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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.
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Hereby we inform you that our products contained SVHC substance lead (CAS 7439-92-1) with concentration higher than 0.1% are now registered in SCIP database at ECHA (European Chemicals Agency). Those products contain aluminium and/or copper alloy in our connecting technology and are mentioned in BBC Cellpack REACH-Declaration of conformity regarding Regulation EC/1907/2006 from 28.02.2022, the products can be sold. The SCIP database number is protected by Data Protection Law and is not listed here.
The reason for the registration in SCIP database is described in Directive (EU) 2018/851, paragraph 38: “When products, materials and substances become waste, the presence of hazardous substances may render that waste unsuitable for recycling or the production of secondary raw materials of high quality. Therefore, in line with the 7th Environment Action Programme, which calls for the development of non-toxic material cycles, it is necessary to promote measures to reduce the content of hazardous substances in materials and products, including recycled materials, and to ensure that sufficient information about the presence of hazardous substances and especially substances of very high concern is communicated throughout the whole life cycle of products and materials. In order to achieve those objectives, it is necessary to improve the coherence among the law of the Union on waste, on chemicals and on products and to provide a role for the European Chemicals Agency to ensure that the information about the presence of substances of very high concern is available throughout the whole life cycle of products and materials, including at the waste stage”.
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End joints and branch joints for medium voltage are not included in the BBC Cellpack product range.
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All cast resins and shrink systems are suitable for sea water. However, they are not directly tested with the common test standards.
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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.
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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.
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The BBC Cellpack sets have not been certified for drinking water.
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BBC Cellpack has different approvals and the list of them is changing, so if you need some special approval – contact us.
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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.
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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.
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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.
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The manufacturer has not specified any maintenance intervals. Taking into consideration the local pollution and the expected precipitation (cleaning effect), however, we recommend that the operator/responsible person regularly inspects/assesses and, if necessary, removes deposits (sand, salts or other dirt) from the sets.
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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”.
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The following conditions must be observed:
1. Instructions for transportation and storage:
Storage conditions
Temperature range | 0…+50°C |
Relative humidity range | 0…50% RH |
Short-term storage conditions (up to a maximum of 120 minutes)
Temperature range | -40...+60°C |
Relative humidity range | 0…70% RH |
Deviations from these conditions during storage can lead to functional limitations of individual components and, in individual cases, make assembly more difficult or impossible. A malfunction of the product cannot then be ruled out. Repeated short-term exceeding of the permanent storage conditions can also lead to restrictions due to the temperature dependency of individual components (filling material, field control mastics).
2. Instructions for assembly:
Mounting instructions are supplied with each product (they are part of the kit). Temperature range for mounting / installation for these products: 0 to +40°C
3. Operation:
Operating temperature range:
Straight-through joints (plastic cable e.g. XLPE to XLPE) | is equal to the maximum continuous conductor temperature of the cable at 90 °C |
Cable terminations (plastic cables, e.g. XLPE) | is equal to the maximum continuous conductor temperature of the cable at 90 °C |
Transition joints (paper-to-plastic cable) | corresponds to the maximum continuous conductor temperature of the paper cable at 60 °C |
Straight-through joints (e.g. paper-to-paper cable) | corresponds to the maximum continuous conductor temperature of the paper cable at 60 °C |
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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.
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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.
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The CE marking is applied to products intended for the internal European Union market. The manufacturers apply such labels to declare that the labelled electrical equipment complies with the applicable health, safety and environmental protection requirements for products in the European Economic Area (EEA).
The CE marking is in accordance with Directive 93/68/EEC and is intended for usage within certain voltage limits. In addition, a product may only feature a CE marking in accordance with EC Directive 765/2008 if the product requirements are defined in at least one corresponding EU directive. Examples of such directives include the Low Voltage Directive (2014/35/EU), the EMC Directive (2014/30/EU), the ATEX Directive (2014/34/EU) and the Radio Equipment Directive (2014/53/EU).
The CE declarations of conformity for low-voltage products are freely available in the download area of our online product catalogue. If none of the directives are applicable, the CE marking is not applied to the product in accordance with the applicable laws. CE conformity is also not issued for such products.
The BBC Cellpack medium-voltage sets listed below do not fall under the EU directives requiring CE marking: CHE… , CHM… , CAE… , CAM… , CGS… , CTS… , CWS… BBC Cellpack medium-voltage sets are nevertheless developed in accordance with the applicable international standards and are subjected to numerous checks and tests during the development process as well as during production to ensure safe and reliable operation, e.g: CENELC HD 629.1, CENELEC HD 629.2 or IEC 60502-4.
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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.
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Differences between CENELEC HD 629.1 S3:2019 and IEC 60502-4:2010 type tests
Test parameter | CENELEC HD 629.1 | IEC 60502-4 |
DC Voltage | not required | 4 U0 / 15 min dry |
Heating cycles (separable connectors, straight joints/ terminations) | 63 in air and 63 under water / 126 cycles | 30 in air and 30 under water / 60 cycles |
Partial discharge | max 10 pC at 2 U0 | max 10 pC at 1,73 U0 |
Dynamic short-circuit test | One short-circuit at Id only for 3 core (depending on the test sequence) | One short-circuit at Id for 1 core and for 3 core (depending on the test sequence) |
Id short-circuit current (initial peak value) in the conductor;
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BBC Cellpack Electrical Products has been selling cable accessories for low and medium voltage applications for more than 40 years. Based on feedback from our customers and their records, as well as the very low number of complaints, it can be stated that safe operation of our cable accessories for low voltage and medium voltage applications is achievable for a period of more than thirty years.
