AusProof联接器：电缆剥离尺寸
Complete Guide for 11kV & 22kV High Voltage Plug Terminations (11kV和22kV高压插头端接完整指南)
AusProof Couplers: Cable Stripping Dimensions (AusProof联接器：电缆剥离尺寸)
Understanding AusProof High Voltage Coupler Systems (了解AusProof高压联接器系统)
AusProof has been designing and manufacturing electrical cable couplers for mining and tunneling operations since 1974, establishing themselves as industry leaders in high voltage connection technology. Their coupler systems are specifically engineered to provide safe, reliable power connections in demanding environments including underground coal mines, metalliferous mines, open-cut operations, and tunnel excavation projects. The genderless design and full phase-to-earth segregation features make AusProof couplers among the safest and most reliable high voltage connectors available globally. (AusProof自1974年以来一直为采矿和隧道作业设计和制造电缆联接器，确立了自己在高压连接技术方面的行业领导地位。他们的联接器系统专门设计用于在要求苛刻的环境中提供安全、可靠的电力连接，包括地下煤矿、金属矿、露天作业和隧道挖掘项目。无性别设计和完整的相对地隔离功能使AusProof联接器成为全球最安全、最可靠的高压连接器之一。)
Proper cable preparation and stripping to precise dimensions is absolutely critical for successful coupler termination and long-term system reliability. Incorrect stripping dimensions can lead to insulation failure, tracking, partial discharge, and catastrophic equipment failure in high voltage systems. This guide provides comprehensive information on cable stripping dimensions and preparation procedures specifically for AusProof 11kV and 22kV coupler systems. (正确的电缆准备和精确尺寸的剥离对于成功的联接器端接和长期系统可靠性至关重要。不正确的剥离尺寸可能导致绝缘失效、表面闪络、局部放电和高压系统中的灾难性设备故障。本指南提供了专门针对AusProof 11kV和22kV联接器系统的电缆剥离尺寸和准备程序的综合信息。)
AusProof High Voltage Coupler Models (AusProof高压联接器型号)
AusProof manufactures several high voltage coupler models designed for different voltage ratings and applications. Understanding the specific model requirements is essential for proper cable preparation. The primary models used in 11kV and 22kV systems are distinguished by their voltage rating, current capacity, and construction features. (AusProof制造几种高压联接器型号，专为不同的电压等级和应用而设计。了解特定型号要求对于正确的电缆准备至关重要。11kV和22kV系统中使用的主要型号通过其电压等级、电流容量和结构特征区分。)
114BKA 11kV Four-Bolt Coupler (11kV四螺栓联接器)
- Voltage Rating: 11,000V (电压等级：11,000V)
- Current Rating: 800A (电流等级：800A)
- Construction: 4-bolt aluminum body (结构：4螺栓铝制本体)
- Application: Open-cut mining operations (应用：露天采矿作业)
- IP Rating: IP68 (far exceeding IP55 standard) (IP等级：IP68)
- Service History: In use since 1997 (使用历史：自1997年起使用)
118BKA 11kV Eight-Bolt Coupler (11kV八螺栓联接器)
- Voltage Rating: 11,000V (电压等级：11,000V)
- Current Rating: 800A (电流等级：800A)
- Construction: 8-bolt aluminum body (结构：8螺栓铝制本体)
- Design Feature: First in Australia with full phase-to-earth segregation (设计特点：澳大利亚首个具有完整相对地隔离)
- Application: Heavy-duty mining and industrial use (应用：重型采矿和工业用途)
- Service History: Released in 1995 (使用历史：1995年发布)
224BKA 22kV Four-Bolt Coupler (22kV四螺栓联接器)
- Voltage Rating: 22,000V (电压等级：22,000V)
- Current Rating: 425A (电流等级：425A)
- Construction: 4-bolt aluminum body (结构：4螺栓铝制本体)
- Design Feature: Genderless design, full phase segregation (设计特点：无性别设计，完整相隔离)
- Application: High voltage mining power distribution (应用：高压采矿配电)
- Service History: Original design 1989, re-released 1996 (使用历史：原始设计1989年，1996年重新发布)
64BKA 6.6kV Four-Bolt Coupler (6.6kV四螺栓联接器)
- Voltage Rating: 6,600V (电压等级：6,600V)
- Current Rating: 800A (电流等级：800A)
- Construction: 4-bolt aluminum, compact design (结构：4螺栓铝制，紧凑设计)
- Design Feature: Guide pin enclosed within body for protection (设计特点：导向销封装在本体内以保护)
- Application: Medium voltage mining operations (应用：中压采矿作业)
- Note: Reference for comparative understanding (注意：参考比较理解)
