1、Designation: F 1835 97 (Reapproved 2007)An American National StandardStandard Guide forCable Splicing Installations1This standard is issued under the fixed designation F 1835; the number immediately following the designation indicates the year oforiginal adoption or, in the case of revision, the yea
2、r of last revision. A number in parentheses indicates the year of last reapproval. Asuperscript epsilon (e) indicates an editorial change since the last revision or reapproval.1. Scope1.1 This guide provides direction and recommends cablesplicing materials and methods that would satisfy the require-
3、ments of extensive cable splicing in modular ship constructionand offers sufficient information and data to assist the ship-builder in evaluating this option of cable splicing for futureship construction.1.2 This guide deals with cable splicing at a generic leveland details a method that will satisf
4、y the vast majority of cablesplicing applications.1.3 This guide covers acceptable methods of cable splicingused in shipboard cable systems and provides information oncurrent applicable technologies and additional information thatthe shipbuilder may use in decision making for the costeffectiveness o
5、f 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 adaptableto higher voltages, such as 5-kV systems. The cables of thisguide relate to all marine cables, domestic and foreign,commercial or U.S.
6、 Navy.1.5 The values stated in SI units shall be regarded asstandard. The values given in parentheses are inch-pound unitsand are for information only.1.6 This standard does not purport to address all of thesafety concerns, if any, associated with its use. It is theresponsibility of the user of this
7、 standard to establish appro-priate safety and health practices and determine the applica-tion of regulatory limitations prior to use.2. Referenced Documents2.1 ASTM Standards:2B 8 Specification for Concentric-Lay-Stranded CopperConductors, Hard, Medium-Hard, or SoftD 2671 Test Methods for Heat-Shri
8、nkable Tubing for Elec-trical Use2.2 IEEE Standards:IEEE 45 Recommended Practice for Electrical Installationson Shipboard32.3 UL Standards:4UL STD 224 Extruded Insulating TubingULSTD 486A Wire Connectors and Soldering Lugs for Usewith Copper Conductors2.4 IEC Standards:IEC 228 Conductors of Insulate
9、d Cables52.5 Federal Regulations:Title 46 Code of Federal Regulations (CFR), Shipping62.6 Military Specifications:6MIL-T-16366 Terminals, Electric Lug and ConductorSplices, Crimp-StyleMIL-T-7928 Terminals, Lug, Splices, Conductors, Crimp-Style, Copper3. Terminology3.1 Definitions of Terms Specific t
10、o This Standard:3.1.1 adhesive, na wide range of materials used exten-sively for bonding and sealing; coating added to the inner wallof heat-shrinkable tubing to seal the enclosed area againstmoisture. Adhesive is for pressure retention and load-bearingapplications (see also sealant).3.1.2 barrel, n
11、the portion of a terminal that is crimped;designed to receive the conductor, it is called the wire barrel.3.1.3 butt connector, na connector in which two conduc-tors come together, end to end, but do not overlap and withtheir axes in line.3.1.4 butt splice, ndevice for joining conductors by butt-ing
12、 them end to end.3.1.5 circumferential crimp, nfinal configuration of abarrel made when crimping dies completely surround the barreland form symmetrical indentations.3.1.6 compression connector, nconnector crimped by anexternally applied force; the conductor is also crimped by suchforce inside the t
13、ube-like connector body.1This guide is under the jurisdiction of ASTM Committee F25 on Ships andMarine Technology and is the direct responsibility of Subcommittee F25.10 onElectrical.Current edition approved May 1, 2007. Published June 2007. Originallyapproved in 1997. Last previous edition approved
14、 in 2002 as F 1835 - 97(2002).2For referenced ASTM standards, visit the ASTM website, www.astm.org, orcontact ASTM Customer Service at serviceastm.org. For Annual Book of ASTMStandards volume information, refer to the standards Document Summary page onthe ASTM website.3Available from Institute of El
15、ectrical and Electronics Engineers, Inc. (IEEE),445 Hoes Ln., P.O. Box 1331, Piscataway, NJ 08854-1331, http:/www.ieee.org.4Available from Underwriters Laboratories (UL), 333 Pfingsten Rd., North-brook, IL 60062-2096, http:/.5Available from the International Electrotechnical Commission, 3 rue deVare
16、mbe, Case Postale 131, CH-1211, Geneva 20, Switzerland.6Available from Standardization Documents Order Desk, Bldg. 4 Section D, 700Robbins Ave., Philadelphia, PA 191115098, Attn: NPODS.1Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.
