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Pyrotenax IW Cable Termination Manual

1. Silver solder pot to cable sheath Pot Figure 83 Braze pot to cable sheath EN PyrotenaxlndustrialWiringCable IM H58121 03 13 67 gt PENTAIR NORTH AMERICA Tel 1 800 545 6258 Fax 1 800 527 5703 Tel 1 650 216 1526 Fax 1 650 474 7711 thermal info pentair com ASIA PACIFIC Tel 86 21 2412 1688 Fax 86 21 5426 2917 cn thermal info pentair com WWW THERMAL PENTAIR COM EUROPE MIDDLE EAST AFRICA Tel 32 16 213 511 Fax 32 16 213 603 thermal info pentair com LATIN AMERICA Tel 1 713 868 4800 Fax 1 713 868 2333 thermal info pentair com Pentair and Pyrotenax are owned by Pentair or its global affiliates All other trademarks are the property of their respective owners Pentair reserves the right to change specifications without prior notice 2007 2013 Pentair THERMAL MANAGEMENT SOLUTIONS EN PyrotenaxIndustrialWiringCable IM H58121 03 13
2. 4 Appendixes Appendix B Epoxy Compound Mixing Instructions A CAUTION Avoid skin contact with epoxy com pound wear safety glasses and protective gloves If accidental contact occurs wash skin with mild soap and water TABLE 4 Number of Packages Reguired Termination Size 1Seal 2Seals 3Seals 4Seals 1 2 1 1 1 2 3 4 1 2 3 4 1 2 3 5 6 1 1 4 2 4 5 7 Storage temperature 65 F to 77 F 18 C to 25 C 1 Ensure package is 65 F 18 C minimum 120 F 49 C maximum before using Open foil envelope and remove plastic clamp separating resin from hardener Figure 74 Remove plastic clamp 2 Hold on to both ends of the plastic package and slide back and forth against an edge for a mini mum of 40 times Ensure resin and hardener are thoroughly mixed before using r Important Product must be used within 10 min utes of mixing EN PyrotenaxIndustrialWiringCable IM H58121 03 13 59 Appendixes Figure 75 Mix resin and hardener 3 Cut one corner of the plastic package to make an opening of about 1 8 in 3 mm Figure 76 Cut one corner of plastic package 4 Squeeze the package to dispense the epoxy compound through the opening Figure 77 Dispense epoxy EN PyrotenaxIndustrialWiringCable IM H58121 03 13 4 Appendixes Appendix C Insulation Resistance IR Test Test Equipment 900 Vdc Megohmmeter IR Testing IR testing is conducted usi
3. Stripping Pyrotenax Alloy 825 Sheath MI Cable Using diagonal cutters Measure from cable end length of cable sheath to strip and mark sheath with marking pen Use a tube cutter to score around the sheath at the mark This will cause the sheath to peel away at the score providing a smooth end when the sheath is stripped The correct depth of score is half the thickness of the sheath Do not cut completely through the cable sheath as this will cause the sheath to curve inwards toward the conductorls Figure 64 Score cable sheath with tubing cutter Grip the edge of the sheath between the jaws of the side cutters and twist clockwise twist counter clockwise if left handed then take a new grip and rotate through a small angle Figure 65 Cut end of sheath and twist clockwise 54 EN PyrotenaxIndustrialWiringCable IM H58121 03 13 4 Appendixes Continue this motion in a series of short rips keeping the side cutters at about 45 to the line of the cable removing sheath spirally Remove com pacted powder insulation to expose conductors Figure 66 Remove sheath and compacted powder insulation Continue removing the sheath to the score mark When about to break into the score bring side cut ters to right angle with cable Finish off with point of side cutters held parallel to the cable The sheath will peel away leaving a clean cut when the score mark is reached Figure 67 Finis
4. 2 2 19a After the epoxy compound at both ends has fully cured 16 hours check the IR again with the 500 Vdc megohmmeter see Appendix C ca Important Under adverse weather conditions lower IR readings may be encountered Figure 25 Check insulation resistance Crimp on Tail Termination Procedure In this procedure the cable end is sealed using the mastic sealing compound or epoxy sealing com pound supplied with the termination kit The tails are formed by removing a short length of the cable sheath and covering the exposed solid conductors with insulating sleeving Insulated stranded wire tails of the reguired length supplied separately or by the customer are then spliced to the solid con ductors using the crimp connectors included in the termination kit Figure 26 shows the components of each termina tion kit Visually check the parts supplied with the termination kit to identify which sealing compound has been supplied and follow the appropriate steps to terminate the cable EN PyrotenaxIndustrialWiringCable IM H58121 03 13 23 Installation Figure 26a Kit parts for mastic sealing compound Spacer disk and insulating sleeving assembly Gland connector Set screw amp pot Crimp 7 Heat shrink connectors tubing Mastic sealing _ compound B Figure 26b Kit parts for epoxy sealing compound Spacer disk and insulating sleeving assembly Gland connector Set s
5. Cut and file end smooth Figure 4 Cut MI cable and mark sheath 2 Place the gland connector and pot on to cable as shown Gland connector Figure 5 Place gland and pot on to cable 3 Using the tubing cutter score cable sheath at the mark see Appendix A for detailed instructions EN PyrotenaxIndustrialWiringCable IM H58121 03 13 7 Installation V Important Do not cut completely through the cable sheath as this will cause the sheath to curve in towards the conductors Mark on sheath Figure 6 Score cable sheath with tubing cutter 4 Grip cable firmly with Pyrotenax hand vise or hold cable in a bench vise V Important Do not remove gland connector and pot from cable Use diagonal side cutters to strip the cable sheath ensuring that the sheath is flared slightly outwards see Appendix A for detailed instructions Figure 7 Strip cable sheath with side cutters Alternatively use the T bar stripping tool to strip the cable sheath ensuring that the cable sheath is flared slightly outwards see Appendix for detailed instructions 10 EN PyrotenaxIndustrialWiringCable IM H58121 03 13 2 Installation Figure 8 Strip cable sheath with T bar tool 5 Straighten the conductors if required and ensure that they are evenly spaced Wipe around and in between all conductors and end of sheath to remove loose powder Wipe around and in between conduct
6. gt PENTAIR E Industrial MI Wiring Cable Termination INSTALLATION MANUAL FOR SYSTEM 2000 AND SYSTEM 2200 WIRING SYSTEMS THERMAL MANAGEMENT SOLUTIONS WWW THERMAL PENTAIR COM Important Safeguards and Warnings A WARNING FIRE AND SHOCK HAZARD Pyrotenax Industrial Wiring Cables must be installed correctly to ensure proper function and to minimize the risk of personal injury or fire Read these impor tant warnings and carefully follow the installation instructions e When MI cable is stripped and terminated cut metal edges can cause cuts and loose powder can cause eye irritation To prevent injury gloves and safety glasses must be worn when carrying out these operations e To prevent burns when drying or brazing the cable allow it to cool until warm to the touch before com pleting the remaining termination instructions e Avoid skin or eye irritation from contact with the epoxy sealing compound If accidental contact occurs wash skin with soap and water or flush eyes with water for 15 minutes Consult MSDS for further pre cautions and treatments e The insulation resistance IR test can cause sparks To prevent fires in hazardous locations be sure there are no flammable vapors in the area before perform ing this test MSDS sheets for the epoxy sealing compoind mastic sealing compound silver solder and the silver braz ing flux are available on our website www thermal pentair com EN PyrotenaxIndustr