High Voltage Cable Construction & Components (高压电缆结构和组件)
Before discussing specific stripping dimensions, it is essential to understand the construction of modern high voltage cables. Medium and high voltage polymeric cables (XLPE or EPR insulation) typically consist of multiple layers, each serving a specific electrical or mechanical function. Proper identification and handling of each layer during cable preparation is critical to avoiding damage that could cause premature failure. (在讨论具体的剥离尺寸之前，了解现代高压电缆的结构至关重要。中高压聚合物电缆（XLPE或EPR绝缘）通常由多层组成，每层都有特定的电气或机械功能。在电缆准备过程中正确识别和处理每一层对于避免可能导致过早失效的损坏至关重要。)
Typical 11kV/22kV Cable Layer Structure (Inside to Outside) (典型11kV/22kV电缆层结构（从内到外）)
1. Conductor (导体)
Material: Stranded copper or aluminum conductor per IEC 60228 / BS EN 60228 (材料：按IEC 60228 / BS EN 60228的绞合铜或铝导体)
Class: Class 2 (stranded) for fixed installations, Class 5 or 6 (flexible) for mobile equipment (等级：固定安装用2类（绞合），移动设备用5或6类（柔性）)
Sizes: Typical range 25mm² to 400mm² for 11kV systems, 95mm² to 300mm² for 22kV systems (尺寸：11kV系统典型范围25mm²至400mm²，22kV系统95mm²至300mm²)
2. Conductor Screen (Semiconductor Layer) (导体屏蔽（半导体层）)
Function: Provides smooth, uniform electric field distribution at conductor surface (功能：在导体表面提供平滑、均匀的电场分布)
Material: Extruded semi-conductive XLPE compound (材料：挤出的半导电XLPE化合物)
Typical Thickness: 0.4mm – 1.5mm depending on voltage and manufacturer (典型厚度：根据电压和制造商0.4mm – 1.5mm)
Type: Extruded, bonded to insulation in triple extrusion process (类型：挤出，在三层共挤过程中与绝缘粘合)
3. Primary Insulation (主绝缘)
Material: XLPE (Cross-Linked Polyethylene) or EPR (Ethylene Propylene Rubber) (材料：XLPE（交联聚乙烯）或EPR（乙丙橡胶）)
11kV Thickness: Typically 3.4mm minimum finished thickness (IEC 60502-2 requirements) (11kV厚度：通常3.4mm最小成品厚度（IEC 60502-2要求）)
22kV Thickness: Typically 5.5mm – 6.0mm depending on conductor size and voltage class (22kV厚度：根据导体尺寸和电压等级通常5.5mm – 6.0mm)
Critical Note: Insulation thickness below 2.95mm for 11kV cables is considered a failure (关键提示：11kV电缆绝缘厚度低于2.95mm被视为失效)
4. Insulation Screen (Semiconductor Layer) (绝缘屏蔽（半导体层）)
Function: Provides smooth electric field distribution at outer insulation surface and contact surface for metallic screen (功能：在外绝缘表面和金属屏蔽接触表面提供平滑的电场分布)
Material: Semi-conductive compound, typically bonded or strippable type (材料：半导电化合物，通常为粘合或可剥离类型)
Typical Thickness: 0.4mm (11kV) to 0.6mm (33kV) per manufacturer specifications (典型厚度：根据制造商规格0.4mm（11kV）至0.6mm（33kV）)
Critical Point: The semicon screen cutback is the most critical point in any termination (关键点：半导体屏蔽切口是任何端接中最关键的点)
5. Metallic Screen / Shield (金属屏蔽)
Types: Copper wire screen, copper tape screen, or combination (类型：铜线屏蔽、铜带屏蔽或组合)
Function: Earth fault current path, equipotential shield, EMI protection (功能：接地故障电流路径、等电位屏蔽、EMI保护)
Wire Screen: Helically applied copper wires, typical diameter 0.7mm – 1.25mm (线屏蔽：螺旋施加的铜线，典型直径0.7mm – 1.25mm)
Tape Screen: Longitudinally applied copper tape with overlap (带屏蔽：纵向施加的重叠铜带)
6. Inner Sheath / Bedding (Three-Core Cables) (内护套/衬垫（三芯电缆）)
Material: PVC or LSZH compound (材料：PVC或LSZH化合物)
Function: Binds cores together, provides bedding for armor (功能：将芯束在一起，为铠装提供衬垫)
Typical Thickness: 1.8mm – 2.5mm depending on cable diameter (典型厚度：根据电缆直径1.8mm – 2.5mm)
7. Armor (SWA – Steel Wire Armor or AWA – Aluminum Wire Armor) (铠装（SWA – 钢丝铠装或AWA – 铝线铠装）)
Material: Galvanized steel wires or aluminum wires (材料：镀锌钢丝或铝线)
Function: Mechanical protection, earth fault current path (SWA only) (功能：机械保护、接地故障电流路径（仅SWA）)
Wire Diameter: Varies with cable size, typically 1.6mm – 3.15mm (线径：随电缆尺寸变化，通常1.6mm – 3.15mm)
8. Outer Sheath (外护套)
