RAYCHEM TFT-350R-SG

TFT-350R-SG

35kV Cold Applied OutdoorTermination for Copper Tape,Wire Shield, Lead Sheath andUniShield Cable

Product Installation Instructions

Raychem Tyco Electronics-Energy8000 Purfoy RoadFuquay-Varina, NC 27526

PII-55099, Rev AGPCN 393397-000Effective Date: August 17, 2001

Energy Division * Unishield is a trademark of BICC General Cable Industries, INC.

PII-55099, Rev AG PCN 393397-000Effective Date: August 17, 2001

2

Cable Type SelectionsNote: There are separateinstructions for each cable typeaddressed in this instruction. Turnto the page denoted below for yourcable type.

Tape Shield Cable (page 4)

1

2

3

4

Wire Shield Cable (page 11)

UniShield Cable (page 17)

Lead Sheath Cable (page 23)


3

General Instructions

1. Select product.

Check kit selection with cablediameter dimensions in table 1opposite.

Table 1

NominalConductor Min/max

Kit Size Insulation ODs*TFT-352R-SG 1/0-250 kcmil 0.85-1.45(22-37mm)TFT-353R-SG 4/0-500 kcmil 1.06-1.70(27-43mm)TFT-354R-SG 500-1250 kcmil 1.49-2.20(38-56mm)

Note: Insulation ODs and nominal conductor sizes are based on 100% compact and concentric stranded cable dimensions

Installation Instructions

Cable preparation tools Clean, lint-free cloths

Non-conducting abrasive cloth,120 grit or finer Electrician's tape

Connector(s) and installation toolsSuggested Installation Equipment (not supplied with kit)

Cleaning the Cable

Use an approved solvent, such asthe one supplied in the P63 CablePrep Kit, to clean the cable. Besure to follow the manufacturer'sinstructions. Failure to follow theseinstructions could lead to productfailure.

Some newer solvents do notevaporate quickly and need to beremoved with a clean, lint-freecloth. Failure to do so couldchange the electrical characteristicsof the cable or leave a residue onthe surface.

Please follow the manufacturer'sinstructions carefully.

Safety Instructions

Warning: When installing electricalpower system accessories, failure tofollow applicable personal safetyrequirements and written installationinstructions could result in serious orfatal injuries.

As Tyco Electronics has no controlover field conditions whichinfluence product installation, it isunderstood that the user must takethis into account and apply his ownexperience and expertise wheninstalling product.

Kit Contents

1 Installation Instruction2 Silicone housings on holdouts1 Stress control patch1 Roll spring1 Solder blocked ground braid2 Adhesive backed copper tape strips1 Cloth tape1 Leakage current collector

Sealant tape strips

Installation Instructions For Tape Shielded Cable


4

2. Prepare cablesDetermine insulation cutback: length Z.

Figure 1: Insulation Cutback (Z)

Note: If no lug is used, Z = 2" (50mm) "Y"Length ofLug Barrel

+= "Z"InsulationCutback

1/4"(6mm)

(6mm)1/4"

Y

Z

481

Refer to Figure 1 and adjacentdrawing to prepare the cable asshown.

Remove the backing from a piece ofcopper foil provided and tape over theend of the shield as shown.

19"(483mm) + Z

Jacket Cutback + Z

Tape Shield Semi-Con

Z (25mm)1"

(25mm)1"

512

Adhesive Back Copper Foil Tape

512b



5

Spring Clamp

1/4" (5mm)

Ground BraidMoistureBlock

516

516a

3. Install ground braid

Flare the moisture blocked end ofthe ground braid and place it ontothe tape shield butted up to thecable jacket. Attach the braid tothe shield by placing two wraps ofthe spring clamp over the braid 1/4from the jacket cutback. Fold thebraid back over the spring clampwraps. Continue to wrap theremaining clamp over the braid.Tighten clamp by twisting it in thedirection it is wrapped.

Apply a small piece of copperadhesive tape foil on top of thespring clamp as shown.

Note: Wrap the copper adhesivetape foil in the same direction asthe spring clamp to tighten thewrap.

4. Make Lug Connection

Crimp the connector using properdie and tool. Clean lug barrel ofinhibitor and dirt and file off anysharp edges.