7. must be main tained at a temperature of 65 F 18 C minimum for 16 hours to fully cure Note that the spacer disk is discarded once the epoxy has cured EN PyrotenaxIndustrialWiringCable IM H58121 03 13 31 Installation Cable must project 1 8 in 3 mm into pot Thread MI cable ZZ Gland ME Silver solder pot to cable sheath Epoxy sealing compound Insulated stranded wire tails Silver soldered joint Pot Figure 34 Completed termination using insulated stranded wire tails cut away pot shown Cable must project 1 8 in 3 mm into pot Thread MI cable Epoxy sealing compound Anchoring beads Spacer disk discard after epoxy cures Gland connector i Insulating Silver solder pot to Silver sleeving cable sheath soldered joint Pot Figure 35 Completed termination using bare stranded wire tails and insulating sleeving cut away pot shown EN PyrotenaxIndustrialWiringCable IM H58121 03 13 2 Installation Tools and Materials Reguired Pyrotenax hand vise Diagonal side cutters Hacksaw Flat file Tubing cutter Workbench Measuring tape or ruler Permanent marker Micrometer 500 Vdc megohmmeter Wire stripper Scribe or pick Medium grit emery paper Clean dry cloth Safety glasses Gloves Oxy acetylene torch with Victor No 0 welding tip or equivalent Handy amp Harman 1 16 in 1 6 mm or 1 32 in 0 8 mm diame
8. tag Hold T bar tool at 45 angle twist handle and revolve tool around the cable carefully Continue twisting the tool around the cable main taining a 45 angle to the line of the cable allowing the metal turnings to spiral along the stripping tool Remove compacted powder insulation to expose conductors When peeling a long length of cable cut and remove the metal turnings frequently Figure 71 Strip cable sheath with T bar tool Continue removing the sheath to the score mark using the T bar stripping tool When about to break into the score use side cutters and bring to right angle with cable Finish off with point of side cutters held parallel to the cable The sheath will peel away leaving a clean cut when the score mark is reached EN PyrotenaxIndustrialWiringCable IM H58121 03 13 57 Appendixes Figure 72 Finish removing sheath at score mark The cable sheath is correctly stripped with the sheath flared slightly outwards as shown in a In b the sheath is neither flared outwards nor bev eled inwards but is acceptable Ensure that the sheath is not curved or beveled inward as shown in c This will occur if the score made with the tube cutter is too deep In this case remove a further 1 4 in 6 mm of sheath Cable is now ready to be sealed Preferred Acceptable Unacceptable Figure 73 Examples of stripped cable EN PyrotenaxIndustrialWiringCable IM H58121 03 13
9. termination must be remade EN PyrotenaxIndustrialWiringCable IM H58121 03 13 3 1 General Information 1 6 Approvals Termination kits are supplied with either a mas tic sealing compound or epoxy sealing compound and are approved for use in the locations shown following U S and Canadian Approvals Kits using mastic sealing compound Ordinary Locations Hazardous Locations Class Div 1 and 2 Groups A B C D SB Class Il Div 1 and 2 Groups E F G c US Class Ill Div 1 and 2 Kits using epoxy sealing compound Ordinary Locations Hazardous Locations G Class I Div 1 and 2 Groups A B C D Class II Div 1 and 2 Groups E F G e OS Class Ill Div 1 and 2 ATEX Approved Components MI Cable Seal Assembly II 2G EEx e ll Baseefa02ATEX0194U Cable Glands II 2GD EEx d UC Ex Baseefa03ATEX0347X CE 1180 4 EN PyrotenaxlndustrialWiringCable IM H58121 03 13 2 Installation 2 1 Strip back Tail Termination Procedure In this procedure the cable end is sealed using the mastic sealing compound or epoxy sealing com pound supplied with the termination kit The tails are formed by removing an appropriate length of the cable sheath and covering the exposed solid conduc tors with insulating sleeving Figure 1 shows the components of each termination kit Visually check the parts supplied with the ter mination kit to identify which sealing compound has been supplied and fol
10. with Victor No 0 welding tip or equivalent e Handy 8 Harmon 1 16 in 1 6 mm or 1 32 in 0 8 mm diameter Braze 560 silver solder or equivalent e Prostar silver brazing flux or equivalent Use emery paper to polish surface of cable sheath all around the area to be brazed Polish all around area to be brazed Solid conductor Emery paper Figure 81 Polish surface of cable sheath Apply flux to the cable sheath and back of pot where it meets the cable sheath This prevents oxidation of themetals during the next step Next remove moisture from cable by heating the last 6 in 150 mm of cable with the oxy acetylene torch Begin 6 in 150 mm back from end and stroke flame towards end see Appendix D for detailed procedure 66 EN PyrotenaxIndustrialWiringCable IM H58121 03 13 4 Appendixes Apply flux around a sheath and back of the pot Figure 82 Heat cable to remove moisture Braze pot to cable sheath while the cable is still hot Ensure silver solder flows all around the pot and sheath by moving the flame around the cable E Important To make a good quality solder joint the silver solder rod must be coated with flux at all times Dip in flux as many times as necessary until brazing operation is complete A CAUTION Cable will be hot Allow cable to cool until just warm to the touch before completing remaining termination steps Oxy acetylene torch Silver solder
11. EN PyrotenaxIndustrialWiringCable IM H58121 03 13 4 Appendixes while maintaining the short sweeping motion of the torch Figure 80 If you heat toward the cable end too quickly you may skip over the moisture and drive it further back into the cable It may be necessary to repeat the above procedure several times to completely remove all moisture from the cable Repeat 4 to 5 times 2 in 50 mm en Figure 79 Heat 2 in 50 mm at a time gt mm ll Figure 80 Stroke flame towards the end When first heated the IR of the cable will decrease however after the flame has been removed and the cable cools the IR will increase to an acceptable level if the moisture has been driven out On comple tion check IR with a 500 Vdc megohmmeter follow ing the instructions in Appendix C If working with shielded twisted pair cable also test IR between the sheath and inner shield Reseal cable end with adhesive lined heat shrink tubing until ready to ter minate cable EN PyrotenaxIndustrialWiringCable IM H58121 03 13 65 4 Appendixes Appendix E Optional Procedure to Braze Pot to Cable Sheath For improved mechanical strength the pot may be brazed to the cable sheath Ensure that the required permits to use an open flame have been obtained from the Authorized Safety Representative prior to proceeding Additional tools and materials required e Oxy acetylene torch
12. Guide Probable Causes 1 Rain or high humidity Nicks or cuts in the cable sheath with moisture present Kinked or crushed cable 4 Arcing created by damage to the cable Corrective Action 1 Dry tails and face of seal Inspect power connection box for moisture or signs of track ing Dry out connections and retest 2 3 4 5 Visually inspect or fault locate cable to find dam aged section of cable Repair or replace cable or contact Pentair Thermal Management technical support for assistance 5 Welding splatter 6 Presence of moisture in 6 Remove termination or termination or temporary temporary seal Dry out cable seal following the procedure in Appendix D Replace termina tion or seal 7 Damaged termination or 7 Replace termination or seal temporary seal 1 Physical damage to cable 1 Check for visual indications is causing a direct short of damage around any area from conductor to sheath Where there may have been maintenance work Repair or replace damaged cable and or terminations 2 Misalignment of the 2 Remake termination conductors within the seal or incorrect and untidy completion of the sheath stripping proce dure during termination 3 Conductors shorted to 3 Remove short and reseal sheath when cut at facto ry only for unterminated cables end EN PyrotenaxIndustrialWiringCable IM H58121 03 13 53 4 Appendixes Appendix A
