IRI-BC2IE-05-EMD



CABLE WIRE & TERMINATIONS

IRI-IE-05MD

EQUIPMENT MAINTENANCE DESCRIPTION

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INDUSTRIAL RESOURCES, INC.

A TRAINING SERVICES COMPANY

©This document is the property of Industrial Resources, Inc. Copies and distribution of this document is prohibited unless written authorization is granted by Industrial Resources, Inc.

PREFACE

This Training Equipment Maintenance Description (EMD) has been designed to assist you in meeting the requirements of the I&E Maintenance Training Program. It contains information about the Cable Wire and Terminations. This includes function, quantity of parts, location of parts, description of the physical construction of the part, and description of the operation of the part, equipment preventive and corrective maintenance, and references.

You should review each chapter objective. In doing so you will be better prepared to learn the required information. You should also inspect the equipment, identifying its components and controls. Should you have additional question about the equipment, ask your supervisor.

A separate document, Cable Wire and Terminations Equipment Maintenance Procedure IRI-IE-05-EMP, covers detailed maintenance of the Cable Wire and Terminations Equipment.

CABLE WIRE AND TERMINATIONS

IRI-IE-05-EMD

TRAINING EQUIPMENT MAINTENANCE DESCRIPTION

TABLE OF CONTENTS

1.0 Introduction 5

1.1 Equipment Function 5

1.2 Equipment Description 5

1.2.1 Cable and Conductor Classification 8

1.2.2 Cable and Conductor Ratings 12

1.2.4 Cable and Conductor Splices 13

1.2.3 Cable and Conductor Terminations 15

1.3 Equipment Connections and Interface 19

2.0 Equipment Major Parts 20

2.1 Cable Termination Equipment 20

2.2 Preparing the Cable for Termination 22

2.3 Attaching the Cable Lug 29

2.4 Cleaning the Cable 30

2.5 Applying Stress Relief Material to the Cable 31

2.6 Positioning and Shrinking the Stress Relief Tube on the Cable 31

2.7 Grounding the Cable Shield 32

2.8 Applying Sealant to the Cable 35

2.9 Placing and Shrinking the HV Tube on the Cable 36

2.10 Completing Outdoor Termination of the Cable 37

3.0 Equipment Preventive and Corrective Maintenance 39

3.1 Cable Termination Preventive Maintenance 39

3.2 Cable Termination Corrective Maintenance 39

List of Figures:

Figure 1 – Conductors

Figure 2 – Solid Conductor

Figure 3 – Stranded Conductor

Figure 4 – Insulated Conductor

Figure 5 – Insulated Conductor with Jacket and Sheath

Figure 6 – Thermal Lug

Figure 7 – Cable and Wire Connectors

Figure 8 – Ring and Spade Terminals

Figure 9 – Typical Wire and Cable Terminators

Figure 10 – Cable and Wire Stripper

Figure 11 – Determining the Required Amount of Insulation Cutback

Figure 12 – Wire Crimper

Figure 13 – Determining the Required Amount of Jacket Cutback

Figure 14 – Insulation Cutback for Cable Shielded with Copper Tape

Figure 15 – Installing Ground Braid on Cable Shielded with Copper Tape

Figure 16 – Insulation Cutback for Cable Shielded with Wire

Figure 17 – Installing the Lug on Wire Shielded Cable

Figure 18 – Insulation Cutback for Cable with UniShield

Figure 19 – Installing Lug for Cable with UniShield

Figure 20 – Insulation Cutback for Cable with Lead Sheath

Figure 21 – Soldering the Ground Braid for Cable With Lead Sheath

Figure 22 – Positioning the Ground Braid for Cable with Lead Sheath

Figure 23 – Applying Red Sealant to Lug Barrel

Figure 24 – Installing the Shim Tube

Figure 25 – Abrading and Cleaning the Cable

Figure 26 – Applying Stress Relief Material to Cable

Figure 27 – Positioning and Shrinking Stress Relief Tube

Figure 28 – Preparing to Ground Cable with Copper Tape or Lead Sheath

Figure 29 – Applying Red Sealant to Cable

Figure 30 – Applying More Red Sealant to Cable

Figure 31 – Preparing to Ground Wire Shield or UniShield

Figure 32 – Cleaning the Jacket for Wire Shield or UniShield

Figure 33 – Continue Wrapping Red Sealant for Wire Shield or UniShield

Figure 34 – Applying Sealant to Cable at Lug

Figure 35 – Applying Sealant to Cable with No Lug

Figure 36 – Placing and Shrinking HV Tube on Cable

Figure 37 – Trimming the HV Tube on Cable

Figure 38 – Positioning Skirt on Cable

Figure 39 – Positioning Skirt for Top Feed Termination

Figure 40 – Adding Extra Skirts on Cable

Figure 41 – Adding Extra Skirts for Top Feed Termination

Tables:

Table 1 – AWG Copper Wire

Table 2 –Ring Terminal Sizes

Table 3 - Cable Termination Kits

References:

Raychem HVT Series Terminations 5-35kV Class

PowerStream Wire Gage and Power Limits

AWG Cable Description – American Wire Gage

Facilities Instruction, Standards, and Techniques Volume 3-3 – “Electrical Connections for Power Circuits” – Facilities Engineering Branch Denver Office Denver, Colorado

1.0 Introduction

Chapter Objectives:

1. State, from memory, the functions of the Cable and Wire Termination equipment.

2. Draw a simplified arrangement of the Cable and Wire Termination equipment.

3. Describe how the Cable and Wire Termination equipment is operated and maintained.

4. List the normal Cable and Wire Termination operating parameters.

1.1 Equipment Function

The function of Cable and Wire Termination is to provide a means of connecting conductors to electrical equipment and completing electrical circuits.

1.2 Equipment Description

A conductor is a metal wire constructed of a material that provides an easy path for the flow of electric current. Almost all materials will conduct electricity, but certain materials, such as copper, aluminum, and silver, are very good conducting materials. Copper is the material that is most commonly used in standard electrical applications.

A cable is a multiple conductor. It is two (2) or more insulated conductors insulated from each other, but bound together by a common covering. The term conductor is used as a general term to identify a single insulated wire. Single conductors may be called cables, and cables may be referred to as conductors.

