There is currently no approval for use in areas subject to explosion hazard.

As long as only the cable sheath (external plastic) has been damaged, the insulation tape can be used as a temporary protection. It does not create a secure seal against moisture. However, if the base insulation is also damaged, simple insulation tape is no longer sufficient. In this case, it is recommended to use a gel, cat resin or heat shrinkable cable joint. The same applies to damages to the core.

BBC Cellpack's polyurethane-based sealing compounds are susceptible to petrol, which can affect their properties.

Organic fertilisers are composed of different chemical substances, such as ammonia or nitrate in varying concentrations. As a result, it is not possible to carry out a meaningful test of the sets with regard to organic fertilisers.

End joints and branch joints for medium voltage are not included in the BBC Cellpack product range.

The gel joints from the EASYCELL® product range are designed for single use only.

The SHE house connection point is not suitable for feed-through in floor slabs.

All cast resins and shrink systems are suitable for sea water. However, they are not directly tested with the common test standards.

The self-sealing tapes with UV stabilisation offered by BBC Cellpack are specified in the overview table in the catalogue.

UV-resistant is generally used as a colloquial term to indicate that the properties of a material do not change at all or not significantly due to UV irradiation. UV-stabilised specifies relevant ambient conditions (e.g. (e.g. irradiance and irradiation duration). UV irradiation can alter the properties of the tapes within acceptable limits.

To create a safe electrical connection, a minimum distance of 5 mm is compulsory for low voltage (up to 1 kV) between the terminals / cores and plastic shell and/or housing of the branch box. This 5 mm distance also applies to gaps between individual non-insulated connectors. Individual measurement sin the BBC Cellpack assembly instructions may vary according to product.

The joint can be used straight after casting and/or when live. The relevant provisions “Working with live parts” must be complied with.

Heat shrinkable components are components that shrink back to their original production state when heat is applied, such as spreader caps, end caps, hoses, or sleeves. A hot-air blower can be used for shrinking. The heat input, however, is lower compared to a gas burner. This prolongs the duration of the shrinking process. The settings and nozzle must be individually selected depending on the hot-air blower used. It is important to make sure that the surface of the shrinkable tube is not burned.

If it is a hose with hot melt adhesive (SRH...), the adhesive will slowly flow out at both ends. Uniform wall thicknesses and straight labelling are important indicators for correct shrinkage.

The formulas of most 2-component cast resins have components with different properties. Using the cast resin within the best-before date guarantees safe handling and ensures that the functions work properly when used properly. The mixture may still work once the best-before date has been exceeded. However, the properties may deviate.

The gel joints can be installed at temperatures of up to -20°C. As with all other joints, care must also be taken that there is no moisture in the entire gel joint area, snow and ice included.

This generally does not prove a problem as long as the housing has been sealed when casting and/or the cat resin cannot escape after the casting until it has hardened.

If the DR-L connectors have a second crimping point in the component application, they can be used on solid conductors. Since the DR connectors are designed shorter and only allow one crimping point, the component application cannot be used for solid conductors. The common crimping pliers have 2 crimping points in the jaws, i.e. on the DR-L, the pliers are applied 2x for left and right. On the DR, the pliers are pressed on both sides with 1x pressing operation. The EASY-FIX system application is in turn available on solid conductors.

(Component application = direct reference to the crimp connector)

As there are a multitude of crimping pliers, this application primarily depends on the tool used. 
We therefore recommend to check and approve this application yourself.

All EASYCELL® joints are tested in accordance with test standard DIN EN 50393. This standard requires for the load to be changed with 0.1 bar water pressure. This means that the joint can be used in water depths of up to 1m. The assembly specifications must be complied with at all times. Deeper applications can be agreed with the manufacturer, but have to be tested separately

The test adapters are exclusively intended for use in threaded shielded T-shaped EPDM cable connections of the types CTS and CTKS. It is not allowed to use the screw inserts in cable connectors from other manufacturers.

Our joints go through extensive tests, such as test standard DIN EN 50393. We thus guarantee that our joints function permanently and are safe. We seriously discourage you from making your own joint so that you do not have to assume responsibility.

