CONTENTS INSTRUCTIONS. UK POWER NETWORKS LV JOINTING MANUAL I Version Section Index I Page 1
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1 CONTENTS 1 INTRODUCTION 2 JOINTING INSTRUCTIONS 2.1 Conductor Sizes Comparison of Cable Ratings Based on Cable Type and Size Jointers Tool Kit New Harmonised Phase Colours Single-Phase Plastic Service Cables Phase Plastic Service and Waveform Cables Single-Phase PILC to Plastic Service Cables Phase PILC Mains/Service to XLPE Mains/Service Cables LV Boards, Pillars and Take-off Cabinets Service Straight Joints Single-Phase 4mm 2 to 4mm 2 Plastic CNE Cables Single-Phase 4mm 2 to 35mm 2 Plastic CNE Cables Single-Phase Transition 4mm 2 Plastic CNE to 4mm 2 2-Core PILC Cables Single-Phase Transition 4mm 2 to 35mm 2 Plastic CNE 2-Core PILC Cables Phase 16mm 2 to 35mm 2 Plastic CNE Cable Phase Transition 16mm 2 to 35mm 2 Plastic CNE Cable to 4-Core PILC Cables Service Branch Joints Single-Phase 4mm 2 to 4mm 2 Plastic CNE Cables Single-Phase 4mm 2 to 35mm 2 Plastic CNE Cables Single-Phase 4mm 2 Plastic CNE to 4mm 2 2-Core PILC Cables Single-Phase Plastic CNE to 2-Core PILC 4mm 2 to 35mm Cables Single or 3-Phase Plastic Service to a 3-Phase Plastic CNE 16mm 2 to 35mm 2 Cables Single or 3-Phase Service to a PILC Service or Main 16mm 2 to 35mm 2 Cables Service Cut and Test Joints 32 UK POWER NETWORKS LV JOINTING MANUAL I Version Section Index I Page 1
2 2.7.1 Single-Phase Plastic CNE Cables 4mm 2 to 35mm Phase Plastic CNE Cables 16mm 2 to 35mm Core PILC Cables 4mm 2 to 35mm Core PILC Service or Main Cables 16mm 2 to 35mm Service Cable Pot Ends Single-Phase Plastic CNE Cables 4mm 2 to 35mm Single-Phase PILC Service Cables 4mm 2 to 35mm Phase Plastic CNE Cables 16mm 2 to 35mm Phase PILC Service Cables 4mm 2 to 35mm Waveform Cables Mains Service Branch Joints Waveform Cables 70mm 2 to 185mm 2 (up to six single-phase or two 3-Phase services) Waveform Cables 240mm 2 to 300mm 2 (up to six single-phase or two 3-Phase services) PILC Mains Service Branch Joints PILC Cables 70mm 2 to 300mm 2 (up to six single-phase or two 3-Phase services) PILC Triple Concentric Cables 70mm 2 to 185mm 2 (up to four single-phase or two 3-Phase services) Mains Straight Joints Waveform to Waveform Straight 95mm 2 to 300mm Waveform to PILC Transition Straight 95mm 2 to 300mm Waveform to CONSAC Transition Straight 95mm 2 to 300mm Waveform to Single or Triple Concentric Transition Straight 95mm 2 to 300mm Mains Branch Joints Waveform to Waveform 95mm 2 to 300mm Waveform to PILC Transition 95mm 2 to 300mm Waveform to Single or Triple Concentric Transition Mains Branch or Mains Service Mains Cut and Test Joints Waveform Cables 70mm 2 to 300mm PILC Cables 70mm 2 to 300mm Temporary LV Joints PILC Mains Cables 95mm 2 to 300mm Waveform Mains Cables 70mm 2 to 300mm Temporary LV Joint Removal Temporary Generator Connection - PILC Mains Cable 70mm 2 to 300mm Temporary Generator Connection - Waveform Mains Cable 70mm 2 to 300mm Loose Connectors and Components Mains Pot End Joints Waveform Cables 70mm 2 to 300mm 2 97 Section Index I Page 2 UK POWER NETWORKS LV JOINTING MANUAL I Version