Material: PVC, LSZH, or PE (polyethylene) depending on application (材料：根据应用PVC、LSZH或PE（聚乙烯）)
Color: Typically black for HV cables, may have color coding bands (颜色：高压电缆通常为黑色，可能有色带编码)
Function: Environmental protection, moisture barrier, abrasion resistance (功能：环境保护、防潮屏障、耐磨性)
Critical Cable Stripping Dimensions for AusProof Couplers (AusProof联接器的关键电缆剥离尺寸)
Proper cable stripping to exact dimensions is the foundation of reliable high voltage coupler terminations. The dimensions provided below represent best practices derived from industry standards for medium and high voltage cable terminations, applicable to AusProof coupler systems. These dimensions ensure proper stress control, adequate creepage and clearance distances, and secure mechanical connections. Always consult specific manufacturer termination kits and installation instructions where available, as dimensions may vary based on coupler model and cable construction. (正确的电缆剥离到精确尺寸是可靠的高压联接器端接的基础。下面提供的尺寸代表从中高压电缆端接行业标准中得出的最佳实践，适用于AusProof联接器系统。这些尺寸确保适当的应力控制、足够的爬电和电气间隙距离以及安全的机械连接。始终查阅特定制造商的端接套件和安装说明（如果可用），因为尺寸可能根据联接器型号和电缆结构而变化。)
| Cable Preparation Step (电缆准备步骤) | 11kV Systems (114BKA / 118BKA) (11kV系统) | 22kV Systems (224BKA) (22kV系统) |
|---|---|---|
| Overall Cable Length Required (所需总电缆长度) | 600mm – 800mm from coupler entry point (从联接器入口点600mm – 800mm) | 700mm – 900mm from coupler entry point (从联接器入口点700mm – 900mm) |
| Outer Sheath Removal (外护套去除) | 450mm – 500mm (450mm – 500mm) | 550mm – 600mm (550mm – 600mm) |
| Armor Wire Removal (SWA/AWA) (铠装线去除) | 400mm – 450mm (bend back for earthing) (400mm – 450mm（弯回用于接地）) | 500mm – 550mm (bend back for earthing) (500mm – 550mm（弯回用于接地）) |
| Inner Sheath Removal (3-Core) (内护套去除（三芯）) | 350mm – 400mm (350mm – 400mm) | 450mm – 500mm (450mm – 500mm) |
| Individual Core Preparation Length (单芯准备长度) | 250mm – 300mm from core separation point (从芯分离点250mm – 300mm) | 300mm – 350mm from core separation point (从芯分离点300mm – 350mm) |
| Metallic Screen Removal (Wire/Tape) (金属屏蔽去除（线/带）) | 100mm – 120mm (100mm – 120mm) | 120mm – 150mm (120mm – 150mm) |
| Insulation Screen (Semicon) Cutback (绝缘屏蔽（半导体）切口) | 18mm – 22mm (Critical Dimension!) (18mm – 22mm（关键尺寸！）) | 22mm – 28mm (Critical Dimension!) (22mm – 28mm（关键尺寸！）) |
| Primary Insulation Removal (主绝缘去除) | 12mm – 15mm (to expose conductor) (12mm – 15mm（暴露导体）) | 15mm – 18mm (to expose conductor) (15mm – 18mm（暴露导体）) |
| Conductor Screen Removal (导体屏蔽去除) | Remove with insulation, 12mm – 15mm (与绝缘一起去除，12mm – 15mm) | Remove with insulation, 15mm – 18mm (与绝缘一起去除，15mm – 18mm) |
| Exposed Conductor Length (暴露导体长度) | 12mm – 15mm for lug/connector crimping (12mm – 15mm用于端子/连接器压接) | 15mm – 18mm for lug/connector crimping (15mm – 18mm用于端子/连接器压接) |
⚠ CRITICAL WARNING – Semicon Screen Cutback (关键警告 – 半导体屏蔽切口)
The insulation screen (semiconductive layer) cutback dimension is THE MOST CRITICAL measurement in high voltage cable termination. Incorrect semicon cutback is the primary cause of premature termination failure. The semicon must be removed in a clean, straight cut without leaving any residual semicon material on the primary insulation, and without scoring or damaging the insulation surface. Any nicks, cuts, or scratches in the primary insulation will create stress concentration points leading to partial discharge and eventual insulation breakdown. Use proper semicon removal tools with preset depth settings (0.4mm for 11kV, 0.6mm for 22kV/33kV) to avoid damaging the primary XLPE insulation. (绝缘屏蔽（半导电层）切口尺寸是高压电缆端接中最关键的测量。不正确的半导体切口是端接过早失效的主要原因。半导体必须以干净、直的切口去除，不在主绝缘上留下任何残留的半导体材料，并且不划伤或损坏绝缘表面。主绝缘中的任何划痕、切口或划伤都会产生应力集中点，导致局部放电和最终的绝缘击穿。使用具有预设深度设置的适当半导体去除工具（11kV为0.4mm，22kV/33kV为0.6mm）以避免损坏主XLPE绝缘。)
