1、Designation: F1835 97 (Reapproved 2012)1An American National StandardStandard Guide forCable Splicing Installations1This standard is issued under the fixed designation F1835; the number immediately following the designation indicates the year oforiginal adoption or, in the case of revision, the year
2、 of last revision. A number in parentheses indicates the year of last reapproval. Asuperscript epsilon () indicates an editorial change since the last revision or reapproval.1NOTEReapproved with editorial changes throughout the guide in October 2012.1. Scope1.1 This guide provides direction and reco
3、mmends cablesplicing materials and methods that would satisfy the require-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 w
4、ith cable splicing at a generic leveland details a method that will satisfy 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
5、thatthe shipbuilder may use in decision making for the costeffectiveness of 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 this
6、guide relate to all marine cables, domestic and foreign,commercial or U.S. 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
7、 any, associated with its use. It is theresponsibility of the user of this 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:2B8 Specification for Concentric-Lay-Stranded Copp
8、erConductors, Hard, Medium-Hard, or SoftD2671 Test Methods for Heat-Shrinkable Tubing for Elec-trical Use2.2 IEEE Standards:IEEE 45 Recommended Practice for Electrical Installationson Shipboard32.3 UL Standards:4UL STD 224 Extruded Insulating TubingUL STD 486A Wire Connectors and Soldering Lugs for
9、Usewith Copper Conductors2.4 IEC Standards:IEC 228 Conductors of Insulated Cables52.5 Federal Regulations:Title 46 Code of Federal Regulations (CFR), Shipping62.6 Military Specifications:MIL-T-16366 Terminals, Electric Lug and ConductorSplices, Crimp-StyleMIL-T-7928 Terminals, Lug, Splices, Conducto
10、rs, Crimp-Style, Copper3. Terminology3.1 Definitions of Terms Specific to 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 r
11、etention and load-bearingapplications (see also sealant).3.1.2 barrel, nthe 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 with their axes in line, but do notov
12、erlap.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 Oct. 1, 2012. Published October 2012. Originallyapproved in 1997. Last previous edition approved in 2007 as F1
13、835 - 97(2007).DOI: 10.1520/F1835-97R12E01.2For 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 In
14、stitute of Electrical 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.,Northbrook, IL 60062-2096, http:/.5Available from the International Electrotechnical Commission, 3
15、 rue deVarembe, 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.Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. Unit
16、ed States13.1.4 butt splice, ndevice for joining conductors by butt-ing 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
17、 applied force; the conductor is also crimped by suchforce inside the tube-like connector body.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
18、, ntubular copper connectors madeto match various wire sizes and fastened to the conductor endsby 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 is usedto fasten electrical connectors to cable conducto
19、rs by forcefullycompressing the connector onto the conductor. This tool mayhave interchangeable dies or “jaws” to fit various size connec-tors.3.1.11 heat-shrink tubing, nelectrical insulation tubing ofa polyolefin material, which shrink in diameter from anexpanded size to a predetermined size by th
20、e application ofheat. It is available in various diameter sizes.3.1.12 primary insulation, nthe layer 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
21、 ingress of moisture to the enclosed area (seealso adhesive).3.1.14 splice, na joint connecting conductors 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
22、 Splicing of cables in the shipbuilding industry, both inNavy and commercial undertakings, has been concentrated inrepair, conversion, or overhaul programs. However, manycommercial industries, including aerospace and nuclear power,have standards defining cable splicing methods and materialsthat esta
23、blish the quality of the splice to prevent loss of poweror signal, ensure circuit continuity, and 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
24、.4.2 This guide resulted from a study that evaluated thevarious methods of cable splicing, current 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
25、a shipbuilder will establishcabling splicing systems that are: simple and safe to install;waterproof; 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 Ca
26、ble splicing requires that cable joints be insulated andsealed with an insulation equal in electrical 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 applicabl
27、e,reestablishment of shielding in shielded cables and electriccontinuity in the armor of armored cables.5.2 Nonsplice ApplicationsUnacceptable areas for cablesplices are established by regulations and concern the restric-tion of being unable to splice cables in defined hazardous areas.Hazardous area
