Cable Joints & Terminations LV

How To Repair Damaged Cables Using Wraparound Cable Repair Kits

Installing Filoform cable repair kits

Integrity of the cable is of prime concern in mission-critical infrastructure.

Whether maintenance is being performed in utilities, telecommunications, or industrial power systems, damaged jacket cables significantly degrade operations and safety. Filoform Heat Shrinkable Reinforced Wrap Around Cable Jacket Repair Sleeves offer a tough, field-proven repair solution for on-site repair of cables, offering durability, environmental sealing, and mechanical protection.

Filoform Jacket Repair Sleeve

The Filoform cable repair sleeve is engineered for reliability in hostile environments. This metal-reinforced, heat-shrinkable wraparound sleeve enables fast, permanent cable jacket repair without cable movement or disconnection.

Cable Repair Product Features

• Heat-activated seal with hot melt adhesive
• Metal channel closure for mechanical reinforcement
• Extensive cable diameter compatibility
• Application for indoor and outdoor use when repairing damaged cables

Cable Repair Installation Guide

Important: Use a soft yellow flame (not pencil type). Always direct heat in the direction of shrinking and maintain a sweeping motion to avoid scorching. Begin shrinking from the centre outward. Ensure uniform shrinking and proper adhesive oozing.

Ensure performance perfection with this precise installation procedure:

Step 1:

Action: Degrease, clean, and dust the cable surface where the sleeve will be applied.

✅ Use solvents that are compatible with the cable material.
✅ Clean 100 mm on both sides of the damaged section.

Step 2:

Action: Abrade the outer jacket of the cable using abrasive tape or sandpaper.

✅ Roughen 100 mm on each side of the damage for optimal adhesion.

Step 3: Remove the Adhesive Film

Action: Peel off the release liner from the adhesive-coated inner surface of the sleeve.

Step 4: Apply the Sleeve and Insert the Metal Channel

Action: Wrap the sleeve around the cable and slide the metal channel along the overlap to lock it.

✅ Extend the channel 10 mm beyond both ends of the sleeve.
✅ Confirm that the sleeve fits snugly around the cable.

Step 5: Start Heat Shrinking at the Center

Action: Begin applying heat at the centre of the sleeve and work outward.

✅ Apply uniform heat all around the sleeve.
✅ Focus extra heat along the metal channel.
✅ If necessary, bend the channel to follow the cable’s contours.

Step 6 Monitor Adhesive Flow

Action: Look for hot melt adhesive uniformly oozing from all edges.

✅ This indicates a secure and sealed installation.
✅ Let the sleeve cool fully before applying any mechanical stress.

Earthing Armoured Cables To Safely Protect LV AC Cables In The Solar Industry

Challenge | This week a Solar EPC client of Thorne & Derrick engaged our Technical Sales Department to assist with ongoing O&M issues relating to the termination connection of steel wire armour (SWA) on 450off 4 core x 240sqmm LV AC cables, 0.6/1kV – the outdoor location cables are connected to a string inverter and the MV station at the remote end on a UK based 50MW solar farm in Derbyshire. The cable armouring provides mechanical protection but is not intended to circulate electrical current.

SWA Cable Steel Wire Armoured Cables | Image FS Cables

BS7671 Clause 522.8.10 

“Except where installed in a conduit or duct which provides equivalent protection against mechanical damage, a cable buried in the ground shall incorporate an earthed armour or metal sheath or both, suitable for use as a protective conductor. The location of buried cables shall be marked by cable covers or a suitable marker tape. Buried conduits and ducts shall be suitably identified. Buried cables, conduits and ducts shall be at a sufficient depth to avoid being damaged by any reasonably foreseeable disturbance of the ground.”

Earthing Armoured Cables

Solution

Initially, from the viewpoint of the above British Standard the client considered connecting the wire armour at the MV station to ensure that during a fault (e.g.cable strike) an earth path exists to allow safe disconnection of the cable. Earthing the armours of buried SWA cables is important for safety – this prevents/reduces the severity of electric shocks and equipment damage should a person dig inadvertently into the cable. The cable wire armours provide a complete earth path around the cable. Utilizing a single phase within a 4 core cable as earth is not sufficient as it does not offer complete protection around the circumference of the cable. Also, in solar farm installations un-earthed wire armours can have induced voltage from excessive current generated. Therefore, the contractor should always consult the circuit designer.