Step-by-Step Cable Preparation Procedure (逐步电缆准备程序)
Proper cable preparation requires following a systematic procedure with precision at each step. The following procedure represents industry best practices for preparing cables for high voltage coupler terminations. Each step must be completed carefully to avoid cable damage and ensure reliable long-term operation. Work must be performed by qualified, competent cable jointers with proper training and certification for high voltage cable work. (正确的电缆准备需要在每个步骤中精确地遵循系统程序。以下程序代表为高压联接器端接准备电缆的行业最佳实践。每个步骤都必须仔细完成，以避免电缆损坏并确保可靠的长期运行。工作必须由具有高压电缆工作适当培训和认证的合格、称职的电缆接线工执行。)
Safety Verification & Cable Identification (安全验证和电缆识别)
Verify cable is de-energized and properly isolated. Confirm cable type, voltage rating, and construction match the coupler specifications. Check cable manufacturer markings for conductor size, insulation type (XLPE/EPR), and screen construction (wire/tape). Ensure proper personal protective equipment (PPE) is worn including insulated gloves, safety glasses, and appropriate work clothing. (验证电缆已断电并适当隔离。确认电缆类型、电压等级和结构符合联接器规格。检查电缆制造商标记以了解导体尺寸、绝缘类型（XLPE/EPR）和屏蔽结构（线/带）。确保佩戴适当的个人防护装备（PPE），包括绝缘手套、安全眼镜和适当的工作服。)
Measure and Mark Cable (测量和标记电缆)
Measure from the intended coupler mounting position and mark all stripping dimensions on the cable outer sheath using a permanent marker or cable marking tags. Use a measuring tape and double-check all measurements before making any cuts. Mark the outer sheath removal point, armor wire cutback point, and individual core preparation lengths. Accurate marking prevents over-stripping which cannot be corrected. (从预期的联接器安装位置测量，并使用永久性记号笔或电缆标记标签在电缆外护套上标记所有剥离尺寸。使用卷尺并在进行任何切割之前仔细检查所有测量。标记外护套去除点、铠装线切口点和单芯准备长度。准确的标记可防止无法纠正的过度剥离。)
Remove Outer Sheath (去除外护套)
Using a cable sheath stripping tool or sharp utility knife, make two circumferential cuts at the marked outer sheath removal point. Make radial cuts between the circumferential cuts and carefully peel away the outer sheath. Work slowly to avoid cutting into the armor wires beneath. For PVC sheaths, a heat gun can be used to soften the material for easier removal. Ensure no damage to underlying layers. (使用电缆护套剥离工具或锋利的多用途刀，在标记的外护套去除点处进行两次周向切割。在周向切割之间进行径向切割，小心剥离外护套。缓慢工作以避免切入下面的铠装线。对于PVC护套，可以使用热风枪软化材料以便更容易地去除。确保不损坏下面的层。)
Prepare Armor Wires for Earthing (准备铠装线用于接地)
Carefully unwind and separate armor wires (SWA/AWA) from the inner sheath. Bend armor wires back along the cable axis to the marked armor cutback dimension. Steel wire armor must be carefully bent to avoid breaking individual wires. Install armor clamp or compression gland at the armor termination point to provide secure mechanical retention and earth bond. Clean any bitumen or protective tape from armor wires to ensure good electrical contact. (小心地从内护套上松开和分离铠装线（SWA/AWA）。将铠装线沿电缆轴向弯回到标记的铠装切口尺寸。钢丝铠装必须小心弯曲以避免破坏单根电线。在铠装端接点安装铠装夹或压缩腺，以提供安全的机械保持和接地连接。清除铠装线上的任何沥青或保护胶带，以确保良好的电气接触。)
Remove Inner Sheath (Three-Core Cables) (去除内护套（三芯电缆）)
For three-core cables, remove the inner sheath (bedding) to expose the individual cores. Make circumferential and radial cuts at the marked inner sheath removal point and carefully peel away. Take extreme care not to damage the metallic screen on individual cores. The inner sheath removal exposes the three individual cores which must be separated and individually prepared. (对于三芯电缆，去除内护套（衬垫）以暴露单个芯。在标记的内护套去除点处进行周向和径向切割，小心剥离。极其小心不要损坏单个芯上的金属屏蔽。内护套去除暴露了三个单独的芯，必须分离并单独准备。)
Remove Metallic Screen (Copper Wire/Tape) (去除金属屏蔽（铜线/带）)
