SVSM. Reinforced splice protection for Railway signalling cable

Transcription

1 SVSM INSTALLATION INSTRUCTION Reinforced splice protection for Railway signalling cable REMARK : this instruction gives general information for installing SVSM kits for following cable types only : AJ-2Y2YDB2Y, AJ-2YOF(L)2YDB2Y, AJ-2Y(L)2YDB2Y Contents 1 Kit content 2 Safety rules 3 Recommended tools 4 Overview components 5 Cable preparation for cables with concentric screen/ induction protection 6 Lead-free connection of the armouring and induction protection (CU or ALU wires) 7 Installation shield continuity wire 8 Installation of Duraseal connectors 9 Installation of SVSM kit 10 Installation of thermoplastic sealing tape (FSTW) 11 Installation of VASS 1 Kit content 1 pc reinforced heat-shrinkable sleeve 1 pc channel(s and under clip only for SVSM-4/1 and 5) 1 pc splice protection 1 pc shield continuity wire 2 pcs cleaning tissue 1 pc abrasive paper 1 pc desiccant 1 pc installation instruction 2 Safety rules Check environment (manhole, handhole,...) for presence of gas and follow locally prescribed precautions. When working with open flame, use standard safety equipment such as gloves, safety glasses, etc... as required by local practice. IMPORTANT : when working with cables laying in areas with high stray currents, it is highly recommended to install an initial shield continuity on the armouring/induction protection of the cable before making any other splicing work. This needs to be done following the instructions of the local railway cable operators. 3 Recommended tools Torch FH-1630-PIE FH-T001-CTDS Nozzle FH-1630-PIE-BN38 Crimping tool DURASEAL connector Hot air heater: HL2010E-230V-EURO with reflector HL1802E : shrinking tool for Duraseal connectors Longitudinal cable cutter: KMS-K-INT 1

2 4 Overview components - not included in the basic kit Table 1 Product description TE Connectivity description Sizing Where used / remarks Connector DURASEAL D CS100 (red) D CS100 (blue conductor Ø 0,9 mm conductor Ø 1,4/1,8 mm waterthight connection for conductors Kit LK 1 pc copper mesh (roll) 2 pcs roll springs 2 pcs contact blades LK-0 LK-1 LK-2 LK-3 LK-4 Cable armouring Ø mm mm mm mm mm Lead-free connection of the armouring and induction protection (CU or ALU wires). For every SVSM installation, 2 LK kits are required. Thermoplastic sealing tape KL-FSTW-DE01 1,80 m Used as final protection of the armouring connection TY-WRAP (UV resistant) E DE01 Fixation of thermoplastic sealing tape Continuity braid EPPA A EPPA A EPPA A EPPA A EPPA A Cross section 7,0 mm ² 12,5 mm ² 16,0 mm ² 25,0 mm ² 35,0 mm ² Used as continuity of the armouring/induction protection Heat-shrinkable tubing LSTT SP LSTT SP LSTT-19-0-SP for EPPA A for EPPA A & A for EPPA A & A Insulation protection of the continuity braid 5 Cable preparation for cables with concentric screen/induction protection Table 2 Product description Sleeve length Outer jacket opening Distance steel armouring Splice protection length INNER Jacket opening Max. splice diameter L1 (mm) A (mm) B (mm) L2 (mm) C ( mm) mm SVSM SVSM SVSM SVSM-4/ SVSM REMARK : number of conductors or quads of the respective cables and consequently the splice length & diameter are a result of the connector type (DURASEAL ) that is used for making the splice. Same is valid for the distance required for installing the continuity components of the armouring/induction protection using EPPA-013 and LK kits. 2

3 6 Lead-free connection of the armouring and induction protection (CU or ALU wires) Table 3 Diameter OVER armouring LK kit Continuity tress Cross section Heat-shrinkable tubing mm LK- 0 EPPA A 7,0 mm ² LSTT SP mm LK-1 EPPA A 12,5 mm ² LSTT SP mm LK-2 EPPA A 16,0 mm ² LSTT SP mm LK-3 EPPA A 25,0 mm ² LSTT 19-0-SP mm LK-4 EPPA A 35,0 mm ² LSTT 19-0-SP REMARK : the cross section of the armouring/induction protection (EPPA-013) chosen, shall be according to the instructions of the local railway cable operator. 6.1 Remove outer jacket of the cable (see A table 2). Clean and abrade the steel armouring according to local practice. 6.2 Select the required LK kit (see table 3). Copper mesh out of the LK kit should be folded according to the picture/drawing. The folded mesh needs first to be applied between the openings of the outer steel layer. (b<= B) b : width of the folded copper mesh B : distance between the wrapping of the outer steel layer Copper mesh PE jacket Outer steel layer Copper mesh layers of copper mesh should be applied over the complete metal zone. The copper mesh should NOT be installed ON the PE jacket of the cable. 6.4 Both contact blades (see LK kit) should be cut to 45 on both sides and shortened in order to get a distance of ± 5mm between both ends when applied over the copper mesh. IMPORTANT: the contact blades should be installed in such a way that the opening is 180 opposite to each other. 6.5 Apply 3 layers of copper mesh over the previously installed contact blades. 3

