Module 62
INSTALLING A CABLE END SHORTING KIT (NEW FEB 2013)
1.
INTRODUCTION
This module is to be applied to all newly laid cables and to all cables which are being
disconnected from the network, whether they are being taken out of commission, but with
the possibility of being put back into commission at some future date or, they are being
abandoned.
Approved protective equipment must be worn (See Section 2)
There are two different types of cable end shorting kit
Heat shrink kit
A heat shrink kit containing; an end cap with conductive mastic and hot melt liner, a
length of 200mm green heat shrink, a heat shrink tube 100mm long. This kit is for
application on any cable, Service, LV or HV (Single phase or multi phase) other than
triplexed cables, in the range 9mm2 to 70mm2
Resin fill kit
A resin fill kit containing: a green shell set and clips, foam strip, copper vernier braid
(shorting link) 400mm long, 16mm long blued tacks x 10off, cable ties x 2 off and foam
end plate for triplex cables. This kit is for application to any cable, LV or HV, triplexed or
multiphase in the range 70mm2 to 300mm2 and 0.1in2 to 0.5 in2.
Associated Drawings:
HSSK2 Issue 1, PCA108K Issue 1.
Commodity
No.
Kit No.
Triplex range
All Other Cables
HSSK2
-
0.0145in² - 0.1in²
9mm² - 70mm²
144415
PCA108K
95 – 185 -300
0.1in² - 0.5in²
70mm² - 300mm²
144414
2.
Code
HSSK2 HEAT SHRINK SHORTING CAP.
Associated Drawing: HSSK2 Issue 1.
Typically used on multicore cables having outside diameter between 13mm and 42mm.
2.1
CABLE PREPARATION.
2.1.1
Cut cable core square with saw.
2.1.2
Abrade outer sheath for a length of 130mm.
2.1.3
Remove outer sheath for 10mm to expose either wire armours or screen wires if
applicable.
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2.2
CABLE BUILD-UP IF DIAMETER LESS THAN 15MM.
2.2.1
Trim build-up tube to 50mm long if required to give two pieces.
2.2.2
Place first piece 40mm in from end and shrink into place, check diameter to ensure it is
15mm minimum in diameter, if required use second piece and repeat.
2.3
APPLY HEAT SHRINK CAP AND GREEN HEAT SHRINK SLEEVE.
2.3.1
Firmly press cap onto cable end, ensure conductive mastic is pressed into core end.
2.3.2
Shrink down end cap from core end onto outer sheath or build-up tubes if applied.
2.3.3
Fit green heat shrink sleeve in line with shoulder of end cap.
2.4
CARRY OUT INSULATION RESISTANCE TEST CABLE TO ENSURE
EFFECTIVE SHORTING.
2.4.1
Using a 500VDC Insulation Resistance tester to test cores from the remote end of the
cable to ensure that the cores are shorted correctly at the end of the procedure.
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3.
PCA108K RESIN FILLED SHORTING KIT , (RESIN VOLUME OF EMPTY
SHELL 2 LTRS).
Associated Drawing: PCA108K Issue 1.
Typically used on multicore cables having outside diameter between 40mm and 82mm and triplex
cables of 95mm² and 300mm² CSA.
3.1
CABLE PREPARATION.
3.1.1
Cut cable end square with saw.
3.1.2
Clean and abrade outer sheath for 100mm.
3.2
FOR TRIPLEX CABLES - SECURE SHORTING LINK.
3.2.1
Temporarily affix the shell set end plate approximately 150mm from cable ends, hold
cables in position with cable ties if required.
3.2.2
Hammer a nail through one end of the shorting link and into the outer-sheath of one of
the cores, into and through the screen and into the core of the cable, approximately
30mm from the end. For best result and ease of application, the chisel pane end of a
chisel pane hammer.
3.2.3
Wrap round to the second core and nail through shorting link into the core
3.2.4
Wrap round to the third core and nail through shorting link into the core
3.2.5
Fold over and nail through the shorting link and into the end of each of the three cores
between the insulation and the solid core so that the nails sits alongside and in contact
with the cores.
Note: For stranded cores nail into the core centre point.
3.3
AFFIX SHELL SET AND POUR RESIN.
3.3.1
Align one half of the shell set in position around cores so that they are approximately
110 – 130mm through the end plate.
3.3.2
Bring second half into position and secure with metal clips provided.
3.3.2
Support shell set and cables prior to filling with resin, check that there is a 10mm
clearance between cable and shell set.
3.3.3
Mix resin (2lts required for empty shell) as per manufacturer’s instruction.
3.3.4
Fit shell cover and allow too cure for manufactures recommended time before backfill.
3.3.5
Continuity test to ensure cores are shorted correctly on remote end before completing
final end of laid cable.
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3.4.
FOR MULTICORE CABLES - SECURE SHORTING LINK.
3.4.1
Hammer a nail through one end of the shorting link, into one of the cable cores.
Note: If the cable is solid aluminium, nail between the insulator and the cores, so that the nails sits
alongside and in contact with the core.
3.4.2
Hammer through the shorting link again into the second core.
3.4.3
Fold the shorting link and align over the third core and nail accordingly.
3.4.4
If the cable is four core, fold the shorting link and align with the fourth core and nail.
3.4.5
Using a fifth nail, nail the shorting link into the cable screen.
3.5
AFFIX SHELL SET AND POUR RESIN.
3.5.1
Trim the shell end at the required section for the cable diameter required.
3.5.2
If required use foam strip to build up diameter to match shell set.
3.5.3
Bring second half into position and secure with metal clips provided.
3.5.4
Support shell set and cable prior to filling with resin, check that there is a 10mm
clearance between cable and shell set.
3.5.5
Mix resin (2lts required for empty shell) as per manufacturer’s instruction.
3.5.6
Fit shell cover and allow too cure for manufactures recommended time before backfill.
3.5.7
Continuity test to ensure cores are shorted correctly on remote end before completing
final end of laid cable.
3.6
CARRY OUT INSULATION RESISTANCE TEST CABLE TO ENSURE
EFFECTIVE SHORTING.
3.6.1
Using a 500VDC Insulation Resistance tester to, test cores from the remote end of the
cable to ensure that the cores are shorted correctly at the end of the procedure.
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