For copper wire screen: Carefully unwind and cut the helically applied copper wires at the marked screen removal point. Keep wire screen intact below this point for earth continuity. For copper tape screen: Score the copper tape circumferentially at the marked point and peel back. Use constant force spring or copper tape clamp to provide uniform compression and good electrical contact at the screen termination point. Clean the exposed insulation screen surface with isopropyl alcohol and lint-free cloth to remove any copper particles or contamination. (对于铜线屏蔽：小心地在标记的屏蔽去除点处松开并切割螺旋施加的铜线。在此点下方保持线屏蔽完整以保持接地连续性。对于铜带屏蔽：在标记点处周向划铜带并向后剥离。使用恒力弹簧或铜带夹在屏蔽端接点提供均匀压缩和良好的电气接触。用异丙醇和无绒布清洁暴露的绝缘屏蔽表面，以去除任何铜颗粒或污染物。)
Remove Insulation Screen (Semicon Layer) – CRITICAL STEP (去除绝缘屏蔽（半导体层）- 关键步骤)
This is THE MOST CRITICAL step in cable preparation. Mark the exact semicon cutback dimension (18-22mm for 11kV, 22-28mm for 22kV) measured from the end of the metallic screen. Use a proper semicon screen scoring tool with preset depth setting (0.4mm for 11kV, 0.6mm for 22kV/33kV) to score around the insulation screen circumference. Make multiple light scoring passes rather than one deep cut. Once scored, “tramline” the semicon longitudinally and peel it away from the XLPE insulation. Use a round file or abrasive cloth to create a smooth chamfered transition from semicon to bare insulation – there must be NO sharp step or edge. Inspect carefully under good lighting for any residual semicon material left on the insulation surface – remove completely with cloth and isopropyl alcohol. Any semicon remaining on insulation will cause tracking and failure. (这是电缆准备中最关键的步骤。标记从金属屏蔽末端测量的精确半导体切口尺寸（11kV为18-22mm，22kV为22-28mm）。使用具有预设深度设置的适当半导体屏蔽划线工具（11kV为0.4mm，22kV/33kV为0.6mm）在绝缘屏蔽周围划线。进行多次轻划线而不是一次深切。划线后，纵向”tramline”半导体并从XLPE绝缘上剥离。使用圆锉或磨布从半导体到裸绝缘创建平滑的倒角过渡 – 不得有尖锐的台阶或边缘。在良好照明下仔细检查绝缘表面上是否有任何残留的半导体材料 – 用布和异丙醇完全去除。绝缘上残留的任何半导体都会导致表面闪络和失效。)
Remove Primary Insulation and Conductor Screen (去除主绝缘和导体屏蔽)
Measure and mark the insulation removal dimension (12-15mm for 11kV, 15-18mm for 22kV) from the semicon cutback point. Use a sharp cable knife or insulation stripping tool to carefully remove the primary XLPE/EPR insulation and conductor screen together. Work slowly and carefully to avoid scoring the conductor surface. Over-stripping insulation reduces the insulation thickness and can lead to flashover. Under-stripping prevents proper connector seating. Inspect the exposed conductor for any nicks or damage – smooth with emery cloth if needed. (测量并标记从半导体切口点开始的绝缘去除尺寸（11kV为12-15mm，22kV为15-18mm）。使用锋利的电缆刀或绝缘剥离工具小心地将主XLPE/EPR绝缘和导体屏蔽一起去除。缓慢小心地工作以避免划伤导体表面。过度剥离绝缘会降低绝缘厚度并可能导致闪络。剥离不足会妨碍适当的连接器就位。检查暴露的导体是否有任何划痕或损坏 – 如果需要，用砂布打磨。)
Clean All Surfaces (清洁所有表面)
Thoroughly clean all exposed surfaces with isopropyl alcohol (IPA) and lint-free cloth. Remove all dirt, oil, grease, copper particles, semicon residue, and other contamination. Pay particular attention to the area around the semicon cutback where the stress control interface will be formed. Any contamination left on surfaces can lead to tracking, partial discharge, and eventual failure. Allow all surfaces to dry completely before proceeding with connector installation. Do not touch cleaned surfaces with bare hands – oils from skin can cause contamination. (用异丙醇（IPA）和无绒布彻底清洁所有暴露的表面。去除所有污垢、油、润滑脂、铜颗粒、半导体残留物和其他污染物。特别注意半导体切口周围将形成应力控制界面的区域。表面上留下的任何污染物都可能导致表面闪络、局部放电和最终失效。在继续安装连接器之前，让所有表面完全干燥。不要用裸手触摸清洁的表面 – 皮肤上的油会导致污染。)
Install Cable Lugs / Connectors (安装电缆端子/连接器)
