Page 1
PCN 556781-000
Effective Date: April 25, 2006
PII 54825, Rev AF
1
HVS-1520S-W Series
15kV Class Splice for Extruded Dielectric (Poly/EPR) Power Cables:
Metallic Tape, Wire Shield, UniShield, or Lead Sheath Cables
Suggested Installation Equipment
(not supplied with kit)
• Cable preparation tools
• Tyco Electronics P63 cable preparation kit or cable manufacturer
approved solvent
• Clean, lint-free cloths
• Non-conducting abrasive cloth, 120 grit or finer
• Electrician's tape
• Connector(s) and installation tools
• Tyco Electronics recommended torch
Safety Instructions
Warning: When installing electrical power system accessories,
failure to follow applicable personal safety requirements and written
installation instructions could result in fire or explosion and serious or
fatal injuries.
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.
To minimize any effect of fumes produced during installation, always
provide good ventilation of confined work spaces.
As Tyco Electronics has no control over field conditions which
influence product installation, it is understood that the user must
take this into account and apply his own experience and expertise
when installing product.
Recommended Tyco Electronics Torches
Install heat-shrinkable cable accessories with a "clean burning" torch,
i.e., a propane torch that does not deposit conductive contaminants
on the product.
Clean burning torches include the Tyco Electronics FH-2629,
FH-2649 (uses refillable propane cylinders) and FH-2618A (uses
disposable cylinder).
Adjusting the Torch
Adjust regulator and torch as required to provide an overall 12- inch
bushy flame. The FH-2629 will be all blue, the other torches will have
a 3- to 4-inch yellow tip. Use the yellow tip for shrinking.
Regulator Pressure
FH-2618A Full pressure
FH-2649 25 psig
FH-2629 15 psig
General Shrinking Instructions
• Apply outer 3- to 4-inch tip of the flame to heat-shrinkable material
with a rapid brushing motion.
• Keep flame moving to avoid scorching.
• Unless otherwise instructed, start shrinking tube at center,
working flame around all sides of the tube to apply uniform heat.
To determine if a tube has completely recovered, look for the following,
especially on the back and underside of the tube:
1. Uniform wall thickness.
2. Conformance to substrate.
3. No flat spots or chill marks.
4. Visible sealant flow if the tube is coated.
Note: When installing multiple tubes, make sure that the surface of
the last tube is still warm before positioning and shrinking the next
tube. If installed tube has cooled, re-heat the entire surface.
Kit Contents
The following items should be included in this kit:
1 Black stress control tube
1 Red insulating tube
1 Black/red dual wall tube
1 Green/Black wraparound rejacketing tube
2 Wraparound channels
1 Channel clip
1 Copper braid
2 Roll springs
1 Installation instruction
2 Ground connectors
4 Strips copper tape
2 Angle-cut strips stress relief material
Rolls copper mesh
Long strips stress relief material
Strips red sealant
Page 2
PCN 556781-000
Effective Date: April 25, 2006
PII 54825, Rev AF
2
3. Prepare cables.
Choose the cable type (Choice 1-3) and
use the dimensions shown in Table 2 to
prepare the cables.
Table 2 Jacket Metallic shield semi-con
Cutback Cutback Cutback
Kit A B C
HVS-1521S-W 9-1/2" (240mm) 8" (203mm) 4-1/2" (115mm)
HVS-1522S-W 10-1/2" (265mm) 9" (230mm) 5" (125mm)
HVS-1523S-W 11-1/2" (290mm) 10" (255mm) 6-1/2" (165mm)
HVS-1524S-W 12" (305mm) 10-1/2" (265mm) 6-1/2" (165mm)
HVS-1525S-W 14" (355mm) 12" (305mm) 8" (203mm)
4. Remove insulation.
Refer to Table 3 and cut back the
insulation as shown.
Table 3 Maximum Connector Dimensions Expansion
Kit Length Diameter Gap "X"
HVS-1521S-W 4-1/4" (108mm) 1.00" (25mm) 1/4" (5mm)
HVS-1522S-W 5-1/2" (140mm) 1.35" (34mm) 1/4" (5mm)
HVS-1523S-W 8" (203mm) 1.60" (41mm) 1/2" (10mm)
HVS-1524S-W 8" (203mm) 1.85" (47mm) 1/2" (10mm)
HVS-1525S-W 11" (279mm) 2.40" (60mm) 1/2" (10mm)
400
5. Abrade insulation.
Abrade the insulation, as necessary to
remove imbedded semi-con, and clean.
249
If Metallic Tape Shield, or Lead Sheath
Cable
CHOICE 1
108
If Drain Wire Shield Cable
CHOICE 2
109
If UniShield Cable
CHOICE 3
110
1. Product selection.
Check kit selection with cable diameter
dimensions in Table 1.
Note: Table is for 100% insulated cable. For
133% insulated cable, check actual cable
dimensions.
2. Check ground braid.
Verify that ground braid(s) or bond wire
have equivalent cross-section to cable
metallic shield. Additional braid may be
needed for lead sheath cables, or if external
grounding or shield interrupting is required.