Customer Service

From initial application, to concept, to design and to sample acceptance by the end client we subsequently completed the despatch and delivery of their order in 5 working days for 450off Armour Earthing Kits.

Important Note

Solderless earth kits that are intended for copper tape screens (MV cables) are a substandard method to earth SWA cables. Solderless earth kits utilize a constant force spring which do not offer a secure earth bond for SWA’s. Also, the cross sectional area of the braid within these kits is inadequate which is why you should always use an armour earth kit for this application. Contact us to discuss your application.

Innovative Connection & Grounding Solutions for LV Cables

Excerpt from Installation Instruction

Heat Shrink Outdoor Armour Earth Kit To Suit

XLPE SWA PVC 

The Heat Shrink Outdoor Armour Earth Kit includes medium wall adhesive lined heat shrink tubes, mastic tapes, solder-blocked earth braids and clamps. Contact us for further information, technical support or for a quotation.

THORNE & DERRICK are Specialist Distributors of LV HV Solar Cable Accessories, Jointing, Termination, Earthing & Electrical Equipment 1500V DC to 33kV – we service UK and global businesses involved in cable installations, jointing, substation and electrical construction.

Since 1985, T&D have established reputation based on SERVICE | INTEGRITY | TRUST – we are highly customer responsive and absolutely committed to providing a world-class service.

We provide expert technical support and supply from a multi-million pound stock holding:

• Cable Joints, Terminations & Connectors
• Earthing & Lightning Protection
• Cable Accessories – Lugs & Glands
• Circuit Protection & Fuses
• Cable Cleats & Clamps
• Electrical Safety Equipment
• Cable Pulling & Laying Equipment
• Arc Flash Protection & Clothing
• Cable Duct Seals & Transit Systems
• Surge Arresters & Bushings
• MV HV Overhead Line & Substation Power Products

>> MORE INFO <<

Further Reading

• Jointing, Grounding & Terminating DC Solar Cables

Thorne & Derrick are Specialist Distributors of Innovation Tooling & Accessories for LV HV Power Systems to facilitate safe and reliable cutting, crimping, preparation, termination and installation of cables, 600V to 132kV.

Overcoming Cable Corrosion On Steel Wire Armoured & Braided Cables

Cable Corrosion Solutions & Products

• uploaded by Chris Dodds - Thorne & Derrick Sales & Marketing Manager

Solutions To Cable Corrosion

3M Electrical Products provide an extensive range of cable repair solutions to prevent and overcome cable corrosion for the utilities, renewable energy, solar, construction, rail, mining, offshore, oil, gas and petrochemical industries – cable corrosion tapes and protection products are available to suit both direct burial (underground) and cables located onto containment in both indoor and outdoor installations.

Cable repair solutions are available for low and medium voltage cables suffering advanced cable damage caused by atmospheric steel corrosion – both onshore and offshore galvanised steel wire armoured and wire braided cables are especially vulnerable.

The Problem 

Formation of Rust

The overall chemical equation for the formation of rust is:

Iron + Water + Oxygen → Rust

Advanced Cable Corrosion & Degradation

The pictured low voltage cables evidently have serious damage caused by long-term cable corrosion effects. The cable sheathing has been aggressively damaged and stripped back down to the galvanised steel wire armours. Steel typically corrodes or rusts rapidly in moist or humid conditions and the rate of corrosion accelerates with exposure to salt water, for instance in the marine and offshore industry.

The cable sheath should provide both waterproof and corrosion protection to the steel wire armours and copper conductors – in this case there is an urgent demand to prevent further cable corrosion damage to both the accessible and inaccessible cables strapped and cable cleated to the cable tray.

The complexity of the cable repair is compounded two-fold : the area is a “no-heat” zone designated a hazardous area location Zone 2 according to the ATEX Directive therefore traditional heat shrink cable repair kits are precluded from consideration due to the presence of a potentially explosive atmosphere. Furthermore due to the brittleness of the cables, resultant from significant corrosion damage, it was not an option to man-handle and subject the cables to further physical movement and mechanical strain.

