56

JOINTS

Energy Division

Joints Heatshrink

Page

EPKE

58

LVJM Low Voltage Joints

59

MXSU Mechanical Joints up to 36 kV

60

EHVS Mechanical Joint 170 kV

65

EPKB Mechanichal Branch Joints

66

SXSU Heatshrink Joints - Inline

70

EPKB Heatshrink Branch Joints / Live End Seals

75

ore MIND cable

EPKJ Heatshrink Transition Joints

76

ore MIND HSL cable

57

EPKE Live End Seals for 12 and 24 kV single core plastic cable

EPKE Live End Seals for Enhanced Cable Protection The EPKE product line includes two different end seal kits covering an application range from 70 to 500 mm2. No special crimping tools are required for the installation. The cable can be energized immediately after installation. Third party damage to cable can be caused by heavy vehicles, such as excavation machinery, etc., during construction work. The live end seals allow partially installed networks to be energized, and therefore enable the detection of third party damage as soon as it occurs. The end seal also protects the cable against moisture ingress.

Features A full product line with only two different sizes. Suitable for both wire and tape shielded cables. Installation requires no need of special tools. (e.g. crimps, etc) Same insulation technology as Raychem joints.

Benefits Covers all commercial cable sizes. Fits most plastic single core cable types. Protects cable against moisture ingress. Enables detection of third party damage. Energizing can take place immediately after installation.

Wire shielded cables

Tape shielded cables

Selection table
Voltage class Uo/U Kit description Cable cross section EPKE 24B/1XU EPKE 24C/1XU 70-240 mm 240-500 mm
2

range insulation 17.6 - 33.6 mm 25.7 - 41.6 mm

range oversheath 25 - 46 mm 33 - 54 mm

6,9/12 and 13,8/24 kV

Installation Instruction EPP 0974-3/04

58

Energy Division

LV Inline Joints for XLPE cables for applications up to 1kV

LV 1 Core Inline Joint Kits C/w Mechanical Connectors
Part Number LVJM-6/35-1 LVJM-25/95-1 LVJM-95/240-1 LVJM-120/300-1 Description 1 Core LV Inline Joint Kit 1 Core LV Inline Joint Kit 1 Core LV Inline Joint Kit 1 Core LV Inline Joint Kit Size Range Cu Conductors 6-35mm
2

Size Range Al Conductors 6-35mm2 25-95mm2 95-240mm2 120-300mm2

25-95mm2 95-240mm2 120-300mm2

LV Multi Core Inline Joint Kits C/w Mechanical Connectors

Part Number LVJM-6/35-4 LVJM-25/95-4 LVJM-95/185-4 LVJM-120/300-4 LVJM-6/35-NS-4 LVJM-25/95-NS-4 LVJM-95/185-NS-4 LVJM-120/300-NS-4 Description 4 Core LV Inline Joint Kit 4 Core LV Inline Joint Kit 4 Core LV Inline Joint Kit 4 Core LV Inline Joint Kit 3 Core + NS LV Inline Joint Kit 3 Core + NS LV Inline Joint Kit 3 Core + NS LV Inline Joint Kit 3 Core + NS LV Inline Joint Kit Size Range Cu Conductors 6-35mm
2

Size Range Al Conductors 6-35mm2 25-70/95*mm2 95-185*mm2 120/300*mm2 6-35mm2 25-70/95*mm2 95-185*mm2 120/300*mm2

25-70/95*mm2 95-185*mm
2

120/300*mm2 6-35mm2 25-70/95*mm2 95-185*mm

2

120/300*mm2

* Pressed Round Note: Other size ranges and custom congurations are also available

LV Reducing End of Run Joints for XLPE cables for applications up to 1kV
LV 1 Core Joint Kits C/w Mechanical Connectors
Part Number LVEK-16/240-1 LVEK-95/400-1 Description 1 Core LV Reducing Joint Kit 1 Core LV Reducing Joint Kit Cable One 16-95 Cu / 25-95 Al 95-240 Cu / AI Cable Two Al 95-240 Cu/Al 185-400 Cu/AI

LV 4 Core / 3 Core + NS Joint Kits C/w Mechanical Connectors

Part Number LVEK-16/185-4 LVEK-95/240-4 LVEK-16/185-NS4 LVEK-95/240-NS4 Description 4 Core LV Reducing Joint Kit 4 Core LV Reducing Joint Kit 3 Core + NS LV Reducing Joint Kit 3 Core + NS LV Reducing Joint Kit Cable One 16-70(95*) Cu / 25-70(95*) Al 95-185* Cu / Al 16-70(95*) Cu / 25-70(95*) Al 95-185* Cu / Al Cable Two 95-185* Cu/Al 185-240 Cu/Al 95-185* Cu/Al 185-240 Cu/ Al

LV Termination kits for XLPE cables for applications up to 1kV

LV Termination Kits C/w Mechanical Lugs
Part Number LVTM-16/95-4 LVTM-95/240-4 LVTM-120/300-4 Description 4 Core LV Termination Kit 4 Core LV Termination Kit 4 Core LV Termination Kit Size Range Cu Conductors 16-95mm
2