13. V Important Hold the tool firmly with vise grips if needed to prevent the tool from turning the pot Apply even pressure on the spacer disk by tight ening the tool until the spacer disk is snugly seated inside the opening of the pot and the cone shaped points crimp the side of the pot This will retain the spacer disk in position The termination is now complete Ea Important It is normal for the mastic sealing compound to squeeze out the side of the pot as pres sure is applied with the crimping and compression tool EN PyrotenaxIndustrialWiringCable IM H58121 03 13 17 2 Installation F MI cable Pot Crimping plate Sleeving Figure 18 Crimp spacer disk into pot 17 On completion of the termination check the IR again with the 500 Vdc megohmmeter see Appendix C r Important Under adverse weather conditions lower IR readings may be encountered Figure 19 Check insulation resistance 18 Apply a drop of Loctite 271 or equivalent perma nent thread lock compound to the top of each set screw 18 EN PyrotenaxIndustrialWiringCable IM H58121 03 13 2 Installation Set screws Figure 20 Apply thread lock compound to set screws 19 Complete the termination at the opposite end following the same procedure if not already done Sealing Cable End Using Epoxy Sealing Com pound continued from Step 13 14a Withdraw the spacer disk and sleeving sub assembly sl
14. ccidental contact occurs wash skin with mild soap and water 20 EN PyrotenaxIndustrialWiringCable IM H58121 03 13 2 Installation Gloves Epoxy resin Tape Figure 22 Fill pot with epoxy 16a Slide sleeving towards pot and adjust its posi tion so that the bottom anchoring bead and half the upper bead are immersed in the epoxy For multi conductor cable maintain proper spacing of conductors with spacer disk and keep disk about 1 1 4 in 30 mm above the pot E Important Bend the conductors slightly so that the sleeving does not slide down into the epoxy Allow 16 hours at 65 F 18 C minimum for the epoxy to cure before moving the termination from the vertical position At lower tempera tures curing will take longer Ea Important Discard spacer disk after the epoxy cures EN PyrotenaxIndustrialWiringCable IM H58121 03 13 21 2 Installation Bend sleeving just above the 7 spacer disk Spacer disk discard after A epoxy cures 1 1 4 in 30 mm Epoxy resin Tape Figure 23 Allow epoxy to cure 17a Apply a drop of Loctite 271 or equivalent perma nent thread lock compound to the top of each set screw Set screws Figure 24 Apply thread lock compound to set screws 18a Complete the termination at the opposite end following the same procedure if not already done 22 EN PyrotenaxIndustrialWiringCable IM H58121 03 13 Installation
15. crew amp OQ pot Crimp 33 gt Heat shrink connectors Ra tubing M Epoxy sealing compound amp Figure 26 Components supplied in crimp on tail termination kits 24 EN PyrotenaxIndustrialWiringCable IM H58121 03 13 Installation The completed termination using the mastic sealing compound is shown in Figure 27 Store the package containing the mastic sealing compound at room temperature prior to use Cable must project Anchoring bead 1 8 in 3 mm into pot Spacer disk Set screws Insulating Insulated sleeving stranded wire tails MI cable Crimp butt Cland connector Thread E connectors Set screw pot Mastic sealing Heat shrink compound Figure 27 Completed mastic sealing compound termination cut away pot shown The completed termination using the epoxy sealing compound is shown in Figure 28 The epoxy sealing compound must be stored at temperatures between 65 F to 77 F 18 C to 25 C and when used must be maintained at a temperature of 65 F 18 C mini mum for 16 hours to fully cure Note that the spacer disk is discarded once the epoxy has cured Cable must project Anchoring beads 18 in 3 mm into pot Spacer disk discard Set screws after epoxy cures Insulating Insulated MI cable sleeving stranded erme mr Gland er Form butt lage Epoxy connectors Set screw pot sealing Heat shrink compound Figure 28 Completed epoxy seali
16. ed wire tails page 33 Steps 1 to 19 e Bare stranded wire tails and insulating sleeving page 33 Steps 1 to 7 8ato 19a For information on installing and supporting Pyrotenax Alloy 825 sheath MI wiring cables refer to the Pyrotenax MI Cable Industrial Wiring Installation Manual H57987 For fire rated systems the termination must be protected from the fire as described in the Pyrotenax MI Cable Industrial Wiring Installation Manual 457987 For technical support or for further information on terminating MI wiring cables please contact your Pentair Thermal Management representative or Pentair Thermal Management directly EN PyrotenaxIndustrialWiringCable IM H58121 03 13 1 General Information 1 2 For additional information contact Pentair Thermal Management 7433 Harwin Drive Houston TX 77036 USA Tel 1 800 545 6258 Tel 1 650 216 1526 Fax 1 800 527 5703 Fax 1 650 474 7711 thermal info pentair com www thermal pentair com Safety Guidelines The instructions contained in this booklet are impor tant Follow them carefully to avoid injuries and to ensure that the MI cable is properly terminated When MI cable is stripped and terminated cut metal edges can cause abrasions to the hands and loose powder may cause irritation if it enters the eyes For these reasons gloves and safety glasses must be used when carrying out these operations e Important instructions are marked r Importa
17. en conductor s and sheath and Between conductor pairs See Appendix C for detailed test procedure and IR test criteria Once IR readings are satisfactory immediately seal the cable end as described in the steps fol EN PyrotenaxIndustrialWiringCable IM H58121 03 13 47 Installation lowing A delay will cause the IR to drop and the cable must be retested prior to sealing the end r Important Opposite end of cable must also be dry and free of grounds and shorts to obtain an acceptable IR reading Low IR readings should be expected if the opposite end has already been terminated with epoxy sealing compound which has not fully cured IR will increase once the epoxy has cured r Important If neither cable end has yet been terminated and IR readings are low dry out both ends following the procedure in Appendix D or cut off shorted end and re test Apply a temporary moisture resistant seal such as hot melt glue or adhesive lined heat shrink tubing to opposite cable end to prevent moisture absorption Figure 59 Check insulation resistance 15a Slide spacer disk and insulating sleeving sub assembly over the bare stranded wire anchoring bead end first If one end of the cable has been terminated test the end to end con tinuity with a continuity tester to ensure that each conductor has the same color sleeving at both ends Colored sleeving assemblies will be marked with a red tag for one end and a green
