30 RN RRS SRE 12. Connecting conductor 12,1A by using Compression Connector Pay attention to compression sequence — Compression sequence 121B by mechanical torque connector Hand tighten all torque connector bolts starting from the outside and working inwards. ‘Then using a Tee bar turn each bolt in sequence 90° until they shear off. Pay attention to shear bolt sequences ‘The shear bolt area must be sealed with sealing tape and shrink sleeve No. 50, 55 or 60. Tightening sequence —t PFISTERER iosl Lid Cable Systems. PFISTERER ios. oanESS/ESP 170 page 28 of 30 an ena amen a eR SSE SESS ts 13, Connecting cable screen to screen pot 13.1A Screen Connection without plumbing cone Apply PI grease to all contact area on cable screen connection. Apply P4 grease to all bolts. Max. torque 40’Nm only where indicated. Only put into service after correct connection of earth to screen pot. roughen outer sheath Legend 12 Tape No. 50 14 Sealing tape 41 Shrink sleeve No, 70 PFISTERER hosl Lid Cable Systeme ‘Audor | Switzerand PFISTERER | wos waaothESS/ESP 170 page 29 of 30 LS AMES MILE RA A NR ES 13.1B Screen Connection with plumbing cone for corrugated and lead sheathed cables Apply PI grease to all contact area on cable screen connection. ‘Apply P4 grease to all bolts, Max. torque 40 Nm only where indicated. Only put into service after correct connection of earth to screen pot. Fie See Fiennes ply P& grease to Mt2 bots and —ighen fo Torque 25m Legend 38 Tinned copper tape for corrugated sheath 14 Sealing tape Lead strips for lead sheath 15 Corrugated or lead sheath 39 Plumb wipe 41 Shrink sleeve No. 70 AR ST NTIS SI PFISTERER os Li. Cable Systems ‘Alder 7 Switzeriand PFISTERER | wos. vest chESS/ESP 170 page 30 of 30 "S02 ASRS CD CR SE TRE ASESTE 14. Check Sheet ESS/ESP 170 Customer: Contract No: Project ‘Termination type: Circuitname: Serial Number: Phase: Name of Terminal point: Jointer name: Signature: Date: Supervisor name Signature: Date: No. Description ‘Valuemm. Before mounting stress cone 1 Dimension F Min, Diameter of prepared core insulation 2 Dimension K Length of K used 3 Dimension t Length of exposed conductor Direct after filling with compound 4 Dimension E Compound level ‘Comment After installation please sign and send back the original check sheets to the address below for final approval: PFISTERER Ixosil Ltd, Cable Systems Gotthardstrasse 31 6460 Altdorf, Switzerland Fax: +41 41 874 7576 2 or et PFISTERER bos Lt Cable Systems. ‘Altdoct 1 Switzerias PFISTERER 1 os wach