ACCESSORIES FOR ELECTRICAL CABLES

Installation instructions

HEAT SHRINKABLE
STRAIGHT JOINT

for single core

plastic or rubber insulated cable
with wire or tape screen
and armour

Highest voltage Um: up to 42 kV

ELCOTERM GLS 85/BDBZ series

DRAWING N° Code Drawn Updated Approved

Date 02/09/2022

ELCON MEGARAD S.p.A.

HEADQUARTER and FACTORY: ARCELLA (AV) ITALY
673/BDBZ
Tel. +39 0825/6077 - Fax +39 0825/607782 Signature G.DA. G.DS.
Web site:www.elconmegarad.com e-mail: elcon@elconmegarad.com

Drawing Nº 673/GDBZ Page 1/8

Ogni diritto sui presenti testi, disegni, prodotti e su ogni singola parte di essi è di esclusiva proprietà di Elcon Megarad S.p.A. Ogni riproduzione e/o distribuzione, anche parziale o tradotta, è strettamente proibita.
All the rights on texts, drawings, products and each single part of them is exclusive property of Elcon Megarad S.p.A. All reproduction and/or distribution, even partial or translated of this document is strictly prohibited.
 THIS PRODUCT MUST BE INSTALLED BY COMPETENT PERSONAL WITH ELECTRICAL
EQUIPMENT AND IN SAFETY CONDITIONS.
READ CAREFULLY ALL THE INSTRUCTIONS BEFORE STARTING CABLE PREPARATION. CHECK
THAT ALL COMPONENTS LISTED ON THE BILL OF MATERIAL ARE AVAILABLE.

HEAT SHRINK THE TUBES FOLLOWING THESE GOLDEN RULES:

 Use only butan or propane gas torch.
 Flame must be soft.
 Heat the tubes uniformely.
 Move the flame all around the circumference of tubes.
 Start from the center of tube, and move slowly toward the end or unless otherwise stated.
 Do not insist on the same part.
 Stop when completely shrunk.

1. CABLE. PREPARATION
WIRE SCREEN CABLE PREPARATION

1.1 Train the cables to overlap both ends for 1 m at least so they are in the rigth position for the connection; mark on to
the cables a reference line in a center of joint. Cut only one cable (shortest cable side) on the reference line, and
the other cable (longest cable side) at 500 mm toward the end from the reference line so to remove the surplus
part.

1.2 Cut and remove the outer jacket according to the dimension " A " from the shortest cable side, and for the
dimension " A + 500 mm " from the longest cable side.

The dimension "A" is indicated in the list of components supplied in the kit.
1.3 Cut and remove the exposed armour so far the outer jacket edge.
1.4 Cut and remove the outer jacket for 40 mm again.
1.5 Secure the armour end by copper wire available in the kit.
1.6 Clean up the outer jacket with a suitable solvent for 1 m at least to avoid dirtiness is transferred to the internal
surface of the heat shrinkable tube.

1.7 Cut and remove the inner jacket leaving exposed 10 mm from armour edge.

Drawing Nº 673/GDBZ Page 2/8

Ogni diritto sui presenti testi, disegni, prodotti e su ogni singola parte di essi è di esclusiva proprietà di Elcon Megarad S.p.A. Ogni riproduzione e/o distribuzione, anche parziale o tradotta, è strettamente proibita.
All the rights on texts, drawings, products and each single part of them is exclusive property of Elcon Megarad S.p.A. All reproduction and/or distribution, even partial or translated of this document is strictly prohibited.
1.8 Don’t cut the wire screen but turn them downwards the outer jacket. Fix the wires on the outer jacket by some layers
of pvc tape ELCOPLAST 51.
1.9 Cut and remove only from the longest cable side the core end for 500 mm.

EACH SIDE OPERATION

1.10 Remove the cable semiconductor (if necessary use appropriate tool), for the dimension " B " from the edge.

The dimension "B" is indicated in the list of components supplied in the kit.

TAPE SCREEN CABLE PREPARATION

1.1a Train the cables to overlap both ends for 0,5 m at least so they are in the rigth position for the connection; mark the
reference line on the cables (middle of overlap).
Cut the cables in such a way as to remove the surplus part in correspondence of the reference line.

1.2a Cut and remove the outer jacket according to the dimension " A ".

The dimension "A" is indicated in the list of components supplied in the kit.
1.3a Cut and remove the exposed armour so far the outer jacket edge.
1.4a Cut and remove the outer jacket for 40 mm again.
1.5a Secure the armour end by copper wire available in the kit.
1.6a Clean up the outer jacket with a suitable solvent for 1 m at least to avoid dirtiness is transferred to the internal surface
of the heat shrinkable tube.

