Installation Instruction PowerAmp A Single Core Rev 2

INSTALLATION INSTRUCTION
Cable Assembly
Single Core PowerAmp-A Cables

&
Bi-metal Cable Lugs
Author: J Storan
Approved by: W Gaertner
1 II PowerAmp-A Single Core Rev 2 15-01-2009


Contents Page
Table of Contents 3
List of Illustrations 4
1. Introduction 5
2. Material and Equipment 5
3. Method 6
3.1. Stripping 6
3.2. ApplicationofContactPaste 9
3.3. PositioningofBimetalCableLug 11
3.4. CrimpingBimetalCableLug 13
3.5. PositioningHeatShrinkSleeve 17
3.6. ShrinkingSleeve.18

Table1. Lug,dieandpressheadselection 20
Table2. Insulation/Sheathstrippinglengths 20

List of Illustrations Page

Photograph 1 Cutting cable Sheath 6
Photograph 2 Removing Cable Sheath 7
Photograph 3 Stripped conductor 8
Photograph 4 Contact Aid Paste 9
Photograph 5 Application of Contact Aid Paste 10
Photograph 6 Pushing cable into Bimetal Lug 11
Photograph 7 Positioning Bimetal Lug 12
Photograph 8 Die Set Type number 13
Photograph 9 1st Indentation with Crimping tool 14
Photograph 10 2nd Indentation with Crimping tool 15
Photograph 11 Crimped Cable Lug 16
Photograph 12 Positioning heat shrink sleeve 17
Photograph 13 Heating Shrink sleeve 18
Photograph 14 Completed Cable end 19

1. Introduction
This Instruction describes the method used to install Bi-Metal Cable lugs onto PowerAmp-A
450/750V Cable. The recommended method is by means of Bi-Metal Cable Lugs, bolted
directly onto equipment bus bars or treaded terminal adaptors.
All the photographs in this installation instruction contain 240mm PowerAmp A cable,
however the same procedure should be followed for all sizes of cable.
2. RequiredMaterialsandEquipment
PowerAmpACable (SeeTable1attached)
ContactPaste IncoreArticleNo.A12BOCG1200
CableLug (SeeTable1attached)
HeatShrinkSleeve

Cablestrippingtool
Smallpaintbrush
Crimpingtool
Setofcrimpingdies
HotairgunorGasTorch
Table 1 contains the article numbers of PowerAmp A Cables, Bi-metal cable lugs and the
recommended die sizes for each cable.

3. Method
3.1. StrippingSheath
TheCSPSheathandEPRinsulationshouldberemoved,foraminimumlength,accordingto
thevaluesshowninTable2,orasadvisedbythecablelugsupplier.Thislengthshouldbe
equivalenttotheinternallengthofthecablelugcrimpbarrel.
Photograph 1
Great care should be taken not to mark or damage the individual conductor wires during
stripping.

Photograph 2
Smoothly remove the sheath and insulation by pulling in a longitudinal direction and turning
slowly in the lay direction of the wire bundles.

Photograph 3
If disturbedduringtheremoval of the sheath and insulation the lay of the wire strands should
be restored, as near as possible, to the original position.
Ensure that the separator tape (foil between conductor and insulation) is removed over the
entire length and circumference of the conductor.

3.2. ApplicationofSpecialContactPaste
Whilethebimetallugsalreadycontainacontactaidpaste,afurthercoatingof
A12BOCG1200pasteshouldbeappliedtothesurfaceofthealuminumconductor.This
pastepreventstheformationofaninsulatingaluminumoxidecoatingonboththe
conductorandcablelugsurfacesanddecreasesthecontactresistance.

Photograph4

Asimplepaintbrushcanbeusedtoapplythepaste.



Photograph5

Sufficientpasteshouldbeappliedanddistributedevenlyovertheentireconductorsurface.
Ensuresurfaceofconductoriscompletelycoveredwiththecontactpaste.


3.3. PositioningCableLug
The stripped conductor end is placed into the crimp barrel of the bimetal cable lug.
Photograph 6
Care should be taken to ensure that all wires of the conductor are within the crimp barrel.

Photograph 7
The conductor should be pushed into the Cable Lug until it touches the inside end of the crimp
barrel.

3.4. CrimpingBimetalCableLug
Inordertomakeagoodmechanicalandelectricalcontactthebarrelofthecablelugis
physicallycompressedaroundtheconductor.Thisisdoneusingafullcycleratchetingcrimp
tool,whichensuresthecrimpisfullycompletedbeforethecablelugcanbereleasedfrom
thetool.
Beforestarting,checkthatbothcrimpingdiesareofthecorrecttype/number,seeTable1
forrecommendedsizes.

Photograph8


Thefirstcrimpshouldbemadeatapproximately5mmfromtheendofthecrimpbarrel
closesttothecopperpalmofthebimetalcablelug.

Photograph9


Thesecondcrimpshouldbemadeatadistanceofapproximately2mmfromthefirstcrimp.
Thepressheadshouldberotatedapproximately30toensurethatthealignmentofthe
hexagonalcrimpsisstaggered,ascanbeseeninPhotograph11.
Thethirdcrimpshouldbeappliedafurtherapproximately2mmalongthecrimpbarrel.The
pressheadshouldberotatedbackapproximately30toalignthishexagonalcrimpwiththe
firstcrimpapplied.SeePhotograph11.