Size Range Al Conductors 25-95mm2 95-185*mm2 120-240*mm2

95-185*mm2 120-300mm
2

* Pressed Round

59

MXSU Raychem jointing system up to 36kV complete with mechanical connectors

MXSU is based on a joint design using mechanical connectors Mechanical connectors for conductor and wire shield are supplied with the kit Kits are widely range taking and cover most conductor constructions including their tolerances No crimping tools or tool maintenance required Short and space saving design for installation Improves installation reliability Has unlimited shelf life, simplifies material logistics and reduces cost Avoids bulky waste and costly waste disposal Exceeds international performance standards including CENELEC HD 629 or IEC 60502-4 for joints

Mechanical shear bolt connectors All joint kits incorporate a Raychem designed screw connector with shear head bolts to ensure a reliable pre-engineered electrical connection for the different conductor materials, shapes and types used in todays network. The pre-set shear torque of the bolts ensures that the correct contact pressure is always achieved. The specially designed contact surface on the inside of the connector breaks up any conductor oxide layer and ensures reliable service over the entire life time of the joint. The connectors have been tested in accordance with IEC 61238-1 class A.

Tyco Electronics Raychem BSM type connectors used for aluminium and copper conductors pre-set shear torque provides safe and reliable installation removable half shell insert provide core centering tin-plated and greased contact surface for corrosion protection shorter length compared to compression connectors excellent tensile performance due to special bolt tip design

Summary of type tests performed on MXSU

CENELEC HD 629.1 S1 IEC 60502-4 Additional tests reflecting future network operation MXSU joints passed all tests for XLPE insulated cables according to CENELEC HD 629.1 S1 or IEC 60502-4 including impact tests at ambient and at low temperature. MXSU joints were subjected to additional tests which are not part of any European standard but reflect future demands in modern network operation: Overload operation of cables: More than 800 hours of electrical heat cycling at conductor temperatures of 130 C with a voltage of 2.5 times the operating voltage U0. Oversheath testing as the routine test method of cable networks: Voltage withstand tests between the screen wires and the water bath for 15 minutes at 15 kV DC and at 8 kV AC. Mechanical connectors used in MXSU joints, pass the requirements in accordance with IEC 61238-1 class A.

IEC 61238-1 class A

60

Energy Division

11kV Inline Joint Kits for XLPE cables

11kV 1 Core Inline Joint Kits C/w Mechanical Connectors
Part Number MXSU-3111 MXSU-3131 MXSU-3141 MXSU-3151 MXSU-3161 Description 11kV 1 Core XLPE Inline Joint Kit 11kV 1 Core XLPE Inline Joint Kit 11kV 1 Core XLPE Inline Joint Kit 11kV 1 Core XLPE Inline Joint Kit 11kV 1 Core XLPE Inline Joint Kit Size Range Al or Cu 25-95mm2 95-240mm2 185-400mm2 500mm2 630mm2

11kV 3 Core Inline Joint Kits C/w Mechanical Connectors

MXSU-3311 MXSU-3331 MXSU-3341 11kV 3 Core XLPE Inline Joint Kit 11kV 3 Core XLPE Inline Joint Kit 11kV 3 Core XLPE Inline Joint Kit 25-95mm2 95-240mm2 185-400mm2

11kV 3 Core to 1 Core Inline Joint Kits C/w Mechanical Connectors

MXSU-3311-1C MXSU-3331-1C MXSU-3341-1C 11kV 3 Core - 1 Core XLPE Inline Joint Kit 11kV 3 Core - 1 Core XLPE Inline Joint Kit 11kV 3 Core - 1 Core XLPE Inline Joint Kit 25-95mm2 95-240mm2 185-400mm2

11kV Transition Joints to join PILC cable to XLPE cable

11kV 3 Core to 3 Core Inline Transition Kits C/w Mechanical Connectors
Part Number MXSU-3321-TS MXSU-3331-TS Description 11kV 3 Core - XLPE Transition Joint Kit 11kV 3 Core - XLPE Transition Joint Kit Size Range PILC mm2 Cu 16-95* / Al 25-95* Cu 95-240* / Al 95-240* Size Range XLPE mm2 Cu 95-240 / Al 95-240 Cu 185-400 / Al 185-400

11kV 3 Core Transition Joint Kits C/w Mechanical Connectors

Part Number MXSU12A-3X/3B MXSU12B-3X/3B MXSU12C-3X/3B MXSU12D-3X/3B MXSU12E-3X/3B MXSU12B-3X/3BTS MXSU12D-3X/3BTS Description 11kV 3 Core Transition Joint Kit 11kV 3 Core Transition Joint Kit 11kV 3 Core Transition Joint Kit 11kV 3 Core Transition Joint Kit 11kV 3 Core Transition Joint Kit 11kV 3 Core Transition Joint Kit 11kV 3 Core Transition Joint Kit Size Range PILC mm2 Cu 16-70* / Al 25-70* Cu 70-120* / Al 70-120* Cu 95-185* / Al 95-185* Cu 150-240* / Al 150-240* Cu 240*-300* / Al 240*-300* Cu 16-95* / Al 25-95* Cu 95-185* / Al 95-185* Size Range XLPE mm2 Cu 16-95 / Al 25-95 Cu 50-150 / Al 50-150 Cu 95-240 / Al 95-240 Cu 150-300 / Al 150-300 Cu 240-400 / Al 240-400 Cu 95-240 / Al 95-240 Cu 185-400 / Al 185-400