Drawing Nº 673/GDBZ Page 3/8

Ogni diritto sui presenti testi, disegni, prodotti e su ogni singola parte di essi è di esclusiva proprietà di Elcon Megarad S.p.A. Ogni riproduzione e/o distribuzione, anche parziale o tradotta, è strettamente proibita.
All the rights on texts, drawings, products and each single part of them is exclusive property of Elcon Megarad S.p.A. All reproduction and/or distribution, even partial or translated of this document is strictly prohibited.
1.7a Cut and remove the inner jacket leaving exposed 10 mm from armour edge.
1.8a Fix the tape screen, to the dimension of 50 mm from the armour edge by some layers of adhesive copper tape.
1.9a Cut and remove the tape screen from the cores end on the adhesive copper tape edge.

EACH SIDE OPERATION

1.10a Remove the cable semiconductor (if necessary use appropriate tool), for the dimension " B " from the edge.

The dimension "B" is indicated in the list of components supplied in the kit.

2. .
COMMON OPERATIONS

FOR BOTH CABLES, WIRE OR TAPE SCREEN

2.1 Remove the cable insulation from the top of the cables
for a length corresponding to HALF CONNECTOR +
5 mm. Take care to do not nick the conductor.

2.2 If necessary, smooth the insulation surface, to be sure that

all semiconducting traces are removed, using the supplied
abrasive cloth without touching the semiconductive layer.
Smooth the insulating cutting edge.
2.3 Clean up the exposed conductor and apply on the edge
some laps of ELCOPLAST 51.

We recommend during the assembling to protect by some paper or carton the tube from direct sun rays.
Furthemore we suggest not to remove the silicon paper supplied with the tube, and to slide the tubes on the cable with
the silicon paper positioned between the upper side of the cable or other tube and the tube's adhesive. In this way any
sticking between the tube and the cable sheath can be avoided, even in presence of high ambient temperature.

2.4 Slip on to the outer jackets of cables the following heat-shrinkable tubes:
- n.1 Sealing MPS tube (black colour);
- n.1 Insulating-Semiconductive GIS tube (red / black colour);
- n. Insulating GMT tube (red colour) supplied:
n.0 for voltage up to 12 kV or
n.1 for voltage 17,5 kV and 24 kV or
n.2 for voltage 36 kV and 42 kV;
- n.1 Stress control MCC tube (black).
Slip some of them on one side and some others on the other side of the cables, according to the available room.
Protect them opportunely from dirtiness.

Drawing Nº 673/GDBZ Page 4/8

Ogni diritto sui presenti testi, disegni, prodotti e su ogni singola parte di essi è di esclusiva proprietà di Elcon Megarad S.p.A. Ogni riproduzione e/o distribuzione, anche parziale o tradotta, è strettamente proibita.
All the rights on texts, drawings, products and each single part of them is exclusive property of Elcon Megarad S.p.A. All reproduction and/or distribution, even partial or translated of this document is strictly prohibited.
2.5 Remove the pvc tape applied on the conductors.
2.6 Connect the conductors with suitable M.V. connector
following any instructions together, shear or crimp it with
suitable tools.

IMPORTANT:
 Remove any anti-oxidant paste that migrates out of the connector;
 Remove any traces present on the connector using the abrasive cloth;
 Clean the insulation of the cable through the supplied with cleaning tissue, proceeding from the connector
to the semiconductor to avoid dragging semi-conductive particles on the insulation primary, if necessary,
clean the semiconductor being careful not to touch the insulation clean before;
 Properly fill with mastic all surface irregularities on the connector, coming from from the crimp voids, or the
breakage of the screws.

The semiconductive tape ELCOSEM 46 must be applied stretching it up to reduce the original width to
the half, approximately.

(ONLY FOR VOLTAGE 24 kV, 36 kV and 42 kV)

2.7 Apply, one half lapped layer of semiconductive tape ELCOSEM 46 on the connector and on conductor exposed
parts.

The stress control tape ELCOMASTIC 85 must be applied stretching it up to reduce the original width to
the half, approximately.

2.8 Apply at least two half-lapped layers of ELCOMASTIC 85, on the connector area, filling uniformely the area between
connector ends and primary insulation, which has to be overlapped for about 15 mm. Anyway, after wrapping, the
final diameter in the connector area should be slightly greater than one of the cable insulation.

2.9 Apply two half lapped layers of ELCOMASTIC 85, on the cable semiconductor edges overlapping it for 10 mm and
the insulation for 20 mm.

Drawing Nº 673/GDBZ Page 5/8

Ogni diritto sui presenti testi, disegni, prodotti e su ogni singola parte di essi è di esclusiva proprietà di Elcon Megarad S.p.A. Ogni riproduzione e/o distribuzione, anche parziale o tradotta, è strettamente proibita.
All the rights on texts, drawings, products and each single part of them is exclusive property of Elcon Megarad S.p.A. All reproduction and/or distribution, even partial or translated of this document is strictly prohibited.
 2.10 Slide the stress control MCC (black colour) on the joint in such a way as to overlap fairly the cable semiconductor
layer on both sides.
Heat-shrink the tube, as for the GOLDEN RULES, starting from the center and moving towards the ends.

The stress control tube MCC and the insulating tubes GMT have to be cleaned after the heat shrinking.