Chemical Corrosion of Cables In Industrial

& Hazardous Area Locations

Hydrocarbons in the onshore and offshore oil/gas exploration and production sector seriously impact upon the integrity and ability of cables and cable accessories to provide uninterrupted service – standard polyurethane cable repair and jointing products would overtime degrade to destruction in the presence of aggressive chemicals.

Consequently, 3M Electrical have developed a chemical resistant cable joint utilising their 1402FR resin for harsh and hazardous cable installation environments where hydrocarbon exposure is expected under normal conditions – the Scotchcast resin cable joints have been adopted as specification standard by international oil and gas companies including Exxon Mobil, Chevron, Total and Royal Dutch Shell.

 ➡ Read our Blog for further information about the selection and specification of cable joints according to the ATEX Directive.

Cable Corrosion – 3M Solution

2 solutions to suppress future cable corrosion using 3M Electrical cable repair products :

• Accessible Cables – 3M Scotchrap 50 Tape provides advanced corrosion protection to cables exhibiting excellent resistance to abrasion, moisture, corrosive salt water, soil acids, alkalis and salts.

3M Scotchrap tapes are UV resistant and also resist impact punctures and tears with a very high weather and corrosion proofing performance for use on underground cables.

3M Scotchfil Electrical Putty can also be used to build-up irregular surfaces to provide a smooth, waterproof taping surface around cables where there is localised pitting type corrosion.

Scotchfil putty provides a versatile corrosion resistance solution to general cable and electrical equipment applications, the Scotchfil putty can be wrapped, stretched or moulded to conform to both standard and irregular surfaces.

3M Scotchfil Electrical Putty when over wrapped with either Super 33+ or Super 88 Vinyl Electrical Tape. Scotchfil™ electrical putty can also be used to build up cable joints and fill out major irregularities and voids.

• Inaccessible Cables – where cable access is limited 3M 1603 Insulation Spray can be used to protect cables and surfaces (including galvanised steel cable tray) against weather, moisture, corrosion, oil, alkalies and acids. 3M 1603 sprays provide easy access to hard-to-reach spots. eabling versatile on-site cable repairs without specialist tooling or requirement to disconnect or isolate cable circuits. 3M insulating spray sealers to spray over insulation on wire and cable splices, as a general-purpose sealer, or for touch-up insulation on motor windings and frames. Precautionary and first aid information for this product may be found in its Material Safety Data Sheet and on the product container.

Another type of cable failure is evidenced by visual indication of burning or arcing on the surface of the semiconductive layer of medium voltage cables. If the burning or arcing becomes extensive, the MV cable can fail from the outside in (pictured below).  

The MV cable failure cause was determined to be a damaged cable sheath or jacket, which created a flowpath for corrosive ground water to penetrate the cable and cause severe corrosion to the metallic shield.

Scotch 70 silicone rubber electrical tape is a high temperature arc-and track-resistant tape composed of self-fusing, inorganic silicone rubber and easy-tear and easy-strip liner – the Scotch 70 tape is used as an over-wrap for protection of high voltage terminations and cables against arcing and tracking.

Some Further Reading : Corrosion Types Encountered With Power Cables : Underground Cables and Anodic Corrosion (Stray DC Currents), Cathodic Corrosion, Galvanic Corrosion, Chemical Corrosion, AC Corrosion, Local Cell Corrosion. By Edvard Csanyi (Electrical Engineering Portal EEP).

Whatever the cable condition or type of installation, 3M can provide innovative cable corrosion protection solutions based on Scotch electrical tapes, Scotchcast resin, heat shrink, cold shrink or spray based technology.

LV Cable Joints (Low Voltage Cables)

Thorne & Derrick stock and distribute LV Joints in Cold Shrink, Heat Shrink or Resin Cast technologies – multicore and multi-pair cable joints are available for immediate backfill and energisation of Low Voltage power, control and instrumentation cables 600V/1000V 3.3kV.

