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INSTALLATION INSTRUCTION
CONNEX cable connector
Inside cone system
Size 3 (3-S) XL
Without voltage tap
For diameter over insulation 45 - 55 mm
For 1-core-cable: lead alloy screen or tape screen

Read the installation instruction

before starting work!
3 (3-S) XL / 040 341 004 (2018-06-28) Index 04
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 3. Technical data
_
3.1 Dimensions and weight(s)
I
English

approx.

approx.

Length, incl. shrink tubing [mm] approx. 680

External diameter, max. [mm] 147
Hole circle [mm] 130
Weight / unit [kg] approx. 3.3

3.2 Cable data

Without voltage tap

Diameter over aluminium
or copper conductor, min. / max. [mm] 19.5 / 34.6
Cross-section, min. / max. [sqmm] 300 / 800
Diameter over insulation, min. / max. [mm] 45.0 / 55.0

3.3 Characteristics

Rated current IN [A] 1250

Max. operating voltage UM [kV] 42 (52)*
Rated short duration power
frequency withstand voltag 50 Hz / 1 min [kV] 95.0 (117)*
Rated lightning impulse
withstand voltage 1,2 / 50 ìs [kV] 200 (250)*
Partial discharge 2 x UO [pC] <= 10
DC voltage test 15 min 6 x UO [kV] 125 (156)*
Rated short-time
withstand current 0,5 sec [kA] 63
1 sec [kA] 50
Rated peak withstand current [kA] 150
*) ( ) = Size 3-S

Seite 8
page
4. Design
_

7
6

4
3
2

Fig. 1: Overview

1 Contact ring
2 Tension cone
3 Thrust piece
4 Insulating part
5 M8 x 45 screws
6 Sealing
7 Bell flange
8 Conical element
9 Shrink tubing

Seite
page 99
 II

page 10
page 11
III

page 12
 Assembly / Installation

7 Assembly / Installation
_ VII
7.1 Cable Positioning, Heating, Straightening

Assembly should be carried out under clean and dry conditions.

The cable has to be straight, it is to be aligned after heating
using a straightening device.
Peel the cable only when it is absolutely straight.
All dimensions are indicated in mm.
1 Mark the so called “jacket cut” (1) measuring 20 mm from the socket
on the cable.
L = min. 400 mm

apcpar .
ox5.050
00 20

Optional - if cable is not straight

2 Heat and straighten the cable from min. 500 mm in front of up to
min. 500 mm behind mark “jacket cut” (1):
Use heating mat to heat the cable at a temperature of approx. 80 °C
(max. 90 °C) for 4 – 6 hours.

3 Straighten the cable after removing the heating mat. If necessary

use alignment rails for 2 hours until the cable is cold. Cable has to
be straight.

Drawing not to scale – Only for Information Size 3 (3-S) XL / lead alloy or tape screen / No. 040 341 004 (2018-06-28) Index 04

www.pfisterer.com 13
 Assembly / Installation

7.2 Cable Preparation

VII _

1 Remove the outer jacket up to 290 mm behind the mark “jacket cut”
(1).
Optional tools:
¡ cable stripper
¡ peeling tool and sheath stripping tool set
2 Sand the outer jacket in the shrink area over 270 mm using emery
cloth (grain 60).
If the outer jacket is conductible, the conductive coating
must be removed over 500 mm from the edge of the outer
jacket. (e.g. by peeling, grinding, washing, ...)
500
270 290 1 L

screen (Al-foil,tape or lead alloy sheath, welded aluminium tube)

3 Clean the roughened area.

4 Apply control mark at 600 mm behind the mark “jacket cut” (1).
5 Wrap one layer of sealing tape around the outer jacket, at 20 mm
behind the edge of the outer jacket.
600
20 1

6 Wrap copper mesh tape with one end around the cable screen and
fold it back. Then solder it leak-proof at the range of the sealing
tape.
Do not solder on the cable - danger of damage.