Thanks to their design, the joint shell and the associated branch-off block are suitable for one continuous main cable and one branch cable.

Public swimming pool water contains a certain concentration of chlorine. This point falls under the term “resistant to chemical effects”. This means that tests with the actual chlorine content and/or composition of the water (e.g. thermal water) are necessary. Of course it has to be assumed that the components have been properly assembled and used as specified.

The BBC Cellpack sets have not been certified for drinking water.

It has to be remembered that the cable cross-section and minimum diameter across the insulation falls within the specified range for the set. The reverse is excluded. In most cases, the applicable system voltages are specified in the documentation available and provided.

The contact pin can be removed with a long socket, which makes it possible to reuse it. We recommend using an additional set, because the surfaces are both cleaned and the lubricant GM1 must be reused. It is also important to ensure appropriate air-release during installation on the feed-through and the termination insert. The required torque is available on request.

Yes, EASYCELL 3V, 4V and 5V can be combined with CU conductors and AL conductors, since they have a tin-plated connection block with separator.

This use is generally possible. However, it has to be ensured that sufficient gel is displaced. This means that both gel surfaces must close around the cable end to ensure a seal against moisture.

It can be used according to the compatibility table. The cross-sectional area deviates from the current standard products.

The screw cable lugs of the connector product range are not suitable for this application. This type of cable is very special and requires deeper inspection for suitability.

The responsible person in the network is responsible for deciding whether a cable sheath can be repaired. This depends on the damage and the properties the cable sheath satisfies. In general, a cable may only be repaired with a sleeve if the damage affects only the outer cable sheath. If additional damage to the core insulation is detected, repairs by means of a sleeve are not permitted. The cable must then be repaired as a complete system, either with additional insulating and sealing components over the damaged core(s) or, if necessary, by installing a straight-through joint over the damaged cable section.

If it decided to use shrinkable sleeves, the sleeve should be selected according to the values mentioned in the catalogue. The operating voltage of the cable is not the deciding factor when selecting the right sleeve. The function of sleeves is described as follows - restoration of the outer cable sheath in its three functions insulation, protection against moisture and mechanical protection.

Straight-through joints are designed for connecting two touching cables. Branch joints, on the other hand, are for a main conductor (that is not cut) and output cable. It is difficult to join all three cable ends in one joint as the inside of the casing is too small and special connectors are required. BBC Cellpack also did not design these joints for this application area. It is recommended to use the following constellation for creating a reliable and safe connection:

The tensile strength of BBC Cellpack sets depends on the system used (e.g.: shell with mounting, screwed connection, tensile connectors). The standard for sets does not include a tensile test of the installed joint. The standard for compression and screw connectors refers to DIN EN 61238-1, which describes the requirements for mechanical testing. A strain relief implies that no tensile forces are applied.

The BBC Cellpack gel products are made from cross-linked silicone. As soon as the silicone has cross-linked, the tolerance is not limited.

The conductor shapes are tested at the factory: RE (round, solid), RM (round, stranded), SE (sector, solid) and SM (sector, stranded). Connectors and cable lugs are approved for conductor class 1 (solid conductor construction) and 2 (stranded conductor construction). Compressed conductors (RMv and SMv) are also supported. There is no approval available for class 5 (fine stranded conductors) and class 6 (extra fine stranded conductors).

A cast resin joint can generally be used for this if the minimum distances are complied with. It is a little more difficult, but generally possible, to seal the flat cable into the round infeed of the shell. Heat shrinkable and gel cable joints are less suitable for this job due to the flat cable.

BBC Cellpack's AK screw branch clamps are suitable for branching aluminium or copper conductors. To ensure that no parts are lost, we recommend that you only open the AK clamp after the cable ends have been prepared. This is done by stripping the main conductor in the contact area without cutting the conductor. The conductor of the branch is also stripped at the end and then placed above the main conductor. To open the AK clamp, remove the contact screw and the upper plastic half. The AK clamp is assembled in the reverse order.
Two aluminium or two copper conductors can also be connected, but aluminium and copper cannot be combined due to the design.