4 6.6 Bend the copper wires over the previously applied copper mesh and cut them to length - they should be cut FLUSH with the PE jacket. If needed, fix them with a copper wire. 6.7 Rest of the copper mesh should be applied over the copper wires. 6.8 Cut the required length of copper braid EPPA-013-x: +/- 2 times distance A of table 2. Make sure it is long enough. Cut the required length of LSTT tubing. Length is 20cm less than the length of the copper braid. Slide it over the continuity braid, leaving +/- 10cm free at each side. Continuity braid should be fixed completely on one side with one roll spring (see LK kit). The first roll spring is installed on the side of the splice. Direction of the continuity braid is AWAY from the splice zone. 6.9 Next to the first roll spring the second one should be installed: Start with 1 layer of the roll spring in between the continuity braid another layer of the roll spring continuity braid has to be folded in the splice direction fix it with the rest of the roll spring. Roll spring has to be hand-tightened in the roll direction of the spring Repeat exactly the same on the other cable side. 7 Installation shield continuity wire 7.1 In order to install the shield continuity wire use the KMS-K-INT tool. Make a 15mm wide and 30mm long cut in the inner cable jacket. Bend the strip slightly up. 7.2 Apply PVC tape (not included in the kit) underneath the cable jacket strip. Install the shield continuity wire on each side of the cable using a standard pair of pliers. Apply PVC tape over and around the clip at each side. 8 Installation of Duraseal connectors REMARK : clean and degrease the conductors carefully using the local approved cleaning agent. 8.1 Cut the wires there were the connector will be installed. Strip 7 mm insulation away of the conductors. 8.2 Crimp the connector on each wire 4

5 8.3 Shrink the crimped splice with a heating gun until it recovers and adhesive melts and flows. 9 Installation of the SVSM kit 9.1 Take the desiccant out of the aluminium bag and place it on the joint. Fix it with PVC tape. 9.2 Before installation of the splice protection, pre-shape it cylindrically by rolling. Wrap the liner tightly around the splice bundle and secure with PVC tape. 9.3 Tape the crowns down using PVC tape, starting from the liner body to the cables with 50% overlap. 9.4 Remove the cleaning tissue from its package and clean the cables over a distance of ± 200mm. Abrade the cables circumferentially over the cleaned length. 9.5 Flame brush the cleaned and abraded zone. The sequence of clean, abrade, flame brush should not be reversed. Make sure to touch the entire cable surface with the yellow tip of the flame. 9.6 Center the heat-shrinkable sleeve over the splice. Slide the channel on. (For SVSM-4/1 and 5 : slide 1 at each side. Leave +/- 50mm in the middle and install the under clip. Slide the channels OVER the under clip.) Notes for heating: - Regulate flame to a total length of 300mm, with a yellow tip of 100mm. - During installation, move the flame continuously to avoid local overheating. - Apply heat until the temperature indicating paint has changed color. 5

6 9.7 Start heating in the centre of the sleeve - opposite to the channel. Shrink the sleeve circumferentially until the TI paint has changed from green to black. Gradually and progressively move towards one end. 9.8 Gradually and progressively move towards one end. White lines should be visible in the slots of the channel(s). If at any point the white lines are not visible, than heat the closure in that are until they appear. 9.9 Press the channel gently down with a blunt tool to give it the shape of the transition Start again in the centre of the sleeve and shrink the other side - follow the same steps Allow the completed joint to cool down for 15 minutes before starting with the VASS installation. 10 Installation of the thermoplastic sealing tape (FSTW) 10.1 Clean outer/inner cable jacket over a distance of ±100mm. 6

7 10.2 Cut a strip of FSTW tape long enough to wrap 1-1 1/2 times around the cable. Remove release paper and fold lengthwise down in the middle of the mastic (mastic should be on the outside) Roll the FSTW strip around the cable jacket next to the roll spring, making at least one full wrap. EPPA-013 continuity braid should be squeezed down on the FSTW strip Start wrapping FSTW tape on the previously installed strip. Peel back a short length of release paper. Make one full wrap and then continue in the direction of the outer jacket. Apply with moderate tension and 50% overlap Cut the FSTW strip Using a tie-wrap, secure the end of the FSTW strip. 11 Installation of VASS (see installation instruction of VASS) Table 4 - Selection table SVSM-VASS SVSM VASS SVSM-1 SVSM-2 SVSM-3 SVSM-4/1 SVSM-5 VASS-75/ VASS-75/ VASS-100/ VASS-125/ VASS-140/

8 CommScope Connectivity Belgium bvba Diestsesteenweg 692 B-3010 Kessel-Lo, Belgium Tel.: Fax: Visit our website or contact your local CommScope representative for more information CommScope, Inc. All rights reserved. All trademarks identified by or are registered trademarks or trademarks, respectively, of CommScope, Inc. This document is for planning purposes only and is not intended to modify or supplement any specifications or warranties relating to CommScope products or services. TC 1235/SIP/IL/1 10/15