MAINTENANCE |
e)Remove the incoming connector from the cable by unscrewing the connector nut from the incoming connector. If the cable inner tube is difficult to remove from the connector assembly, carefully slit it lengthwise with a knife up to the brass connector.
f)Cut the cable control wires where they meet the cable jacket or else unsolder the connection where they connect to the terminal lead assembly. If you cut the wires, strip the cut end 3/8 inch (9.5 mm) from the end.
g)Cut off the damaged section of cable and strip off the outer jacket as shown in Figure E.2. Be careful not to cut the insulation on the control wires while stripping the jacket. Strip the red and white control leads 3/8 inch (9.5 mm) from the end.
NOTE: The cable contains three control leads. Any two control leads can be used, provided the two col- ors used are the same at both ends. The extra lead is a spare that can be used if one of the other leads breaks.
h)Check that the cable boot, boot nut, cable handle, strain relief housing and collar nut are on the cable. Slip the connector nut over the copper strands with the threaded end out. Orient the connector assem- bly so the red and white control leads will have the straightest possible routings to the sockets on the back side of the connector. Assemble the incoming connector to the cable by forcing the steel tube of the connector into the inside diameter of the cable inner tube until the copper strands are butted against the incoming connector shoulder. Keeping the copper strands against the shoulder, pull the connector nut over the copper strands, engage the incoming connector threads, and tighten in place. Refer to Figure E.3.
NOTE: For best results, insert a rod through the connector and into the core of the cable approxi- mately 5.00” (127 mm) when pushing the connector tube into the cable core tube. A .219”/.240”
mm) diameter rod is required for 300 and 400 amp cables. To tighten, hold the connector in place while turning the nut, then remove the rod from the core. This procedure assures the inner core does not kink while assembling or tightening.
j)Solder the terminal lead assemblies from step (f) to the control leads stripped in step (g). Insulate both soldered connections using either heat shrink tub- ing or electrical tape.
k)Fully insert the two control lead pins into the sock- ets on the incoming connector. Tape the leads in place in the necked down area of the connector. Keeping the leads as close to the connector and nut as possible, tape the insulated, soldered connec- tions and the spare lead to the cable in the area between the cable jacket and connector nut. This must be done neatly and kept as low as possible or the cable handle will not slide over this area.
l)Position the strain relief to the dimension shown in Figure E.5 and secure with the strain relief housing. On older cables install the cable clamp on the cable jacket within 1/8” (3.2 mm) from the end of the jack- et and tighten.
m)Slide the collar nut and cable handle over the con- nection and into place. Anchor the cable handle with the screw removed in step (c). Slide the boot and boot nut into place and tighten.
NOTE: If the cable handle becomes difficult to slide over connection, try rotating it.
n)Install and trim the liner per “Removal, Installation and Trimming Instructions for Magnum® Liners”.
Central Adapter Assembly
4.10 (104 mm) | Strain Relief |
Terminal Lead Assembly | Strain Relief Housing |
Cable Handle |
|
| Boot Nut |
Connector Nut | Cable Boot |
Collar Nut
Incoming Connector Assembly