The sealing mastic ELCOFIL 62 must be applied sligthly stretched.

2.11 Apply one half lapped layer of ELCOFIL 62, starting from the MCC tube edges overlapping for 30 mm the
semiconductor on both sides.

2.12 Center on the MCC tube and then heat shrink the insulating tubes GMT (red colour) supplied in the kit, beginning
with the short type and then the other one, according to the instructions before mentioned.

2.13 Position the shrinkable insulating and semiconductive tube GIS (red/black colour) on the joint in such a way to
center it on the previously applied tube, heat shrink it as above.

Drawing Nº 673/GDBZ Page 6/8

Ogni diritto sui presenti testi, disegni, prodotti e su ogni singola parte di essi è di esclusiva proprietà di Elcon Megarad S.p.A. Ogni riproduzione e/o distribuzione, anche parziale o tradotta, è strettamente proibita.
All the rights on texts, drawings, products and each single part of them is exclusive property of Elcon Megarad S.p.A. All reproduction and/or distribution, even partial or translated of this document is strictly prohibited.
 3. SHIELDING OPERATIONS

WIRE SCREEN CABLE

3.1 Wrap the ELCOSHIELD 49 tinned copper tape, with an overlap 20 %, on the joint to overlap completely the wire
screen on the armour zone on both sides. Fix the extremity, at the end of the taping, by a knot obtained by the same
tape.
3.2 Secure the ELCOSHIELD 49 tapping on the armour, near the outer jacket edge by copper wire available in the kit.

3.3 Turn the wires screen on to the joint, twist the wires together in order to obtain a strand shape conductor. After
having removed the exceeding length, connect the conductors so obtained by a screen connector contained in the
kit, out of central area of joint. Fix the wire shield and the connector to the joint by some layers of ELCOPLAST 51.

EACH SIDE OPERATION

3.4 Position and fix the ground copper braid on the final parts of
ELCOSHIELD 49 taping (in correspondence of the underneath
armour) by two laps of constant force spring (for armour),
refold the copper braid on the constant force spring and wrap the
rest of constant force spring on it. Twisting the constant force
spring so far tight definitively.
3.5 Fix the ground copper braid also on the ELCOSHIELD 49
taping (in correspondence of the underneath wire screen) by
constant force spring (for screen if present in the kit).
Twisting the constant force spring so far tight definitively.
3.6 Fix the ground copper braid on the joint by some laps of pvc tape
ELCOPLAST 51.

TAPE SCREEN CABLE

3.1a Wrap the ELCOSHIELD 49 tinned copper tape, with an overlap 20 %, on the joint to overlap completely the armour
on both sides. Fix the extremity, at the end of the taping, by a knot obtained by the same tape.

Drawing Nº 673/GDBZ Page 7/8

Ogni diritto sui presenti testi, disegni, prodotti e su ogni singola parte di essi è di esclusiva proprietà di Elcon Megarad S.p.A. Ogni riproduzione e/o distribuzione, anche parziale o tradotta, è strettamente proibita.
All the rights on texts, drawings, products and each single part of them is exclusive property of Elcon Megarad S.p.A. All reproduction and/or distribution, even partial or translated of this document is strictly prohibited.
 EACH SIDE OPERATION
3.2a Position and fix the ground copper braid on the final parts of ELCOSHIELD 49 taping (in correspondence of the
underneath armour) by two laps of constant force spring (for armour), refold the copper braid on the constant
force spring and wrap the rest of constant force spring on it. Twisting the constant force spring so far tight definitively.
3.3a Fix the ground copper braid also on the ELCOSHIELD 49 taping (in correspondence of the underneath tape screen)
by constant force spring (for screen). Twisting the constant force spring so far tight definitively.
3.4a Fix the ground copper braid on the joint by some laps of pvc tape ELCOPLAST 51.

4. OUTER JACKET BUILD UP OPERATIONS

FOR BOTH CABLES, WIRE OR TAPE SCREEN

4.1 Roughen, the outer jacket for 200 mm on both sides using the supplied abrasive cloth.
4.2 Place, on both sides of the joint, one layer of sealing mastic ELCOFIL 62 half way on the outer jacket edge, cover
for 50 mm the outer jacket and the constant force springs areas.

4.3 Slide on the joint the sealing tube MPS overlapping for equality dimension the outer jacket on both sides.
4.4 Heat shrink the tube, as before mentioned, until it perfectly stick to the cable.
The adhesive that will come out from the ends of the tube shows that the heat shrinking has been sufficient.

4.5 The joint is completed.

Drawing Nº 673/GDBZ Page 8/8

Ogni diritto sui presenti testi, disegni, prodotti e su ogni singola parte di essi è di esclusiva proprietà di Elcon Megarad S.p.A. Ogni riproduzione e/o distribuzione, anche parziale o tradotta, è strettamente proibita.
All the rights on texts, drawings, products and each single part of them is exclusive property of Elcon Megarad S.p.A. All reproduction and/or distribution, even partial or translated of this document is strictly prohibited.