BBC Cellpack's FK overhead line terminals are suitable for branching copper conductors. To ensure that no parts are lost, we recommend that you only open the FK terminal after the cable ends have been prepared. This is done by stripping the main conductor in the contact area without cutting the conductor. The conductor of the branch is also stripped at the end and then placed above the main conductor. To open the FK clamp, remove the nut. The FK clamp is assembled in the reverse order. Two copper conductors can also be connected.

BBC Cellpack's KP branch clamps are suitable for branching copper conductors. To open the KP clamp, turn the screw to the end of the thread. The main cable and the branch cable are then positioned in the housing recesses provided for this purpose without stripping them. To assemble the KP clamp, the screw is tightened again, while the wires are contacted by the integrated cutting contact.

There are different options:

1) Copper press cable lugs in accordance with DIN 46235 and aluminium press cable lugs in accordance with DIN 46239 are pressed using the hex method in accordance with DIN 48083. The press insert to be used depends on the external diameter, which is always stated on the component. The pressing process evenly deforms the individual cores, thus creating a stable electrical and mechanical connection.

2) If the cable lug is specific to a manufacturer (so-called tube cable lug), it is only permissible for the copper area and cable class 2 in accordance with DIN 60228 in most cases. In such case, the system specific to the manufacturer must always be used.

In both cases, the pressing process starts from the centre of the bore hole (as marked) and continues toward the cable. The pressing makes the connector a little longer. A pressing excess of 5 mm (Cu) and 10 mm (Al) is therefore accounted for when preparing the cable.

For screw connectors with shear bolts, all bolts must be tightened in sequence during assembly.

If there are two bolts per cable side, the bolt toward the cable is then sheared off first followed by the bolt to the centre of the connector. For screw connectors with just one bolt each, these must be tightened evenly until shearing off.

Unused cast resin hardens in the bag. Once fully hardened and as long as components A and B have been fully mixed, it can be simply discarded with the residual waste.

A tube is initially extruded from polyolefin pellets. Depending on the type of tube, the hot melt adhesive is introduced in this step (co-extruded). The tubes are then electron beam cross linked. This changes the molecular structure and the tubes receive a “memory”. In another work step with heat supply, the tube is expanded to the required diameter, then cooled down and cut. When heating up, the tube “remembers” its original state and shrinks back.

This is used for easily feeding cables and cores through walls in buildings.

Simply put, it is a shrinkable tube that is positioned on a formative metal spiral. Once installed, the cable is pushed through the duct in the house and sealed by simply heating up the ends of the house duct. This is the assembly process:

First drill a hole through the brickwork. It is recommended to refer to the BBC Cellpack data sheet to ensure that the right drill bit with the right diameter is being used. The cable centering aid can be used for aligning the house connection point. When the distances are correct, the sealing compound can be prepared. Like the cast resin, it is mixed in a two-chamber bag but has a much quicker reaction time. A homogenous sealing is now created with a spatula. Due to the shorter processing time, a separate bag can be used for the inside and outside.

STEP 1: Ideally, the bag has a temperature of around 20 °C.
STEP 2: Before starting the mixing process, the separator between resin and hardener has to be removed. The sealed mixing bag makes contact with the two components impossible.
STEP 3: During the mixing process, both components must be mixed until one homogenous mass as best as possible. The times specified in the processing instructions, 3 minutes, must be complied with.
STEPS 4+5: It is not enough to simply sway or shake the bag. To prevent cast resin losses as much as possible, it is recommended to spread the cast resin from the corners and roll up the empty end.
STEPS 6+7: Afterwards, one corner of the bag can be cut open to pour the cast resin into the joint. Below is an image of the assembly instructions with the separate steps:

In the assembly instructions for the VASMI and SMHF telecommunication joints, this step is described as follows:

A) Preparing the cables
Overlap the cables as shown in drawing:

The cables are prepared exactly like the straight-through joints, depending on cable type.

B) Screen connection

Create screen connection like the straight-through joint.

Assemble screen connection branch clamp and wire (take from MSFA and assemble according to the assembly instructions).

The MSFA accessories set is only required for branch joints.

