ABB Installation Products 69TCT20N232PABN 69kV, Transmission Cable Terminator, Base and Top Module, Housing Size 0, Connection…

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How to Install the ELASTIMOLD TCT Outdoor Transmission Cable Termination

This guide provides step-by-step instructions for the safe and proper installation of the ELASTIMOLD TCT outdoor transmission cable termination, including cable preparation, component assembly, and final mounting. All apparatus must be de-energized during installation, and only competent personnel trained in high-voltage safety practices should perform this procedure.

Estimated time: 3h

1. Perform Pre-Installation Checks and Safety Procedures

   Ensure all apparatus is de-energized before starting. Verify the package contents are complete and undamaged, and all components fit properly with the cable. Read the entire instructions, gather all required tools, and maintain cleanliness. This installation must be performed by competent personnel trained in high-voltage safety practices.

2. Prepare the Cable End

   Straighten the cable and place it in its final position using the spade contact as a guide. Square cut the cable end and note the depth of the spade contact hole (X).

3. Remove Outer Jacket and Install Heat Shrink Sleeve

   Carefully remove the outer jacket material to a distance of 45.5 inches (111.6 cm) from the cable end to expose the cable shield. Slide the heat shrink sleeve onto the cable.

4. Remove Cable Shield

   Remove the cable shield to a distance of 43.5 inches (110.5 cm) from the cable end.

5. Remove Non-Metallic Screen

   Remove the non-metallic screen to a distance of 40 inches (101.5 cm) from the end of the conductor. DO NOT cut or nick the exposed insulation, as this could lead to cable failure. Chamfer the non-metallic screen edge for a minimum of 1/2 inch (1.5 cm).

6. Square Cut and Chamfer Cable Insulation

   Using a hose clamp as a guide, square cut the cable insulation at X+1 inch from the end of the conductor, being careful not to nick the conductor. Remove the hose clamp. Sand out all nicks and abrasions on the extruded non-metallic screen chamfer and cable insulation. Chamfer the edge of the cable insulation for approximately 3 inches (7.5 cm).

7. Clean and Paint Cable Insulation

   Using cable cleaner, clean the cable insulation and extruded non-metallic screen, cleaning toward the outer jacket to prevent semi-conductive particles from contaminating the insulation. Place a vinyl tape marker on the cable insulation surface at 39.5 inches (100.5 cm) from the end of the conductor. Stir the supplied semi-conductive paint well. Paint the exposed insulation and a minimum of 1 inch (2.5 cm) of the extruded non-metallic screen with the semi-conductive paint. Remove the vinyl tape within 5 to 15 minutes, ensuring the paint edge is smooth and square. Allow the paint 60 minutes to dry.

8. Place Second Vinyl Tape Marker

   Place a vinyl tape marker onto the cable non-metallic shield 2 inches (5 cm) from the edge of the paint.

9. Assemble Clamps and Winch Assembly

   Assemble the Cable Clamp at least 55 inches (140 cm) back from the conductor and tighten it securely. Place the Winch Assembly in front of the Cable Clamp and attach stationary hooks to the Cable Clamp. Attach Adapter Plates to the Housing Clamp with the supplied bolts. Assemble the Housing Clamp around the Terminator Base Section. Extend the steel cable(s) on the Winch Assembly until the hooks reach the Housing Clamp, then hook the cables to the Housing Clamp. Thoroughly lubricate the cable in the specified area and direction with the supplied lubricant.

10. Assemble Terminator Base and Module Sections

    Assemble the Terminator Base Section on the cable approximately 12 inches from the end. Release tension on each steel cable. Extend the steel cables and Housing Clamp. Position the Terminator Module Section in the Housing Clamp. Install until units overlap and continue assembling mated units until the Terminator Base Section is flush with the tape marker. Remove the Winch Assembly, Housing Clamp, Adapter Plate, and Cable Clamp.

11. Connect Conductor and Apply Mastic

    Remove the tape marker on the insulation shield. Remove the cut section of insulation on the cable to expose the conductor. Wirebrush the conductor of the cable and immediately insert it into the spade contact. Crimp the connector according to the enclosed crimping instructions, starting at the crimp line and working outward toward the TCT. Remove any excess inhibitor. Apply two layers of mastic: one at the end of the stress cone and one 2 inches (5 cm) back from the end of the cable jacket.

12. Install Grounding and Seal Components

    Install the scintillation ring and #12 AWG copper drain wire. Solder the flat braid and the #12 drain wire to the shield. Apply a second layer of mastic over the drain wire, on top of the previously applied mastic around the base of the stress cone. Apply a second layer of mastic over the flat braid, on top of the previously applied mastic on the cable jacket. Slide the heat shrink sleeve up to the grounding eye of the base of the terminator. Apply heat to the sleeve, starting in the middle and continuing toward each end of the tube until mastic sealer squeezes from the ends. Connect the flat braid to the system ground. Seal the cable end with mastic tape between the contact and cable insulation. Apply two half-lapped layers of silicone tape covering the crimp connector, mastic tape, and the upper portion of the terminator skirt.

13. Mount Terminated Cables to Supporting Structure

    Mount the terminated cables to a supporting structure. Ensure that a minimum clearance of 4.0 inches (10 cm) is maintained between the terminator stress cone base and the supporting structure. All apparatus must be installed and operated in accordance with individual user, local, and national work rules.

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