17、3.1.7 cold-shrink tubing, ntubular rubber sleeves that arefactory expanded and assembled onto a removable core. Noheat is used in installation. Also known as prestretched tubing(PST).3.1.8 crimp connectors, ntubular copper connectors madeto match various wire sizes and fastened to the conductor ends
18、by means of a crimping tool.3.1.9 crimping die, nportion of the crimping tool thatshapes the crimp.3.1.10 crimping tool, na mechanical device, which isused to fasten electrical connectors to cable conductors byforcefully compressing the connector onto the conductor. Thistool may have interchangeable
19、 dies or “jaws” to fit various sizeconnectors.3.1.11 heat-shrink tubing, nelectrical insulation tubing ofa polyolefin material, which shrink in diameter from anexpanded size to a predetermined size by the application ofheat. It is available in various diameter sizes.3.1.12 primary insulation, nthe l
20、ayer of material that isdesigned to do the electrical insulating, usually the first layer ofmaterial applied over the conductor.3.1.13 sealant, ninner-wall coating optional to shrinkabletubing to prevent ingress of moisture to the enclosed area (seealso adhesive).3.1.14 splice, na joint connecting c
21、onductors with goodmechanical strength and good conductivity.3.1.15 tensile, namount of axial load required to break orpull wire from the crimped barrel of a terminal or splice.4. Significance and Use4.1 Splicing of cables in the shipbuilding industry, both inNavy and commercial undertakings, has be
22、en concentrated inrepair, conversion, or overhaul programs. However, manycommercial industries, including aerospace and nuclear power,have standards defining cable splicing methods and materialsthat establish the quality of the splice to prevent loss of poweror signal, ensure circuit continuity, and
23、 avoid potential cata-strophic failures. This guide presents cable splicing techniquesand hardware for application to commercial and Navy ship-building to support the concept of modular ship construction.4.2 This guide resulted from a study that evaluated thevarious methods of cable splicing, curren
24、t technologies, priorstudies and recommendations, performance testing, and theexpertise of manufacturers and shipbuilders in actual cablingsplicing techniques and procedures.4.3 The use of this guide by a shipbuilder will establishcabling splicing systems that are: simple and safe to install;waterpr
25、oof, corrosion, and impact resistant; industry acceptedwith multiple suppliers available; low-cost methods; and suit-able for marine, Navy, and IEC cables.5. General Requirements for Cable Splicing5.1 Cable splicing requires that cable joints be insulated andsealed with an insulation equal in electr
26、ical and mechanicalproperties to the original cable. Cable splicing shall consist ofa conductor connector, replacement of conductor insulation,replacement of the overall cable jacket, and where applicable,reestablishment of shielding in shielded cables and electriccontinuity in the armor of armored
27、cables.5.2 Nonsplice ApplicationsThe only unacceptable areafor a cable splice is established by regulations and concerns therestriction of being unable to splice cables in defined hazardousareas. Hazardous areas are locations in which fire or explosionhazards may exist as a result of flammable gases
28、 or vapors,flammable liquids, combustible dust, or ignitable fibers orflyings.6. Cable Splicing6.1 Cable splicing presented in this guide uses a system ofcompression-crimp, tubular-metal connectors for butt connec-tion of cable conductors and insulating systems of shrinkabletubing to reinsulate the
29、individual conductors and replace theoverall cable jacket.6.2 Crimp ConnectorsFor splice connection of conduc-tors, compression-crimped connectors shall be used for joiningan electrical conductor (wire) to another conductor. The jointrequires proper compression to achieve good electrical perfor-manc
30、e while not overcompressing and mechanically damagingthe conductor. Compression connections are accomplished byapplying a controlled force on a barrel sleeve to the conductorwith special tools and precision dies.6.3 Conductor ReinsulationThin-wall shrinkable tubingshall be used to reinsulate the con
31、ductor and the installedconnector. The insulation tubing, when shrunk or recovered,shall be equal in electrical and mechanical properties to theoriginal conductor insulation. Tubing used for conductor rein-sulation does not require an interior adhesive sealant coating.6.4 Cable Jacket ReinsulationSh
32、rinkable tubing shall beused to envelop the overall splice. To satisfy more abusiveconditions that cable jackets are exposed to, a flame-retardant,thick-wall tubing construction with factory applied sealantshall be used.7. Cable Preparation7.1 Cables to be spliced shall be prepared to the dimensions
33、specified in Fig. 1 and Fig. 2. Fig. 1 provides cable preparationfor power cables from single to four conductor sizes. Dimen-sions for multiple conductor cables (conductor size of No. 14or less) are shown in Fig. 2.7.2 Care must be exercised when preparing the cable endsso that conductor insulation