Conductors can be divided into two (2) categories: bare conductors and insulated conductors. A bare conductor, shown in Figure 1, is a length of bare metal wire. The amount of current a bare conductor can carry is determined by the type of metal it is made of and its size.

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Figure 1 – Conductors

Conductors can be either solid or stranded. A solid conductor, shown in Figure 2, is made of a single strand of wire. A stranded conductor, shown in Figure 3, made up of several strands of wire wound together to form a single conductor. Stranded conductors are easier to manipulate than solid conductors because stranded conductors are more flexible.

An insulated conductor is either a solid or stranded bare conductor that is surrounded with insulating material, as shown in Figure 4. Insulating materials are materials that offer high resistance to current flow, such as glass, rubber, and plastic. Each of these materials is a poor conductor.

The insulation around a conductor provides both electrical protection and mechanical protection. Insulation helps to keep the current flow within its boundaries, thereby affording electrical protection. It also helps to prevent the metal portion of the conductor from mechanical damage such as nicks or scrapes.

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Figure 2 - Solid Conductor

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Figure 3 - Stranded Conductor

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Figure 4 - Insulated Conductor

Figure 5 shows an insulated conductor with two (2) additional layers, a jacket and a sheath. The first layer of insulation around this conductor is made of rubber, a common insulating material. A conductor might need additional mechanical protection due to special circumstances. Some conductors need extra protection when being pulled through conduit. In that case, it might be necessary to use a conductor that is covered with a jacket. A jacket covers the primary, or initial, layer of insulation. Jackets are commonly made of hard plastic material that provides additional mechanical protection. A sheath is sometimes placed over a jacket to provide additional mechanical protection. A sheath might be used on a conductor that is designed for direct burial in the earth.

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Figure 5 - Insulated Conductor with Jacket and Sheath

1.2.1 Cable and Conductor Classification

The classification of cables and conductors is based on two (2) factors: the size of the metal wire and the type of insulation surrounding the wire. Systems have been developed within the industry to classify cables and conductors by trade size and by insulation type.

Wire Size

The "trade" size of a cable or conductor is the standard size of the wire as recognized in the electrical industry. There are two (2) systems used to express the size of a metal wire: the American Wire Gauge (AWG) system and the circular mil system.

Most of the wires used in routine electrical work are sized according to the AWG system. The sizes range from number 40, which is the smallest size in the system, to number 4/0 (four (4) ought), which is the largest size. As the AWG number decreases from 50, the actual size of the conductor increases. Therefore, a number one (1) AWG conductor is a great deal larger than a number 50 AWG conductor. The four (4) largest sizes in the AWG system are the ought sizes from one ought (1/0 or 0), which is the smallest, to four (4) ought (4/0 or 0000), which is the largest.

Table 1 shows the various AWG wire gages as well as the Diameter [in mils], the resistance per 1000 foot, the current carrying capability [Ampacity], and Pounds per Foot [number of feet required to weigh 1 pound].

|Table 1 - AWG Copper Wire |

|AWG |Diam. |Circular mils |Ohms/1000ft |

| |(mils) | | |

|22-18 |6 |100 |83-6111 |

| |8 |100 |83-6121 |

|16-14 |8 |100 |83-6161 |

| |10 |100 |83-6171 |

| |10 |1000 |84-6171 |

|12-10 |8 |50 |83-6211 |

| |10 |50 |83-6221 |

| |1/4 |50 |83-6231 |

Ring terminals, shown in Figure 8, are typically the best choice unless the terminal screw is captive. In that case, use flanged spade connectors. Figure 9 shows typical wire terminators.

Use butt connectors for applications where the equipment is supplied with wire leads instead of terminals. Step-down butt connectors let you connect heavy supply wires to lighter leads. To simplify servicing, it can be a good idea to make the connection with blade or snap connectors instead of butt connectors. Three-way connectors are useful for tapping into an existing circuit.

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Figure 8 - Ring and Spade Terminals

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Figure 9 - Typical Wire and Cable Terminators

For larger cable sizes and voltage ratings (5kV and up) the proper cable termination kit must be used for the particular cable being terminated. A list of cable types and the appropriate kit to use are listed in Table 3. When using any termination procedure and kit, several steps are necessary. These steps are:

1. Gathering the required tools for termination of the specific cable

2. Determining the amount of insulation cutback required

3. Installing the lug, if used

4. Abrading and cleaning the end of the cable

5. Applying stress relief material (SRM) to the cable

6. Grounding the cable insulation

7. Applying sealant to the end of the cable

8. Positioning and shrinking the HV tube

9. Trimming the HV tube

10. Applying skirt(s) for outdoor termination

Not all of these steps are require for all types on terminations and cable sizes. Proper performance of these steps is described in detail in section 2.0 of this system description.