11kV 1 Core - 3 Core Transition Joint Kits C/w Mechanical Connectors

Part Number MXSU12A-1X/3B MXSU12B-1X/3B MXSU12C-1X/3B MXSU12D-1X/3B MXSU12E-1X/3B Description 11kV 1C XLPE - 3C PILC Joint Kit 11kV 1C XLPE - 3C PILC Joint Kit 11kV 1C XLPE - 3C PILC Joint Kit 11kV 1C XLPE - 3C PILC Joint Kit 11kV 1C XLPE - 3C PILC Joint Kit Size Range PILC mm2 Cu 25-70* / Al 25-70* Cu 70-150* / Al 70-150* Cu 95-185* / Al 95-185* Cu 150-240* / Al 150-240* Cu 240-300* / Al 240-300* Size Range XLPE mm2 Cu 25-95 / Al 25-95 Cu 50-150 / Al 50-150 Cu 120-300 / Al 95-240 Cu 150-300 / Al 150-300 Cu 240-400 / Al 240-400

MXSU12B-1X/3BTS MXSU12D-1X/3BTS

11kV 1C XLPE - 3C PILC Joint Kit 11kV 1C XLPE - 3C PILC Joint Kit

Cu 16-70* / Al 25-70* Cu 95-185* / Al 95-185*

Cu 95-240 / Al 95-240 Cu 240-300 / Al 240-300

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Energy Division

11kV Inline Joints for MIND paper screened/belted (PILC) cables

11kV Inline Joint Kits for MIND Paper Screened/Belted Cables C/w Mechanical Connectors
Part Number HVSAM-16/35 HVSAM-50/95 HVSAM-95/185 HVSAM-240/300 Description 11kV 3 Core PILC Inline Joint Kit 11kV 3 Core PILC Inline Joint Kit 11kV 3 Core PILC Inline Joint Kit C/w Split V Connectors 11kV 3 Core PILC Inline Joint Kit C/w Split V Connectors Size Range 16-35mm2 50-95*mm2 95-185*mm2 185-300*mm2

11kV Inline Joint Kits for MIND Paper Screened/Belted Cables C/w Mechanical Connectors - Sheath Testable to 2.5kV
Part Number HVSAM-16/35-ST HVSAM-50/95-ST HVSAM-95/185-ST HVSAM-240/300-ST Description 11kV 3 Core PILC Inline Joint Kit Sheath Testable 11kV 3 Core PILC Inline Joint Kit Sheath Testable 11kV 3 Core PILC Inline Joint Kit Sheath Testable C/w Split V Connectors 11kV 3 Core PILC Inline Joint Kit Sheath Testable C/w Split V Connectors Size Range 16-35mm2 50-95*mm2 95-185*mm2 185-300*mm2

* Pressed Round

11kV Repair Joints for XLPE cables

11kV 1 Core Inline Repair Joint Kits C/w 440mm Long Mechanical Connectors
Part Number MXSU-3111-L MXSU-3131-L MXSU-3132-L Description 11kV 1 Core XLPE Inline Repair Joint Kit 11kV 1 Core XLPE Inline Repair Joint Kit 11kV 1 Core XLPE Inline Repair Joint Kit Size Range Al or Cu 25-95mm2 95-240mm2 150-300mm2

11kV 3 Core Inline Repair Joint Kits C/w 440mm Long Mechanical Connectors
Part Number MXSU-3311-L MXSU-3331-L MXSU-3332-L Description 11kV 3 Core XLPE Inline Repair Joint Kit 11kV 3 Core XLPE Inline Repair Joint Kit 11kV 3 Core XLPE Inline Repair Joint Kit Size Range Al or Cu 25-95mm2 95-240mm2 150-300mm2

11kV Branch Joints for XLPE cables

11kV Branch Joint 1/Core XLPE unarmoured
Part Number Conductor Cross Section Overall Cable Diameter Min. EPKB 12A 1XU-2XU EPKB 12B 1XU-2XU EPKB 12C 1XU-2XU
62

Min. Diameter over Insulation of Main Cable 23.5 26.0 32.1

Max. 32 37.5 43

35 - 95mm2 95 - 150mm2 185 - 300mm

2

23.5 26.0 32.1

Energy Division

22kV Inline Joints for XLPE cables

22kV 1 Core Inline Joint Kits C/w Mechanical Connectors
Part Number MXSU-5111 MXSU-5131 MXSU-5141 MXSU-5151 MXSU-5161 Description 22kV 1 Core XLPE Inline Joint Kit 22kV 1 Core XLPE Inline Joint Kit 22kV 1 Core XLPE Inline Joint Kit 22kV 1 Core XLPE Inline Joint Kit 22kV 1 Core XLPE Inline Joint Kit Size Range Al or Cu 35-95mm2 95-240mm2 185-400mm2 500mm2 630mm2

22kV 3 Core Inline Joint Kits C/w Mechanical Connectors

Part Number MXSU-5311 MXSU-5331 MXSU-5341 Description 22kV 3 Core XLPE Inline Joint Kit 22kV 3 Core XLPE Inline Joint Kit 22kV 3 Core XLPE Inline Joint Kit Size Range Al or Cu 35-95mm2 95-240mm2 185-400mm2