Lug

518

5. Abrade (sand) and cleaninsulation

Abrade and clean the surface of theprimary insulation using the solventsupplied with the termination or anyother approved solvent. Be sure toremove any conductive particles orcontamination.

Note: Use aluminum oxideabrasive strip only.

Abrade &Clean

518a

Copper Adhesive Tape

516b



6

6. Install sealant

Start wrapping sealant at end of lugbarrel. Continue wrapping (no halflaps) until sealant is same thicknessas insulation (at least two wraps).

Continue wrapping on to the cableinsulation for 1/2. Snap off anyadditional mastic.

Solvent clean and abrade (sand)jacket. Using light tension, wrap onelayer of sealant onto the cable jacket,even with the jacket cutback asshown.

Press the solder-blocked portion ofthe braid into the sealant. Wrap anadditional layer of sealant over thebraid solder-block, sandwiching thesolder-block between layers ofsealant.

To ensure the correct positioning ofthe termination, place a marker tape4-1/4 (108mm) from the semi-concutback as shown.

Tape sealant 515

Note: Some Lug Barrel May Be Showing

Overlap Insulation1/2"(10mm)

518c

Tape sealant 515a

TapeSealant

Start Here

Insulation

Same ThicknessAs Insulation

500

501

Tape sealant

4-1/4"(108mm)

515d

7. Apply Stress Patch

Note: The stress patch easilysticks to itself and loose particles.

Note: The patch may berectangular. Follow the direction ofthe arrow on the backing paper ofthe stress patch. Longer dimensiongoes around the cable.

Remove backing paper from thepatch. Using light tension andoverlapping the semi-con by1(25mm), wrap the entire patcharound the semi-con as shown.Avoid wrinkles and creases.

StressRelief Patch

Overlap semi-conby 1"(25mm)

approx. 4-3/4"

(120mm)

519

8. Tape over sharp edges

Using cloth tape provided, tape overall sharp edges of the ground clampassembly.

Tape over sharp edges

1/4" (6.5mm) Gap519a

9. Loosening TerminationThis operation is vital to thesimple installation of theproduct.

There are two terminations inthis kit (one with three sheds,the other with five). Loosenboth in the manner shownopposite. Install the five shedtermination first.Hold the termination in one handand the holdout in the other.Gripping firmly, twist the terminationand holdout in opposite directions.Repeat twisting the termination andholdout, moving the hand in shortincrements up the termination untilthe entire termination is felt to moveon the holdout. Slide thetermination until it lines up with theend of the holdout tube as shown.

Note: Take care not to slide thetermination off the end of theholdout. Stop the terminationabout 1/4 from the end of theholdout.



7

Holdout Sheds Lug symbol band

Flipped-back end

1/4" Stop Here

Termination

523ca



8

1/4"(6mm)

1-1/4"(32mm)Sealant

15"(381mm)

Align end with edge of tape marker

Twist clockwise and counterclockwisewhile pulling out

Align the end of the holdout with the edge of the sealant

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10. Installing the termination.

Position the holdout over the cableuntil it meets the jacket cutback. Twistthe termination and slowly push it tothe end of the holdout.

Slide the termination off the holdoutwith a twisting motion holding thetermination that is on the holdout inone hand and pulling the holdout withthe other.

Note: Do NOT stretch thetermination.

Do NOT hold the termination that ispartially installed and attempt to pullthe remaining termination off theholdout, as this will stretch thetermination and generate animproperly installed termination if notrepositioned.

Using the pull tabs, pull the flip-backportion away from the maintermination, at the same time workingthe first two fingers of each handbetween the flip-back and maintermination. Pull the stretched out flip-back over the cable jacket andsealant.

After installation, gently slide thetermination so that the end aligns withthe edge of the marker tape installedin step 6. Make sure the terminationlength is in accordance with thedimensions shown.

Having positioned the termination,now wrap one layer tape sealant overthe end of the termination and1/4(6mm) onto the cable insulation asshown.

Remove tape marker.



9

Slide the three-shedded termination over the cable until it meets the leading edge of the sealant strip as shown.Twist the termination and slowly push it to the end of the holdout.