Table 3 - Cable Termination Kits

|Kit |Voltage |Conductor |Max./Min. Insulation Diameter |Max. Jacket Diameter |

| | |Size | | |

| | | |(inches) |(mm) |(inches) |(mm) |

|HVT-80-G(SG) |5 kV |#4-#1 AWG |0.35 – 0.60 |9 - 15 |0.95 |24 |

|HVT-81-G(SG) | |1/0-250 kcmil |0.60 – 0.95 |15 - 24 |1.20 |30 |

|HVT-82-G(SG) | |300-500 kcmil |0.80 – 1.25 |20 - 32 |1.50 |38 |

|HVT-83-G(SG) | |600-1750 kcmil |1.10 – 1.75 |28 - 44 |2.10 |53 |

|HVT-84-G(SG) | |1500-2500 kcmil |1.60 – 2.45 |41 - 62 |2.75 |70 |

|HVT-80-G(SG) |8 kV |#6-#2 AWG |0.35 – 0.60 |9 - 15 |0.95 |24 |

|HVT-81-G(SG) | |#1-4/0 AWG |0.60 – 0.95 |15 - 24 |1.20 |30 |

|HVT-82-G(SG) | |250-500 kcmil |0.80 – 1.25 |20 - 32 |1.50 |38 |

|HVT-83-G(SG) | |600-1750 kcmil |1.10 – 1.75 |28 - 44 |2.10 |53 |

|HVT-84-G(SG) | |2000-2500 kcmil |1.60 – 2.45 |41 - 62 |2.75 |70 |

|HVT-151-G(SG) |15 kV |#4-1/0 AWG |0.60 – 0.95 |15 - 24 |1.20 |30 |

|HVT-152-G(SG) | |2/0-350 kcmil |0.80 – 1.25 |20 - 32 |1.50 |38 |

|HVT-153-G(SG) | |400-1000 kcmil |1.10 – 1.65 |28 - 42 |2.10 |53 |

|HVT-154-G(SG) | |1250-2500 kcmil |1.60 – 2.45 |41 - 62 |2.75 |70 |

|HVT-252-G(SG) |25 kV |#2-250 AWG |0.80 – 1.25 |20 - 32 |1.50 |38 |

|HVT-253-G(SG) | |300-750 kcmil |1.10 – 1.65 |28 - 42 |2.10 |53 |

|HVT-254-G(SG) | |1000-1750 kcmil |1.60 – 2.45 |41 - 62 |2.75 |70 |

|HVT-255-G(SG) | |2000-2500 kcmil |2.05 – 3.30 |52 - 84 |3.45 |88 |

|HVT-352-G(SG) |35 kV |#1-1/0 AWG |0.80 – 1.25 |20 - 32 |1.50 |38 |

|HVT-353-G(SG) | |2/0-500 kcmil |1.10 – 1.65 |28 - 42 |2.10 |53 |

|HVT-354-G(SG) | |750-1750 kcmil |1.60 – 2.45 |41 - 62 |2.75 |70 |

|HVT-355-G(SG) | |2000-2500 kcmil |2.05 – 3.30 |52 - 84 |3.45 |88 |

5 Equipment Connections and Interface

Cable and Wire Termination do not require the use of instrumentation.

2.0 Equipment Major Parts

Chapter Objectives:

1. Describe how the equipment parts perform their function:

2. Draw from memory a diagram of the equipment showing major parts

3. State from memory, the names and functions of the major parts

4. Describe the location of the major parts

2.1 Cable Termination Equipment

In order to properly terminate cables, the proper installation equipment must be used. Installation equipment includes:

1. Termination kit (5 kV and up)

2. Cable preparation tools

3. Cable preparation kit or approved solvent

4. Clean, lint-free cloths

5. Non-conducting abrasive cloth (120 grit or finer)

6. Electrician’s tape

7. Connector(s) and installation tools

8. Approved Torch (if required)

The specific equipment used depends upon the size and application of the cable being terminated. For small wire sizes and voltages, the typical equipment would require the following

1. Cable Stripper

2. Crimping tool

3. Electrical tape

For higher voltage applications, a typical termination kit contains:

1. One (1) non-tracking tube (red)

2. One (1) stress control tube (black)

3. Two (2) mastic strips (red)

4. One (1) angle-cut mastic strip (yellow)

5. One (1) ground clamp spring

6. One (1) solder-blocked braid

7. One (1) copper-backed tape strip

8. One (1) short shim tube (25 & 35 kV only) (red)

9. Heat shrinkable skirts

a. One (1) for 8 kV

b. Two (2) for 15 kV

c. Three (3) for 25 kV

d. Four (4) for 35 kV

10. One (1) set of installation instructions

Torch must be “clean-burning”, meaning that the torch does not deposit conductive contaminants on the cable. Examples of clean-burning torches are Raychem FH-2629 (using refillable propane cylinders) and Raychem FH-2616A1 (using disposable propane cylinders).

Adjust the torch when preparing the cable and terminating it by doing the following:

1. Adjust regulator and torch as required to provide an overall flame that is 12-inches long and “bushy”.

2. Raychem FH-2629 will have a blue flame.

3. All other torches will have a yellow tip that is 3 to 4 inches long.

4. Use the yellow tip for shrinking.

5. Regulator pressure for Raychem FH-2629 is 15 psig and for Raychem FH-2616A1 is full pressure.

To properly use the torch on the cable, do the following:

1. Use the 3-inch to 4-inch torch flame tip in a rapid brushing motion.

2. Keep the flame moving to avoid scorching.

3. Unless otherwise instructed, start shrinking the tube at its center, working the flame along all sides of the tube in order to apply heat uniformly.

4. When installing multiple tubes, make sure that the surface of the last tube is still warm before positioning and shrinking the next tube. If the installed tube has cooled, reheat the entire surface.

To determine if a tube has fully recovered from shrinking, check the following, especially on the back and underside of the tube:

1. Uniform wall thickness

2. Conformance to substrate

3. No flat spots

4. No chill marks

5. Visible sealant flow (if the tube is coated)

8 Preparing the Cable for Termination

To prepare the cable, select the cable type to determine the amount of insulation cutback required on the cable to properly prepare it. For small unshielded cable and wire sizes and low voltage applications (less than 5 kV), uses an insulation stripping tool, as shown in Figure 10.

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Figure 10 - Cable and Wire Stripper

Remove only enough insulation for the wire to reach the end of the barrel of the terminal, as shown in Figure 11.

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Figure 11 - Determining the Required Amount of Insulation Cutback

A crimping tool is required for all mechanical terminations. Never use pliers to attempt to crimp cable and wire terminals. A simple crimper, as shown in Figure 12, can be used for crimping the terminals on small cable and wire. For larger cable and wire, a ratcheting industrial grade crimper is required.

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Figure 12 – Wire Crimper

Grip the terminal in the correct die in the crimper, fully insert the wire into the terminal, and squeeze. If the barrel has a seam, the crimp indent should be opposite.

Some terminals feature a sleeve that can be crimped over the insulated wire to add mechanical strength. This type of terminal is usually installed with a double crimp tool. If your crimper doesn't have a double-crimp die, crimp the terminal to the wire first, then reposition the crimper and crimp the sleeve to the insulation.

There is only one (1) accepted field test for a crimp terminal. Pull on it. Test every crimp terminal using this method. Without using any tool, grip the terminal and the wire and try to separate them. If they come apart, the crimp was bad. Cut off the end of the wire to remove it from the terminal. Strip the insulation, install and new terminal, crimp the terminal to the wire, and test the crimp.