Tyco Electronics HVS-EG supplies ground
braid, spring clamp and suggested
modifications to make an external ground or
shield interrupt.
Table 1 Maximum Insulation Maximum Connector
Nominal Jacket Diameter Dimensions
Kit Cable Range Diameter Range Length Diameter
HVS-1521S-W #2-4/0 AWG 1.25 (32mm) 0.65-1.05 (17-27mm) 4.25 (108mm) 0.90 (23mm)
HVS-1522S-W 250-350 kcmil 1.50 (38mm) 0.90-1.30 (23-33mm) 5.50 (140mm) 1.15 (29mm)
HVS-1523S-W 500-750 kcmil* 1.85 (47mm) 1.10-1.60 (28-41mm) 8.00 (203mm) 1.60 (41mm)
HVS-1524S-W 750-1000 kcmil 2.10 (53mm) 1.25-1.80 (32-46mm) 8.00 (203mm) 1.85 (47mm)
HVS-1525S-W 1250-2000 kcmil 2.80 (71mm) 1.60-2.50 (41-64mm) 11.00 (279mm) 2.40 (60mm)
* For 750 kcmil 133% insulation level, use HVS-1524S-W
C
A
B
L
C
C
A
L
C
C
A
L
C
Z
"Z"
X
Insulation
Cutback
=
"X"
Expansion
Gap
+
Y
Abrade
Insulation
Abrade
Insulation
"Y"
1/2 Length
of Connector
Page 3
PCN 556781-000
Effective Date: April 25, 2006
PII 54825, Rev AF
3
8. Install connector.
After installation, deburr connector.
Using an approved solvent, clean the
insulation as shown.
603
Remove backings from the short
angle-cut piece of SRM. Place tip of
SRM at semi-con cutback and tightly
wrap to fill semi-con step. Overlap
semi-con and insulation as shown.
Taper SRM down to meet insulation.
Note: If using Unishield cable, apply
SRM as shown to fill conductive jacket
step.
606
10. Apply SRM at semi-con cutback.
604
9. Apply SRM over connector.
Remove backing from one side of the
long strip of Stress Relief Material
(sRM). Roll the SRM and remaining
backing strip into a convenient size.
Remove the remaining backing strip
and tightly wrap the SRM around the
connector and exposed conductor. Be
sure to fill the gaps and low spots
around the connector.
Continue to wrap SRM onto the solvent
cleaned insulation as shown.
Note: If connector diameter is larger
than insulation diameter, apply two halflapped layers of SRM over the entire
connector. Discard any excess SRM
(long strips).
605
7. Place nested tubes over cable as
shown.
Protect tubes from end of conductor as
they are placed over cable end.
602
6. Clean cable jackets.
Clean cable jackets for the length of the
tubes.
271
30"
(760mm)
Clean
Clean
30"
(760mm)
Black/Red Dual Layer Tube
Red Insulating Tube
Black Stress Control Tube
Cable Jacket
Insulation
Semi-Con
Metallic Shield
1/4"
(5mm)
Clean
Connector
SRM
Insulation
Semi-con
Stretch SRM to
1/2 Original Width
Fill gaps
1/4"
(5mm)
Stretch SRM to
(5mm)
1/4" wide
SRM
1/4"
(5mm)
(5mm)
1/4"
Insulation Overlap
Semi-con Overlap
Page 4
PCN 556781-000
Effective Date: April 25, 2006
PII 54825, Rev AF
4
608
13. Position red insulating tube;
shrink in place.
Center the tube over the black stress
control tube. Shrink in place using the
same method as in step 12.
607
12. Position black stress control tube;
shrink in place.
Center the tube over the splice. Begin
shrinking at the center (1) of the tube,
working the torch around all sides of the
tube. After the center portion shrinks,
work towards one end (2), then to the
opposite end (3).
Note: Do not point the flame at the cable
semi-con.
The rings from the SRM wraps may be
visible as the tubing is shrunk.
Post heat the connector area until the tube
surface is smooth and the under-lying
SRM wraps are no longer visible.
609
14. Apply red sealant.
Remove backing from red sealant.
Using light tension, wrap sealant over
the cable, butted against the tubes as
shown. Build the sealant to the level of
the red insulating tube.
106
15. Position black/red dual layer tube;
shrink in place.
Center tube over the red insulating tube.
Shrink in place using the same method as
in Step 12.
113a
11. Apply Silicone Grease.
Snip open the end of the silicone grease
tube and apply a thin film of grease on the
SRM over the connector and semi-con
steps.
Apply thin film of SG over surface of installed SRM
SG SG
SG
Torch
2 3
11
Black
Stress Control Tube
Center tube
between jacket cutbacks
Visible wrap
lines
Shrink tube
until smooth profile
Red Insulating Tube
Red Sealant
Red Sealant
Red Insulating Tube
Black/Red Dual Layer Tube
Torch
Page 5
PCN 556781-000
Effective Date: April 25, 2006
PII 54825, Rev AF
5
610
If Drain Wire or Unishield Cable
Pigtail the shield wires on each side.