Slide the termination completely off the holdout using a twisting and pulling motion as shown.

Using the pull tabs, pull the flip-back portion away from the main termination, at the same time working the firsttwo fingers of each hand between the flip-back and main termination. Pull the stretched out flip-back over thesealant.



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11. Installing the termination (continued).

7Installation Instructions


10

12. Complete installation

If necessary, adjust the three-sheddedtermination to overlap the sealant onthe lug barrel (see drawing below).Place the leakage current collector1/4(6mm) from the end of thetermination as shown. Use a copperwire to connect the current collector tothe ground braid.

Wipe over the surface of thetermination to remove any dirt orgrease.

Note: Be sure to position terminationat lug end so that there is a bead ofsealant exposed as shown.

This completes the installation.

Leakage CurrentCollector

1/4"(6mm)

Sealant 534jcn

Installation Instructions For Wire Shield Cable


11





1/4"(6mm)

(6mm)1/4"

Y

Z

481

Refer to Figure 1 and adjacentdrawing to prepare the cable asshown. Pull back drain wires asshown. Do not pigtail wires at thistime. (50mm)

Cable Jacket Shield Wires

Semi-Con

2"

Z

19"(483mm)+ Z

513



Lug

518k




Abrade &Clean

518l



12



518m

TapeSealant

Start Here

Insulation


500d

501d

4. Install sealant

Start wrapping sealant at end of lugbarrel. Continue wrapping (no halflaps) until sealant is samethickness as insulation (at least twowraps).


5. Apply tape sealant

Lift the drain wires away from thecable jacket. Solvent clean andabrade jacket. Using light tension,wrap one layer of sealant onto thecable jacket as shown.

Lay the drain wires evenly backover the jacket and press them intothe sealant.

Wrap an additional layer of sealantover the drain wires and previouslyapplied sealant.

To ensure the correct positioning ofthe termination, place a markertape 4-1/4 (108mm) from the semi-con cutback as shown.

Tape sealant

Press wires into sealant

521b

533b

533c

4-1/4"(108mm)

533d



13





StressRelief Patch

1" (25mm) Onto Semi-con

approx. 4-3/4"

(120mm)

519f



Note: Take care not to slide thetermination off the end of theholdout. Stop the terminationabout 1/4 from the end of theholdout

523ca


Flipped-back end

1/4" Stop Here

Termination

8. Installing termination






After installation, gently slide thetermination so that the end aligns withthe edge of the marker tape installedin step 5. Make sure the terminationlength is in accordance with thedimenisions shown.

Having positioned the termination,now wrap one layer tape sealant overthe end of the termination and 1/4(6mm) onto the cable insulation as shown.

Remove tape maker.

525ca



14


524ca

526ca

Twist clockwise and counterclockwise while pulling out

527ca

15"(381mm)


1/4"(6mm)

1-1/4"(32mm)Sealant

528ca

529ca



15






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7Installation Instructions


16







1/4"(6mm)

Sealant 534lca

Installation Instructions For UniShield Cable


17





1/4"(6mm)

(6mm)1/4"

Y

Z

481

Refer to Figure 1 and adjacentdrawing to prepare the cable asshown. Pull back drain wires asshown before cutting semi-con/jacket. (50mm)2"

Shield Wires Cable Jacket / Semi-Con

Z

19"(483mm)+ Z

514



Lug

518g




Abrade &Clean

518h



18



518i

TapeSealant

Start Here

Insulation


500c

501c

4. Install sealant

Start wrapping sealant at end of lugbarrel. Continue wrapping (no halflaps) until sealant is samethickness as insulation (at least twowraps).


5. Apply tape sealant

Lift the drain wires away from thecable jacket. Solvent clean andabrade jacket. Using light tension,wrap one layer of sealant onto thejacket as shown.

Lay the drain wires evenly backover the jacket and press them intothe sealant.

Wrap an additional layer of sealantover the drain wires and previouslyapplied sealant.

To ensure the correct positioning ofthe termination, place a markertape 4-1/4 (108mm) from the semi-con cutback as shown.