Use Table 3 to determine which termination kit should be used for higher voltage (5 kV and up) cable terminations.

To prepare the cable, select the cable type to determine the amount of insulation cutback required on the cable to properly prepare it. Use Figure 13 to determine the jacket cutback.

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Figure 13 - Determining the Required Amount of Jacket Cutback

Then use A + Z to determine the exact amount of cutback required. The “A” values to use with a cable on which a lug is be used for termination are:

1. If 5 kV or 8 kV, use A of 6.50 inches.

2. If 15 kV, use A of 11 inches.

3. If 25 kV, use A of 22 inches.

4. If 35 kV, use A or 29 inches.

If no lug is used, choose Z as 2 inches.

Then determine what type of cable shielding is used. The types include:

1. Cable shielded with copper tape

2. Cable shielded with wire

3. Cable has UniShield

4. Cable shielded with lead

The exact method used to prepare the cable depends upon the type.

Copper Tape Shield

If the cable is shielded with copper tape, use Figure 14 to cut back the insulation:

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Figure 14 - Insulation Cutback for Cable Shielded with Copper Tape

Install the ground braid by doing the following, as shown in Figure 15:

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Figure 15 - Installing Ground Braid on Cable Shielded with Copper Tape

1. Flare the moisture-blocked end of the ground braid and place it onto the metallic tape butted up to the cable jacket.

2. Attach the braid to the shield by placing two (2) wraps of the field clamp over the braid.

3. Fold the braid back over the spring clamp wraps.

Wire Shield

If the cable is shielded with wire, use Figure 16 to cut back the insulation:

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Figure 16 - Insulation Cutback for Cable Shielded with Wire

If a lug is to be used, install the lug and then clean and deburr the lug as shown in Figure 17.

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Figure 17 - Installing the Lug on Wire Shielded Cable

If the step between the lug barrel and the insulation is greater than 1/8-inch (3 mm), taper (chamfer) the insulation to meet the lug barrel. Conventional penciling is not required.

UniShield

If the cable has a UniShield, use Figure 18 to cut back the insulation.

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Figure 18 - Insulation Cutback for Cable with UniShield

If a lug is to be used, install the lug and then clean and deburr the lug as shown in Figure 19.

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Figure 19 - Installing Lug for Cable with UniShield

If the step between the lug barrel and the insulation is greater than 1/8-inch (3 mm), taper (chamfer) the insulation to meet the lug barrel. Conventional penciling is not required.

Lead Sheath

If the cable has a lead sheath, use Figure 20 to cut back the insulation:

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Figure 20 - Insulation Cutback for Cable with Lead Sheath

Butt the end of the braid up against the cable jacket as shown in Figure 21 and solder to the lead sheath.

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Figure 21 - Soldering the Ground Braid for Cable with Lead Sheath

Bend the braid back over the cable jacket so that the braid solder block is positioned as shown in Figure 22.

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Figure 22 - Positioning the Ground Braid for Cable with Lead Sheath

2.3 Attaching the Cable Lug

If voltage is 25 kV or 35 kv, this step is required. For lower voltage, the following requirements are not necessary.

Apply red sealant on lug barrel, as shown in Figure 23. Using light tension, wrap two (2) layers of red sealant around the lug barrel.

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Figure 23 - Applying Red Sealant to Lug Barrel

To install the shim, place the shim tube over the end of the red sealant, butted against the insulation. Use Figure 24. Shrink into place. Apply heat in a smooth, brushing motion.

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Figure 24 - Installing the Shim Tube

2.4 Cleaning the Cable

Abrade the insulation, if necessary, to remove imbedded semi-con, as shown in Figure 25.

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Figure 25 - Abrading and Cleaning the Cable

Using an oil-free solvent, clean the cable. (A copper-tape cable is shown in Figure 25 as an example. Any cable can be used.)

2.5 Applying Stress Relief Material to the Cable

Apply stress relief material (SRM) at the semi-con cutback, as shown in Figure 26. Begin by removing backings from the short angle-cut piece of SRM.

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Figure 26 - Applying Stress Relief Material to Cable

Place the tip of the SRM at the semi-con cutback and stretch to one-half of its original width. Tightly wrap three (3) to four (4) layers to fill the semi-con step. Overlap semi-con and insulation. Taper the SRM down to meet insulation. If using UniShield cable, apply the SRM as shown to fill the conductive jacket step.

2.6 Positioning and Shrinking the Stress Relief Tube on the Cable

Position black stress control tube and shrink into place by doing the following on the cable, as shown in Figure 27. Position the black stress control tube 1-inch (25 mm) from the jacket cutback (or wire whipback).

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Figure 27 - Positioning and Shrinking Stress Relief Tube

Begin shrinking at the ground end and work the torch with a smooth brushing motion around the tube toward the lug end.

2.7 Grounding the Cable Shield

Complete grounding for the type of cable being terminated. If the cable has a copper tape shield or a lead shield, prepare for grounding by doing the following as shown in Figure 28:

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Figure 28 - Preparing to Ground Cable with Copper Tape or Lead Sheath

Lift the ground braid away from the cable jacket. Using an oil-free solvent, clean the jacket for 2½ inches (60 mm) below the jacket cutback point.

Remove the backing from the red sealant. Using light tension, wrap two (2) layers of red sealant onto the jacket under the braid, as shown in Figure 29.

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Figure 29 - Applying Red Sealant to Cable

Lay the braid back over the jacket and press the moisture blocked section of braid into the red sealant. Using light tension, wrap two (2) more layers of red sealant over the braid and first two (2) layers of sealant, as shown in Figure 30.

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Figure 30 - Applying More Red Sealant to Cable

If the cable has a wire shield or is a UniShield cable, use the following method to prepare to ground the shield.

Lift the drain wires away from the cable jacket. Using an oil-free solvent, clean the jacket as shown in Figure 31.

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Figure 31 - Preparing to Ground Wire Shield or UniShield

Remove the backing from the red sealant. Using light tension, wrap two (2) layers of red sealant onto the jacket under the drain wires, as shown in Figure 32.