22kV Repair Joints for XLPE cables

22kV 1 Core Inline Repair Joint Kits C/w 440mm Long Mechanical Connectors
Part Number MXSU-5111-L MXSU-5131-L MXSU-5132-L Description 22kV 1 Core XLPE Inline Repair Joint Kit 22kV 1 Core XLPE Inline Repair Joint Kit 22kV 1 Core XLPE Inline Repair Joint Kit 1 Size Range Al or Cu 25-95mm2 95-240mm2 50-300mm2

22kV 3 Core Inline Repair Joint Kits C/w 440mm Long Mechanical Connectors
Part Number MXSU-5311-L MXSU-5331-L MXSU-5332-L Description 22kV 3 Core XLPE Inline Repair Joint Kit 22kV 3 Core XLPE Inline Repair Joint Kit 22kV 3 Core XLPE Inline Repair Joint Kit Size Range Al or Cu 25-95mm2 95-240mm2 150-300mm2

22kV Branch Joints for XLPE cables

22kV Branch Joint 1/Core XLPE unarmoured, with mechanical connectors
Part Number Conductor Cross Section Overall Cable Diameter Min. EPKB 24A 1XU-2XU EPKB 24B 1XU-2XU EPKB 24C 1XU-2XU 35 - 95mm
2

Min. Diameter over Insulation of Main Cable 25.2 31.8 36.4

Max. 38 40 47

25.2 31.8
2

95 - 150mm2 185 - 300mm

36.4

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Energy Division

22kV Termination Kits for XLPE Cables

22kV 1 Core Termination Kits C/w Mechanical Lugs
Part Number Indoor IXSU-F5121-M IXSU-F5131-M IXSU-F5141-M IXSU-F5151-M Outdoor OXSU-F5121-M OXSU-F5131-M OXSU-F5141-M OXSU-F5151-M Cable Type Description 22kV 1 Core XLPE Termination Kit 22kV 1 Core XLPE Termination Kit 22kV 1 Core XLPE Termination Kit 22kV 1 Core XLPE Termination Kit Al or Cu 25-70mm2 95-240mm2 185-400mm2 500-630mm2

22kV 3 Core Termination Kits C/w Mechanical Lugs

Part Number Indoor IXSU-F5321-M IXSU-F5331-M IXSU-F5341-M Outdoor OXSU-F5321-M OXSU-F5331-M OXSU-F5341-M Cable Type Description 22kV 3 Core XLPE Termination Kit 22kV 3 Core XLPE Termination Kit 22kV 3 Core XLPE Termination Kit Al or Cu 25-50mm2 70-150mm2 185-400mm2

33kV Inline Joints for XLPE cables

33kV 1 Core Inline Joint Kits C/w Mechanical Connectors
Part Number MXSU-6111 MXSU-6121 MXSU-6131 MXSU-6141 MXSU-6151 MXSU-6161 SXSU-6151-NZ01 SXSU-6151-NZ02 Description 33kV 1 Core XLPE Inline Joint Kit 33kV 1 Core XLPE Inline Joint Kit 33kV 1 Core XLPE Inline Joint Kit 33kV 1 Core XLPE Inline Joint Kit 33kV 1 Core XLPE Inline Joint Kit 33kV 1 Core XLPE Inline Joint Kit 33kV 1 Core XLPE Inline Joint Kit 33kV 1 Core XLPE Inline Joint Kit Size Range Al or Cu 35-95mm2 70-150mm2 150-300mm2 240-400mm2 500mm2 630mm2 Cable A 630mm2/ Cable B 800mm2 800mm2

33kV 3 Core Inline Joint Kits C/w Mechanical Connectors

Part Number MXSU-6311 MXSU-6321 MXSU-6331 MXSU-6341 Description 33kV 3 Core XLPE Inline Joint Kit 33kV 3 Core XLPE Inline Joint Kit 33kV 3 Core XLPE Inline Joint Kit 33kV 3 Core XLPE Inline Joint Kit Size Range Al or Cu 35-95mm2 70-150mm2 150-300mm2 240-400mm2

64

Raychem Inline and Shield-Break Joint EHVS for 123 kV up to 170 kV

Application The joint is a pre-fabricated three-piece design for voltage classes up to 170 kV. Polymeric insulated cables of various designs can be adopted with respect to shielding and metal sheath.