Select appropriate cable lugs or connectors matching the conductor size and coupler contact requirements. For AusProof couplers, single-piece contacts are typically used. Clean the conductor surface and lug bore with wire brush. Apply joint compound or petroleum jelly to conductor and lug interior. Insert conductor fully into lug barrel ensuring conductor bottoms out. Use proper crimping tool with correct die set for the conductor size and lug type. Crimp at locations marked on the lug barrel – typically 2-3 crimps for HV applications. Verify crimp is secure and uniform. For very large conductors (240mm² and above), shear-bolt connectors may be specified. (选择与导体尺寸和联接器接触要求匹配的适当电缆端子或连接器。对于AusProof联接器，通常使用单件接触。用钢丝刷清洁导体表面和端子孔。在导体和端子内部涂抹接头化合物或凡士林。将导体完全插入端子套筒，确保导体触底。使用具有导体尺寸和端子类型正确模具组的适当压接工具。在端子套筒上标记的位置压接 – 高压应用通常为2-3次压接。验证压接牢固且均匀。对于非常大的导体（240mm²及以上），可能指定剪切螺栓连接器。)
Final Inspection Before Coupler Assembly (联接器组装前的最终检查)
Perform a thorough visual inspection of all prepared cable ends before installing into the coupler: Verify all stripping dimensions are correct. Check semicon cutback is clean, straight, and smooth with proper chamfer. Confirm no damage to primary insulation surface. Verify conductors are properly prepared and lugs are securely crimped. Check all surfaces are clean and dry. Ensure metallic screen and armor earth connections are properly made. Take photographs of prepared cable ends for quality records. Any defects found at this stage must be corrected before proceeding – it is far easier to correct issues now than after energization. (在安装到联接器之前对所有准备好的电缆端进行彻底的目视检查：验证所有剥离尺寸是否正确。检查半导体切口是否干净、直、平滑且具有适当的倒角。确认主绝缘表面没有损坏。验证导体是否正确准备且端子是否牢固压接。检查所有表面是否干净和干燥。确保金属屏蔽和铠装接地连接已正确进行。拍摄准备好的电缆端的照片用于质量记录。在此阶段发现的任何缺陷必须在继续之前纠正 – 现在纠正问题比通电后容易得多。)
⚠ Competent Person Requirement (合格人员要求)
High voltage cable preparation and coupler termination must only be performed by competent, qualified cable jointers who have received proper training and hold valid certifications for medium/high voltage cable work. Improper cable preparation can result in equipment failure, fire, explosion, serious injury, or death. If you are not qualified and certified for HV cable work, do not attempt these procedures. Consult with qualified electrical contractors or cable jointing specialists. (高压电缆准备和联接器端接必须仅由已接受适当培训并持有中高压电缆工作有效认证的合格、称职的电缆接线工执行。不正确的电缆准备可能导致设备故障、火灾、爆炸、严重伤害或死亡。如果您没有高压电缆工作的资格和认证，请不要尝试这些程序。咨询合格的电气承包商或电缆接线专家。)
Common Cable Preparation Errors to Avoid (要避免的常见电缆准备错误)
Understanding common errors in cable preparation helps prevent termination failures. The following issues have been identified through field inspections and failure analysis of high voltage cable terminations, and apply equally to coupler terminations. Each of these errors can lead to premature failure, often months or years after installation when the cost and consequences of failure are much greater. (了解电缆准备中的常见错误有助于防止端接失效。以下问题已通过高压电缆端接的现场检查和故障分析确定，同样适用于联接器端接。这些错误中的每一个都可能导致过早失效，通常在安装后数月或数年时，此时故障的成本和后果要大得多。)
1. Incorrect Semicon Screen Cutback (不正确的半导体屏蔽切口)
Problem: Semicon cutback dimension too long (>25mm) or too short (<15mm for 11kV). (问题：半导体切口尺寸过长（>25mm）或过短（11kV<15mm）。)
Consequence: Electric field stress concentration, partial discharge, tracking, premature failure. (后果：电场应力集中、局部放电、表面闪络、过早失效。)
Prevention: Use proper measuring tools, mark clearly, verify dimension before cutting. (预防：使用适当的测量工具，清晰标记，切割前验证尺寸。)
2. Damage to Primary Insulation (主绝缘损坏)
Problem: Nicks, cuts, or scratches on XLPE insulation surface during semicon removal or handling. (问题：在半导体去除或处理过程中XLPE绝缘表面的划痕、切口或划伤。)
Consequence: Stress concentration points leading to partial discharge and insulation breakdown over time. (后果：应力集中点导致局部放电和绝缘随时间击穿。)
