ASTM F1835-97(2002)
(Guide)Standard Guide for Cable Splicing Installations
Standard Guide for Cable Splicing Installations
SCOPE
1.1 This guide provides direction and recommends cable splicing materials and methods that would satisfy the requirements of extensive cable splicing in modular ship construction and offers sufficient information and data to assist the shipbuilder in evaluating this option of cable splicing for future ship construction.
1.2 This guide deals with cable splicing at a generic level and details a method that will satisfy the vast majority of cable splicing applications.
1.3 This guide covers acceptable methods of cable splicing used in shipboard cable systems and provides information on current applicable technologies and additional information that the shipbuilder may use in decision making for the cost effectiveness of splicing in electrical cable installations.
1.4 This guide is limited to applications of 2000 V or less, but most of the materials and methods discussed are adaptable to higher voltages, such as 5-kV systems. The cables of this guide relate to all marine cables, domestic and foreign, commercial or U.S. Navy.
1.5 The values stated in SI units shall be regarded as standard. The values given in parentheses are inch-pound units and are for information only.
1.6 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the application of regulatory limitations prior to use.
General Information
Relations
Standards Content (Sample)
An American National Standard
Designation: F 1835 – 97 (Reapproved 2002)
Standard Guide for
Cable Splicing Installations
This standard is issued under the fixed designation F 1835; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (e) indicates an editorial change since the last revision or reapproval.
1. Scope IEEE 45 Recommended Practice for Electrical Installations
on Shipboard
1.1 This guide provides direction and recommends cable
2.3 UL Standards:
splicing materials and methods that would satisfy the require-
UL STD 224 Extruded Insulating Tubing
ments of extensive cable splicing in modular ship construction
UL STD 486A Wire Connectors and Soldering Lugs for Use
and offers sufficient information and data to assist the ship-
with Copper Conductors
builder in evaluating this option of cable splicing for future
2.4 IEC Standards:
ship construction.
IEC 228 Conductors of Insulated Cables
1.2 This guide deals with cable splicing at a generic level
2.5 Federal Regulations:
and details a method that will satisfy the vast majority of cable
Title 46 Code of Federal Regulations (CFR), Shipping
splicing applications.
2.6 Military Specifications:
1.3 This guide covers acceptable methods of cable splicing
MIL-T-16366 Terminals, Electric Lug and Conductor
used in shipboard cable systems and provides information on
Splices, Crimp-Style
current applicable technologies and additional information that
MIL-T-7928 Terminals, Lug, Splices, Conductors, Crimp-
the shipbuilder may use in decision making for the cost
Style, Copper
effectiveness of splicing in electrical cable installations.
1.4 This guide is limited to applications of 2000 V or less,
3. Terminology
but most of the materials and methods discussed are adaptable
3.1 Definitions of Terms Specific to This Standard:
to higher voltages, such as 5-kV systems. The cables of this
3.1.1 adhesive, n—a wide range of materials used exten-
guide relate to all marine cables, domestic and foreign,
sively for bonding and sealing; coating added to the inner wall
commercial or U.S. Navy.
of heat-shrinkable tubing to seal the enclosed area against
1.5 The values stated in SI units shall be regarded as
moisture. Adhesive is for pressure retention and load-bearing
standard. The values given in parentheses are inch-pound units
applications (see also sealant).
and are for information only.
3.1.2 barrel, n—the portion of a terminal that is crimped;
1.6 This standard does not purport to address all of the
designed to receive the conductor, it is called the wire barrel.
safety concerns, if any, associated with its use. It is the
3.1.3 butt connector, n—a connector in which two conduc-
responsibility of the user of this standard to establish appro-
tors come together, end to end, but do not overlap and with
priate safety and health practices and determine the applica-
their axes in line.
tion of regulatory limitations prior to use.
3.1.4 butt splice, n—device for joining conductors by butt-
2. Referenced Documents ing them end to end.
3.1.5 circumferential crimp, n—final configuration of a
2.1 ASTM Standards:
barrel made when crimping dies completely surround the barrel
B 8 Specification for Concentric-Lay-Stranded Copper
2 and form symmetrical indentations.
Conductors, Hard, Medium-Hard, or Soft
3.1.6 compression connector, n—connector crimped by an
D 2671 Test Methods for Heat-Shrinkable Tubing for Elec-
3 externally applied force; the conductor is also crimped by such
trical Use
force inside the tube-like connector body.
2.2 IEEE Standards:
3.1.7 cold-shrink tubing, n—tubular rubber sleeves that are
Available from the Institute of Electrical and Electronic Engineers, IEEE
This guide is under the jurisdiction of ASTM Committee F25 on Ships and
Service Center, 445 Hoes Lane, P.O. Box 1331, Piscataway, NJ 08554-1331.
Marine Technology and is the direct responsibility of Subcommittee F25.10 on 5
Available from Underwriters Laboratories, Inc., 333 Pfingsten Rd., Northbrook,
Electrical.