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Figure 32 - Cleaning the Jacket for Wire Shield or UniShield

Lay the drain wires evenly back over the jacket and press them into the red sealant. Using light tension, wrap two (2) more layers of red sealant over the braid and the first two (2) layers of sealant, as shown in Figure 33.

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Figure 33 - Continue Wrapping Red Sealant for Wire Shield or UniShield

Discard the spring clamp, braid, and foil tape.

2.8 Applying Sealant to the Cable

Apply red sealant to the Cable. If there is a lug (or lug and shim) on the end of the cable, using light tension, wrap red sealant on the lug barrel (or over the shim). Build up the lug diameter to the cable insulation and overlay the insulation by ½-inch (10 mm), as shown in Figure 34.

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Figure 34 - Applying Sealant to Cable at Lug

If there is no lug on the cable, wrap two (2) layers of red sealant onto the cable insulation, as shown in Figure 35. Note: the sealant will not prevent water ingress between the strands.

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Figure 35 - Applying Sealant to Cable with No Lug

2.9 Placing and Shrinking the HV Tube on the Cable

Position the red HV tube and shrink into place. Position the HV tube at the bottom edge of the red sealant on the jacket. Begin shrinking at the ground end and work toward the lug, as shown in Figure 36.

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Figure 36 - Placing and Shrinking HV Tube on Cable

If the cable has a wire shield or is a UniShield cable, twist the drain wires to make a ground lead.

Then trim the HV tube, as shown in Figure 37. Allow the tube to cool enough to touch before proceeding.

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Figure 37 - Trimming the HV Tube on Cable

If necessary, trim excess tubing from the lug area as shown. Inspect the installation. Reheat any flat spots or wrinkles.

If the termination is indoors, termination is complete.

2.10 Completing Outdoor Termination of the Cable

If the termination is outdoors, position the skirt and shrink into place, as shown in Figures 38 and Figure 39.

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Figure 38 - Positioning Skirt on Cable

Position the first skirt as shown in Figure 38 and shrink into place. Hold the edge of the skirt lightly with pliers. Brush the flame tip around the outside of the skirt collar. Only the collar will shrink.

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Figure 39 - Positioning Skirt for Top Feed Termination

If the termination is outdoors, position additional skirts, if needed. For 5 kV and 8 kV, only one (1) skirt is needed. If the termination is for 15 kV, two (2) skirts are required. If the termination is for 25 kV, three (3) skirts are required. If the termination is for 35 kV, four (4) skirts are required.

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Figure 40 - Adding Extra Skirts on Cable

Figure 28 -

Position the remaining skirts, facing the skirts in the same direction as the first skirt, as shown in Figure 40 and Figure 41.

Shrink the skirt(s) into place.

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Figure 41 - Adding Extra Skirts for Top Feed Termination

Check that the skirts have been evenly shrunk and appear symmetrical, with no tilt or sag.

3.0 Equipment Preventive and Corrective Maintenance

3.1 Cable Termination Preventive Maintenance

Preventive maintenance on the cables is limited to visual inspection.

3.2 Cable Termination Corrective Maintenance

Corrective maintenance is not performed except through specific procedures, preferably with the advice and assistance of the relay manufacturer.

CABLE AND WIRE TERMINATIONS

IRI-IE-05–EMP

TRAINING EQUIPMENT MAINTENANCE PROCEDURE

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INDUSTRIAL RESOURCES, INC.

A TRAINING SERVICES COMPANY

August 24, 2005

©This document is the property of Industrial Resources, Inc. Copies and distribution of this document is prohibited unless written authorization is granted by Industrial Resources, Inc.

PREFACE

This Training Equipment Maintenance Training Procedure (EMP) has been designed to assist you in meeting the requirements of Module IRI-IE-05 of the I&E Section Training Program. It contains information pertaining to maintenance of the Cable and Wire Termination. This includes purpose, precautions, limits and setpoints, procedures and references for maintaining equipment.

You should also inspect the equipment, identifying its components and controls. Should you have additional question about the equipment maintenance, ask your supervisor.

CABLE AND WIRE TERMINATION

IRI-IE-05–EMP

TRAINING EQUIPMENT MAINTENANCE PROCEDURE

TABLE OF CONTENTS

I. Purpose 3

II. Precautions, Limitations, and Setpoints 3

III. Procedure 3

A. Operating Procedure 3

B. Preventive Maintenance 12

C. Corrective Maintenance 12

Purpose

This procedure provides information and guidance for the correct and safe use and maintenance of the Cable and Wire Terminations.

Precautions, Limitations, and Setpoints

A. When installing electrical power system accessories, failure to follow applicable personal safety replacements and written installation instructions could result in fire or explosion and serious or fatal injuries.

B. To avoid risk of accidental fire or explosion when using gas torches, always check all connections for leaks before igniting the torch and follow the torch manufacturer’s safety instructions.

C. To minimize any effect of fumes produced during installation, always provide good ventilation of confined workspaces.

D. The torch used for cable splicing and termination must be “clean-burning”, meaning that the torch does not deposit conductive contaminants on the cable.

Procedure

The following procedures provide detailed instructions for splicing and terminating cables and wires.

A. Terminating Cable and Wire

Preparing to Splice or Terminate Cable

1. Determine the exact size and type of cable.

2. Select the proper termination kit for the cable. (Only on large high voltage cable)

3. Verify that all required contents of the kit are in the kit.

4. Verify that the following equipment is available:

a. Cable preparation tools

b. Cable preparation kit or approved solvent

c. Clean, lint-free cloths

d. Non-conducting abrasive cloth (120 grit or finer)

e. Electrician’s tape

f. Connector(s) and installation tools

g. Approved Torch for heat shrink

5. Determine the exact amount of insulation cutback required for the type of cable being spliced or terminated.

6. If the cable is unshielded, small, and low voltage, do the following to prepare the cable/wire.

a. Remove the required amount of insulation with a wire stripper.

b. Remove enough insulation for the wire to reach the end of the barrel of the terminal.