18. gnesium oxide pow der in the exposed cable end with metal filings if contaminated remove with a pick EN PyrotenaxIndustrialWiringCable IM H58121 03 13 37 2 Installation EE MI cable Emery paper Figure 43 Remove flux and lightly sand conductors 10 Place a mark at a length E refer to table below from end of sheath TABLE 2 Pot Size Length E to mark 1 2 in 13 mm 5 16 in 8 mm 3 4 in 19 mm 7 16 in 11 mm 1 in 25 mm 9 16 in 14 mm 1 1 4 in 32 mm 5 8 in 16 mm x amp Mark sheath Figure 44 Mark sheath at length E 11 Align back of the pot previously installed with mark Cable end will project approximately 1 8 in 3 mm into the pot E Important Cable end must project 1 8 in 3 mm into the pot in order to make an effective seal 38 EN PyrotenaxIndustrialWiringCable IM H58121 03 13 Installation Mark Cable end must project 1 8 in 3 mm into pot Figure 45 Align back of pot with mark 12 Apply flux to the cable sheath and back of the pot where it meets the cable sheath This pre vents oxidation of the metals during the next step Next remove moisture from cable by heating the last 6 in 150 mm of cable with the oxy acetylene torch Begin 6 in 150 mm back from end and stroke flame towards the end see Appendix D for detailed procedure Apply flux around sheath and back of the pot Figure 46 Heat cable to remove moistu
19. h of solid conductor tail is required adjust the dimensions shown accord ingly and strip the required length of cable sheath sheath Cut and file end smooth Figure 29 Cut MI cable and mark sheath 2 Follow Steps 2 through 19 of the Strip back Tail Termination Procedure to terminate the cable using the mastic sealing compound page 7 then continue with Step 3 below Follow Steps 2 through 19a of the Strip back Tail Termination Procedure to terminate the cable using the epoxy sealing compound page 7 then continue with Step 3 below 3 If the cable ends were terminated using the epoxy sealing compound proceed only after the epoxy has fully cured and discard the spacer disk Strip just enough insulating sleeving so that the end of the solid conductor touches the center EN PyrotenaxIndustrialWiringCable IM H58121 03 13 27 2 Installation stop in the crimp connector the sleeving sup plied with the termination kit may be longer than the solid conductor tails Strip the insulation from the insulated stranded wire not shown just enough to touch the cen ter stop in the crimp connector Strip enough sleeving so that conductor touches center stop Ss in crimp connector Figure 30 Strip insulating sleeving 4 Insert the stripped conductors into the crimp connector and crimp the connector using a crimping tool which has been approved by a certifying agency for use with the connec
20. h removing sheath at score mark The cable sheath is correctly stripped with the sheath flared slightly outwards as shown in a In b the sheath is neither flared outwards nor bev eled inwards but is acceptable Ensure that the sheath is not curved or beveled inward as shown in c This will occur if the score EN PyrotenaxIndustrialWiringCable IM H58121 03 13 55 Appendixes made with the tube cutter is too deep In this case remove a further 1 4 in 6 mm of sheath Cable is now ready to be sealed Preferred Acceptable Unacceptable Figure 68 Examples of stripped cable Using the T bar stripping tool Measure from cable end length of cable sheath to strip and mark sheath with marking pen Use a tube cutter to score around the sheath at the mark This will cause the sheath to peel away at the score providing a smooth end when the sheath is stripped The correct depth of score is half the thickness of the sheath Do not cut completely through the cable sheath as this will cause the sheath to curve inwards toward the conductorls Figure 69 Score cable sheath with tubing cutter EN PyrotenaxIndustrialWiringCable IM H58121 03 13 4 Appendixes Cut the end of the sheath of the MI cable with side cutters as shown and peel sheath to give approxi mately 5 8 in 15 mm tag Straighten the tag and insert into slot in T bar stripping tool Figure 70 Cut end of sheath to make
21. ialWiringCable IM H58121 03 13 Table of Contents 1 General Information 1 1 1 Use of the Manual 1 1 2 Safety Guidelines 2 1 3 Moisture Absorption 3 1 4 Grounding Earthing 3 1 5 Field Testing 3 1 6 Approvals 4 2 Installation 5 2 1 Strip back Tail Termination Procedure 5 2 2 Crimp on Tail Termination Procedure 23 2 3 Brazed on Tail Termination Procedure 29 3 Troubleshooting Guide 52 4 Appendixes 54 EN PyrotenaxIndustrialWiringCable IM H58121 03 13 EN PyrotenaxIndustrialWiringCable IM H58121 03 13 General Information 1 1 Use of the Manual This installation manual covers the termination procedure for Pyrotenax Alloy 825 sheath mineral insulated MI wiring cables The instructions show how to make MI cable terminations using strip back tails crimp on tails or brazed on tails with either the mastic sealing compound or epoxy seal ing compound Use the chart following to identify which termination kit has been supplied and read the appropriate instruction steps completely before per forming the termination procedure Strip back Tail Termination Procedure e Mastic sealing compound page 9 Steps 1 to 19 e Epoxy sealing compound page 9 Steps 1 to 13 14a to 19a Crimp on Tail Termination Procedure e Mastic sealing compound page 27 Steps 1 to 6 e Epoxy sealing compound page 27 Steps 1 to 6 Brazed on Tail Termination Procedure uses epoxy sealing compound e Insulated strand
22. ightly to allow space to fill the pot with epoxy Ensure conductors are spaced an egual dis tance apart from each other and the inside of the pot Temporarily wrap 4 to 5turns of electrical tape around the cable sheath tightly in contact with the back ofthe pot This prevents the epoxy sealing compound from leaking out of the pot Prepare epoxy sealing compound in accordance with Steps 1 and 2 of the instructions see Appendix B for details F Important Use epoxy within 10 minutes after mixing The pot should still be warm following Step 10 or procedure in Appendix E if not heat the cable and then the pot with the torch until just warm to the touch before filling with epoxy Be careful not to melt the electrical tape EN PyrotenaxIndustrialWiringCable IM H58121 03 13 19 2 Installation r Important To avoid forming bubbles in the epoxy do not apply heat to the cable or the pot while filling the pot with epoxy or after it has been filled Insulating sleeving Spacer disk Anchoring beads Set screw pot 4 to 5 turns of electrical tape MI cable jp tight to back of pot Figure 21 Prepare pot for epoxy 15a Cut one corner of plastic package containing epoxy to make an opening of 1 8 in 3 mm Maintaining cable end vertically sgueeze the epoxy into the pot Pour it down one side of the pot until it is completely filled N CAUTION Avoid skin contact with epoxy compound If a
23. lean for brazing Emery paper Cut and file end smooth face of conductors must be clean Figure 37 Polish surface of cable sheath EN PyrotenaxIndustrialWiringCable IM H58121 03 13 2 Installation 3 Ensure that the end of the MI cable to be ter minated is straight for approximately 9 in 230 mm Place a mark on the sheath 3 16 in 5 mm from end of the cable this is the length of sheath to strip Figure 38 Cut MI cable and mark sheath 4 Place the gland connector and the pot on to cable as shown r Important If the pot does not fit over the MI cable measure the cable diameter using a micrometer and drill the hole in the pot to a size that is 0 002 to 0 004 in 0 05 to 0 1 mm larger than the cable diam eter using a drill press and appropriately sized drill bits Figure 39 Place gland and pot on to cable EN PyrotenaxIndustrialWiringCable IM H58121 03 13 35 2 Installation 5 Using the tubing cutter score cable sheath at the mark see Appendix A for detailed instructions V Important Do not cut completely through the cable sheath as this will cause the sheath to curve in towards the conductors Figure 40 Score cable sheath with tubing cutter 6 Grip cable firmly with Pyrotenax hand vise or hold cable in a bench vise if available r Important Do not remove gland assembly and pot from cable Use diagonal side cutters to strip the cable sheath ens