7 Fix the copper mesh tape with a roll spring.

Drawing not to scale – Only for Information Size 3 (3-S) XL / lead alloy or tape screen / No. 040 341 004 (2018-06-28) Index 04

14 www.pfisterer.com
 Assembly / Installation

VII

8 Apply another layer of sealing tape directly onto the first one.
9 Remove the cable screen up to the mark “jacket cut” (1).
1

10 Mark the end of the cable for a temporary cut 400 mm from the “jacket
cut” (1) and saw it off accordingly with a metal saw.
1 400

Only for “fully bonded” semi-conducting layer

11 At the range between 300 mm and 400 mm in front of the “jacket Measure
cut” (1) peel the semi-conducting layer for checking. Then measure semi-conducting layer -
the difference from semi-conducting layer to peeled insulation using insulation
the enclosed measuring-device, difference < 2 mm means
8 Diameter of insulation must be within the limits of the normale semi-conducting layer
insulating part (see designation at the insulating part). difference > 2 mm means
thick semi-conducting layer
1 400
300

12 Measure a length of 210 mm from the mark “jacket cut” and saw the
conductor off accordingly with a metal saw – do not use a cable cutter!
1 210

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 Assembly / Installation
VII
If the semi-conducting layer is:
easy strippable / removable:
L = 10 mm
thick ( semi-conducting layer -
insulation > 2 mm): L = 20 mm
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16 www.pfisterer.com
Only for normal thick (< 2 mm) “fully bonded” semi-conducting layer
13 Peel off the extruded fully bonded semi-conducting layer up to 40
mm in front of the “jacket cut” (1) using a cutter (to operate the
cutter, see operating instructions).
1 40
Only for “easy strippable”/”removable” semi-conducting layer
Only for thick (> 2 mm) “fully bonded” semi-conducting layer
14 Peel off the easy strippable / removable or thick semi-conducting
layer up to length L in front of the mark “jacket cut” (1).
1
L
15 Strip the conductor over a length of 85 mm and bevel the end of the
insulation to create a slightly bevelled edge
1 125 85
16 Apply a protective wrapping at the end of the insulation.
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 Assembly / Installation

VII

Only for “easy strippable”/”removable” semi-conducting layer

Only for thick (> 2 mm) “fully bonded” semi-conducting layer
17 Wrap self-adhesive insulating tape around the insulation, 85 mm
from its beginning. Lay the adhesive side outward to create a
straight border of the dry graphite. Then put a protective wrapping
on the insulation in the direction of the conductor.
1
(40) 85

18 Apply an well opaque additional conducting layer with dry graphite

to the conductor insulation and the semi-conducting layer. Ensure
that there is 85 mm of conductor insulation remaining. Polish the
graphite with a dry cloth.
Remove protective wrapping from the insulation.
(40) 85

19 Stretch self-fusing semi conductive tape until it is about 1/2 longer.

Cut off a thick end. Beginning with the thin end of semi-conductive
tape apply 2 layers over 30 mm, in a way that there is 20 mm in
front of and 10 mm behind the mark “jacket cut” (1). (Edge of cable
screen must be wrapped.) Cut off remaining semi-conductive tape.
For “easy strippable”/”removeable” semi-conducting layer:
Edge of semi-conducting layer must be wrapped.
1
10 20

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 Assembly / Installation

7.3 Checking
VII _
7.3.1 Measurements
_

1
600 210
270 290 125 85
20 (40) 85
10 20

7.3.2 Comparison diameter of insulation with application range of

the insulating part
_
Check whether the diameter of the peeled insulation is within the limits
stated below. If the diameter is not within these limits, DO NOT INSTALL
THE INSULATING PART.

Prepared insulation Insulating part

diameter range (b) No.