Features Pre-fabricated three-piece joint design Torque-controlled conductor sleeves Integrated moisture barrier using H/S components Short cut-back dimensions No special tools required to install the joint Can adapt shield-break applications Cable size transition is possible Factory tested Si-rubber parts Type tested according to IEC 60840 and IEEE 404 standards

Major Design Elements The joint consists of connector (1), cable adapters (2) including stress cones and main joint body (3) containing Faraday cage (7) and outer serving by heat-shrink technology (9,12). The conductors of the cable are connected by a mechanical connector sleeve (1) using torque controlled shear-off bolts. The connector sleeve is suitable for stranded aluminium and copper conductors. The Si-rubber cable adapters (2), accommodating the various cable insulation diameters, build up the connection area to an almost constant diameter. This allows to cover different cable cross-sections with just one main insulation joint body (3). Therefore cross-section transitions are possible without any extra components. No extra tooling is needed to push-on the Si-rubber cable adapters (2) and the Si-rubber joint main body (3) due to its excellent elasticity. A metal shielding clamp (7) on top of the connector ensures perfect heat transmission and a smooth interface fit. The fixing rings (6) keep the cable adapter and the cable dielectric in position. During the installation the main body is parked on the over sheath of the cable. This keeps the cut back length and cable preparation time as short as possible. Mechanical solderless connector technologies (8) are used to connect metal shields copper wires, metal sheath and CAS. Heat-shrink technologies (9,12) replace the cable serving and the moisture barrier. The joint concept is similar for the shield-break joints, despite the shield continuity. Special sealant components make it possible to use double-insulated ground leads, and thereby to utilise the proven heat-shrink technology.

Inline Joint

2 3 5

9 10 11

12

Shield-Break Joint

4 1 2 3 4 Mechanical connector Adapter Main body Stress cone

2 3 5 6 1 5 6 7 8

9 10 11

12 9 Conductive tubing 10 Copper mesh 1 1 Insulating tubing 12 Outer protection with integrated moisture barrier
65

HV electrode Fixing ring Metal shielding clamp Solderless shield connection

EPKB Heat-shrinkable medium voltage branch joints for single core polymeric cables up to 24 kV

Features Shear bolt connector Connector and insulation in one kit Range taking kit Compact, robust and buriable Benefits No special installation tools or dies needed No other engineering required Wide range of application Space saving, low total costs

Special features The design of the connector, specially engineered to fit the insulation components, also enables the user to connect different conductor sizes. This provides great flexibility in the range of cables which can be connected in this branch joint. The connector uses bolts designed to shear off at a preset level of torque and isinstalled with a standard socket set. This technique ensures that the connector performs consistently for a wide range of conductor diameters. As the installation of the complete joint is similar to the installation of a heat-shrinkable inline joint, time requirements are low and no additional installer skills are needed. The complete kit has been tested to meet Raychems performance standards. For performance specifications and available sizes please see last page.

Selection Table
Voltage class kV 12 Conductor cross-section mm2 35- 95 95-150 185-300 35- 95 24 95-150 185-300 Overall cable diameter min 23.5 26.0 32.1 25.2 31.8 36.4 max 32 37.5 43 38 40 47 14.8 19.3 23.9 19.0 23.5 28.1 EPKB 12A 1XU-2XU EPKB 12B 1XU-2XU EPKB 12C 1XU-2XU EPKB 24A 1XU-2XU EPKB 24B 1XU-2XU EPKB 24C 1XU-2XU Min. diameter over insulation of main cable EPKB kit description

66

Energy Division

Test Sequence

Test Voltage Highest Voltage for Cable Um (kV) 12/17 24 1 min 10 positive and 10 negative, 1.2/50 s, between conductor and grounded screen 63 cycles 5 h heating, 3 h cooling Conductor temperature on XLPE cables: 95 1 s symmetrical fault with conductor temperature as in the cable specification as above, with cable in 1 m water (oversheath removed) as above 4h repeat 30 min 15 12 24 95 48 30 24 48 150 96 25 12 95 15 55 24 150 30

Result

A.C. Voltage Withstand Partial Discharge Impulse Voltage Withstand Load Cycling

no breakdown 20 pC no breakdown no breakdown

Partial Discharge Thermal Short Circuit

12

24

20 pC no functional damage no breakdown 20 pC no breakdown no breakdown no breakdown

Load Cycling Partial Discharge A.C. Voltage Withstand Impulse Voltage Withstand D.C. Voltage Withstand Notes:

1. Um is the highest phase to phase voltage. All other voltages are stated as phase to ground values. 2. Further details are given in Raychem specification PPS 3013.

Electrical stress control The mechanical connector is covered with yellow void filler tape and JSCR stress control tubing. These are the same materials used in Raychems inline medium voltage joints.

Spacer profile This specially extruded profile is made from a red high-performance insulating elastomer. The material properties guarantee a voidfree crutch filling and tight electrical interfaces between the two branch cables.

Breakout cap The adhesive coated two finger breakout provides water sealing for the branch side in the same way as the jacket does for the single side. This also gives the flexibility needed to ensure good sealing under temperature changes due to load cycling.

67

Joints for Polymeric Insulated Cables 72.5 kV

The elastomeric Raychem 72.5 kV joints are suitable for all polymeric cables and can accommodate various cross-bonding shield break and external grounding arrangements. Quick cable preparation No need for insulation pencilling Simplified installation No specialists required. A qualified medium-voltage jointer will be trained in one day.

Pre-engineered wall thickness All product dimensions are set and checked at the factory before the product is shipped to the field. Time savings Due to short installation time outages are kept to a minimum in repair situations. High reliability The combination of long experience and rigorous testing to international standards leads to high joint reliability.

Designed for easy jointing The Raychem joint design comprises of a connector that allows even large crosssections to be jointed and two dual-wall, heat-shrinkable sleeves. A heavy-walled co-extrusion of two layers of red insulation forms the inner sleeve. The outer sleeve consists of a thick layer of red insulation co-extruded under a black outer conductive layer which acts as the joint screen.