3 PILC Cables 50mm 2 to 95mm PILC Cables 120mm 2 to 300mm Breaking down Heatshrink Pot End Joints on Plastic Cables Breaking down Heatshrink Pot End Joints on PILC Cables Mains Pole Terminations Waveform Cables 70mm 2 to 185mm 2 for Direct Connection on to the Overhead Line Waveform Cables 70mm 2 to 185mm 2 for Connection to Pole Mounted Fuses (PC400 s) Cut-Outs New Single-Phase 25A PME Cut-Outs New Single-Phase 100A PME Cut-Outs New Single-Phase 100A SNE Cut-Outs New 3-Phase 100A PME Cut-Outs New 3-Phase 200A PME and SNE Cut-Outs on Waveform Cables New 3-Phase 400 and 600A PME and SNE Cut-Outs on Waveform Cables Multi-Service Distribution Boards Termination of Waveform Cables into LV Distribution Cabinets or onto LV Distribution Boards and 4-Way LV Link Boxes Tailed Link Boxes Waveform Cable in to an Un-Tailed Box PILC Cable into an Un-Tailed Box Installation of Plastic Pit Frame and Pavement Cover Replacement Pit Frames and Pavement Covers Service Distribution Units Waveform Mains Cable Single-Phase Concentric Service Cables Phase Concentric Service Cables 187 UK POWER NETWORKS LV JOINTING MANUAL I Version Section Index I Page 3
4 3 PROCEDURES FOR STRIPPING LOW VOLTAGE CABLES 3.1 Scope Paper Insulated Lead Sheathed Cables (PILC) Removing the Outer Serving Removing Steel Wire Armour Removing Steel Tape Armour Removing the Inner Bitumen Layer Use of Temporary Continuity Bond Removing the Lead Sheath Removing the Belt Papers and Filters Cutting the Phase Cores Removing the Paper Core Insulation (Cable Core End) Removing the Paper Core Insulation (Through Cable Cores) Waveform Cables Branch and Service Joints Removing the Outer PVC Sheath Removing the Outer Bedding Layer Preparing the CNE Wires Removing the Inner Bedding Layer Separating the Phase Cores Waveform Cables Straight Joints Removing the Outer PVC Sheath Removing the Outer Bedding Layer Preparing the CNE Wires Removing the Inner Bedding Layer Separating the Phase Cores Cutting the Phase Cores Removing the XLPE Core Insulation New Single-Phase Concentric Service Cables Removing the Outer PVC Sheath Preparing the CNE Wires Removing the Core Insulation New 3-Phase Concentric Service Cables Removing the Outer PVC Sheath Preparing the CNE Wires Removing the Inner Bedding Layer and Fillers 35 Section Index I Page 4 UK POWER NETWORKS LV JOINTING MANUAL I Version
5 3.6.4 Removing the Core Insulation Live Single-Phase Concentric Service Cables Removing the Outer PVC Sheath Preparation of CNE Wires - Live Cut Cutting the Phase Core for Pot End Preparation of CNE Wires - Live Branch Joints Live 3-Phase Concentric Service Cables Removing the Outer PVC Sheath Preparation of CNE Wires - Live Cut Cutting the Phase Cores for Pot End Live 3-Phase Concentric Branch Joints Removing the Inner Bedding Layer and Fillers CONSAC Cables Removing the Outer PVC Sheath and Bitumen Layer Aluminium Sheath Tools Cutting or Opening the Aluminium Sheath on a Continuous Main Opening and Cutting the Aluminium Sheath on a Cable End Removing the Belt Papers Cutting the Phase Cores Removing the Paper Core Insulation (Cable Core End) Removal of Paper Core Insulation (Through Cable Cores) Single and Triple Concentric Cables Removing the Outer Servings/Armours Fitting the Temporary Earth Bond Removing the Lead Sheath Removing the Belt Papers Removing the Neutral Strands Fitting Temporary Shrouding