big cables

[fotlong]

has anyone ever terminated a 400 mm 4 core swa how hard and how much space do you need

 

[Dave_]

You´ll need a hand - not planning on doing this alone no? It´ll be really difficult to bend, and heavy to lift into position etc, a 2 man job. Youll need a fair bit of space, but every situation is different so its hard to say.

 

[bugsy]

Yes and as stated two man job, what are you terminating into? and are you dropping from tray / ladder or comming in from the bottom?

 

[Deleted member 26818]

A large hammer, bit of rope and a lever bar will be usefull, if there's any bending involved.

 

[fotlong]

its 2 x 4core 400mm in parrallel into floor mounted switch board with a 1.8m deep cable pit underneath
dont fancy my chances

 

[Dave_]

Do you mean a big switch panel? cables enter from pit below.... where do they terminate into? Hope its not awkward to gland in, that would make life tough...! You may struggle more with bending the cores depending on what space you have. Also you will need a very big crimping tool to get the lugs on.... You can hire them from most wholesalers if you dont already own one.

 

[Engineer54]

Another thing you need to think about with these larger sized cables is the core sequence. Your cable cores need to be in the correct orientation for the equipment it's being connected too. Otherwise it'll look like a pig's ear of a job!! lol!!! Nothing worse than to see cable cores crossing to connect into your switchgear.

Bit of a tip here, instead of using a standard 400mm screwed SWA gland, use the bolt-on type tube gland. (for the life of me i can't recall the correct name of them) The type where you attach the steel wire armour to the exterior of the tube with either lengths of twisted armouring or long terry type clamps. and heat shrink over the completed gland termination. I also like to seal the cable end with heat shrink trousers. Using this method, is far easier to terminate large cables and gives a professional finish to the job...

 

[Engineer54]

Do you mean a big switch panel? cables enter from pit below.... where do they terminate into? Hope its not awkward to gland in, that would make life tough...! You may struggle more with bending the cores depending on what space you have. Also you will need a very big crimping tool to get the lugs on.... You can hire them from most wholesalers if you dont already own one.

Your right there, ....rarely do these Switch Panels allow you enough space to dress the lager cable tails/cores and fotlong has Two of them to dress in. But coming up from a pit into the panel, makes life a little easier, ....no tight bends to worry about....

Professional switchgear terminators will have a whole host of self made core bending/dressing tools, life gets very hard when you don't have them, and your relying on brute force, ...unless your Mr Atlas of course ...lol!!!

 

[Knobhead]

You have my sympathy.
Add to the rope some wooden blocks to chock the cable in to place. If you can lay your hands on some chain block you’ll find them handy, especially for bending the cable. I’ve resorted to chain blocks and an Enerpack jack together to get the cables in to place.
I hope you’ve got 18” stilsons for the glands. Once the glands are made off then there’s the fun of the core terminations.
Stand back and look at the job before jumping in with both feet and making work for yourself.

 

[Dave_]

I hope you’ve got 18” stilsons for the glands. Once the glands are made off then there’s the fun of the core terminations.

Good point forgot about the stilsons.... The biggest thing you´ll need is strength! and patience..... watch you dont skag the cable when you pull the cores through the hole you cut, the weight of the cable could catch you out there... you can leave the inner insulation on, (not core insulation, but insulation around this) score it first though as you may struggle to get a nice cut on it once in situ (will protect cable when fitting to panel)

hope this helps

 

[Engineer54]

Won't need the Stiltons, if he uses those bolt on tube glands, as mentioned above. It will make this job a good deal easier for him, without a doubt!!! What he may need however is a good chain lever wrench with some protection around the chain. Very handy for turning the cable, a quarter turn or so....

Been involved with literary hundreds of these types of switchgear cable connections, and if he doesn't plan out his operation, and have a good range of tools, rope, levers, and the like handy or to hand, ...he could be in for a very rough time under that switchgear panel.


Edit.....

Just remembered the name of those bolted on SWA glands ''Top Hat'' glands. ...Often used to gland off multi core HV SWA cables into switch gear etc.

There quicker and easier to install any large multi core cables into switchgear. So forget about mucking around trying to screw clamping 400mm SWA into a normal type gland and use a Top Hat gland....

 

[bugsy]

Your pit will have to be deep enough to allow approx 1m from the bottom to the gland plate , 240 x 2 is not that bad actually, but i think pump pliers as opposed to stilsons - they won't get near it. measure it of ( gland to terminal lugs ), gland it and fit the lugs before you actually install it

 

[Dave_]

Re: big cables

Won't need the Stiltons, if he uses those bolt on tube glands
​

But i love Stilton.... and camembert!

Engineer 54 - got any more info on these glands, very interested!! anything to make life easier!! many a late night had struggling with big SWA matey

but i think pump pliers as opposed to stilsons - they won't get near it.

I personally much prefer stilsons.... no chance of slipping when your busting your balls trying to tighten the gland....


​

 

[Engineer54]

Dave_


I'm sorry i haven't!! But i know that Raychem stock them, (look up there website) and i dare say most of the well know cable gland manufacturers (check them out too). One thing is for sure, they are a god send when having to terminate the larger sized multi core SWA cables.

Straight forwardly terminate the cable SWA onto the gland etc, then push the inner cores into the Switchgear chanmber and connect the the gland to the switchgear base via the 4 bolts (which you previously lined up and drilled) Pull up the heat shrink and shrink over the SWA connection. Whats more the finished gland termination gives a professional look/finish to the job!!!

Alas then i'm afraid your still left with the dressing of those larger sized cores. But the cable is solidly attached to the that switchgear ...lol!!!

 

[Engineer54]

Theres a bit on top hat glands here CABLE GLANDS, TOP HAT GLANDS, 11KV SWA CABLE GLANDS, HV GLANDS, CAST INTEGRAL EARTH GLANDS, 6.6KV 33

I found that page too, but these are a bit over the top and very dedicated to an HV installation, which is far more involved than what the OP needs, (but does give an idea of how it's used). The one's i'm familiar with, are more basic and generally made from Zinc plated steel. (they too can, and are used to terminate HV cables) and far more suited to the type of LV termination the O/P requires....