IL 60062.
Current edition approved Nov. 10, 1997. Published October 1998. 6
Available from the International Electrotechnical Commission, 3 rue de
Annual Book of ASTM Standards, Vol 02.03.
Varembe, Case Postale 131, CH-1211, Geneva 20, Switzerland.
Annual Book of ASTM Standards, Vol 10.02. 7
Available from Standardization Documents Order Desk, Bldg. 4 Section D, 700
Robbins Ave., Philadelphia, PA 19111–5098, Attn: NPODS.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.
F 1835
factory expanded and assembled onto a removable core. No for a cable splice is established by regulations and concerns the
heat is used in installation. Also known as prestretched tubing restriction of being unable to splice cables in defined hazardous
(PST). areas. Hazardous areas are locations in which fire or explosion
3.1.8 crimp connectors, n—tubular copper connectors made hazards may exist as a result of flammable gases or vapors,
to match various wire sizes and fastened to the conductor ends flammable liquids, combustible dust, or ignitable fibers or
by means of a crimping tool. flyings.
3.1.9 crimping die, n—portion of the crimping tool that
shapes the crimp. 6. Cable Splicing
3.1.10 crimping tool, n—a mechanical device, which is
6.1 Cable splicing presented in this guide uses a system of
used to fasten electrical connectors to cable conductors by
compression-crimp, tubular-metal connectors for butt connec-
forcefully compressing the connector onto the conductor. This
tion of cable conductors and insulating systems of shrinkable
tool may have interchangeable dies or “jaws” to fit various size
tubing to reinsulate the individual conductors and replace the
connectors.
overall cable jacket.
3.1.11 heat-shrink tubing, n—electrical insulation tubing of
6.2 Crimp Connectors—For splice connection of conduc-
a polyolefin material, which shrink in diameter from an
tors, compression-crimped connectors shall be used for joining
expanded size to a predetermined size by the application of
an electrical conductor (wire) to another conductor. The joint
heat. It is available in various diameter sizes.
requires proper compression to achieve good electrical perfor-
3.1.12 primary insulation, n—the layer of material that is
mance while not overcompressing and mechanically damaging
designed to do the electrical insulating, usually the first layer of
the conductor. Compression connections are accomplished by
material applied over the conductor.
applying a controlled force on a barrel sleeve to the conductor
3.1.13 sealant, n—inner-wall coating optional to shrinkable
with special tools and precision dies.
tubing to prevent ingress of moisture to the enclosed area (see
6.3 Conductor Reinsulation—Thin-wall shrinkable tubing
also adhesive).
shall be used to reinsulate the conductor and the installed
3.1.14 splice, n—a joint connecting conductors with good
connector. The insulation tubing, when shrunk or recovered,
mechanical strength and good conductivity.
shall be equal in electrical and mechanical properties to the
3.1.15 tensile, n—amount of axial load required to break or
original conductor insulation. Tubing used for conductor rein-
pull wire from the crimped barrel of a terminal or splice.
sulation does not require an interior adhesive sealant coating.
6.4 Cable Jacket Reinsulation—Shrinkable tubing shall be
4. Significance and Use
used to envelop the overall splice. To satisfy more abusive
4.1 Splicing of cables in the shipbuilding industry, both in
conditions that cable jackets are exposed to, a flame-retardant,
Navy and commercial undertakings, has been concentrated in
thick-wall tubing construction with factory applied sealant
repair, conversion, or overhaul programs. However, many
shall be used.
commercial industries, including aerospace and nuclear power,
have standards defining cable splicing methods and materials
7. Cable Preparation
that establish the quality of the splice to prevent loss of power
7.1 Cables to be spliced shall be prepared to the dimensions
or signal, ensure circuit continuity, and avoid potential cata-
specified in Fig. 1 and Fig. 2. Fig. 1 provides cable preparation
strophic failures. This guide presents cable splicing techniques
for power cables from single to four conductor sizes. Dimen-
and hardware for application to commercial and Navy ship-
sions for multiple conductor cables (conductor size of No. 14
building to support the concept of modular ship construction.
or less) are shown in Fig. 2.
4.2 This guide resulted from a study that evaluated the
7.2 Care must be exercised when preparing the cable ends
various methods of cable splicing, current technologies, prior
so that conductor insulation is not cut when removing the
studies and recommendations, performance testing, and the
overall cable jacket, shield, or cable armor, where applicable.
expertise of manufacturers and shipbuilders in actual cabling
Similar care is required when removing the individual shield or
splicing techniques and procedures.
insulation protecting the conductor to prevent cuts or nicks on
4.3 The use of this guide by a shipbuilder will establish
the individual conductor strands.
cabling splicing systems that are: simple and safe to install;
7.2.1 Insulation cutting tools that limit depth of cut should
waterproof, corrosion, and impact resistant; industry accepted
be used to prepare cable ends so that underlying insulation is
with multiple suppliers available; low-cost methods; and suit-
not cut. Similar care is required when removing the individual
able for marine, Navy, and IEC cables.
conductor insulation to protect the conductor copper strands
5. General Requirements for Cable Splicing
from nicks and cuts.