28、s are locations in which fire or explosionhazards may exist as a result of flammable gases or vapors,flammable liquids, combustible dust, or ignitable fibers orflyings.6. Cable Splicing6.1 Cable splicing as presented in this guide uses a systemof compression-crimp, tubular-metal connectors for butt
29、con-nection of cable conductors and insulating systems of shrink-able tubing to reinsulate the individual conductors and replacethe overall cable jacket.6.2 Crimp ConnectorsFor splice connection ofconductors, compression-crimped connectors shall be used forjoining an electrical conductor (wire) to a
30、nother conductor. Thejoint requires proper compression to achieve good electricalperformance while not overcompressing and mechanicallydamaging the conductor. Compression connections are accom-plished by applying a controlled force on a barrel sleeve to theconductor with special tools and precision
31、dies.6.3 Conductor ReinsulationThin-wall shrinkable tubingshall be used to reinsulate the conductor 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-s
32、ulation does not require an interior adhesive sealant coating.6.4 Cable Jacket ReinsulationShrinkable 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 sealants
33、hall be used.7. Cable Preparation7.1 Cables to be spliced shall be prepared to the dimensionsspecified 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
34、 Fig. 2.7.2 Care must be exercised when preparing the cable endsso that conductor insulation is not cut when removing theoverall cable jacket, shield, or cable armor, where applicable.Similar care is required when removing the individual shield orF1835 97 (2012)12FIG. 1 Splice Dimensions for Power C
35、ablesF1835 97 (2012)13insulation protecting the conductor to prevent cuts or nicks onthe individual conductor strands.7.2.1 Insulation cutting tools that limit depth of cut shouldbe used to prepare cable ends so that underlying insulation isnot cut. Similar care is required when removing the individ
36、ualconductor 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 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 arrangeme
37、nt 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 final position beforebeing spliced.8. Materials and Tools8.1 Cable Splicing MaterialsThe following sections pro-vide an overview of the
38、 various splice materials. In addition,FIG. 2 Splice Dimensions for Control-Multiple Conductor CablesF1835 97 (2012)14specific recommendations and suggested guidelines are offeredthat would enhance the cable splicing process.8.1.1 Crimp-Type ConnectorsSplice connectors shall becompression-type, butt
39、 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.8.1.1.2 Butt connector shall have positive center wire stopsfor proper depth of conductor insertion.8.1.1.3 Connectors shall be marke
40、d 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 sizes No. 10 (AWG) orlarger shall be the “long barrel” type to permit multiple crimpson each side of the connector for greater ten
41、sile 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 be spaced half way between theend of the connector and the center wire stop.8.1.1.6 Connector shall be color-coded in accordanc
42、e withTable 1 or Table 2.8.1.2 Conductor Reinsulating MaterialTo reinsulate theconductor and 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.
43、1.2.2 Shrink tubing used for conductor reinsulation shallbe heat-shrink tubing. The tubing shall 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 ran
44、ge 55 to +135CMinimum shrinkage temperature +121CLongitudinal shrinkage 5 %Electrical rating 600-V continuous operationDielectric strength in accordance withTest Methods D267119.7 kV/mm (500 V/mil) min8.1.2.3 Shrink tubing to cover the connection of individualconductors does not require an interior
45、coating of adhesive(mastic) sealant.8.1.3 Cable Jacket Replacement MaterialsSeveral meth-ods 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
46、 and ease of installation replacement of cablejacket and to envelop the splice area, however, 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 conductorinsulati
47、on (see Table 3).8.1.3.2 The tubing used for cable jacket replacement shallbe thick wall, also 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
48、 a splice bundle shallhave an interior coating of adhesive (mastic) sealant.8.1.3.5 Table 3 provides dimensions for thick-wall tubingused for rejacketing of cables.TABLE 1 Connector Data (English Units)Conductor Size AWG orMCM DesignationConnector OverallLength (min)Depth of Each Side ofBarrel (min)
49、Overall Diameter ofBarrel (Approximate)Color CodeAConductor NominalDiameter, in.Number of Crimps/EndB225814 0.150 0.025 1205814 0.150 0.039 1185814 0.150 0.049 1165814 0.150 0.061 1145814 0.150 0.077 11234516 0.212 0.092 11034516 0.212 0.108 18134131614 red 0.146 26238 118516 blue 0.184 24238 118516 gray 0.226 23258 11438 white 0.254 22258 114716 brown 0.282 21278 13812 green 0.317 410 278 13812 pink 0.363 420 318 112916 black 0.407 430 318 11258 orange 0.457 440 338 158111