Removing the Core Papers Removing the Outer Phase Strands Insulating the Outer Phase Core Earth Pins and Cables Earth Cable Preparation Fitting the Earth Cable to an Earth Pin Breaking Down Compound Filled Lead Sleeve Joints Breaking Down Compound Filled Lead Sleeve Straight Joints Breaking Down Compound Filled Lead Sleeve Service Branch Joints Making Room for a New Straight Joint Behind a Broken Down Joint Stripping and Preparation of PVC Insulated Steel Wire Armoured Cable 94 UK POWER NETWORKS LV JOINTING MANUAL I Version Section Index I Page 5
6 Outer PVC Sheath and Steel Wire Armour Removal Steel Wire Armour Termination Inner PVC Sheath Removal 97 4 INSTALLING MECHANICAL CONNECTORS AND COMPONENTS 4.1 Installing Mechanical Neutral Earth Connectors NET1 for Consac Joints NE19 for Concentric Service Joints NE13, 14 and 26 for Waveform Joints Installing Mechanical Service and Mains/Service Connectors SS4W for 4mm 2 (0.007in) Service Joints SS35/4 for 16mm 2 (0.0225in) to 35mm 2 (0.04in) Service Joints MSD Insulated Insulation Piercing Connectors To Convert a MSD IIPC into a MSD2 IIPC MF2 and MF4 Insulated Tunnel Connectors NMS Insulted mains Service Branch Connectors MB21 Insulated Service Branch Connectors Installing Mechanical Mains Straight Connectors UM 95, 185 and 300 for PILC or Waveform Mains Straight Joints Service Bridge Piece for UM Connectors Installing Mechanical Mains Branch Connectors LVM 1, 2 and 3 for PILC and Waveform Branch Joints WB Neutral Connectors for Waveform to PILC Branch Joints Installing Mechanical Pole Termination Connectors MF15/1, 2 and 3 for Waveform Cables Direct Overhead Line Connection ML1 and 2 Lugs for Pole Terminations PC400 Connections Installing Mechanical End Termination Connectors UMT and UT Connectors for Cut-Outs, LV Boards and Multi-Service Distribution Boards Installing Mechanical Earth Bonds for PILC Cables Constant Force Spring Service Termination Bond Constant Force Spring Service Joint Bond PILC Mains PME Bond PILC Heatshrink Mains Pot End Joints Installing Joint Shells and Polyurethane Resin Plastic Joint Shells 42 Section Index I Page 6 UK POWER NETWORKS LV JOINTING MANUAL I Version
7 4.8.2 Mixing and Pouring JEM Resin Installing Insulation Materials Velcro-Edged Temporary Insulation Moulded Waveform Neutral Earth Connector Shrouds Non-Adhesive PVC Tape Permanent CR Sheet Insulation Patches Permanent Dip-Moulded Insulation Shrouds Permanent Injection Moulded Insulation Shrouds Installing Heatshrink Tubing and Components Thin-Wall Tube Heavy-Duty Adhesive-Lined Tube Breakouts End Caps Zipper Sleeves 54 5 CUT-OUT CHANGES 5.1 Single-Phase Two Piece Insulated Cut-Out Containing Plastic Service Cable Single-Phase Two Piece Insulated Cut-Out Containing PILC Cable One Piece Insulated Cut-Out Containing PILC Cable PILC Cable Consumer Earth Bonds LIVE Cut-Out Change Decision Flowchart Breaking Down a Single Phase Metal Clad Compound Filled Cut-Out Containing PILC Cable Breaking Down a Single Phase Insultaed Compound Filled Cut-Out Containing PILC Cable Installing a New Single Phase Cut-Out on to an Existing Single Phase PILC Cable 64 UK POWER NETWORKS LV JOINTING MANUAL I Version Section Index I Page 7
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