This is the kit The set of pre-engineered components and the Raychem connector require no special installation tools. After placing the heat-shrinkable components over the cable end, the connector is installed by tightening the special bolts, which shear off cleanly when the correct contact force is reached. Each sleeve in turn is placed over the connector area and shrunk down. Copper shielding mesh and an adhesive-coated outer sleeve for water sealing then complete the joint.

Controlled-torque connector The connector design allows cables to be jointed without special tools, heat treatment or dressing/filing after installation. Shear-head bolts ensure a pre-engineered electrical connection. In developing this new connector, much effort was devoted to simplifying the installation steps. Consequently, the key reliability features are engineered into the connector, before it leaves the factory. The outside surface is already machined smooth. The shear-head bolts break off at a predetermined level below the outer surface of the connector, at a defined torque. This ensures the correct contact pressure is reached every time. Oxide-breaking and corrosion prevention is performed by the contact grease inside the connector body. The stable voltage drop provided by this concept has been demonstrated in field installations which closely follow the predictions of longterm load-cycling tests. Comprehensive qualification procedures like IEC 61238-1996 and ANSI 119.4 1993 prove the excellent long-term performance.

Electrical stress control A material with stress adjusting characteristics is applied onto the connector and cable screen ends. This heat-shrinkable sleeve incorporates a conductive coating in the connector area which equalizes potential in the manner of a Faraday cage. It extends over the dielectric to accommodate possible insulation shrink-back.

68

Energy Division

Elastomeric Technology Two dual-wall, heat-shrinkable elastomeric sleeves are at the heart of the joint. Because of the unique elastromeric technology used in their manufacture, these dual-wall sleeves shrink rapidly and deliver pre-engineered, uniform layers of thick insulation. In each case the outer wall of the co-extruded sleeve is heatshrinkable, while the inner layer is an elastomer held out in an expanded form by the bond to the outer layer. Application of heat to the outer wall causes it to shrink to a pre-determined diameter and simultaneously allows the inner layer to contract, conforming tightly to the joint. In two short steps the installer applies the required insulation thickness and joint screen. When the cable is in service the rubber-like characteristics of the insulation allow the joint to conform to the dimensional changes of the cable insulation during load cycling.

Cross-bonding/shield break The use of heat-shrinkable sleeves for stress control, insulation, and screening provides a location for the shield break at the end of the joint. A mastic installed under the heatshrinkable outer sleeve ensures high dielectric strength at this point. The crossbond can be made without influencing the electrical field in the joint, and does not require any special additional components. Requirements according to IEC 60840:2004 Annex H and IEEE 404-2000 are fulfilled.

Outer sealing The cable oversheath is replaced with a thick-wall heat-shrinkable insulating sleeve, which provides the required dielectric strength and is internally coated with a hot-melt adhesive. The heat of installation causes the adhesive to melt and flow to create an effective water seal and corrosion protection. Grounding leads are sealed by an adhesive coated clip.

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Energy Division

Joints In-line
Design of Joints without Connectors For cables with wire or tape screen At the screen end and over the connectors yellow, void filling mastic is applied. The jointing area of each cable core is covered with a heat-shrinkable stress control tubing. A heat-shrinkable, elastomeric tubing provides the correct thickness of insulation and the screening over the insulation. Copper mesh wrapped around the joint area rebuilds the metallic screen. For cables with tape screen a separate solderless earth kit is available. For cables with armour, a metal case or metal tape provide additional mechanical protection. The outer sealing and protection is performed by an adhesive coated, thick wall, heat-shrinkable tubing.

11kV XLPE Screened Cables unarmoured without connectors 1/Core

Part Number
SXSU-3111 SXSU-3121 SXSU-3131 SXSU-3141 SXSU-4141

Conductor Size mm2

16-70 95-185 185-300 400-500 400-630

Max Connector Length (mm)

110 160 180 220 270

Max Connector Diameter (mm)

23 29 34 44 42

3/Core
Part Number
SXSU-3311 SXSU-3321 SXSU-3331

Conductor Size mm2

16-70 95-185 185-300

Max Connector Length (mm)

110 160 180

Max Connector Diameter (mm)

23 29 34

11kV XLPE Screened Cable armoured 1/Core to 3/Core

Part Number
SXSU-3311-1C SXSU-3321-1C SXSU-3331-1C

Conductor Size mm2

16-70 95-185 185-300

Max Connector Length (mm)

110 160 180

Max Connector Diameter (mm)

23 29 34

3/Core
Part Number
SXSU-3311-W SXSU-3321-W SXSU-3331-W

Conductor Size mm2

16-70 95-185 185-300

Max Connector Length (mm)

110 160 180

Max Connector Diameter (mm)

23 29 34

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Energy Division

Joints In-line
11kV MIND Paper Screened/Belted Cables 1/Core
Part Number Conductor Size mm2 Max Connector Length (mm)
140 190 200

Max Connector Diameter (mm)