24. low the appropriate steps to terminate the cable EN PyrotenaxIndustrialWiringCable IM H58121 03 13 5 Installation Figure 1a Kit parts for mastic sealing compound Spacer disk and insulating NR sleeving assembly 777 yr Cland connector Set screw c amp pot amp Mastic sealing A compound 4 Figure 1b Kit parts for epoxy sealing compound Spacer disk and insulating sleeving assembly Gland connector Epoxy sealing compound Figure 1 Components supplied in strip back tail termination kits EN PyrotenaxIndustrialWiringCable IM H58121 03 13 Installation The completed termination using the mastic sealing compound is shown in Figure 2 Store the package containing the mastic sealing compound at room temperature prior to use Cable must project 1 8 in 3 mm into pot Set screws Anchoring bead Spacer disk MI cable Insulating Gland connector sleevin Thread Mastic sealing 7 Set screw pot compound Figure 2 Completed mastic sealing compound termination cut away pot shown The completed termination using the epoxy sealing compound is shown in Figure 3 The epoxy sealing compound must be stored at temperatures between 65 F to 77 F 18 C to 25 C and when used must be maintained at a temperature of 65 F 18 C mini mum for 16 hours to fully cure Note that the spacer disk is discarded once the epoxy has cured Cable must projec
25. ng a megohmmeter and tests the integrity of the cable between the conductor s and the cable sheath and between con ductor pairs in multi conductor cables Test Criteria The minimum IR for a clean dry properly installed cable should reflect the values shown below regard less of the cable length e Ina warm dry environment IR readings should be 200 MA or higher e In an outdoor environment or indoors in wet or humid conditions IR readings should all be above 100 MA e Prior to initial start up commissioning mini mum 25 MA e After any maintenance or repair work minimum 25 MA e Any large difference in readings between simi lar cables under similar conditions should be investigated Ea Important If IR readings are low follow the instructions in Appendix D to dry out the cable Test Procedure 1 Set megohmmeter test voltage at 0 Vdc or off 2 Connect the positive earth lead to the cable sheath Figure 78 3 Connect the negative line lead to one conductor 4 Turn on the megohmmeter and set the voltage to 500 Vdc apply the voltage for one minute Meter needle should stop moving Rapid deflec tion indicates a short Note the insulation resis EN PyrotenaxIndustrialWiringCable IM H58121 03 13 61 4 Appendixes tance value It should correspond to the values shown under Test Criteria 5 Turn off the megohmmeter 6 If testing a single conductor cable proceed to
26. ng compound termination cut away pot shown EN PyrotenaxIndustrialWiringCable IM H58121 03 13 25 2 Installation Tools and Materials Reguired Pyrotenax T bar stripping tool Pyrotenax hand vise Pyrotenax crimping and compression tool lif ter minating cable using mastic sealing compound Diagonal side cutters Hacksaw Flat file Measuring tape or ruler Tubing cutter Adjustable pliers vise grips Oxy acetylene or mapp gas torch to dry out cable Permanent marker 500 Vdc megohmmeter Electrical tape if terminating cable using epoxy seal Wire stripper Scribe or pick Medium grit emery paper Loctite 271 or eguivalent permanent thread lock compound Allen wrench set 1 16 3 32 and 1 8 Crimping tool approved for use with supplied crimp connectors Heat gun Clean dry cloth Safety glasses Gloves Insulated stranded wire of appropriate AWG mm size length and temperature rating supplied separately or by customer 26 EN PyrotenaxIndustrialWiringCable IM H58121 03 13 2 Installation A CAUTION Wear safety glasses and gloves dur ing the termination procedure 1 With hacksaw cut the end of the MI cable square and file the end smooth Ensure that the end of the MI cable to be ter minated is straight for 10 in 250 mm Place a mark on the sheath 4 in 100 mm from end of the cable this is the length of sheath to strip r Important If a longer lengt
27. ng towards the pot and adjust its position so that the bottom anchoring bead and half the upper bead are immersed in the epoxy For multi conductor cable maintain proper spacing of conductors with spacer disk and keep disk about 1 1 4 in 30 mm above the pot r Important Bend the conductors slightly so that the sleeving does not slide down into the epoxy Allow 16 hours at 65 F 18 C minimum for the epoxy to cure before moving the termination from the vertical position At lower tempera tures curing will take longer V Important Discard spacer disk after the epoxy cures 50 EN PyrotenaxIndustrialWiringCable IM H58121 03 13 2 Installation Spacer disk discard after epoxy cures 1 1 4 in 30 mm Epoxy resin _ iW Figure 62 Allow epoxy to cure 18a Complete the termination at the opposite end following the same procedure if not already done 19a After the epoxy compound at both ends has fully cured 16 hours check the IR again with the 500 Vdc megohmmeter see Appendix C F Note Under adverse weather conditions lower IR readings may be encountered Figure 63 Check insulation resistance EN PyrotenaxlndustrialWiringCable IM H58121 03 13 51 3 Troubleshooting Guide Symptom Insulation resistance is less than expected Short circuits and direct earth faults 52 EN PyrotenaxIndustrialWiringCable IM H58121 03 13 3 Troubleshooting
28. nt e Safety warnings are marked A WARNING e Safety cautions are marked AN CAUTION EN PyrotenaxIndustrialWiringCable IM H58121 03 13 General Information 1 3 1 4 1 5 Moisture Absorption Because the magnesium oxide insulation of MI cable is hygroscopic it will absorb moisture when exposed to air for any length of time resulting in decreased insulation resistance IR This can be corrected by one of the following methods 1 When the cable sheath is stripped the mois ture affected magnesium oxide insulation will normally be removed during the termination procedure To prevent further absorption of moisture the termination should be completed immediately following the IR test 2 If excess cable is available 6 to 12 in 150 to 300 mm of cable may be removed from the end before proceeding with the termination 3 Follow the drying out procedure in Appendix D Grounding Earthing If one conductor is to be used as a grounding con ductor ensure that it is identified with an appropri ately colored marker or tape The sleeving supplied with the termination kit used to identify the ground ing conductor may not be a standard color such as green or green yellow Field Testing The IR of MI cables should be checked with a 500 Vdc megohmmeter While an IR value of infinity is desirable minimum acceptable IR values and the test procedure are shown in Appendix C Where low IR readings are obtained the