Crimp the ground braid onto one
pigtail with the connector provided.
Lay braid across splice tubes and
attach to pigtail on the other side. Cut
off excess braid and trim pig-tailed
wires.
Discard spring clamps and foil tape.
Go to step 17.
CHOICE 1
Note: If External Grounding or Shield Interrupting
Refer to Tyco Electronics HVS-EG, "Guide for External Grounding and Shield Interrupting of Power Cable Splices" for
modifications to these instructions.
611
If Metallic Tape shield Cable
(1) Flare one end of the ground braid
and place it onto the metallic tape
butted up to the installed splice tubes.
(2) Attach the braid to the shield by
placing two wraps of the spring clamp
over the braid. (3) Fold the braid back
over the spring clamp wraps. Continue
to wrap the remaining clamp over the
braid. Tighten clamp by twisting it in
the direction it is wrapped and secure
with copper foil tape provided.
CHOICE 2
612
(4) Lay the braid across the splice
tube and onto the exposed tape
shield on the other side. (5) Make two
wraps of the clamp over the braid. (6)
Fold the braid back toward the splice
and finish wrapping the clamp.
Tighten and secure. Cut off excess
braid.
Discard connectors.
Go to step 17.
16. Install ground.
Choose the appropriate cable type
(Choice 1-3) and follow the directions
given.
Ground
Braid
Drain Wire Connector Ground Braid
Black/Red Dual Layer Tube
Spring
Clamp
Black/Red Dual Layer Tube
12 3
Black/Red Dual Layer Tube
456
Page 6
PCN 556781-000
Effective Date: April 25, 2006
PII 54825, Rev AF
6
614
17. Install the shielding mesh.
Wrap a half-lapped layer of the mesh
across the entire splice and tie-off.
Abrade and solvent clean cable jackets
as shown to provide an oil-free surface.
613
If Lead Sheath Cable
Solder ground braid(s) or bonding wire
on to lead sheath. Deburr connection.
Discard spring clamps, connectors,
and foil tape.
CHOICE 3
614a
18. Apply red sealant.
Remove release paper from red
sealant and place one full wrap at
cable jacket cutbacks as shown.
614b
19. Position wraparound sleeve.
Remove or tape over all sharp points
to prevent puncture of wraparound
sleeve. Remove backing from the
wraparound sealing sleeve and center
sleeve over splice. Slide metal
retention clip onto the butted rails.
614c
20. Install channels.
Connect the channels by overlapping
the retention clip as shown at right.
Note: Channels must overlap sleeve
edge by 1/4 inch (5mm) minimum.
If channels slide on easily go to
step 21. If channel fit seems tight,
continue with next paragraph.
As shown in illustration A, make sure
flap is not pinched between the rails.
Push the sleeve up from the bottom
and down from the top while sliding
on channel as shown in illustration B.
The idea is to flatten the rails together
to prevent the channels from binding.
Black/Red Dual Layer Tube
Clean
8"
(200mm)
Shielding Mesh
Black/Red Dual Layer Tube
1 wrap
Red Sealant
Retention Clip
Black / Green Wraparound Sleeve
Clean
8"
(200mm)
Channels slide over
retention clip
(5mm)
1/4"
minimum
Retention
Clip
1/4"
minimum
(5mm)
Page 7
PCN 556781-000
Effective Date: April 25, 2006
PII 54825, Rev AF
7
A B
22. Shrink the wraparound sleeve.
Preheat evenly along both sides of the
rail/channel area until this area begins
to shrink. To achieve uniform heating,
move the flame back and forth from one
side of the channel to the other as
shown in illustration “A” while moving
flame along the entire length of the
channel as shown in illustration “B” until
the sleeve starts to shrink. This
technique will assure a properly
preheated rail and channel area.
Begin shrinking at the center of the
sleeve and work toward each end.
Apply heat until the sleeve is fully
shrunk and the heat-sensitive green
paint is completely converted to black.
Continue heating the rail/channel area
for another 5 seconds per foot. A white
line should be visible in the channel
gaps indicating sufficient heating.
Note: Green heat-sensitive paint
will turn black as sleeve shrinks in
place.
This completes the splice.
Note: Allow to cool before moving or
placing in service.
614d
The Information contained in these installation instructions is for use only by installers trained to make electrical power installations and is intended to describe the correct method of
installation for this product. However, Tyco Electronics has no control over the field conditions which influence product installation. It is the user's responsibility to determine the
suitability of the installation method in the user's field conditions. Tyco Electronics' only obligations are those in Tyco Electronics' standard Conditions of Sale for this product and in no
case will Tyco Electronics be liable for any other incidental, indirect or consequential damages arising from the use or misuse of the products. Raychem is a trade mark of Tyco
Electronics Corporation. * UniShield is a registered trademark of BICC General Cable Industries, Inc.
White indicator
Adhesive Flow (Both Ends)
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