Important note on warranty:
BBC Cellpack Electrical Products is only supplying components (kit) with installation instructions describing their assembly steps. The assembly of the cable accessories itself is not carried out by BBC Cellpack, but by the customer or an assembly company appointed by the customer. In general, in accordance with legal requirements, BBC Cellpack Electrical Products can only provide warranty for the components (kit) supplied, but not for the assembled cable accessories, as BBC Cellpack Electrical Products has no necessary influence on the quality of cable preparation and assembly of the cable accessory or their operation in the network. The cable accessories are free from material defects if they are suitable for the use stipulated in the contract at the time of handover to the customer. The specification of the expected lifetime does not represent a guarantee, assurance, quality agreement or other commitment binding on the seller and also does not represent an extension of the warranty period beyond the warranty within the framework of the statutory periods.
Description of various factors influencing the service life of cable accessories:
There are several factors that can negatively affect the service life of a cable accessory. In our experience, these include normally and not exclusively cable preparation and assembly, network operation or the network conditions themselves, as well as the storage of the kit or the temperature at which the installation is carried out. Due to the many possible influencing factors, this list does not claim to be complete. A legally binding general statement on the service life by BBC Cellpack Electrical Products is therefore not possible and will not be given by us. Influence of cable preparation and assembly on the service life of cable accessories: Basic requirement to achieve the lifetime are careful and clean cable preparation in accordance with the state of technology, but also careful and conscientious compliance with the work steps specified in BBC Cellpack installation instructions. In addition to this requirement, only components supplied from the manufacturer as part of the kit or recommended or approved by the manufacturer, for example connectors qualified according to IEC61238, may be used for proper installation and function of the product. For proper installation as a prerequisite for a long service life, user training is recommended for new products or technically complex solutions.
Influence of network operation or network conditions on the service life of cable accessories:
The service life of a product always depends on the conditions of the power supply network acting on the product. BBC Cellpack Electrical Products cable accessories are type-tested in the low-voltage range in accordance with or based on the EN50393 standard, and in the medium-voltage range in accordance with or based on the HD629 standard. Electrical, mechanical or thermal stresses exceeding the requirements of these standards may have significant effects, i. e. lead to a reduction in the service life of the cable accessories. Thus, no estimate of the possible or remaining service life can be made if, for example, effects of short circuits or transient voltage increases due to switching operations or lightning surge voltages have occurred. The application of the aforementioned standards is not legally binding. However, even if all standards are applied, not all of the influencing factors that may affect the service life of cable accessories are conclusively.
Influence of the storage conditions of the delivered product as well as the temperature during installation on the service life of cable accessories:
In the question of proper storage conditions, a distinction must be made according to the technology used: Components and products using cast resin, gel or cold shrink technology or other cold-applied products may be subject to restrictions on storage time, restrictions on storage conditions or recommendations on installation conditions. Corresponding information on the maximum permitted storage time, the recommended storage conditions and the recommended temperature range for assembly can be found in the product documentation and is also listed in brief form on the product label/label.
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- What is the system voltage? AC or DC voltage?
- Which type of cable accessories is required? And for which application is it used? (Example: cable termination for a switchgear or for a motor terminal box)
- Check the cable data and compare it with the description of the selected cable accessories
* Conductor material and conductor cross-section (copper or aluminium)
* Number of cores, conductor cross-section, conductor shape and conductor class
* Screen type (wire, tape, al-foil bonded etc.)
* Diameter over insulation and over cable sheath
* Material of insulation and cable sheath
* Armouring – yes/no
* Concentric conductor (Ceander) – yes/no - Where is it installed? (e.g. explosion-proof areas, mining applications, fire precautions and water depths, etc.)
- In what ambient conditions (temperature, sand and dirt, etc.) will it be installed?
- Choosing of preferred connection technology (screw, crimp)
- What ambient conditions? (Temperature, sand and dirt, etc.)
- Select a product according to voltage (system and cable) and current
- Which standards and approvals are relevant?
- If a specific adjustment is required, please consult your contact
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Due to the wide variety of cleaning agents, we cannot rule out the possibility that some of them may contain ingredients that permanently damage the properties of our components. We therefore recommend only using Universal Cleaner 121 or other cleaning agents containing isopropanol.
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Due to the large number of cleaning agents, it cannot be ruled out that some of them contain ingredients that have a lasting effect on the properties of our components. Therefore, it is recommended to use only the cleaning cloth RT, the Universal Cleaner 121 or possibly other isopropanol cleaning agents (propan-2-ol). Furthermore, a maximum concentration of 10% aliphatic hydrocarbons (C6-C8) in the recipe of the cleaning agent must be observed
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Use standard over-the-counter crimping pliers. Please enquire with the manufacturer of your choice.
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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.
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For easier handling of the two tools, a lubricant can be applied to the desired location or conductive layer. We recommend our silicone grease (item no.: 124055) for this purpose. Lubricant residues should be removed with a cleaning cloth or another suitable cleaning agent, e.g: Universal Cleaner 121.
The use of product-specific lubricants such as GM1, GM2 or GM3 is not recommended, as the enclosed quantities are adapted to the assembly of the respective product.
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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.