45.0 – 47.0 566 305 001

46.5 – 49.0 566 305 002
48.5 – 51.0 566 305 003
50.5 – 53.0 566 305 004
52.5 – 55.0 566 305 005

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 Assembly / Installation

7.4 Assembly
_ VII

1 Apply protective wrapping made of self-adhesive insulating tape

with adhesive side outward to the dry graphite.
2 Push heat-shrink tubing and bell flange over the cable.
3 Clean insulation of conductor (we recommend benzine 100/140 or
acetone).
4 Apply thin and even PFISTERER MV special grease to conductor
insulation.
1
CONNEX Gr./Size 3
PFISTERER

5 Remove protective wrapping from dry graphite.

6 Check whether the insulating part is clean and apply thin and even
PFISTERER MV special grease inside.

7 Slide the insulating part onto the conductor insulation without

turning until 10 mm of the conductor insulation stick out. Remove
spare grease.
ca. 10
CONNEX Gr./Size 3
PFISTERER

8 Remove protective wrapping from conductor.

9 Position thrust piece with the round side towards insulating part
onto the conductor.
CONNEX Gr./Size 3
PFISTERER

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 Assembly / Installation

VII

10 Push tension cone onto the conductor up to thrust piece.

Conductor may not stick out!
No grease at tension cone!
CONNEX Gr./Size 3
PFISTERER

11 Push contact ring onto the tension cone.

CONNEX Gr./Size 3
PFISTERER

12 Fix contact ring at the tension cone by using the impact device. The
contact ring may not be turnable.
Required tool:
¡ impact device
CONNEX Gr./Size 3
PFISTERER

13 Press on contact ring at the tension cone by using a hydraulic

hand-operated compression tool, until the compression tool
releases automatically.
Required tool:
¡ hydraulic hand-operated compression tool
CONNEX Gr./Size 3
PFISTERER

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 Assembly / Installation

VII

14 Slide the insulating part without turning to the thrust piece.

CONNEX Gr./Size 3
PFISTERER

15 Push bell flange onto the insulating part.

CONNEX Gr./Size 3
PFISTERER

16 Slide back the conical element from the end of the bell flange.
CONNEX Gr./Size 3
PFISTERER

17 Clean surface of the insulating part and apply thin and even
PFISTERER MV special grease. Use protective gloves.
CONNEX Gr./Size 3
PFISTERER

18 Clean the bushing inside. Apply thin and even PFISTERER MV

special grease to the bushing inside. Use clean protective gloves
(e.g. from latex, plastic).

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 Assembly / Installation

VII

19 Plug in the separable connector into the bushing.

The bell flange must be hold with force to the bushing until
the screws fix it.

CONNEX Gr./Size 3
PFISTERER

Optional
20 If there is a M12 inside thread near the bushing:
a) Screw in the chain at the inside thread.
b) Fit the assembly lever at the chain.
c) Use the assembly lever to push the bell flange to the outer
flange of the bushing.
d) Thighten the screws in several steps alternatly using hexagonal
screwdriver SW6 (restrict the torque at approx. 15 Nm).
CONNEX Gr./Size 3
PFISTERER

21 Thighten the screws in several steps alternatly using hexagonal

screwdriver SW6 (restrict the torque at approx. 15 Nm).
CONNEX Gr./Size 3
PFISTERER

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 Assembly / Installation

VII

22 Fit the conical element in the bell flange again.

CONNEX Gr./Size 3
PFISTERER
23 Check the fit of the separable connector: The control mark must be
at 620 mm behind the bell flange – or else push the cable to right
position.
Let the control mark at the cable (do not remove it).
24 Clean the bell flange outside.
25 Position heat-shrink tubing above the ribbing of the bell flange.
620
CONNEX Gr./Size 3
PFISTERER

26 Heat the shrink tubing evenly beginning at the bell flange until it
evenly encloses the former and the internal adhesive protrudes on
both sides (see arrows).
CONNEX Gr./Size 3
PFISTERER

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 Assembly / Installation

7.5 Earthing
VII _

1 Cut the copper mesh tapes to the necessary length and connect to
the ground connection of the equipment.
2 The bell flange offers an optional earthing point (see arrow).
3 Apply the first cable clamp at approx. 800 mm from the equipment
flange.
4 The product can now be operated within the unit observing all
safety regulations.
800

CONNEX Gr./Size 3
PFISTERER
ground connection

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