7.2.2 Cable preparation shall result in stripping the indi-
5.1 Cable splicing requires that cable joints be insulated and
vidual conductors so that the bare copper is long enough to
sealed with an insulation equal in electrical and mechanical
reach the full depth of the butt connector plus 3.2 mm ( ⁄8 in.).
properties to the original cable. Cable splicing shall consist of
7.3 Match the geometrical arrangement between cables to
a conductor connector, replacement of conductor insulation,
replacement of the overall cable jacket, and where applicable, be spliced using conductor color code identification to elimi-
nate crossovers or mismatch when splicing.
reestablishment of shielding in shielded cables and electric
continuity in the armor of armored cables. 7.4 Cable ends shall be in or near their final position before
5.2 Nonsplice Applications—The only unacceptable area being spliced.
F 1835
FIG. 1 Splice Dimensions for Power Cables
F 1835
FIG. 2 Splice Dimensions for Control-Multiple Conductor Cables
8. Materials and Tools 8.1.1.3 Connectors shall be marked with wire size for easy
identification.
8.1 Cable Splicing Materials—The following sections pro-
vide an overview of the various splice materials. In addition, 8.1.1.4 Connector shall have inspection holes to allow
specific recommendations and suggested guidelines are offered visual inspection for proper wire insertion.
that would enhance the cable splicing process.
8.1.1.5 Butt connector for wire sizes No. 10 (AWG) or
8.1.1 Crimp-Type Connectors—Splice connectors shall be
larger shall be the “long barrel” type to permit multiple crimps
compression-type, butt connectors conforming to the require-
on each side of the connector for greater tensile strength. The
ments of UL STD 486A and shall be satisfactory to Section
conductor ends shall be fully inserted to the “stop” at the center
20.11 of IEEE 45.
of the connector. For smaller conductor sizes (No. 10 AWG or
8.1.1.1 Connector shall be seamless, tin-plated copper.
less), a single crimp should be spaced half way between the
8.1.1.2 Butt connector shall have positive center wire stops
end of the connector and the center wire stop.
for proper depth of conductor insertion.
F 1835
8.1.1.6 Connector shall be color-coded in accordance with cross-linked polyolefin tubing.
Table 1 or Table 2.
8.1.3.3 Shrink tubing shall be flame retardant (FR-1) in
8.1.2 Conductor Reinsulating Material—To reinsulate the accordance with UL STD 224 requirements.
conductor and the installed connector, heat-shrink tubing shall
8.1.3.4 Tubing used for rejacketing of a splice bundle shall
be used. (see Table 3). have an interior coating of adhesive (mastic) sealant.
8.1.2.1 When recovered or shrink, the tubing used shall be
8.1.3.5 Table 3 provides dimensions for thick-wall tubing
equal to or greater than the thickness of the original conductor
used for rejacketing of cables.
insulation.
8.1.3.6 Tubing shall have the following performance re-
8.1.2.2 Shrink tubing used for conductor reinsulation shall
quirements:
be heat-shrink tubing. The tubing shall be thin-wall cross-
Shrink ratio 3:1
Operating temperature range –55 to +135°C
linked polyolefin tubing, flame-retardant (FR-1) construction
Minimum shrinkage temperature (for
in accordance with UL STD 224 requirements. Performance
heat-shrink tubing) +121°C
requirements shall include:
Longitudinal shrinkage 65%
Electrical rating 600-V continuous operation
Shrink ratio 2:1
Dielectric strength in accordance with 7.9 kV/mm (200 V/mil) min
Operating temperature range –55 to +135°C
Test Methods D 2671
Minimum shrinkage temperature +121°C
Longitudinal shrinkage 65%
8.1.4 Shield Terminations—Cables that require continued
Electrical rating 600-V continuous operation
Dielectric strength in accordance with 19.7 kV/mm (500 V/mil) min shielding shall have at least a 13-mm ( ⁄2-in.) overlap between
Test Methods D 2671
the replacement shielding material and the permanent shielding
and shall be attached with either solder-type connectors or a
8.1.2.3 Shrink tubing to cover the connection of individual
mechanical connection using inner and outer compression
conductors does not require an interior coating of adhesive
(crimp-type) rings.
(mastic) sealant.
8.2 Splicing Tools:
8.1.3 Cable Jacket Replacement Materials—Several meth-
ods and a variety of materials are available that will provide the 8.2.1 Cable Preparation—The basic tools required for cable
splice preparation include a cable cutter, measuring tape or
mechanical protection, moisture-sealing properties, and elec-
trical performance characteristics needed in a cable splice. For ruler, and a wire insulation stripper. Following the cable
a splice reliability and ease of installation replacement of cable preparation, the types of tools required to complete a cable
jacket and to envelop the splice area, howe
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