29 42 52

EPKJ-17B/1HL-1HL 95-185 EPKJ-17C/1HL-1HL 240-400 EPKJ-17D/1HL-1HL 500-630

3/Core
Part Number
HVSA-3-1151 HVSA-3-1152 HVSA-3-1153 HVSA-3-1154

Conductor Size mm2

16-35 50-95 120-185 185-300

Part Number
SPEC SPEC SPEC SPEC SPEC SPEC 1431 1432 1433 1435 1436 1437

Conductor Size mm2 Large

240-300 240-300 240-300 300 185 50-95

Conductor Size mm2 Small

16-35 150-185 95-150 150 16 16-35

Conductor Size Transition to be used with HSVA Joint

71

Energy Division

Joints In-line
22kV XLPE Screened Cables unarmoured 1/Core
Part Number
SXSU-5121 SXSU-5131 SXSU-5141 SXSU-5151

Conductor Size mm2

35-95 120-240 300-500 630-800

Max Connector Length (mm)

120 140 230 250

Max Connector Diameter (mm)

23 34 44 58

3/Core
Part Number
SXSU-5322 SXSU-5332 SXSU-5342

Conductor Size mm2

35-95 120-240 300

Max Connector Length (mm)

120 145 200

Max Connector Diameter (mm)

22 32 35

1/Core to 3/Core
Part Number
SXSU-5322-1C SXSU-5332-1C SXSU-5342-1C

Conductor Size mm2

35-95 120-240 300

Max Connector Length (mm)

120 145 200

Max Connector Diameter (mm)

22 32 35

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Joints In-line
22kV MIND Paper Screened/Belted Cables unarmoured 1/Core
Part Number
EPKJ-24 B/1HL-1HL EPKJ-24 C/1HL-1HL EPKJ-24 D/1HL-1HL

Conductor Size mm2

35-70 95-240 300-400

Max Connector Length (mm)

140 160 200

Max Connector Diameter (mm)

25 36 40

3/Core unarmoured
Part Number
EPKJ-24 EPKJ-24 EPKJ-24 EPKJ-24 A/3SB-3SBW B/3SB-3SBW C/3SB-3SBW D/3SB-3SBW

Conductor Size mm2

25 35-70 95-240 300-400

Max Connector Length (mm)

110 140 160 200

Max Connector Diameter (mm)

20 25 36 44

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Energy Division

Joints In-line
33kV XLPE Screened Cables unarmoured 1/Core
Part Number
SXSU-6121 SXSU-6131 SXSU-6141 SXSU-6151

Conductor Size mm2

50-70 95-150 185-400 500-630

Max Connector Length (mm)

140 160 220 240

Max Connector Diameter (mm)

22 29 42 52

3/Core
Part Number
SXSU-6322NZ SXSU-6332NZ SXSU-6342NZ

Conductor Size mm2

50-70 95-150 185-400

Max Connector Length (mm)

140 160 220

Max Connector Diameter (mm)

22 32 42

1/Core to 3/Core
Part Number
SXSU-6322NZ-1C SXSU-6332NZ-1C SXSU-6342NZ-1C

Conductor Size mm2

50-70 95-150 185-400

Max Connector Length (mm)

140 160 220

Max Connector Diameter (mm)

22 29 42

33kV MIND Paper Screened Cables 3/Core

Part Number
EPKJ-36A/1HL-1HL EPKJ-36B/1HL-1HL EPKJ-36C/1HL-1HL EPKJ-36D/1HL-1HL

Conductor Size mm2

50-70 95-150 185-400 500-630

Max Connector Length (mm)

140 160 200 240

Max Connector Diameter (mm)

22 29 42 52

3/Core unarmoured
Part Number Conductor Size mm2 Max Connector Length (mm)
50-70 95-150 185-400

Max Connector Diameter (mm)

140 160 200 22 29 42

EPKJ-36A/3SB-3SB-W EPKJ-36B/3SB-3SB-W EPKJ-36C/3SB-3SB-W

74

Energy Division

Branch Joints & Live End Seals

11kV Branch Joint 1/Core XLPE unarmoured
Part Number
EPKB 12A 1XU-2XU EPKB 12B 1XU-2XU EPKB 12C 1XU-2XU

Conductor Cross Section mm2

35 - 95 95 - 150 185 - 300

Overall Cable Diameter Min.

23.5 26.0 32.1

Min. Diameter over Insulation of Main Cable

23.5 26.0 32.1

Max.
32 37.5 43

22kV Branch Joint 1/Core XLPE unarmoured with mechanical connectors

Part Number
EPKB 24A 1XU-2XU EPKB 24B 1XU-2XU EPKB 24C 1XU-2XU

Conductor Cross Section mm2

35 - 95 95 - 150 185 - 300

Overall Cable Diameter Min.