During the kneading process, the resin and hardener are mixed and start an exothermic chemical reaction. The assembly instructions provided show a bag mixing time of 3 minutes. If the mixing time is shorter, the components are not sufficiently mixed. Contrary to popular opinion, the cast resin does not “dry”; if the reaction cannot occur, the mix will not harden. The electrically and mechanically required properties are not met in this case.

The hardening time of the liquid EG cast resin depends on the ambient temperature, component temperature and cast resin volume. The following diagramme contains more information on this topic: 

Firstly, position the shrinkable tube. Initially set the blow torch to a soft yellow flame. Now start the heating process from the centre and radiating outward. Continue this movement whilst initially shrinking one full side. Now change back to the centre and repeat the process on the other side.
If the tube contains hot melt adhesive (SRH...), the adhesive slowly escapes at both ends. Important indicators that the shrinking process has been completed correctly are even wall strengths and straight labelling. Below is an image from straight-through joint assembly instructions:

Firstly, position the spreader cap on the cable joint. Initially set the blow torch to a soft yellow flame. Now start heating up the interstice (1) radially. Continue this movement whilst shrinking the shaft (2+3) toward the cable sheath. Now change back to the shaft and evenly shrink the fingers (4) toward the core; also heat up the inside of the splice. The adhesive slowly escapes at the end of the shaft and the spreader fingers after a short period. Important indicators that the shrinking process has been completed correctly are even wall strengths and straight labelling.

The EASYCELL joints can be installed in a range from -10°C to +60°C.

After installation, the joints can be operated in a temperature range from -20°C to +90°C.

The heat shrinkable kits offered by BBC Cellpack are suitable for concealed installation. We do not recommend using individual tubes without hot-melt adhesive, since in this case, there is no protection against the penetration of moisture and the insulating function of the hose over the offset cable cannot be fulfilled.

Conductive outer layer of the body of EPDM absorb UV radiation and, in most cases, there is UV-exposure which leads to partly surface aging at the border of material with outside atmosphere. Due to this feature of the material, damage of deeper layers through UV-exposure is not expected. The usage of UV-stabilized PVC band (No. 228 or No. 328) on the cable entry is recommended.

No, this is not recommended. The lubricants are assigned to specific cable accessories. Most have electrical properties in special areas (e.g. dissipation factor or dielectric constant). A standardisation is not possible.

The SRAT heat shrinkable tube can be used as a core insulating tube for end closures and as protection against corrosion. It must not be used to protect busbars or to shorten the distances between these busbars. This function has not been tested. It cannot be guaranteed. The SRBB hose is the right solution for this application.

Whether a shrinkable sleeve can be used for repairing the cable sheath is based on the damage assessment of the cable manufacturer. The shrinkable sleeve is only used for mechanical protection and prevents the moisture ingress. The shrinkable sleeve does not fulfil any beneficial properties for operating E90 cables.

Deposits in the form of uniform crystallisation on the inner surface of EPDM insulating bodies are process-related degradation products of the peroxide used in the manufacturing process.

There are no negative findings on effects of such crystallisation that would impair the function of the device. Depending on storage temperatures and duration, these crystal formations can occur on all surfaces. In case of very strong crystallisation, we recommend wiping the inner surfaces as part of the inspection and cleaning process prior to assembly in order to avoid influences when screwing in the insulating terminations or placing the insulating body on the entry point.

Test standard DIN EN 50393 does not contain any test of the entire system for the impact of gases.

Changes in the properties depending on the substance and concentration are also not tested.

If assembled correctly in accordance with the specifications in the assembly instructions, the cast resin systems are protected against water penetration up to 1m depth.

Test standard DIN EN 50393 contains corresponding tests at a water depth of 1m.

The term “alkaline earth metals”  is a generalisation for alkaline earth metals such as magnesium and calcium that together with water form a chemical solution. This solution can trigger chemical reactions. Different reactions may occur depending on the concentration of a substance in the solution. A solution can generally be summarised under the point “chemical stability”.