7. Grip the terminal in the correct die in the crimper.

8. Fully insert the wire into the terminal and squeeze.

9. If the terminal contains a sleeve, reposition the crimper and crimp the sleeve to the insulation.

10. Test the condition of the crimp by trying to pull the wire from the terminal using normal hand force.

11. If the wire pulls loose from the terminal, cut the terminal off the wire and repeat steps 6 through 10.

12. If the cable is shielded with copper tape, do the following to prepare the cable:

a. Cut back the required amount of insulation.

b. Flare the moisture blocked end of the ground braid.

c. Place the braid onto the metallic tape butted up to the cable jacket.

d. Attach the braid to the shield by placing two wraps of the field clamp over the braid.

e. Fold the braid back over the spring clamp wraps.

13. If the cable is shielded with wire, do the following to prepare the cable:

a. Cut back the required amount of insulation.

b. If a lug is to be used, install the lug and then clean and deburr the lug.

c. If the step between the lug barrel and the insulation is greater than 1/8-inch (3 mm), taper (chamfer) the insulation to meet the lug barrel. Conventional penciling is not required.

14. If the cable is a UniShield cable, do the following to prepare the cable:

a. Cut back the required amount of insulation.

b. If a lug is to be used, install the lug and then clean and deburr the lug.

c. If the step between the lug barrel and the insulation is greater than 1/8-inch (3 mm), taper (chamfer) the insulation to meet the lug barrel. Conventional penciling is not required.

15. If the cable is shielded with lead, do the following to prepare the cable:

a. Cut back the required amount of insulation.

b. Butt the end of the braid up against the cable jacket.

c. Solder the braid to the lead sheath.

d. Bend the braid back over the cable jacket.

16. If the cable is to be used in 25 kV or 35 kV application, attach the lug by doing the following:

a. Apply red sealant on lug barrel. Using light tension, wrap two layers of red sealant around the lug barrel.

b. Place the shim tube over the end of the red sealant, butted against the insulation.

c. Shrink into place. Apply heat in a smooth, brushing motion.

17. Abrade the cable insulation, if necessary, to remove imbedded semi-con.

18. Using an oil-free solvent, clean the cable.

Applying Stress Relief Material (SRM) to Cable

1. Apply stress relief material (SRM) at semi-con cutback.

a. Remove backings from the short angle-cut piece of SRM.

b. Place the tip of the SRM at the semi-con cutback and stretch to one-half of its original width.

c. Tightly wrap 3 to 4 layers to fill the semi-con step.

d. Overlap semi-con and insulation.

e. Taper the SRM down to meet insulation.

f. If using UniShield cable, apply the SRM to fill the conductive jacket step.

g. Position black stress control tube and shrink into place.

h. Position the black stress control tube 1 inch (25 mm) from the jacket cutback (or wire whipback).

i. Begin shrinking at the ground end and work the torch with a smooth brushing motion around the tube toward the lug end.

Complete Grounding of Cable Shielding

1. If the cable has a copper tape shield or a lead shield, do the following:

a. Lift the ground braid away from the cable jacket.

b. Using an oil-free solvent, clean the jacket for 2-1/2 inches (60 mm) below the jacket cutback point.

c. Remove the backing from the red sealant.

d. Using light tension, wrap two layers of red sealant onto the jacket under the braid.

e. Lay the braid back over the jacket and press the moisture blocked section of braid into the red sealant.

f. Using light tension, wrap two more layers of red sealant over the braid and first two layers of sealant.

2. If the cable has a wire shield or is a UniShield cable, do the following:

a. Lift the drain wires away from the cable jacket.

b. Using an oil-free solvent, clean the jacket.

c. Remove the backing from the red sealant.

d. Using light tension, wrap two layers of red sealant onto the jacket under the drain wires.

e. Lay the drain wires evenly back over the jacket and press them into the red sealant.

f. Using light tension, wrap two more layers of red sealant over the braid and the first two layers of sealant.

g. Discard the spring clamp, braid, and foil tape.

Placing the HV Tube on the Cable

1. Apply red sealant to the cable by doing the following:

a. If there is a lug (or lug and shim) on the end of the cable, using light tension, wrap red sealant on the lug barrel (or over the shim).

b. Build up the lug diameter to the cable insulation and overlay the insulation by ½-inch (10 mm).

c. If there is no lug on the cable, wrap two layers of red sealant onto the cable insulation.

NOTE: the sealant will not prevent water ingress between the strands.

2. Position the red HV tube and shrink into place:

a. Position the HV tube at the bottom edge of the red sealant on the jacket.

b. Begin shrinking at the ground end and work toward the lug.

c. If the cable has a wire shield or is a UniShield cable, twist the drain wires to make a ground lead.

3. Trim the HV tube, after allowing the tube to cool enough to touch:

a. If necessary, trim excess tubing from the lug area.

b. Inspect the installation.

c. Reheat any flat spots or wrinkles.

d. If the termination is indoors, termination is complete.

Outdoor Cable Termination

1. Position the skirt and shrink into place:

a. Place the first skirt in the proper position on the cable.

b. Hold the edge of the skirt lightly with pliers.

c. Brush the flame tip around the outside of the skirt collar. Only the collar will shrink.

d. Position additional skirts, if needed:

e. For 5 kV and 8 kV, only one skirt is needed.

f. If the termination is for 15 kV, two (2) skirts are required.

g. If the termination is for 25 kV, three (3) skirts are required.

h. If the termination is for 35 kV, four (4) skirts are required.

i. Position the remaining skirts, facing the skirts in the same direction as the first skirt.

j. Shrink the skirt(s) into place.

k. Check that the skirts have been evenly shrunk and appear symmetrical, with no tilt or sag.

B. Preventive Maintenance

1. Except for periodic inspection, no preventive maintenance is required for cable splicing and termination.

C. Corrective Maintenance

1. No corrective maintenance is required for cable splicing and termination.

I&E Technician IRI-IE-05-JDC

Performance Measure: Cable and Wire Termination

Name: __________________________________

All Parts Satisfactorily Completed:

________________________________________ ____________________

(Supervisor’s Signature) (Date)

Supervisor’s Comments: __________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

References:

• Training Module IRI-IE-05

Materials Needed:

• Pencil and Clipboard

• Equipment Maintenance Description – Cable and Wire Termination IRI-IE-05-EMD

• Equipment Maintenance Procedure – Cable and Wire Termination IRI-IE-05-EMP

• Associated Maintenance Checklist, Charts, Parts List, Technical Manuals

Safety/Environmental:

• Wear hard hats, safety glasses, safety toe shoe, and ear plugs as required.

