Cable sheath preparation

• Remove the oversheath to dimensions A+25mm and a+25mm on each cable end.
• Keep the armor and inner sheath intact as shown in Fig.2.
  • For tape-armored cable, follow the instructions in ① of Fig.2.
  • For wire-armored cable, refer to ② of Fig.2.
  • For non-armored cable, remove only the oversheath.
• Overlap the cable cores to be jointed and mark a reference line at the center of the overlap.
• Cut the cables at the reference line without forcing the cable cores apart when aligning.

Copper Shield and Semi-Con Screen Treatment

• Keep the copper tape and semi-con screen intact as shown in Fig.3.
• Bevel the edge of the semi-con screen to ensure a smooth transition to the core insulation.
• Remove the core insulation following dimension L.
• Bevel the core insulation for 30mm and leave 5mm of the inner semi-con layer as shown in Fig.3.

Applying Stress Relief Mastics and Installing Stress Control Tube

• Scrape and clean the surface of the core insulation.
• Wrap stress relief mastic, overlapping 5mm onto both the semi-con screen and the core insulation.
• Apply a thin layer of lubricating grease to the core insulation where the stress control tube will be placed.
• Position the stress control tube over the core insulation and shrink it, ensuring it overlaps the outer semi-con screen by dimension B.

Placing Tubes Over Cable Ends

• Slip the copper mesh onto one end of the cable.
• Slide the set of tubes onto the other cable end in this order:
  1. First, place insulation tube-1.
  2. Next, slide on insulation tube-2.
  3. Finally, add the semi-conductive tube.

Follow Fig.5 for reference. Let me know if you’d like further simplifications!

Installing the Connector

• Insert the conductors into the connector and secure them properly.
• Smooth out any sharp edges and clean off any residues.
• Fill the bolt holes with semi-conductive tape to create a smooth surface.
• Stretch the semi-conductive tape and wrap it around the connector with a half-overlap, continuing onto the conductor screen.
• Press the end of the semi-conductive tape firmly for 5 seconds to ensure it stays in place.

Preparations Pre- Installing for Insulation Tubes

• Apply filling mastic over the semi-conductive tape and onto the tapers. Ensure the mastic is wrapped to match the level of the original insulation.
• Clean the surface of the core insulation thoroughly.
• Wrap stress relief mastic at the connection between the stress control tube and the core insulation, overlapping both the stress control tube and insulation by 5mm.
• Apply a thin layer of lubricating grease over the stress control tube, core insulation, and the connector area.
• Avoid getting grease on the semi-conductive screen.

Installing Insulation Tube-1 and Tube-2

• Place insulation tube-1 so it is centered over the connector area.
• Shrink the tube starting at the center and working towards the ends.
• Position insulation tube-2 over insulation tube-1, centering it properly.
• Shrink insulation tube-2 in the same manner, starting at the center and moving outward.

Wrapping Sealing Mastics

• Wrap sealing mastics around the copper shield cut.
• Continue wrapping the mastics onto the end of insulation tube-2 to ensure a secure seal.

Installing the Semi-Conductive Tube

• Align the semi-conductive tube so it is centered over the joint area.
• Begin shrinking the tube from the center and work towards the ends.
• Wrap semi-conductive tape around both ends of the semi-conductive tube, extending 10mm onto the tube and 10mm onto the copper shield to ensure a secure connection.

Installing Copper Mesh and Earth Wire

• Scrape the copper shield to prepare it for connection.
• Attach the copper mesh and earth wire to the copper shield using constant force springs as shown in the diagram.
• Cover the constant force springs with vinyl tape to protect against sharp edges and burrs.

Note: Leave 10-20mm of the earth wire free and wrap one layer of the constant force spring over it. Bend back the reserved portion and continue wrapping the remaining spring to secure the earth wire.

Inner Sheath Rebuilding (Skip for Non-Armored Cable)

• Fill the gaps between the cable cores using clean cable filler and bind the three cores together.
• Scrape and clean the surface of the inner sheath.
• Wrap sealing mastic around the inner sheath to create a moisture barrier. The barrier should be 20mm wide and 1-2mm thick.
• Place the first protective tube-1 over one inner sheath, ensuring it overlaps the inner sheath, and shrink it into place.
• Wrap sealing mastic around the end of the shrunk tube to reinforce the overlap.
• Position the second protective tube-1 over the other inner sheath, overlap it, and shrink it as well.

Note: Ensure all overlapping areas are cleaned, abraded, and wrapped with sealing mastic for proper sealing.

Securing Armor Earth Wire (Skip for Non-Armored Cable)

• Scrape the armor surface to prepare it for connection.
• Attach the armor earth wire to the armor using constant force springs, with two springs used on each side for wires.
• Cover the constant force springs with vinyl tape to protect against sharp edges and burrs.

Note: Leave 10-20mm of the earth wire free and wrap one layer of the constant force spring over it. Bend back the reserved portion and continue wrapping the remaining spring to firmly secure the earth wire.

Oversheath Rebuilding

• Scrape the oversheath on both sides for 100mm and wrap sealing mastic around each oversheath to create a moisture barrier. The barrier should be 20mm wide and 1-2mm thick.
• Place the first protective tube-2 over one side, overlapping the oversheath by 100mm.
• Shrink the tube into place, starting from the center and working towards the ends.
• Wrap sealing mastic around the end of the shrunk tube to reinforce the overlap.
• Position the second protective tube-2 over the other side, overlapping the oversheath by 100mm.
• Shrink the tube starting from the center and working towards the ends.
• Termination is now completed.

Note: Ensure all overlapping areas are cleaned, abraded, and wrapped with sealing mastic.