GUIDELINES FOR XLPE

USING IN CABLE EXTRUDING

Polycom - October 20, 2017

Stop die exchange Stop machine, no

Prepare materials Check machine Operate machine
and machine and restart production

Operation processes
STANDARD TEMPERATURE SETTING

ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE 5 NECK HEAD DIE

200oC
o o o o o o o o o o o
150 C 160 C-170 C 170 C-180 C 180 C-185 C 180 C-185 C 190 C 200 C Gas flame

Steps Detail Instruction Pictures description

I. Prepare XLPE compound for cable extruding
I.1.1 Check XLPE packaging bag conditions before using
+ Be sure to check XLPE bag packaging conditions before using without
any air leakage or soft. Must separate any bags with leaked, penetrated,
broken or soft to examination place and no use.
Possibly reuse bags in case of softening by transportation from warehouse
to production or within 08-10 hours after being soft.
In case opened normal bags, if not use empty, could be reused within 8~10
hours with good storage condition as Picture 01
Notice : Must check packaging condition when receiving the goods from delivery
before storing in the warehouse, if finding soft bags, must return the supplier or
confirming packaging condition between delivery and warehouse keeper for evidence
I.1.2 Drying the catalyst (2-steps Sioplas XLPE only)
Regularly, the catalyst (contained in small bag) already dried before
into Kraft bag before delivering by the supplier then ready to use. However, Picture 1 Picture 2
it's better to dry again the catalyst before using at 80oC within 02hrs.
This method is used to prevent no moiturse penetration.
Attention : Do not dry XLPE compound.
I.1.3 Mixing compound for cable production (2-steps Sioplas XLPE only)
I - Some requirements for mixing compound
+ Must use mixing machine, no use hand. If mixing by hands, contaminated
parts, sweat will penatrate XLPE material. In case, no available for mixing
machine but using hands, must wear tools to prevent contaminated penetration.
+ Cleaning mixing machine, no use water-penatrated tools for cleaning
the mixing machine, inside mixing machine must be dry as picture 3
+ Start for mixing after prepare machine and start machine
+ Mixing time within 2-3 mins.

I.1.4 Suck XLPE to the silos

After mixing XLPE, sucking XLPE to the silos for production Picture 3 Picture 4
Some attentions when sucking XLPE to material silos:
Suck a litte quantity of XLPE to the silos. Then opening silos cover to check
for sure that balancing the mixing rate between two parts of catalyst and XLPE compound
if still remains catalyst in the silos wall, must be mixed more again.
- If catalyst no remain in silos wall, could suck as normal
- In case of finding catalyst still remains in the silos wall, must :
+The bag after mixing, no suck into silos but remix by hands then suck later.

I.2. Prepare for machine operation

- Temperature settings
- Machine cleaning
- Prepare conductor Picture 5 Picture 6
II. Check machine conditions
- Mixing machine should be always clean.
- Cooling sytem including cool water and cool fan. See picture 5, picture 6
- The machine and its parts already being clean as picture 7, picture 8, picture 9
- Set the machine temperature as supplier's recommended setting, or experence
- Conductor
II - Filter mesh could be used with size 40/100/40, 80/100, 100/100
All equipments must be kept in the approriate performance capacity.

Picture 7 Picture 8 Picture 9

 III. Machine operation
Start production after preparing materials and machine
- Start machine in slow speed first when discharging XLPE into hopper extruder
- Gradually increase the machine speed based on operator's experience.
- After seeing XLPE compound output, adjust machine conductor alignment
then check melting rate and surface of XLPE good, at last installing conductor
for extruding cable production. See picture 10.
- Increase machine line speed until meeting with presets as required.
III
Attention when operating the machine
+ When start to run the machine, must align the wire/cable with the machine
During stop machine time, XLPE easier to be pre-crosslinked Picture 10 Picture 11
Therefore, it's required to not stop the machine when aligning wire/cable
conductor but must always maintain for machine screw running as picture 11.
- After stabling the machine, should keep machine line speed stable,
without sudden increase or decrease the machine line speed.

IV. Stop, change die and restart the machine:

- Because XLPE possibly being pre-crosslinked inside screw cylinder during stop time
for changing dies, then as better as for preventing the pre-crosslinked with changing
time within 15~20 mins.
- If cleaning time of die head longer than expected, must disassemble coupling,
IV neck and discharging XLPE remains to outside, if longer, will be pre-crosslinked
as picture 12
- After cleaning with new die exchange, discharging XLPE until the surface Picture 12 Picture 13
is good and installing conductor for extruding cable with XLPE insulation as picture 13

V. Stop the machine, no production

- When no production, decrease the machine temperature until 120-140oC
then replace XLPE by PVC for easier in disassembling the screws
- Disassembling screws, cleaning all parts of screws, shaft, cylinder or any
V parts with remain XLPE. Make sure that no remains of XLPE inside cylinder
* Notice :
- Temperature operating of the machine is very high, so should be careful and
wear thermal gloves for safety, no direct contact with high temperature source.
Before cleaning After cleaning

DANGER 1. Contact with electricity: Electric shock.

& RISK 2. Contact with high temperature: hot, skin burning.
 Troubleshooting Guide
Problem Phenomenon Cause Solution
- Water leaking into extruder - Rectify
- Moisture (Catalyst or Grafter) - Dry
Immediately on start-up
- Exceeded shelf-life - Replace
Scorch
- Too much catalyt added - Reduce
(Precrosslink)
- Stagnation in extruder - Reduce changing time of die, conductor
After extended run time - Melt temp, too high - Reduce RPM
- Lower cylinder temp.
- Melt temp. too low - Increase die temp.
Rough continuous surface (internally - Line speed too high - Gas flame on die.
Melt fracture
smooth) - Use processing aid.
- Reduce line/screw speed
- Insufficient silane contents - Increase silane addition
- Insufficient cure time - Increase cure time
Sample elongates and brakes
Poor Hot/Set - Insufficient catalyst added - Increase catalyst addition
- Insufficient graffing degree - Increase extruder temp.
Sample snap brakes - Defects on the insulation layer - Eliminate the scorch & void
- Low molecular weight material extruding and plating- - Use gas flame on die.
Die drool Build-up of material around the die
out - Addition of processing aid
- Ungrafted silane - Increase cylinder temp.
Voids Holes in the insulation - Reduce silane content
- Waterthrough closer to die.