• Discuss environmental hazards associated with performing maintenance of the equipment.

• Discuss any safety precaution that must be observed while performing the procedure.

Note: Always observe all plant safety rules in accordance with Safety and Health Procedures and all Federal, State and/or Local OSHA Standards.

Part A: Locate Equipment

Locate and identify the following equipment and major components.

1. Types of cables used in distribution

2. Contents of a termination kit

3. Equipment used for cable termination

4. Types of torches that may be used

Satisfactorily Completed ____________________________

Part B: Controls/Breakers

Locate and identify the following isolation devices.

1. Power Supply/Circuit Breaker for circuit being spliced or terminated.

Satisfactorily Completed _________________________

Part C: Preparation for Maintenance

This is to be performed under direction of the Supervisor.

Demonstrate the following preparation for Cable and Wire Termination.

1. Determine the exact size and type of cable.

2. Select the proper termination kit for the cable. (Only on large high voltage cable)

3. Verify that all required contents of the kit are in the kit.

4. Verify that all the required equipment is available.

5. Isolate the power supply or breaker supplying power to the circuit being terminated.

Satisfactorily Completed __________________________

Part D: Operating Procedure

This is to be performed under direction of the Supervisor.

Demonstrate the following operational steps for the safe and efficient operation of the Cable and Wire Termination.

Low Voltage Unshielded Cable and Wire

19. Determine the exact amount of insulation cutback required for the type of cable being spliced or terminated.

20. Remove the required amount of insulation with a wire stripper.

21. Remove enough insulation for the wire to reach the end of the barrel of the terminal.

22. Grip the terminal in the correct die in the crimper.

23. Fully insert the wire into the terminal and squeeze.

24. If the terminal contains a sleeve, reposition the crimper and crimp the sleeve to the insulation.

25. Test the condition of the crimp by trying to pull the wire from the terminal using normal hand force.

26. If the wire pulls loose from the terminal, cut the terminal off the wire and repeat steps 1 through 7.

Cable Shielded with Copper Tape

1. Cut back the required amount of insulation.

2. Flare the moisture blocked end of the ground braid.

3. Place the braid onto the metallic tape butted up to the cable jacket.

4. Attach the braid to the shield by placing two wraps of the field clamp over the braid.

5. Fold the braid back over the spring clamp wraps.

Cable Shielded with Wire

1. Cut back the required amount of insulation.

2. If a lug is to be used, install the lug and then clean and deburr the lug.

3. If the step between the lug barrel and the insulation is greater than 1/8-inch (3 mm), taper (chamfer) the insulation to meet the lug barrel. Conventional penciling is not required.

(Continued on next page.)

Part D: Operating Procedure (Continued)

UniShield Cable

1. Cut back the required amount of insulation.

2. If a lug is to be used, install the lug and then clean and deburr the lug.

3. If the step between the lug barrel and the insulation is greater than 1/8-inch (3 mm), taper (chamfer) the insulation to meet the lug barrel. Conventional penciling is not required.

Cable Shielded with Lead

1. Cut back the required amount of insulation.

2. Butt the end of the braid up against the cable jacket.

3. Solder the braid to the lead sheath.

4. Bend the braid back over the cable jacket.

25 kV or 35 kV Application

1. Apply red sealant on lug barrel. Using light tension, wrap two layers of red sealant around the lug barrel.

2. Place the shim tube over the end of the red sealant, butted against the insulation.

3. Shrink into place. Apply heat in a smooth, brushing motion.

4. Abrade the cable insulation, if necessary, to remove imbedded semi-con.

5. Using an oil-free solvent, clean the cable.

Applying Stress Relief Material (SRM) to Cable

2. Apply stress relief material (SRM) at semi-con cutback.

3. Remove backings from the short angle-cut piece of SRM.

4. Place the tip of the SRM at the semi-con cutback and stretch to one-half of its original width.

5. Tightly wrap 3 to 4 layers to fill the semi-con step.

6. Overlap semi-con and insulation.

7. Taper the SRM down to meet insulation.

8. If using UniShield cable, apply the SRM to fill the conductive jacket step.

9. Position black stress control tube and shrink into place.

10. Position the black stress control tube 1 inch (25 mm) from the jacket cutback (or wire whipback).

11. Begin shrinking at the ground end and work the torch with a smooth brushing motion around the tube toward the lug end.

(Continued on next page.)

Part D: Operating Procedure (Continued)

Complete Grounding of Cable Shielding

1. If the cable has a copper tape shield or a lead shield, do the following:

2. Lift the ground braid away from the cable jacket.

3. Using an oil-free solvent, clean the jacket for 2-1/2 inches (60 mm) below the jacket cutback point.

4. Remove the backing from the red sealant.

5. Using light tension, wrap two layers of red sealant onto the jacket under the braid.

6. Lay the braid back over the jacket and press the moisture blocked section of braid into the red sealant.

7. Using light tension, wrap two more layers of red sealant over the braid and first two layers of sealant.

8. If the cable has a wire shield or is a UniShield cable, do the following:

9. Lift the drain wires away from the cable jacket.

10. Using an oil-free solvent, clean the jacket.

11. Remove the backing from the red sealant.

12. Using light tension, wrap two layers of red sealant onto the jacket under the drain wires.

13. Lay the drain wires evenly back over the jacket and press them into the red sealant.

14. Using light tension, wrap two more layers of red sealant over the braid and the first two layers of sealant.

15. Discard the spring clamp, braid, and foil tape.

Placing the HV Tube on the Cable

1. Apply red sealant to the cable by doing the following:

2. If there is a lug (or lug and shim) on the end of the cable, using light tension, wrap red sealant on the lug barrel (or over the shim).