Photograph10

Photograph 11
When the crimp is completed there should be no sharp edges along the surface or trumpeting at the
end of the crimp barrel. In case sharp edges have formed during the crimping process these should
be removed to avoid damage to the heat shrink sleeve. Any sharp edges can either be removed using
a file or by flattening with a hammer. If a hammer is used care should be taken not to cause any
disfiguration to the lug.

3.5. PositioningHeatShrinkSleeve
When the bimetal cable lug has been crimped onto the conductor a heat shrink sleeve should
be applied. The purpose of this sleeve is to prevent the ingress of moisture or dirt at the
junction between the insulation end and the back of the cable lug. The heat shrink sleeve
contains glue, which melts and creates a seal when heated.
A practical indication for the length of the heat shrink sleeve would be twice the length of the
cable lug crimp barrel. It should be positioned with one end flush with the end of the crimp
barrel closest to the copper section of the bimetal cable lug.
Photograph 12

3.6 Shrinking The Heat Shrink Sleeve

When positioned the sleeve should be heated until it has been reduced to fit tightly over both
the cable and bimetal cable lug. The heat can be applied by means of a naked flame or a hot
air gun. Care should be taken not to overheat or burn the sleeve during shrinking. When
using a naked flame only the outer yellow section of the flame should come into contact with
the sleeve. The heat should first be applied in the center of the sleeve and from there towards
both ends individually. Once the sleeve has been reduced to fit tightly remove the heat source
to prevent burning of the sleeve and further reduction which could cause splitting.
Photograph 13

Photograph 14
Finished assembly

TABLE 1
PowerAmp Cable Cable Lug Die Size Presshead
Incore Article No Size Bi-Metal

E98A01C010EAKxx3 10mm A27A BMCL 0800/0801 Cu 95 RHC131 or RHU131-C
E98A01C016EAKxx3 16mm A27A BMCL 0900/0901 Cu 95 RHC131 or RHU131-C
E98A01C025EAKxx3 25mm A27A BMCL 1000/1001 MK20-C RHC131 or RHU131-C
E98A01C095EAKxx3 95mm A27A BMCL 1400 MK25-C RHC131 or RHU131-C
E98A01C120EAKxx3 120mm A27A BMCL 1500 MK25-C RHC131 or RHU131-C
E98A01C150EAKxx3 150mm A27A BMCL 1600 MK32L-C RHC131 or RHU131-C
E98A01C185EAKxx3 185mm A27A BMCL 1700 MK32L-C RHC131 or RHU131-C
E98A01C240EAKxx3 240mm A27A BMCL 1800/1801 MK34L-C RHU131-C
E98A01C300EAKxx3 300mm A27A BMCL 1900/1901 M38 3D ECW-H3D
E98A01C400EAKxx3 400mm A27A BMCL 2000/2001 M46 3D ECW-H3D
In the article no. xx denotes the colour of the cable as follows:

BK = Black. BL = Blue. BN = Brown. GR = Grey. OR = Orange. YL = Yellow.
GY = Green/Yellow
TABLE 2
PowerAmp A Minimum
Cable Lug
Cable Stripping length
6mm A27A BMCL 0700/0701 42mm
10mm A27A BMCL 0800/0801 42mm
16mm A27A BMCL 0900/0901 42mm
25mm A27A BMCL 1000/1001 42mm
35mm A27A BMCL 1100/1101 43mm
50mm A27A BMCL 1200/1201 43mm
70mm A27A BMCL 1300/1301 43mm
95mm A27A BMCL 1400 60mm
240mm A27A BMCL 1800/1801 62mm
300mm A27A BMCL 1900/1901 70mm
400mm A27A BMCL 2000/2001 75mm

Installation Instruction PowerAmp A Single Core Rev 2

Caricato da

Informazioni sul documento

Descrizione originale:

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Installation Instruction PowerAmp A Single Core Rev 2

Caricato da

Copyright:

Formati disponibili

INSTALLATION INSTRUCTION

Single Core PowerAmp-A Cables

Approved by: W Gaertner

1 II PowerAmp-A Single Core Rev 2 15-01-2009

2 II PowerAmp-A Single Core Rev 2 15-01-2009

3 II PowerAmp-A Single Core Rev 2 15-01-2009

List of Illustrations Page

4 II PowerAmp-A Single Core Rev 2 15-01-2009

5 II PowerAmp-A Single Core Rev 2 15-01-2009

6 II PowerAmp-A Single Core Rev 2 15-01-2009

7 II PowerAmp-A Single Core Rev 2 15-01-2009

8 II PowerAmp-A Single Core Rev 2 15-01-2009

9 II PowerAmp-A Single Core Rev 2 15-01-2009

10 II PowerAmp-A Single Core Rev 2 15-01-2009

11 II PowerAmp-A Single Core Rev 2 15-01-2009

12 II PowerAmp-A Single Core Rev 2 15-01-2009

13 II PowerAmp-A Single Core Rev 2 15-01-2009

14 II PowerAmp-A Single Core Rev 2 15-01-2009

15 II PowerAmp-A Single Core Rev 2 15-01-2009

16 II PowerAmp-A Single Core Rev 2 15-01-2009

17 II PowerAmp-A Single Core Rev 2 15-01-2009

3.6 Shrinking The Heat Shrink Sleeve

18 II PowerAmp-A Single Core Rev 2 15-01-2009

19 II PowerAmp-A Single Core Rev 2 15-01-2009

PowerAmp Cable Cable Lug Die Size Presshead

Incore Article No Size Bi-Metal

In the article no. xx denotes the colour of the cable as follows:

20 II PowerAmp-A Single Core Rev 2 15-01-2009

Potrebbero piacerti anche