Resistance to chemical effects must always relate to a substance and specific property and their changes. “Good resistance to chemical effects” generally refers to a broad tolerance. Tests with acids (e.g. 10% hydrochloric acid), lyes (e.g. 10% NaOH), polar (e.g. isopropanol / water() and apolar solvents (e.g. transformer oil) are usually a prerequisite.

The designation FE180 indicates that insulating properties are maintained for 180 minutes in accordance with a corresponding electrotechnical test standard. The designation E90 means that a complete system maintains functional integrity for 90 minutes. This abbreviation stands for special behaviours of the cable system in the case of fire.

Polyurethane (PUR) cast resins consist of two components, one resin and one hardening component. Elements of the hardening component react more easily with water than with the PUR resin component. The mixture foams on contact with moisture. The electrically and mechanically required properties are not met in this case. Special cast resin systems, such as the UWR cast resin, are available when working in humid conditions.

Our cast resin systems have been tried and tested over decades. The electrical and mechanical properties after hardening create a permanent and reliable cable connection. We provide a wide range of cast resins for multiple application areas.

This new technology combines easy handling, unlabelled material and indefinite storage periods. The electrical properties after hardening create a permanent and reliable cable connection. We recommend to keep a minimum wiring distance between the terminals / cores and walls of the branch boxes.

Our heat shrinkable products have been tried and tested over decades. The electrical and mechanical properties after cooling down create a permanent and reliable cable connection. Heat shrinkable products can be ordered for stockpiling as they can be stored for indefinite periods.

The hardening time describes the time required for hardening 100% with the mechanical properties of components A and B. The pot life is a standardised term which colloquially is defined as processing period. Reactions may be quick or slow, depending on different temperatures.

For low voltage, a joint or cable termination must be used for recreating the basic insulation and sheath. Cast resins, silicone gels or heat shrinkable tubes can be used to do this.
The insulating parameters are much higher in the medium voltage range. The electrical field also has to be treated. Field control elements are used to do so as well as a special system component geometry.

The recommended processing temperature of POWER GEL is between +15 °C and +30 °C, whereas the thermal stability is between -40 °C and +150 °C.

The low voltage heat shrinkable tubes must meet the requirements of the DIN EN 50393 standard. This standard gives a detailed description of test methods and requirements for sets with a nominal voltage of 0.6 / 1.0 (1.2) kV. The standard properties and requirements for heat shrinkable tubes are contained in the DIN IEC 60684 standard (Part 1: Terminology and general requirements; Part 2: Test methods; Part 3: Requirements for individual tube types).
The allocation of protection classes (protection types) is part of DIN EN 60529 (VDE 0470). According to this standard, the scope of the protection provided by a housing against access to hazardous components, penetration of solid contaminants and/or water penetration has been proven with standardised test methods. In both cases (low voltage heat shrinkable cable joints / tubes), there is no additional housing, which makes it impossible to test the protection class.

The tightening torque is 30Nm.

Shielded plug or screw cable connectors with and without metal housing are earthed materials that can be safely touched during fault-free operation if they have been earthed and installed properly.

We generally recommend not touching any live separable cable connectors as it is not always apparent from the outside of they are operating properly.

The requirements placed by the customer/user on the end product and the requirement for its proper function in its operating environment are important.

In general, halogen-free heat shrinkable components can also be used on cables that contain halogen (PVC) and heat shrinkable components that contain halogen (e.g. flame-retardant hoses) can generally also be used on halogen-free cables (PE, XLPE).

The recommended storage temperature for PUR cast resin products offered by BBC Cellpack is between 15°C and 35°C.

firstly, the area in which the joint is to be installed has to be known. Sometimes special characteristics, such as explosion protection areas, mining applications, fire protection precautions, water depths, etc, have to be taken into consideration. The cable data is also particularly important. Most of the time, this information is stated in the manufacturer’s data sheet:

• Conductor material (copper or aluminium)

• Number of cores, conductor cross-section, type and class

• External diameter of the cable sheath

• Material used for insulating the cable sheath

If a concentric conductor (Ceander) or armouring are installed, they have to be taken into account when selecting the joint. The BBC Cellpack catalogue already contains an allocation table for most of the cables and cores.