25.2 31.8 36.4

Min. Diameter over Insulation of Main Cable

25.2 31.8 36.4

Max.
38 40 47

11kV Live End Seal

Part Number
EPKE EPKE EPKE EPKE EPKE EPKE EPKE EPKE EPKE 24B / 1XU-70 24B / 1XU-95 24C / 1XU-120 24C / 1XU-150 24C / 1XU-185 24C / 1XU-240 24D / 1XU-300 24D / 1XU-400 24D / 1XU-500

Cable Cross Section mm2

70 95 120 150 185 240 300 400 500

Overall Length (mm)

400 400 400 400 400 400 400 400 400

22kV Live End Seal

Part Number
EPKE EPKE EPKE EPKE EPKE EPKE EPKE EPKE EPKE 24B / 1XU-70 24B / 1XU-90 24C / 1XU-120 24C / 1XU-150 24C / 1XU-185 24C / 1XU-240 24D / 1XU-300 24D / 1XU-400 24D / 1XU-500

Cable Cross Section mm2

70 95 120 150 185 240 300 400 500

Overall Length (mm)

400 400 400 400 400 400 400 400 400

3/Core Live End Seals available on request

75

Energy Division

Joints Transition for compression connectors

11kV XLPE MIND Paper 3/Core to XLPE 3/Core unarmoured
Part Number
EPKJ-12A/3XU-3SB EPKJ-12B/3XU-3SB EPKJ-12C/3XU-3SB

Conductor Size mm2

16-70 95-185 185-300

Max Connector Length (mm)

110 160 180

Max Connector Diameter (mm)

21 29 34

11kV XLPE MIND Paper 3/Core to XLPE 1/Core unarmoured

Part Number
EPKJ-12A/1XU-3SB EPKJ-12B/1XU-3SB EPKJ-12C/1XU-3SB

Conductor Size mm2

16-70 95-185 185-300

Max Connector Length (mm)

110 160 180

Max Connector Diameter (mm)

21 29 34

11kV XLPE MIND Paper 1/Core to XLPE 3/Core unarmoured

Part Number
HVS-1581-D HVS-1582-D HVS-1583-D HVS-1584-D

Conductor Size mm2

50-95 120-185 300-400 400-500

Max Connector Length (mm)

114 140 178 203

Max Connector Diameter (mm)

23 29 41 47

3/Core MIND cable 3/Core MIND cable

3/Core MIND cable 3/Core MIND cable

3/Core MIND HSL cable 3/Core MIND HSL cable

1/Core MIND cable 1/Core MIND cable

3/Core XLPE armoured cable 3/Core XLPE armoured cable

3/Core XLPE cable 3/Core XLPE cable

76

Energy Division

Joints Transition
22kV XLPE MIND Paper 3/Core to XLPE 3/Core unarmoured
Part Number
EPKJ-24A/3XU-3SB EPKJ-24B/3XU-3SB EPKJ-24C/3XU-3SB EPKJ-24D/3XU-3SB

Conductor Size mm2

25 35-70 95-240 300-400

Max Connector Length (mm)

110 140 160 200

Max Connector Diameter (mm)

20 25 36 44

22kV XLPE MIND Paper 3/Core to XLPE 1/Core unarmoured

Part Number
EPKJ-24A/1XU-3SB EPKJ-24B/1XU-3SB EPKJ-24C/1XU-3SB EPKJ-24D/1XU-3SB

Conductor Size mm2

25 35-70 95-240 300-400

Max Connector Length (mm)

110 140 160 200

Max Connector Diameter (mm)

20 25 36 44

22kV XLPE MIND Paper 1/Core to XLPE 3/Core unarmoured

Part Number
EPKJ-24A/1XU-1HL EPKJ-24B/1XU-1HL EPKJ-24C/1XU-1HL EPKJ-24D/1XU-1HL

Conductor Size mm2

25 35-70 95-240 300-400

Max Connector Length (mm)

110 140 160 200

Max Connector Diameter (mm)

20 25 36 44

1/Core XLPE cable 1/Core XLPE cable

3/Core XLPE armoured cable 3/Core XLPE armoured cable

3/Core MIND cable

3/Core MIND cable

3/Core MIND cable

3/Core MIND cable

3/Core MIND cable

3/Core MIND cable

3/Core MIND HSL cable

3/Core MIND HSL cable

77

Energy Division

Joints Transition
33kV MIND Paper 3/Core to XLPE 3/Core unarmoured
Part Number
EPKJ-36A/3XU-3SB EPKJ-36B/3XU-3SB EPKJ-36C/3XU-3SB

Conductor Size mm2

50-70 95-150 185-400

Max Connector Length (mm)

140 160 200

Max Connector Diameter (mm)

22 29 42

33kV MIND Paper 3/Core to XLPE 1/Core unarmoured

Part Number
EPKJ-36A/1XU-3SB EPKJ-36B/1XU-3SB EPKJ-36C/1XU-3SB

Conductor Size mm2

50-70 95-150 185-400

Max Connector Length (mm)

140 160 200

Max Connector Diameter (mm)

22 29 342

33kV MIND Paper 1/Core to XLPE 3/Core unarmoured

Part Number
EPKJ-36A/3XU-1HL EPKJ-36B/3XU-1HL EPKJ-36C/3XU-1HL

Conductor Size mm2

50-70 95-150 185-400

Max Connector Length (mm)

140 160 200

Max Connector Diameter (mm)

22 29 42

33kV MIND Paper 1/Core to XLPE 1/Core unarmoured

Part Number
EPKJ-36A/1XU-1HL EPKJ-36B/1XU-1HL EPKJ-36C/1XU-1HL EPKJ-36D/1XU-1HL

Conductor Size mm2

50-70 95-150 185-400 500-630

Max Connector Length (mm)

140 160 200 240

Max Connector Diameter (mm)

22 29 42 52

78

Energy Division

79