3. Build up the lug diameter to the cable insulation and overlay the insulation by ½-inch (10 mm).

4. If there is no lug on the cable, wrap two layers of red sealant onto the cable insulation.

5. Note: the sealant will not prevent water ingress between the strands.

6. Position the red HV tube and shrink into place:

7. Position the HV tube at the bottom edge of the red sealant on the jacket.

8. Begin shrinking at the ground end and work toward the lug.

9. If the cable has a wire shield or is a UniShield cable, twist the drain wires to make a ground lead.

10. Trim the HV tube, after allowing the tube to cool enough to touch:

(Continued on next page.)

Part D: Operating Procedure (Continued)

11. If necessary, trim excess tubing from the lug area.

12. Inspect the installation.

13. Reheat any flat spots or wrinkles.

14. If the termination is indoors, termination is complete.

Outdoor Cable Termination

1. Position the skirt and shrink into place:

2. Place the first skirt in the proper position on the cable.

3. Hold the edge of the skirt lightly with pliers.

4. Brush the flame tip around the outside of the skirt collar. Only the collar will shrink.

5. Position additional skirts, if needed:

6. For 5 kV and 8 kV, only one skirt is needed.

7. If the termination is for 15 kV, two (2) skirts are required.

8. If the termination is for 25 kV, three (3) skirts are required.

9. If the termination is for 35 kV, four (4) skirts are required.

10. Position the remaining skirts, facing the skirts in the same direction as the first skirt.

11. Shrink the skirt(s) into place.

12. Check that the skirts have been evenly shrunk and appear symmetrical, with no tilt or sag.

Satisfactorily Completed __________________________

Part E: Preventive Maintenance

This is to be performed under direction of the Supervisor.

Demonstrate the steps on Cable and Wire Terminations required performing the following preventive maintenance tasks.

1. Except for periodic inspection, no preventive maintenance is required for cable and wire and termination.

Satisfactorily Completed __________________________

Part F: Corrective Maintenance

This is to be performed under direction of the Supervisor.

Demonstrate the steps on Cable and Wire Terminations required to perform the following corrective maintenance.

1. Except for periodic inspection, no corrective maintenance is required for cable and wire and termination.

Satisfactorily Completed __________________________

Part G: Personnel and Equipment Safety

Performed all aspects of the JDC using safe operating practices, and following plant safety and environmental procedures.

Satisfactorily Completed __________________________

1. (IRI-IE-05) A conductor is a metal wire constructed of a material that provides an ______________ for the flow of electric current.

A. open circuit

B. unrestricted

C. easy path

D. impossible path

2. (IRI-IE-05) _____________ materials will conduct electricity.

A. Almost all

B. Few

C. Three

D. Insulating

3. (IRI-IE-05) _________ is the material that is most commonly used in standard electrical applications as a conductor.

A. Copper

B. Silver

C. Aluminum

D. Carbon Steel

4. (IRI-IE-05) A __________ is a multiple conductor. It is two or more insulated conductors insulated from each other, but bound together by a common covering.

A. conductor

B. wiring harness

C. twisted pair

D. cable

5. (IRI-IE-05) The amount of current a bare conductor can carry is determined by the type of metal it is made of and its __________.

A. shape

B. voltage

C. size

D. power factor

6. (IRI-IE-05) There are two (2) systems used to express the size of a metal wire: the (AWG) system and the ____________ system.

A. IEEE

B. NEC

C. circular mill

D. ANSI

7. (IRI-IE-05) Most of the wires used in routine electrical work are sized according to the ___________________system.

A. AWG

B. IEEE

C. NEC

D. ANSI

8. (IRI-IE-05) In the AWG system the smallest size a _________.

A. 0

B. 50

C. 0000

D. 100

9. (IRI-IE-05) In the AWG system the largest size a _________.

A. 0

B. 50

C. 0000

D. 100

10. (IRI-IE-05) If the diameter of a wire is 0.010”, the AWG size is___________.

A. 10

B. 20

C. 30

D. 40

11. (IRI-IE-05) This same 0.010” diameter wire would have a circular mill size of _________.

A. 1000

B. 100

C. 10

D. 1

12. (IRI-IE-05) Cables and conductors are rated on the basis of two factors: (1) the current carrying capability of the conductor, which is commonly referred to as its ______________, and (2) the value of the voltage that the insulation can withstand.

A. ampacity

B. impedance

C. capacitance

D. inductance

13. (IRI-IE-05) A _______________ is a point at which two or more conductors are connected together to extend the overall length of the conductor.

A. termination

B. ring terminal

C. spade terminal

D. splice

14. (IRI-IE-05) Splices can be divided into two categories: _______________ and mechanical splices.

A. mechanical connectors

B. mechanical pressure

C. thermal splices

D. twisted pairs

15. (IRI-IE-05) ____________ provide a means of connecting conductors to electrical equipment and completing electrical circuits.

A. Terminations

B. Split bolt connectors

C. Splice connectors

D. Butt spade connectors

16. (IRI-IE-05) ______________ are typically the best choice unless the terminal screw is captive.

A. spade terminals

B. blade disconnect

C. Ring terminals

D. Bullet disconnect

17. (IRI-1E-05) For larger cable sizes and voltage ratings (5kV and up) the proper cable _______________ must be used for the particular cable being terminated.

A. stripper

B. termination kit

C. crimper

D. size

18. (IRI-1E-05) For small unshielded cable, small wire sizes and low voltage applications (less than 5 kV), insulation should be removed with ________________________.

A. a cutoff wheel100

B. a pocket knife

C. an insulation stripping tool

D. a box cutter

19. (IRI-1E-05) For small unshielded cable, small wire sizes and low voltage applications (less than 5 kV), remove only enough insulation for the wire ________________________________.

A. equal to the length of the lug barrel plus 1/2”

B. equal to the length of the lug barrel plus 1/4”

C. 6.5”

D. to reach the end of the barrel of the terminal

20. (IRI-1E-05) The only accepted field test for a crimp terminal is ________________.

A. to pull on it

B. an impedance test

C. a leak test

D. and ultrasonic test

-----------------------

“Y”

Depth of

Terminal

Hole

=

“Z”

Insulation

Cutback

................
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