When assembling screw connectors and screw cable lugs, forces occur which can no longer be compensated manually. As a result, deformations can occur in the transition area. Deformations can impair the function of the set and damage the conductor material. We recommend using a counter-holder, because of its leverage effect with various tools.

If a cable lug is not already supplied by BBC Cellpack, it should be selected according to specific criteria. In addition to the conductor (material, cross section, shape), the length and diameter of the hole, the longitudinal watertightness is particularly important. This is due to the fact that the set is directly exposed to environmental influences (such as rain).

Cast resin have excellent electrical insulating properties. Different cast resins can be selected for different application areas:

EG: Universal cast resin for plastic, paper-insulated low voltage cables, telecommunication cables and messaging cables. EG is protects medium voltage cables from mechanical impacts and moisture.

GG: Special cast resin for health and safety at work due to reduced hazardous substance labelling. GG is suitable for plastic aand paper-insulated low voltage cables.

FG: Flexible cast resin is suitable for repairing damaged cable sheaths and connecting flexible cables.

UG: Meets tougher fire protection requirements and is used in the mining industry.

UWR: Is water-resistant and makes it possible to cast whilst exposed to moisture.

WG: The hardened moulding material can be easily removed again using small tools.

CG: Environmentally friendly removable cold casting mass made on a hydrocarbon basis. CG is free from silicones and isocyanates and has no hazardous substances label.

Compression cable lugs according to DIN 46235 and compression connectors according to DIN 46267 are generally suitable for a hexagonal compression of class 5 and 6 conductors (DIN/IEC 60228), this can be verified in a separate test sequence (e.g.: DIN IEC 61238).

For concentric conductors (without a fixed conductor shape), compression connectors tested according to DIN 46267 can be used. Screw solutions are also possible, but they must first be checked for suitability.

Use standard over-the-counter crimping pliers. Please enquire with the manufacturer of your choice.

Standard over-the-counter crimping pliers can be used for insulated connectors. Please enquire with the manufacturer of your choice.

The SR1F and SR1F3 tubes are permitted in accordance with UL. Both tube types are listed in the UL list under document number E172094.

• The tools in the table have been tried and tested as assembly tools. A manufacturer-independent release of impact wrenches is not possible according to the current status, since only tested devices can be released (product liability).
• Notes on assembly: The tools must not have any defects and must be used properly and according to the enclosed instructions. They must also be positioned correctly and perpendicular to the shear bolt.
• There must be no leverage effect on the shear bolt. Suitable tool inserts (one-piece) must be used. The battery must be sufficiently charged. The assembly must be carried out according to the assembly instructions. The connectors or cable lugs must be approved for the respective application.

Apart from their connection techniques, our joints are fundamentally different:

• Heat shrinkable cable joints have inner sleeves made from shrinkable tubes that recreate the core insulation. A larger heat shrinkable tube serves as the cable sheath.

• Cast resin joints use a polyurethane 2-component cast resin which is poured into a plastic shell for creating the electric insulation and mechanical protection.

• Gel joints insulate the connector through gel displacement. The formative shell provides mechanical protection.

Special sets are required as these are flexible cables. Product allocation cannot be generalised due to the varied application areas. BBC Cellpack provides several solutions. Please contact us for further information.

There are currently no sets available for EX areas due to normative changes.

There are different options: 

1) Copper press connectors in accordance with DIN 46267-1 and aluminium press connectors in accordance with DIN 46267-2 are pressed using the hex method in accordance with DIN 48083. The press insert to be used depends on the external diameter, which is always stated on the component. The pressing process evenly deforms the individual cores, thus creating a stable electrical and mechanical connection.

2) If the press connector is specific to a manufacturer (so-called butt splice-connector), the manufacturer’s instructions must always be complied with.

In both cases, the pressing process starts from the centre of the connector (as marked) and continues toward the cable. The pressing makes the press connector a little longer. A pressing excess of 5 mm (Cu) and 10 mm (Al) is therefore accounted for when preparing the cable.

stets angegeben ist. Durch die Pressung werden die Einzelleiter gleichmäßig verformt und so eine stabile elektrische und mechanische Verbindung hergestellt.