29. ntaining cable end vertically sgueeze the epoxy into the pot Pour it down one side of the pot until it is completely filled N CAUTION Avoid skin contact with epoxy compound If accidental contact occurs wash skin with mild soap and water Gloves W Figure 50 Fill pot with epoxy MI cable 42 EN PyrotenaxIndustrialWiringCable IM H58121 03 13 2 Installation 17 Allow 16 hours at 65 F 18 C minimum for the epoxy to cure before moving the termination from the vertical position At lower tempera tures curing will take longer a Tails Epoxy resin LI Figure 51 Allow epoxy to cure 18 Complete the termination at the opposite end following the same procedure if not already done 19 After the epoxy compound at both ends has fully cured 16 hours check the IR again with the 500 Vdc megohmmeter see Appendix C r Important Under adverse weather conditions lower IR readings may be encountered EN PyrotenaxIndustrialWiringCable IM H58121 03 13 43 2 Installation Figure 52 Check insulation resistance Bare Stranded Wire Tails and Insulating Sleeving Termination continued from Step 7 8a Lightly coat only the face of the solid conductor s with flux Do not allow the mag nesium oxide at the end of the cable to become contaminated with flux if contaminated you must cut off 1 2 in 13 mm of cable and start over from Step 2 Next braze the bare s
30. o Step 11 otherwise continue with Step 10 10 Remove moisture from cable by heating the last 6 in 150 mm of cable with the mapp gas or oxyacetylene torch Begin 6 in 150 mm back from end and stroke flame towards end see Appendix D for detailed procedure A CAUTION Cable will be hot Allow cable to cool until just warm to the touch then continue with the steps following to seal the cable end Figure 13 Heat cable to remove moisture EN PyrotenaxlndustrialWiringCable IM H58121 03 13 13 Installation 11 Slide spacer disk and insulating sleeving sub assembly over conductors anchoring bead end first If one end of the cable has been ter minated test the end to end continuity with a continuity tester to ensure that each conduc tor has the same color sleeving at both ends Colored sleeving assemblies will be marked with a red tag for one end and a green tag for the other A cable should not be terminated with the same colored tag at both ends Spacer disk Pot Insulating sleeving Anchoring bead Figure 14 Place insulating sleeving sub assembly over conductors 12 Using a 500 Vdc megohmmeter check the insu lation resistance IR of the cable to ensure it is free of grounds and shorts Between conductor s and sheath and Between conductor pairs See Appendix C for detailed test procedure and IR test criteria Once IR readings are satisfactory immediately apply the approp
31. ors Figure 9 Clean conductors 6 Using emery paper lightly sand around and in between all conductors for a length of 1 in 25 mm from the end of cable and the last 1 in 25 mm of conductors Avoid contaminating the magnesium oxide pow der in the exposed cable end with the metal filings if contaminated remove with a pick EN PyrotenaxIndustrialWiringCable IM H58121 03 13 1 2 Installation Emery paper S Figure 10 Lightly sand conductors 7 Place a mark ata length E refer to table below from end of sheath TABLE 1 Pot Size Length E to mark 1 2 in 13 mm 5 16 in 8 mm 3 4 in 19 mm 7 16 in 11mm 1 in 25 mm 9 16 in 14 mm 1 1 4 in 32 mm 5 8 in 16 mm Figure 11 Mark sheath at length E 8 Align back of the pot previously installed with mark Cable end will project approximately 1 8 in 3 mm into the pot Tighten set screws to hold pot in place 12 EN PyrotenaxIndustrialWiringCable IM H58121 03 13 2 Installation E Important Cable end must project 1 8 in 3 mm into pot in order to make an effective seal Set screw Pot Mark Cable end must project 1 8 in 3 mm into pot Figure 12 Align pot with mark and tighten set screws 9 Optional For added mechanical strength the pot may be brazed to the cable sheath as shown in Appendix E If brazing the pot to the cable sheath complete the steps in Appendix E first then proceed t
32. oved will cause the magnesium oxide insulation white powder to absorb moisture lowering the IR The cable must be heated out to remove the moisture and bring the IR back to anacceptable level Drying out the MI cable to remove any moisture will normally be unnecessary providing the termination seal is com pleted within a few minutes of removing the sheath If moisture is found in the cable when checking IR it may be removed using one of the following methods 1 If excess cable is available 6 to 12 in 150 to 300 mm of cable may be removed from the end before sealing the cable 2 Apply heat to the cable following the procedure below r Important Moisture will not normally penetrate more than 12 in 300 mm into the cable If moisture is detected in the cable use an oxy acetylene or mapp gas torch with a large flame and heat out the cable beginning 12 in 300 mm back from the end Gradually stroke toward and past the cable end Pyrotenax Alloy 825 sheath cables should be heated to a dull red color Take care not to over heat any one area of the cable sheath as this could damage the cable Use a short sweeping motion of the torch and heat about 2 in 50 mm of cable at a time repeating 4 to 5 times Stroke the flame towards the cable end as shown in Figure 79 Do not stroke the flame in the opposite direction as this will drive the moisture into the cable Gradually move the flame toward the end 64
33. pposite end has already been terminated with epoxy sealing compound which has not fully cured IR will increase once the epoxy has cured EN PyrotenaxIndustrialWiringCable IM H58121 03 13 Installation r Important If neither cable end has yet been terminated and IR readings are low dry out both ends following the procedure in Appendix D or cut off shorted end and re test Apply a temporary moisture resistant seal such as hot melt glue or adhesive lined heat shrink tubing to opposite cable end to prevent moisture absorption Figure 48 Check insulation resistance 15 Ensure conductors are spaced an equal dis tance apart from each other and the inside of the pot Prepare epoxy sealing compound in accordance with Steps 1 and 2 of the instructions see Appendix B for details Ea Important Use epoxy within 10 minutes after mixing The pot should still be warm following Step 13 if not heat the cable and then the pot with the torch until just warm to the touch before filling with epoxy r Important To avoid forming bubbles in the epoxy do not apply heat to the cable and the pot during or after the pot has been filled with epoxy EN PyrotenaxIndustrialWiringCable IM H58121 03 13 41 2 Installation Insulated stranded wire tails Pot MI Figure 49 Prepare pot for epoxy 16 Cutone corner of plastic package containing epoxy to make an opening of 1 8 in 3 mm Mai
34. re 13 Braze pot to cable sheath while the cable is still hot Ensure silver solder flows all around the pot and sheath by moving the flame around the cable r Important To make a good guality solder joint the silver solder rod must be coated with flux at all times Dip in flux as many times as necessary until brazing operation is complete EN PyrotenaxIndustrialWiringCable IM H58121 03 13 39 Installation E Important Take care when heating the pot since excess heat will cause the solder at the conductor joints to melt A CAUTION Cable will be hot Allow cable to cool until just warm to the touch then continue with the steps following to seal the cable end Oxy acetylene torch Silver solder Silver solder pot to cable sheath Pot Figure 47 Braze pot to cable sheath 14 Using a 500 Vdc megohmmeter check the insu lation resistance IR of the cable to ensure it is free of grounds and shorts Between conductor s and sheath and Between conductor pairs See Appendix C for detailed test procedure and IR test criteria Once IR readings are satisfactory immediately seal the cable end as described in the steps fol lowing A delay will cause the IR to drop and the cable must be retested prior to sealing the end F Important Opposite end of cable must also be dry and free of grounds and shorts to obtain an acceptable IR reading Low IR readings should be expected if the o