34、is not cut when removing theoverall cable jacket, shield, or cable armor, where applicable.Similar care is required when removing the individual shield orinsulation protecting the conductor to prevent cuts or nicks onthe individual conductor strands.7.2.1 Insulation cutting tools that limit depth of
35、 cut shouldbe used to prepare cable ends so that underlying insulation isnot cut. Similar care is required when removing the individualconductor insulation to protect the conductor copper strandsfrom nicks and cuts.7.2.2 Cable preparation shall result in stripping the indi-vidual conductors so that
36、the bare copper is long enough toreach the full depth of the butt connector plus 3.2 mm (18 in.).7.3 Match the geometrical arrangement between cables tobe spliced using conductor color code identification to elimi-nate crossovers or mismatch when splicing.7.4 Cable ends shall be in or near their fin
37、al position beforebeing spliced.F 1835 97 (2007)2FIG. 1 Splice Dimensions for Power CablesF 1835 97 (2007)38. Materials and Tools8.1 Cable Splicing MaterialsThe following sections pro-vide an overview of the various splice materials. In addition,specific recommendations and suggested guidelines are
38、offeredthat would enhance the cable splicing process.8.1.1 Crimp-Type ConnectorsSplice connectors shall becompression-type, butt connectors conforming to the require-ments of UL STD 486A and shall be satisfactory to Section20.11 of IEEE 45.8.1.1.1 Connector shall be seamless, tin-plated copper.8.1.1
39、.2 Butt connector shall have positive center wire stopsfor proper depth of conductor insertion.8.1.1.3 Connectors shall be marked with wire size for easyidentification.8.1.1.4 Connector shall have inspection holes to allowvisual inspection for proper wire insertion.8.1.1.5 Butt connector for wire si
40、zes No. 10 (AWG) orlarger shall be the “long barrel” type to permit multiple crimpson each side of the connector for greater tensile strength. Theconductor ends shall be fully inserted to the “stop” at the centerof the connector. For smaller conductor sizes (No. 10 AWG orless), a single crimp should
41、 be spaced half way between theend of the connector and the center wire stop.FIG. 2 Splice Dimensions for Control-Multiple Conductor CablesF 1835 97 (2007)48.1.1.6 Connector shall be color-coded in accordance withTable 1 or Table 2.8.1.2 Conductor Reinsulating MaterialTo reinsulate theconductor and
42、the installed connector, heat-shrink tubing shallbe used. (see Table 3).8.1.2.1 When recovered or shrink, the tubing used shall beequal to or greater than the thickness of the original conductorinsulation.8.1.2.2 Shrink tubing used for conductor reinsulation shallbe heat-shrink tubing. The tubing sh
43、all be thin-wall cross-linked polyolefin tubing, flame-retardant (FR-1) constructionin accordance with UL STD 224 requirements. Performancerequirements shall include:Shrink ratio 2:1Operating temperature range 55 to +135CMinimum shrinkage temperature +121CLongitudinal shrinkage 65%Electrical rating
44、600-V continuous operationDielectric strength in accordance withTest Methods D 267119.7 kV/mm (500 V/mil) min8.1.2.3 Shrink tubing to cover the connection of individualconductors does not require an interior coating of adhesive(mastic) sealant.8.1.3 Cable Jacket Replacement MaterialsSeveral meth-ods
45、 and a variety of materials are available that will provide themechanical protection, moisture-sealing properties, and elec-trical performance characteristics needed in a cable splice. Fora splice reliability and ease of installation replacement of cablejacket and to envelop the splice area, however
46、, either theheat-shrink or the cold-shrink (prestretched) type shall be used.8.1.3.1 The tubing used, when recovered or shrunk, shall beequal to or greater than the thickness of the original conductorinsulation (see Table 3).8.1.3.2 The tubing used for cable jacket replacement shallbe thick wall, al
47、so referred to as heavy-duty shrink tubing,cross-linked polyolefin tubing.8.1.3.3 Shrink tubing shall be flame retardant (FR-1) inaccordance with UL STD 224 requirements.8.1.3.4 Tubing used for rejacketing of a splice bundle shallhave an interior coating of adhesive (mastic) sealant.8.1.3.5 Table 3
48、provides dimensions for thick-wall tubingused for rejacketing of cables.8.1.3.6 Tubing shall have the following performance re-quirements:Shrink ratio 3:1Operating temperature range 55 to +135CMinimum shrinkage temperature (forheat-shrink tubing) +121CLongitudinal shrinkage 65%Electrical rating 600-
49、V continuous operationDielectric strength in accordance withTest Methods D 26717.9 kV/mm (200 V/mil) min8.1.4 Shield TerminationsCables that require continuedshielding shall have at least a 13-mm (12-in.) overlap betweenthe replacement shielding material and the permanent shieldingand shall be attached with either solder-type connectors or amechanical connection using inner and outer compression(crimp-type) rings.8.2 Splicing Tools:8.2.1 Cable PreparationThe basic tools required for cablesplice preparation include a cable cutter, measur