Complete range of LV Cable Accessories  ➡

Cable Breakouts | Cable Caps | Cable Lugs | Cable Cleats | Cable Trough | Cable Duct | Feeder Pillars | for 11kV/33kV/66kV networks see MV HV Joints & Terminations

Pfisterer | Nexans Euromold | Prysmian | Cable Joints & Terminations MV HV

Cold Shrink by 3M | Joints | Abandonment | Terminations | Low Voltage LV Cables

Cable Jointing of Signalling Power Cables – What’s It All About?

Jointing Signalling Power Cables

Cable Jointing

Signalling Power Cables

• Special thanks to Paul Darlington from Rail Engineer for kind permission to republish this article

The Network Rail standard for enhanced unarmoured Signalling Power Distribution cables – NR/L2/SIGELP/27408 was introduced to tighten the specification for signalling power cables and support the introduction of Class II methodology.

The cable standard introduced several key requirements that drive the need to correctly specify the cable and the associated accessories – specifically the cable joints and jointing methodology used.

The cable standard re-introduces the use of aluminium as a conductor of choice alongside the traditional and more expensive stranded copper option. For the aluminium option NR/L2/SIGELP/27408 specifies solid conductors up to 95sqmm and allows both solid and stranded conductors for sizes equal or greater than 120sqmm.

To protect the cable from water and rodent-related degradation, the cable standard requires the use of water blocking tapes and fibreglass-woven rodent resistant tapes.

To supplement NR/L2/SIGELP/27408 and support the required target asset life of 35+ years, specific accessories standards have been written. NR/L2/SIGELP/27423 covers the requirement for cable joints and connectors. The standard says that, to achieve the target asset life, joints using resinous compounds are preferred.

Previous Cable Jointing History

The history of jointing signalling power cables is chequered – at one end of the scale there are manufacturer assembled, fully compatible and tested rail cable joints, which include connectors designed and tested to meet the Network Rail requirements of the day.

At the other end of the scale are cable joints assembled by third parties at the last minute to try to fulfil a particular urgent need, and which may or may not have been approved by Network Rail.

At both ends of this scale there would be a mix of technologies which may or may not produce a reliable installed joint capable of protecting the cable and meeting the Network Rail asset life expectations. This chequered history might have influenced the cautious approach of the industry related to the speed of the reintroduction of aluminium conductors.

Next generation cable joints

The standard NR/L2/SIGELP/27423 relates to joints intended for connecting signalling power cables, where the electrical system is either TN or IT and the nominal voltage is up to 650V AC. The cable types are defined as follows:

a) Enhanced unarmoured cable to NR/L2/SIGELP/27408.

b) B2 ethylene propylene rubber (EPR) cable to RT/E/PS/00005.

c) Armoured cable to BS 5467.

d) Armoured cable to BS 6346.

Within the joints standard, particular attention has been focussed on the conductor connectors or splices which requires full compliance with BS EN 61238-1 for both aluminium and copper conductors:

“Connector resistance, temperature, mechanical strength and short-circuit behaviour shall be in accordance with a Class A connector as specified in BS EN 61238-1.” (Network Rail, 2015)

In particular, connections between dissimilar metals, i.e., copper and aluminium, are specified to be made using bi-metallic connectors. These are required by NR/L2/SIGELP/27423 to be made by friction welding and similarly tested and approved to BS EN 61238-1.

Mixed experience

Network Rail has mixed experience with the aluminium conductor type cables leading to a previous preference for the copper conductors. However, driven by the recent high copper prices these cables are significantly more expensive and more liable to theft.

Looking outside of the rail sector it was noted that the UK power utilities had been using aluminium conductors and their associated joints and connections without significant problems for over 40 years. It was also recognised that the industry had tight product specification and training requirements in place.

To ensure an equivalent success rate on the product specification, the Network Rail joint standard sets out specific requirements for conductor connections and their installation:

“Unlike copper conductor based distribution systems, aluminium cable is very intolerant of poorly designed and badly made-up connectors. Failure of a connector can lead to loss of the power distribution system, which in turn can cause severe operational disruption. This specification has been developed to ensure that connectors used in signalling power distribution systems are made to a consistent standard and the measures identified in this standard, when adhered to, prevent premature failure.” (Network Rail, 2015)

Focussing on installation, the Network Rail accessory standard requires that all connectors supplied shall be suitable for installation in accordance with BS 7609. This is the ‘Code of practice for Installation and inspection of uninsulated compression and mechanical connectors for power cables with copper or aluminium conductors’ and covers installation methodology, tooling and the maintenance and calibration of tooling.