Prevention: Use proper screen scoring tools with preset depth, make multiple light passes. (预防：使用具有预设深度的适当屏蔽划线工具，进行多次轻划线。)
3. Residual Semicon on Insulation (绝缘上的残留半导体)
Problem: Black semiconductive material left on white XLPE insulation beyond cutback point. (问题：半导体切口点之外的白色XLPE绝缘上留下黑色半导电材料。)
Consequence: Surface tracking along the semicon residue leading to flashover between phases or to ground. (后果：沿半导体残留物的表面闪络导致相间或对地闪络。)
Prevention: Clean thoroughly with IPA and cloth, inspect under good lighting, remove all black residue. (预防：用IPA和布彻底清洁，在良好照明下检查，去除所有黑色残留物。)
4. Over-Stripping of Insulation (绝缘过度剥离)
Problem: Too much primary insulation removed, reducing insulation thickness below minimum requirements. (问题：去除过多主绝缘，使绝缘厚度降低到最低要求以下。)
Consequence: Insufficient dielectric strength, risk of flashover, cable becomes defective and must be replaced. (后果：介电强度不足，闪络风险，电缆变得有缺陷并必须更换。)
Prevention: Measure carefully, mark precisely, use cable stripping tools with stops for consistent depth. (预防：仔细测量，精确标记，使用具有停止器的电缆剥离工具以获得一致的深度。)
5. Poor Semicon Cutback Transition (半导体切口过渡不良)
Problem: Sharp 90-degree step between semicon and bare insulation instead of smooth chamfer. (问题：半导体和裸绝缘之间的尖锐90度台阶而不是平滑倒角。)
Consequence: Electric field stress concentration at the sharp edge causing corona, partial discharge, and eventual failure. (后果：尖锐边缘处的电场应力集中导致电晕、局部放电和最终失效。)
Prevention: Use round file or abrasive cloth to create smooth 30-45 degree chamfer at semicon edge. (预防：使用圆锉或磨布在半导体边缘创建平滑的30-45度倒角。)
6. Contaminated Cable Surfaces (污染的电缆表面)
Problem: Dirt, oil, grease, copper particles, or moisture on insulation or connector surfaces. (问题：绝缘或连接器表面上的污垢、油、润滑脂、铜颗粒或湿气。)
Consequence: Tracking paths, reduced dielectric strength, increased leakage current, premature aging. (后果：闪络路径、介电强度降低、泄漏电流增加、过早老化。)
Prevention: Clean all surfaces with IPA and lint-free cloth before connector installation, work in clean environment. (预防：在连接器安装之前用IPA和无绒布清洁所有表面，在清洁环境中工作。)
Quality Assurance and Testing (质量保证和测试)
After completing cable preparation and coupler installation, proper testing and quality assurance procedures must be followed before energization. These tests verify the integrity of the cable preparation, the quality of connections, and the absence of defects that could lead to failure. Never energize a high voltage system without proper testing by qualified personnel using calibrated test equipment. (完成电缆准备和联接器安装后，必须在通电之前遵循适当的测试和质量保证程序。这些测试验证电缆准备的完整性、连接的质量以及可能导致失效的缺陷的不存在。切勿在没有由合格人员使用校准的测试设备进行适当测试的情况下对高压系统通电。)
Pre-Energization Test Requirements (通电前测试要求)
1. Visual Inspection (目视检查)
- Verify all cable preparation dimensions are correct and within specified tolerances (验证所有电缆准备尺寸正确且在规定公差范围内)
- Confirm semicon cutback is clean, smooth, and properly chamfered (确认半导体切口干净、平滑且适当倒角)
- Check no damage to primary insulation, no nicks, cuts, or contamination (检查主绝缘没有损坏、没有划痕、切口或污染)
- Verify cable lugs are properly crimped with no gaps or misalignment (验证电缆端子正确压接，没有间隙或错位)
- Confirm metallic screen and armor earthing connections are secure (确认金属屏蔽和铠装接地连接牢固)
- Check coupler body is properly closed and all bolts are torqued to specification (检查联接器本体正确关闭，所有螺栓按规格拧紧)
2. Insulation Resistance Test (Megger Test) (绝缘电阻测试（兆欧表测试）)
- Test voltage: 5kV DC for 11kV systems, 10kV DC for 22kV systems (测试电压：11kV系统5kV DC，22kV系统10kV DC)
- Test duration: Minimum 1 minute, record readings at 30 seconds and 60 seconds (测试持续时间：最少1分钟，在30秒和60秒记录读数)
- Minimum acceptable values: >1000 MΩ for new installations, >100 MΩ for existing cables (最小可接受值：新安装>1000 MΩ，现有电缆>100 MΩ)
- Test phase-to-phase and phase-to-ground on all three phases (在所有三相上测试相对相和相对地)