Tape sealant

Press wires into sealant

521

533a

533e

4-1/4"(108mm)

533t



19




Remove backing paper from thepatch. Using light tension andoverlapping the semi-con by1(25mm), wrap the entire patcharound the semi-con jacket asshown. Avoid wrinkles and creases.

StressRelief Patch

1"(25mm) Onto Semi-Con/Jacket

approx. 4-3/4"

(120mm)

519e





Flipped-back end

1/4" Stop Here

Termination

523ca

8. Installing termination






After installation, gently slide thetermination so that the end aligns withthe edge of the marker tape installedin step 5. Make sure the terminationlength is in accordance with thedimenisons shown.

Having positioned the termination,now wrap one layer tape sealant overthe end of the termination and 1/4(6mm) onto the cable insulation asshown.

Remove tape meter.

525ca



20


524ca

526ca

Twist clockwise and counterclockwise while pulling out

527ca

15"(381mm)

Align end with edge of tape marker 528ca

1/4"(6mm)

1-1/4"(32mm)Sealant

529ca



21






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22


7







1/4"(6mm)

Sealant 534lca

Installation Instructions For Lead Sheath Cable


23

1. Prepare cables.Determine insulation cutback: length Z.




1/4"(6mm)

(6mm)1/4"

Y

Z

481

Refer to Figure 1 and adjacentdrawing to prepare the cable asshown.

Z(25mm)1"

(25mm)1"

(50mm)2"

Cable Jacket Lead Sheath

Semi-Con

19"(483mm)+ Z

512a



24

GroundBraid

MoistureBlock 519y

2. Install ground braid

Flare the moisture blocked end ofthe ground braid and place it ontothe lead sheath butted up to thecable jacket and solder to the leadsheath.



Lug

518b




Abrade &Clean

518d



25

5. Install sealant

Start wrapping sealant at end of lugbarrel. Continue wrapping (no halflaps) until sealant is same thicknessas insulation (at least two wraps).


Solvent clean and abrade (sand)jacket. Using light tension, wrap onelayer of sealant onto the cable jacket,even with the jacket cutback asshown.

Press the solder-blocked portion ofthe braid into the sealant. Wrap anadditional layer of sealant over thebraid solder-block, sandwiching thesolder-block between layers ofsealant.

To ensure the correct positioning ofthe termination, place a marker tape4-1/4 (108mm) from the semi-concutback as shown.

Tape sealant 515b



518e

Tape sealant 515c

TapeSealant

Start Here

Insulation


500a

501a

Tape sealant

4-1/4"(108mm)

515s





StressRelief Patch

approx. 4-3/4"

(120mm)

Overlap semi-conby 1"(25mm)

519c






26


Flipped-back end

1/4" Stop Here

Termination

523ca

7. Tape over sharp edges

Using cloth tape provided, tape overall sharp edges of the ground clampassembly.

Tape over sharp edges

1/4" (6.5mm) Gap519z

Installation Instructions9. Installing termination






After installation, gently slide thetermination so that the end aligns withthe edge of the marker tape installedin step 5. Make sure the terminationlength is in accordance with thedimensions shown.

Having positioned the termination,now wrap one layer tape sealant overthe end of the termination and 1/4(6mm) onto the cable insulation asshown.

Remove tape marker.


27

1/4"(6mm)

1-1/4"(32mm)Sealant

15"(381mm)




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526jcn

527jcn

528jcn

529jcn



28






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PII-55099, Rev AGPCN 393397-000Effective Date: August 17, 2001

2001 Tyco Electronics CorporationPrinted USA 8/17/2001

29

The Information contained in these installation instructions is for use only by installers trained to make electrical power installations and is intended to describe thecorrect method of installation for this product. However, Tyco Electronics has no control over the field conditions which influence product installation. It is theuser's responsibility to determine the suitability of the installation method in the user's field conditions. Tyco Electronics' only obligations are those in TycoElectronics' standard Conditions of Sale for this product and in no case will Tyco Electronics be liable for any other incidental, indirect or consequential damagesarising from the use or misuse of the products. Raychem is a trade mark of Tyco Electronics Corporation.

7* Unishield is a trademark of BICC General Cable Industries, INC.

Installation Instructions11. Complete installation






1/4"(6mm)

Sealant 534jcn

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RAYCHEM TFT-350R-SG