The Network Rail standard says that the preferred crimping tools are either battery-powered or electro-hydraulic and includes requirement for auto-checking. It also requires that manufacturers of connectors, such as Cembre or Klauke, provide the necessary training packages to support their use.

Wire electric cable on wooden coil or spool isolated

Prysmian Group

Prysmian Group has over 40 years’ experience in the development and testing of crimp connectors, including our in-house friction welding facility. To fulfil the Network Rail requirements the company has developed, tested, and qualified a completely new range of copper, aluminium, and bi-metallic connectors specifically to fully meet the Network Rail requirements.

These Network Rail-approved connectors are fully compatible with the new Prysmian Group joint range. This means that all of its signalling power joints are supplied with the correct connectors for their application.

The Network Rail standard requires that all joints are compliant with BS EN 50393 and are classified as rigid Type II. As noted, in order to fulfil a target asset life of 35+ years, joints made using resinous compounds are preferred. In addition, to provide adequate flood resistance, the joints must demonstrate that they meet the water immersion tests defined in BS EN 50393. (Note: BS EN 50393 requires joints to function within their parameters after being subjected to immersion for 21 days with a 1 metre head of water.)

In order to ensure useability and safety the Network Rail standard specifically requires that the resinous compounds used shall be classification LMP/LI-LT (Low voltage, Mechanical Protection / Low voltage, Insulation protection and Low Temperature curing) as per the requirements defined in BS 7933-1. In a move to maintain the highest levels of health and safety, the standard requires that the resinous compounds and joint capsules used shall be non-toxic and non-hazardous.

Prysmian Group & Network Rail

Working in collaboration with the Network Rail approvals team, Prysmian Group has developed and fully product approved a completely new range of NR/L2/SIGELP/27423 and BS EN 50393 compliant joints. These joints utilise the company’s enhanced, low hazard, JEM jointing resin. Over 30 million litres of Prysmian Group JEM has been used extensively by many of the UK power utilities, with no electrical failures reported.

Prysmian Group’s JEM resin can be mixed and will cure at temperatures as low as -15°C, meeting the Network Rail low temperature curing requirements that may be encountered in the UK climate. It is also a low viscous material which makes it extremely easy to mix, and also extremely searching, minimising any voids that can occur with traditional resins.

Prysmian JEM Resin For Low Voltage Cable Jointing

JEM resin is supplied in clear pouches which allows mixing to be observed during the process enabling the jointer to ensure mixing is complete prior to filling the joints. Another benefit of the JEM system is that when poured the filled joints, if undisturbed, may be energised immediately. From a safety perspective JEM resin is non-volatile, non-flammable, non-irritating and non-sensitizing in line with Network Rail expectations.

In order to meet the Network Rail reliability requirements, the joint system was put through the Network Rail product approval process which not only required the product to be fully compliant to BS EN 50393 type II but, by using tools like DFMEA and reliability and maintainability analysis throughout the development process, looks at ensuring the robustness of the product.

In order to support this robust approach, it is a requirement that the joints are supplied with a detailed set of installation instructions which include stage-by-stage photographs and instructions of the installation.

Low Voltage LV Industrial Cable Joints – Prysmian MPJEM-U

Jointing System Training

As part of the Network Rail accessories standard NR/L2/SIGELP/27423, Network Rail has included a specific requirement for training and competence on the accessory:

“Manufacturers shall have a comprehensive training programme that supports their product range. Note: Human factors and good workmanship drive asset life, without which the risk of premature failure becomes increasingly high. Successful completion of the training course shall be recorded in the candidate’s parent company’s competence management system.” (Network Rail, 2015)

It is clear that in order to meet the +35 years life expectancy of Network Rail the approved joints must be installed exactly as those tested and approved. Therefore, the requirement for specific training on the approved jointing system makes perfect sense. For some this training will be a refresher but, for those new to the industry, this training will be an entry point into the world of cable jointing.