- Record temperature and humidity conditions during testing (记录测试期间的温度和湿度条件)
3. Continuity Tests (连续性测试)
- Conductor continuity: Verify low resistance path through all phases (导体连续性：验证通过所有相的低电阻路径)
- Earth continuity: Verify earth bond through metallic screen, armor, and coupler body (接地连续性：验证通过金属屏蔽、铠装和联接器本体的接地连接)
- Typical acceptable resistance: <1Ω for conductors, <5Ω for earth path (典型可接受电阻：导体<1Ω，接地路径<5Ω)
4. Phase Rotation Check (相序检查)
- Verify correct phase rotation (ABC or clockwise rotation) using phase rotation meter (使用相序表验证正确的相序（ABC或顺时针旋转）)
- Confirm phase identification matches system requirements (确认相识别符合系统要求)
5. High Potential (Hi-Pot) Test (If Required) (高电位（Hi-Pot）测试（如果需要）)
- Performed only when specified by project requirements or after repairs (仅在项目要求或维修后指定时执行)
- Test voltage: Typically 2.5 x rated voltage + 1000V DC for 1 minute (测试电压：通常为2.5 x额定电压+ 1000V DC持续1分钟)
- Must be performed by qualified high voltage test technicians only (必须仅由合格的高压测试技术人员执行)
6. Documentation (文档)
- Record all test results, date, time, technician name, and equipment serial numbers (记录所有测试结果、日期、时间、技术人员姓名和设备序列号)
- Photograph completed installation before and after testing (在测试前后拍摄完成的安装照片)
- File documentation for future reference and troubleshooting (归档文件以供将来参考和故障排除)
Anhui Feichun High Voltage Cable Solutions (安徽飞纯高压电缆解决方案)
Anhui Feichun Special Cable Co., Ltd. manufactures high-quality 11kV and 22kV mining cables specifically designed for use with AusProof coupler systems and other high voltage connectors. Our cables meet international standards including IEC 60502-2, BS 6622, and are suitable for demanding mining and industrial applications. We provide complete technical support including cable selection guidance, stripping dimension specifications, and installation recommendations. (安徽飞纯特种电缆有限公司制造高质量的11kV和22kV采矿电缆，专门设计用于AusProof联接器系统和其他高压连接器。我们的电缆符合IEC 60502-2、BS 6622等国际标准，适用于要求苛刻的采矿和工业应用。我们提供完整的技术支持，包括电缆选择指导、剥离尺寸规格和安装建议。)
Standards Compliance (标准符合性)
All cables manufactured to IEC 60502-2, BS 6622, and AS/NZS standards with certified test reports for electrical, mechanical, and environmental performance. (所有电缆按IEC 60502-2、BS 6622和AS/NZS标准制造，并有电气、机械和环境性能的认证测试报告。)
Triple Extrusion Technology (三层共挤技术)
Conductor screen, XLPE insulation, and insulation screen extruded simultaneously for smooth interfaces and enhanced reliability. (导体屏蔽、XLPE绝缘和绝缘屏蔽同时挤出，实现平滑界面和增强可靠性。)
Mining Grade Construction (采矿级结构)
Heavy-duty armor (SWA/AWA), enhanced mechanical protection, resistant to impact, abrasion, and harsh environmental conditions. (重型铠装（SWA/AWA），增强机械保护，抗冲击、磨损和恶劣环境条件。)
Custom Configurations (定制配置)
Available in various conductor sizes (25mm² to 400mm²), single-core or three-core, with copper or aluminum conductors to match specific requirements. (提供各种导体尺寸（25mm²至400mm²）、单芯或三芯、铜或铝导体以满足特定要求。)
Technical Support (技术支持)
Engineering team provides cable selection assistance, stripping dimension specifications, and on-site installation support for critical projects. (工程团队为关键项目提供电缆选择协助、剥离尺寸规格和现场安装支持。)
Quality Assurance (质量保证)
ISO 9001 certified manufacturing with 100% testing of electrical parameters, dimensional verification, and mechanical strength before shipment. (ISO 9001认证制造，出货前对电气参数、尺寸验证和机械强度进行100%测试。)
Contact Anhui Feichun Special Cable Co., Ltd. (联系安徽飞纯特种电缆有限公司)
For technical specifications, cable selection guidance, stripping dimension information, or quotations for high voltage mining cables compatible with AusProof coupler systems, please contact our technical team: (如需技术规格、电缆选择指导、剥离尺寸信息或与AusProof联接器系统兼容的高压采矿电缆报价，请联系我们的技术团队：)
