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Product Installation Instructions

HVS-500 Series
5-8kV Class
Splice for Non-Shielded
Extruded Dielectric
(Poly/EPR) Power Cables

Raychem Corporation PII-53016, Rev. AB

Electrical Products Group DCR C23542
300 Constitution Drive PCN 210811-000
Menlo Park, CA 94025-1164 Effective Date: June 1991
 General Instructions
Suggested Installation Equipment (not supplied with kit)

• Cable preparation tools • Clean, lint-free cloths • Raychem recommended torch

• Raychem P42 cable preparation • Non-conducting abrasive cloth,
kit or cable manufacturer approved 120 grit or finer
solvent • Electrician's tape
Recommended Raychem Torches

Install heat-shrinkable cable Clean burning torches include the

accessories with a "clean burning" Raychem FH-2629 (uses refillable
torch i.e., a propane torch that does propane cylinders) and FH-2616A1
not deposit conductive (uses disposable cylinder).
contaminants on the product.

Safety lnstructions

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.
Adjusting the Torch
To avoid risk of accidental fire or To minimize any effect of fumes
explosion when using gas produced during installation, always
torches, always check all provide good ventilation of confined
connections for leaks before work spaces.
igniting the torch and follow the
torch manufacturer's safety
instructions.

Adjust regulator and torch as The FH-2629 will be all blue, the Regulator Pressure
required to provide an overall 12- other torch will have a 3- to 4-inch
inch bushy flame. yellow tip. Use the yellow tip for FH-2616A1 Full pressure
shrinking. 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.

Installation Instructions
1. Product selection.

Check kit selection with cable

diameter dimensions in Table 1.

Table 1 Nominal Insulation Maximum Maximum Connector

Cable Range Diameter Jacket Dimensions
Kit Range Diameter Length Diameter
HVS-501 #6-#1 AWG 0.40-0.70" (10-18mm) 0.80" (20mm) 3.0" (76mm) 0.65" (16mm)
HVS-502 1/0-300 kcmil 0.65-1.05" (16-27mm) 1.20" (30mm) 4.0" (101mm) 1.00" (25mm)
HVS-503 350-1000 kcmil 0.95-1.65" (24-42mm) 1.85" (47mm) 6.0" (152mm) 1.85" (47mm)

PII-53016, Rev AB 2 PCN 210811-000

DCR C23542 Effective Date: June 1991
 Installation Instructions
2. Prepare cables. Table 2 Figure 1 CL
Jacket
Cutback A
Use the dimensions shown in
Table 2 and Figure 1 to prepare Kit A
the cables. HVS-501 4" (100mm)
HVS-502 4" (100mm)
HVS-503 6" (150mm)

1080

3. Remove insulation. Table 3

Maximum Connector Dimensions Expansion
Refer to Table 3 and Figure 2; Kit Length Diameter Gap "X"
cutback the insulation as shown. HVS-501 3.0" (76mm) 0.65" (16mm) 1/4" (5mm)
HVS-502 4.0" (100mm) 1.00" (25mm) 1/4" (5mm)
HVS-503 6.0" (152mm) 1.85" (47mm) 1/2" (10mm)

Figure 2: Insulation Cutback.

Z
"Z" "X" "Y"
X Insulation = Expansion + 1/2 Length
Cutback Gap of Connector

Y
1081

4. Clean cable jackets.

30" Clean 6"
Clean (152mm)
Clean cable jackets for the as (760mm)
shown.

1082

5. Place splice tubes over cable Black Rejacketing Tube

as shown. Red Insulating Tube
Cable Jacket
Protect tubes from end of conductor
as they are placed over cable end.

1083

6. Install connector.
Clean
After installation, deburr connector.

Using an oil-free solvent, clean the Insulation Insulation

insulation as shown. Remove any
residual solvent with a clean, dry 1084

cloth.

PII-53016, Rev AB 3 PCN 210811-000

DCR C23542 Effective Date: June 1991
 Installation Instructions
7. Apply SRM over connector.

Remove backing from one side of Stretch SRM to

the long strip of Stress Relief 1/2 Original Width
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 Fill gaps
the connector.
1085

Continue to wrap SRM onto the

insulation for 1/4" (5mm) as shown. 1/4" 1/4"
(5mm) (5mm)
Note: If connector diameter is larger
than insulation diameter, apply two
half-lapped layers of SRM over the
entire connector. Discard any SRM
excess SRM (long strips). 1086

8. Position red insulating tube;

shrink in place.
Torch
Center red insulating tube over
splice as shown. Begin shrinking at
center of tube (1), working torch
with a smooth brushing motion 2 1 3
around the tube. After center
portion shrinks, work torch as Red Insulating Tube
before toward one end (2), then to
the opposite end (3). Apply
sufficient heat to ensure softening
of the SRM, indicated by a smooth
surface profile. 1087

9. Apply red sealant.

Red Sealant
Remove backing from red sealant.
Using light tension, wrap sealant
over the cable, butted against the
red insulating tube as shown. Build
the sealant to the level of the red
insulating tube. 1088

10. Position black tube; shrink in

place. Torch

Center black tube over the red

insulating tube so that it overlaps
both strips of red mastic. Shrink
tube in place using same method
as in Step 8.
Black Tube
This completes the splice.

Note: Allow splice to cool to the

touch before moving or placing in
1089
service.
PII-53016, Rev AB 4 ã 1991Raychem Corporation
DCR C23542, PCN 210811-000
Effective Date: June 1991