35. riate sealing compound as described in the steps following A delay will cause the IR to drop and the cable must be retested prior to sealing the end r Important Opposite end of cable must also be dry and free of grounds and shorts to obtain an acceptable IR reading Low IR readings should be expected if the opposite end has already been terminated with epoxy sealing compound which has not fully cured IR will increase once the epoxy has cured EN PyrotenaxIndustrialWiringCable IM H58121 03 13 2 Installation E Important If neither cable end has yet been terminated and IR readings are low dry out both ends following the procedure in Appendix D or cut off shorted end and re test Apply a temporary moisture resistant seal such as hot melt glue or adhesive lined heat shrink tubing to opposite cable end to prevent moisture absorption Figure 15 Check insulation resistance 13 For kits supplied with mastic sealing compound immediately complete Steps 14 through 19 For kits supplied with epoxy sealing compound immediately complete Steps 14a through 19a 14 Withdraw spacer disk and sleeving sub assem bly slightly to allow sealing compound to be packed in Ensure conductors are spaced an equal dis tance apart from each other and the inside of the pot The pot should still be warm following Step 10 if not heat the cable and then the pot with the torch until just warm to the touch before filling wi
36. step 7 If testing a multi conductor cable pro ceed to step 8 7 Testing is complete If the megohmmeter does not self discharge discharge phase connec tion to ground with a suitable grounding rod Disconnect the megohmmeter 8 If testing a multi conductor cable repeat steps 3 through 5 for remaining conductors 9 Next remove the positive earth lead from the cable sheath and connect it to one of the other conductors Figure 78 10 Test the cable as in steps 3 through 5 11 Repeat for all conductor pair combinations 12 Testing is complete If the megohmmeter does not self discharge discharge phase connec tion to ground with a suitable grounding rod Disconnect the megohmmeter A WARNING Fire hazard in hazardous locations Megohmmeter tests can produce sparks Be sure there are no flammable vapors in the area before performing this test 62 EN PyrotenaxIndustrialWiringCable IM H58121 03 13 4 Appendixes Figure 78 Testing IR between cable sheath and conductors and between conductor pairs EN PyrotenaxlndustrialWiringCable IM H58121 03 13 63 4 Appendixes Appendix D Improving Insulation Resistance r Important Wear a full face shield when drying out the MI cable To maintain the high performance of MI cable the cable must be properly stored and the ends must remain sealed Damaged terminations or heat shrinkable end caps that are damaged missing or rem
37. t Anchoring beads 1 8 in 3 into pot 8 in 3 mml into po Spacer disk Set screws discard after epoxy cures MI cable Gland aed Insulating Thread Epoxy sealing Sleeving Set screw pot compound Figure 3 Completed epoxy sealing compound termination cut away pot shown EN PyrotenaxIndustrialWiringCable IM H58121 03 13 Installation Tools and Materials Reguired Pyrotenax T bar stripping tool Pyrotenax hand vise Pyrotenax crimping and compression tool lif ter minating cable using mastic sealing compound Diagonal side cutters Measuring tape or ruler Hacksaw Flat file Tubing cutter Adjustable pliers vise grips Oxy acetylene or mapp gas torch to dry out cable Permanent marker 500 Vdc megohmmeter Electrical tape if terminating cable using epoxy seal Scribe or pick Medium grit emery paper Loctite 271 or eguivalent permanent thread lock compound Allen wrench set 1 16 3 32 and 1 8 Clean dry cloth Safety glasses Gloves EN PyrotenaxIndustrialWiringCable IM H58121 03 13 2 Installation A CAUTION Wear safety glasses and gloves dur ing the termination procedure 1 With a hacksaw cut the end of the MI cable square and file the end smooth Ensure that the end of the MI cable is straight for approximately the tail length required plus 6 in 150 mm Place a mark on the sheath for the tail length required 12 in 300 mm is standard
38. tag for the other One cable should not be termi nated with the same colored tag at both ends 48 EN PyrotenaxIndustrialWiringCable IM H58121 03 13 2 Installation Ensure conductors are spaced an egual dis tance apart from each other and the inside of the pot Prepare epoxy sealing compound in accordance with Steps 1 and 2 of the instructions see Appendix B for details r Important Use epoxy within 10 minutes after mixing The pot should still be warm following Step 13a if not heat the cable and then the pot with the torch until just warm to the touch before filling with epoxy r Important To avoid forming bubbles in the epoxy do not apply heat to the cable and the pot during or after the pot has been filled with epoxy Insulating sleeving Spacer disk J Anchoring beads Bare stranded wire Pot MI cable Figure 60 Prepare pot for epoxy 16a Cut one corner of the plastic package containing epoxy to make an opening of 1 8 in 3 mm Maintaining cable end vertically squeeze the epoxy into the pot Pour it down one side of the pot until it is completely filled EN PyrotenaxIndustrialWiringCable IM H58121 03 13 49 2 Installation A CAUTION Avoid skin contact with epoxy compound If accidental contact occurs wash skin with mild soap and water Spacer disk Anchoring ry beads MI cable Figure 61 Fill pot with epoxy 17a Slide sleevi
39. ter Braze 560 silver solder or equivalent Prostar silver brazing flux or equivalent Drill press and appropriately sized drill bits required if the pot was not pre drilled at the factory A CAUTION Wear safety glasses and gloves dur ing the termination procedure 1 Prepare bare or insulated stranded wire tails for use later Ifinsulated stranded wire is supplied in the termination kit strip 3 16 to 1 4 in 5 to 6 4 mm of insulation from ends r Important Two tails of the same color are reguired one for each end of each conductor in the cable EN PyrotenaxIndustrialWiringCable IM H58121 03 13 33 Installation Apply flux to one end of a group of conductors Align group along edge of workbench and tin using oxy acetylene torch and silver solder ensuring that a small ball of solder forms on the end of each con ductor If insulated stranded wire is supplied with the kit take care not to melt the insulation Stranded Silver wire tails solder p 7 Oxy acetylene torch Ball of silver solder on end of gt 46 bin conductor s 6 4 mm Figure 36 Tin the ends of the conductors 2 With hacksaw cut the end of the MI cable sguare and file end smooth Make sure face of conductors is completely clean of all foreign material Use emery paper to polish all around surface of cable sheath from end to about 2 in 50 mm back from end sheath must be c
