How to terminate a steel wire armoured cable?

Terminating a steel wire armoured cable is a critical process that requires precision, knowledge, and the right tools. As a supplier of Steel Wire Armoured Cables, I understand the importance of proper cable termination to ensure the safety and efficiency of electrical systems. In this blog post, I will guide you through the step-by-step process of terminating a steel wire armoured cable, highlighting key considerations and best practices along the way.

Understanding Steel Wire Armoured Cables

Before we dive into the termination process, let's briefly understand what steel wire armoured cables are and why they are used. Steel wire armoured cables consist of a core of conductors, insulation, a metallic sheath, and an outer layer of steel wires. The steel wires provide mechanical protection to the cable, making it suitable for use in harsh environments where the cable may be exposed to physical damage, such as underground installations, industrial settings, and outdoor applications.

Tools and Materials Required

To terminate a steel wire armoured cable, you will need the following tools and materials:

• Cable cutter
• Insulation stripper
• Wire brush
• Heat gun
• Cable gland
• Termination kit (including insulation cones, stress control tubes, and sealing compounds)
• Electrical tape
• Screwdriver
• Wrench

Step-by-Step Guide to Terminating a Steel Wire Armoured Cable

Step 1: Prepare the Cable

• Cut the Cable: Use a cable cutter to cut the cable to the desired length, leaving enough slack for the termination process.
• Strip the Outer Sheath: Use an insulation stripper to remove the outer sheath of the cable, exposing the steel wire armour. Make sure to cut the sheath cleanly and evenly, without damaging the armour or the inner conductors.
• Remove the Steel Wire Armour: Use a wire brush to remove any loose strands of steel wire from the armour. Then, use a pair of pliers to carefully bend back the armour wires and cut them off close to the cable.
• Strip the Inner Insulation: Use an insulation stripper to remove the inner insulation from the conductors, exposing the bare copper wires. Make sure to strip the insulation to the appropriate length, as specified in the termination kit instructions.

Step 2: Install the Cable Gland

• Select the Right Cable Gland: Choose a cable gland that is suitable for the size and type of cable you are terminating. Make sure the gland is rated for the environmental conditions in which the cable will be installed.
• Install the Gland: Insert the cable through the gland and tighten the gland nut using a wrench. Make sure the gland is securely tightened, but do not over-tighten it, as this may damage the cable.

Step 3: Apply the Termination Kit

• Prepare the Termination Kit: Follow the instructions provided in the termination kit to prepare the insulation cones, stress control tubes, and sealing compounds. Make sure to wear appropriate personal protective equipment (PPE) when handling the sealing compounds, as they may be hazardous.
• Install the Insulation Cones: Slide the insulation cones onto the conductors, making sure they are properly aligned and seated. Then, use a heat gun to shrink the cones onto the conductors, following the recommended temperature and time settings.
• Install the Stress Control Tubes: Slide the stress control tubes over the insulation cones, making sure they are properly aligned and seated. Then, use a heat gun to shrink the tubes onto the insulation cones, following the recommended temperature and time settings.
• Apply the Sealing Compound: Apply the sealing compound to the joint between the cable and the termination kit, making sure to fill any gaps or voids. Then, use a spatula to smooth the surface of the compound and remove any excess.

Step 4: Connect the Conductors

• Twist the Conductors: Twist the bare copper wires of the conductors together tightly, making sure the strands are evenly distributed.
• Install the Terminals: Slide the terminals onto the conductors, making sure they are properly aligned and seated. Then, use a crimping tool to crimp the terminals onto the conductors, following the recommended crimping force and dimensions.
• Insulate the Terminals: Use electrical tape to insulate the terminals, covering the exposed copper wires and the crimped connections. Make sure to wrap the tape tightly and evenly, without leaving any gaps or overlaps.

Step 5: Test the Termination

• Check the Continuity: Use a multimeter to check the continuity of the conductors, making sure there are no breaks or shorts in the circuit.
• Test the Insulation Resistance: Use an insulation resistance tester to test the insulation resistance of the cable, making sure it meets the required specifications.
• Perform a High-Voltage Test: If required, perform a high-voltage test on the cable termination to ensure its integrity and reliability.

Step 6: Seal the Termination

• Apply Sealing Compound: Apply a layer of sealing compound over the entire termination, including the insulation cones, stress control tubes, and terminals. Make sure to fill any gaps or voids and smooth the surface of the compound.
• Install the Sealing Cap: Install the sealing cap over the termination, making sure it is properly aligned and seated. Then, use a heat gun to shrink the cap onto the termination, following the recommended temperature and time settings.

Key Considerations and Best Practices

• Follow the Manufacturer's Instructions: Always follow the instructions provided in the termination kit and the cable manufacturer's guidelines when terminating a steel wire armoured cable. This will ensure that the termination is performed correctly and safely.
• Use the Right Tools and Materials: Make sure you have the right tools and materials for the job, and that they are in good condition. Using the wrong tools or materials can result in a poor-quality termination and may pose a safety hazard.
• Wear Appropriate PPE: When handling cables, termination kits, and sealing compounds, make sure to wear appropriate personal protective equipment (PPE), such as gloves, safety glasses, and a respirator. This will protect you from potential hazards, such as electrical shock, chemical exposure, and heat burns.
• Inspect the Termination: After completing the termination process, inspect the termination carefully to make sure it is properly installed and sealed. Look for any signs of damage, such as cracks, gaps, or loose connections, and make any necessary repairs or adjustments.
• Test the Termination: Before putting the cable into service, test the termination to make sure it meets the required specifications and is functioning properly. This will help to prevent any potential problems or failures in the electrical system.

Conclusion

Terminating a steel wire armoured cable is a complex process that requires careful planning, preparation, and execution. By following the step-by-step guide and best practices outlined in this blog post, you can ensure that your cable termination is performed correctly and safely, and that your electrical system operates efficiently and reliably.

If you are in the market for high-quality steel wire armoured cables or termination kits, YJV YJV22 YJV32 Low Voltage Copper and High Voltage Flexible Cables for New Energy Electric Vehicles are just some of the products we offer. We also supply RVVP Shielded Cable for various applications. Contact us today to discuss your specific requirements and to learn more about our products and services. We look forward to working with you to meet your cable termination needs.

References

• "Cable Termination Guide," Electrical Installation Guide, International Electrotechnical Commission (IEC), 2019.
• "Steel Wire Armoured Cable Installation and Termination Manual," Manufacturer's Manual, ABC Cable Company, 2020.
• "Best Practices for Cable Termination," Electrical Safety Handbook, National Fire Protection Association (NFPA), 2021.