The Prysmian Group training course is designed to give the delegates the knowledge and practical skills to joint two core and four core aluminium and copper rail signalling power distribution cables using the approved Prysmian Group RPJ enhanced cold pour resin joint kits. The course includes both classroom theory and practical sessions to ensure that the trainees can correctly and safely specify and install the Prysmian Group RPJ joints.

The course includes transferable skills such as:

• Electrical site safety.
• Best practice for reliable jointing of 1kV power cables.
• Understanding the risks of poor cable jointing and how to mitigate them.
• Understanding the perceived issues associated with jointing aluminium conductors.
• Safe cable handling methods (during jointing process).
• Identifying types of rail signalling power cable and understanding how to prepare them using the correct cable preparation tools and materials

The course also offers system specific skills such as:

• Selection of the correct joint kit for a specific installation and cables.
• Conductor preparation – particularly to overcome aluminium oxide build up prior to crimping.
• Demonstrating the correct crimp and die selection to produce reliable compression connections.
• Mixing and pouring of the approved JEM cold pour resin.
• Construction of the RPJ series joint kits in accordance with the Network Rail approved Prysmian Group jointing instructions.

Over the two-day course, trainees will receive both classroom theory and hands on practical sessions whereby, following expert demonstrations, they will get the opportunity to practice making their own cable joints. The course is concluded with an assessed multiple-choice theory questionnaire and the preparation of an assessed cable joint. Successful participants will receive a certificate of competence and the commensurate level of CPD hours.

Vertical coils industrial wires. Many turns of main electrical cable is closeup. Roll of outdoor fiber optic signal shielded cables. Wooden Coils of powerful black telecommunications wire

Network Rail has developed a robust set of standards for cables and accessories for signalling power cables. These standards are ensuring the networks of the future are robust and live up to the high expectation of the UK travelling public and Network Rail itself.

With the direction of Network Rail, Prysmian Group has developed a range of cable joints that facilitate the requirement for a long lasting, robust, and easily maintainable signalling power network.

From training courses that have been completed to date, feedback suggests such an event adds value to the already approved product and enhances the probability of making better joints on the Network Rail system.

Original Source Rail Engineer Magazine article written by Paul Darlington 

About Rail Engineer

Rail Engineer is the leading independent quality monthly magazine for engineers, project managers, directors and leading rail executive decision makers.

Besides publishing the latest up-to-date rail engineering news, our team of engineer writers report on the engineering and technical aspects of many of the major projects being undertaken day in, day out, above and below ground, and across the globe.

In the UK we work in close consultation with Network Rail, Docklands Light Railway and the Underground, where our team of rail engineers actively visit the project sites, meet project engineers and provide in-depth analysis on the engineering skills being used and the latest innovations.

From trams and fleet refurbishment to new rolling stock and high speed rail, the rail engineer reports on the engineering and environmental challenges for manufacturers and operators. Our engineers visit factories and depots, meeting with specialist engineers to bring you the latest engineering updates on all aspects of rolling stock, whether onboard technology or mechanical enhancements focussing on safety, energy and the passenger experience.

To Subscribe Click Here

RAIL ENGINEER SEPT / OCt 2022

View the latest edition below or click the following link where the original Jointing of Signalling Power Cables – What’s All The Fuss About? can be found https://www.railengineer.co.uk/rail-engineer-september-october-2022/

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Paul Darlington joined British Rail as a Trainee Telecoms Technician in September 1975. He became an instructor in telecommunications and moved to the telecoms project office in Birmingham, where he was involved in designing customer information systems and radio schemes. By the time of privatisation, he was a project engineer with BR Telecommunications Ltd, responsible for the implementation of telecommunication schemes included Merseyrail IECC resignalling.

With the inception of Railtrack, Paul moved to Manchester as the Telecoms Engineer for the North West. He was, for a time, the Engineering Manager responsible for coordinating all the multi-functional engineering disciplines in the North West Zone.