40. th mastic sealing compound Do not allow compound to become contami nated with any foreign matter once package is opened Press mastic sealing compound into EN PyrotenaxlndustrialWiringCable IM H58121 03 13 15 2 Installation pot with thumb behind the wrapper to ensure cleanliness Slightly overfill pot with sealing compound pressing from one side only to pre vent air pockets from forming Sealing com pound will come out the opposite side of the pot when full r Important Store mastic sealing compound at room temperature until ready to use a Figure 16 Pack in sealing compound 15 Using a screwdriver or other tool push spacer disk into open end of the pot ensuring that the anchoring beads on sleeving butt against inside face of the spacer disk Do not push on the sleeving as it may be forced back through the cap and butt against the end of the cable preventing the compound from making an effec tive seal 16 EN PyrotenaxIndustrialWiringCable IM H58121 03 13 2 Installation Mastic sealing compound ae V GE Anchoring bead Figure 17 Push spacer disk into the open end of the pot 16 Place the set screw pot into the body of the crimping and compression tool hand adjustable type shown making sure that the sleeving is inserted through the hole in the crimping plate The spacer disk end of the pot must fit inside the three cone shaped points on the crimping plate
41. tor Crimp connector N er Ne Insulated stranded wire Figure 31 Crimp the connectors 28 EN PyrotenaxIndustrialWiringCable IM H58121 03 13 Installation 2 3 5 Place supplied heat shrink tubing over the crimp connector ensuring the heat shrink over laps the insulating sleeving and the insulated stranded wire tail equally and apply heat to shrink the tubing in place over the connector Take care not to damage the heat shrink insu lating sleeving or insulated stranded wire when applying heat Insulating sleeving Heat shrink tubing ai over crimp connector E Insulated stranded wire Figure 32 Apply heat to shrink tubing 6 Complete the termination at the opposite end following the same procedure if not already done Brazed on Tail Termination Procedure In this procedure the cable end is sealed using the epoxy sealing compound supplied with the termina tion kit The termination kit may be supplied with insulated stranded wire tails or with bare stranded wire tails and insulating sleeving For both termi nations the stranded wire tails are silver soldered brazed to the solid MI conductor and the pot is sil ver soldered to the cable sheath Follow the appro priate steps to complete the termination Figure 33 shows the components of each termina tion kit Visually check the parts supplied with the termination kit to identify which type of tails have been supplied and follo
42. tranded wire prepared in Step 1 to the face of each solid conductor by applying heat to the solid conductor This will draw the solder ball from the stranded con ductor to the solid conductor making a strong joint AK MI cable Figure 53 Braze the conductors 44 EN PyrotenaxIndustrialWiringCable IM H58121 03 13 2 Installation 9a Using a thin strip of emery paper lightly sand around and in between all conductors to remove magnesium oxide powder from solid conductors and any excess flux from brazed joint Avoid contaminating the magnesium oxide pow der in the exposed cable end with metal filings if contaminated remove with a pick gt MI cable Emery paper Figure 54 Remove flux and lightly sand conductors 10a Place a mark at a length E refer to table below from end of sheath TABLE 3 Pot Size Length E to mark 1 2 in 13 mm 5 16 in 8 mm 3 4 in 19 mm 7 16 in 11 mm 1 in 25 mm 9 16 in 14 mm 1 1 4 in 32 mm 5 8 in 16 mm sheath Figure 55 Mark sheath at length E EN PyrotenaxIndustrialWiringCable IM H58121 03 13 45 2 Installation 11a Align back of the pot previously installed with mark Cable end will project approximately 1 8 in 3 mm into the pot E Important Cable end must project 1 8 in 3 mm into the pot in order to make an effective seal Mark Pot Ill Cable end must project 1 8 in 3 mm into pot Fig
43. ure 56 Align back of pot with mark 12a Apply flux to the cable sheath and back of the pot where it meets the cable sheath This pre vents oxidation of the metals during the next step Next remove moisture from cable by heating the last 6 in 150 mm of cable with the oxy acetylene torch Begin 6 in 150 mm back from end and stroke flame towards end see Appendix D for detailed procedure Apply flux around ae sheath and back of the pot Figure 57 Heat cable to remove moisture 46 EN PyrotenaxIndustrialWiringCable IM H58121 03 13 2 Installation 13a Braze pot to cable sheath while the cable is still hot Ensure silver solder flows all around the pot and sheath by moving the flame around the cable r Important To make a good guality solder joint the silver solder rod must be coated with flux at all times Dip in flux as many times as necessary until brazing operation is complete V Important Take care when heating the pot since excess heat will cause the solder at the conductor joints to melt A CAUTION Cable will be hot Allow cable to cool until just warm to the touch then continue with the steps following to seal the cable end Oxy acetylene torch Silver solder Silver solder pot Pot to cable sheath Figure 58 Braze pot to cable sheath 14a Using a 500 Vdc megohmmeter check the insulation resistance IR of the cable to ensure it is free of grounds and shorts Betwe
44. uring that the sheath is flared slightly outwards see Appendix A for detailed instructions Figure 41 Strip cable sheath with side cutters 36 EN PyrotenaxIndustrialWiringCable IM H58121 03 13 2 Installation 7 Ifthe termination kit is supplied with insulated stranded wire tails continue with Step 8 If the termination kit is supplied with bare stranded wire tails and insulating sleeving con tinue with Step 8a 8 Lightly coat only the face of the solid conductor s with flux Do not allow the mag nesium oxide at the end of the cable to become contaminated with flux if contaminated you must cut off 1 2 in 13 mm of cable and start over from Step 2 If one end of the cable has been terminated test the end to end continuity with a continuity tester to ensure that each conductor has the same color stranded wire tails at both ends Next braze the appropriate color insulated stranded wire prepared in Step 1 to the face of each solid conductor by applying heat to the solidconductor This will draw the solder ball from the stranded conductor to the solid con ductor making a strong joint Sn MI cable Lil Brazed joint Insulated stranded wire Figure 42 Braze the conductors 9 Using a thin strip of emery paper lightly sand around and in between all conductors to remove magnesium oxide powder from solid conductors and any excess flux from brazed joint Avoid contaminating the ma
45. w the appropriate steps to terminate the cable EN PyrotenaxIndustrialWiringCable IM H58121 03 13 29 Installation r Important As an alternative to the brazed on pot termination kits may be supplied with set screw pots as shown in Section 2 1 Figure 1 These pots do not have to be silver soldered to the cable sheath To install the set screw pot when using insulated stranded wire tails replace Step 11 Step 12 and Step 13 with Step 8 and Step 10 of Section 2 1 To install the set screw pot when using bare stranded wire tails and insulating sleeving replace Steps 11a 12a and 13a with Step 8 and Step 10 of Section 2 1 30 EN PyrotenaxIndustrialWiringCable IM H58121 03 13 Installation Figure 33a Brazed on tails for insulated stranded wire Insulated stranded wire tails Gland connector Epoxy sealing compound Figure 33b Brazed on tails for bare stranded wire and insulating sleeving Spacer disk and insulating sleeving assembly Gland connector Bare stranded wire tails Epoxy sealing compound Figure 33 Components supplied in brazed on tail termination kits Figure 34 shows the completed termination using insulated stranded wire tails Figure 35 shows the completed termination using bare stranded wire tails and insulating sleeving The epoxy sealing compound must be stored at temperatures between 65 F to 77 F 18 C to 25 C and when used

Pyrotenax IW Cable Termination Manual

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