His next role was Head of Telecommunications for Network Rail in London, where the foundations for Network Rail Telecoms and the IP network now known as FTNx were put in place. He then moved back to Manchester as the Signalling Route Asset Manager for LNW North and led the control period 5 signalling renewals planning. He also continued as Chair of the Safety Review Panel for the national GSM-R programme.

After a 37-year career in the rail industry, Paul retired in October 2012 and, as well as writing for Rail Engineer, is the Managing Editor of IRSE News.

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Thorne & Derrick are leading Specialist Distributors & Stockists of LV, MV & HV Cable Installation, Jointing, Substation & Electrical Equipment to the Rail industry.

RAIL CABLE ACCESSORIES, ELECTRIFICATION

& INSTALLATION EQUIPMENT

Thorne & Derrick stock and distribute an extensive range of 400V-33kV Rail Cable Accessories & Power Distribution Systems including feeder pillars to contractors undertaking Low Voltage Power Distribution, HV Electrification & Substations, DC Traction & Networks, OLE and Track Feeder Cable Renewals – complete range of Network Rail PADS approved track terminations, cable joints, cable repair and connection products up to 25kV, including 3M Cold Shrink, Pfisterer CONNEX and Nexans Euromold products.

Pfisterer SICON CopperTop | Aluminium To Copper Conductor

SICON CopperTop by Pfisterer

332 907 082

Secure Conductor Material Transition From Aluminium To Copper

PFISTERER Sicon offer a range of mechanical shearbolt cable connectors with stepless shear-off bolts providing the right connector for any termination application for medium voltage power cables up to 66/72kV.

For years now, bolted clamps, connectors and cable lugs have been gaining ground as bolted connectors offer technical and practical advantages that conventional cable crimping and compression technology such as copper tube lugs cannot match.

With the Sicon CopperTop range of electrical connectors PFISTERER connects both the well-known SICON technology and the material transition from aluminium to copper in one cable lug. At the same time the copper/aluminium material transition is shifted to an area that easily can be covered with a heat shrink tube and can be secured against environmental impacts.

This allows for example a safe and corrosion resistant connection to copper bus bars, especially in outdoor use. Additionally, the SICON CopperTop 332 907 082 is an alternative for connections in elbow connectors from aluminium cable to copper connection elements.

SICON technology

Like all other SICON connectors the CopperTop can be used independently of the conductor material and type*. The special aluminium alloy allows a safe and corrosion resistant connection of both aluminium and copper material with perfect electrical characteristics.

Thanks to the patented SICON step-less shear off bolts, optimal contact force is always achieved and avoids mounting failures.

 SICON CopperTop Benefits

• Al/Cu transition in the cable lug
• Safe and reliable connection of copper connection elements, especially in outdoor use
• Proven SICON technology
• Material transition easy shrinkable
• Reliable connection for all conductors
• Optimal contact force for all conductors
• No damage to individual strands
• Installation with standard tools

THORNE & DERRICK

Thorne & Derrick stock and distribute PFISTERER CONNEX Connectors for medium / high voltage cable connection and termination to electrical systems up to 33kV – we provide competitive prices for PFISTERER CONNEX connectors used to terminate and connect polymeric insulated MV-HV cables into gas insulated switchgear and electrical equipment from extensive UK stocks.

Thorne & Derrick are national distributors of LV, MV & HV Cable Installation, Jointing, Substation & Electrical Equipment – servicing businesses involved in cabling, jointing, substation, earthing, overhead line and electrical construction at LV, 11kV, 33kV, 66kV and EHV. Supplying a complete range of power cable accessories to support the installation and maintenance of low/medium and high voltage cable systems:

• Slip-on Cable Terminations
• Cold-shrink Cable Terminations
• Heat-shrink Cable Terminations
• Cable Joints – Heat & Cold-shrink
• Separable Connectors (Euromold)
• Surge Arresters & Switchgear/Transformer Bushings

Key Product Categories: Duct Seals | Cable Cleats | Cable Glands | Electrical Safety | Arc Flash Protection | Cable Jointing Tools | Cable Pulling | Earthing | Feeder Pillars | Cable Joints LV | Joints & Terminations MV