Professional installation procedures for medium voltage separable connectors according to VDE and IEC standards
(N)TSCGEWÖU电缆与Pfisterer Connex中压插头端接操作指南：按照VDE和IEC标准的专业中压可分离连接器安装程序
Terminating (N)TSCGEWÖU Cables into Pfisterer Connex MV Plugs: A Step-by-Step Guide
Professional installation procedures for medium voltage separable connectors according to VDE and IEC standards
(N)TSCGEWÖU电缆与Pfisterer Connex中压插头端接操作指南：按照VDE和IEC标准的专业中压可分离连接器安装程序
Introduction to (N)TSCGEWÖU Cable Termination — (N)TSCGEWÖU电缆端接介绍
The (N)TSCGEWÖU designation represents a specific German medium voltage cable construction designed according to VDE 0276-620 standards. This cable type features a copper conductor (Cu), XLPE insulation, copper wire screen, and a special polyurethane (PUR) outer sheath optimized for high mechanical stress and oil resistance in industrial environments. (N)TSCGEWÖU标识代表根据VDE 0276-620标准设计的特定德国中压电缆结构。该电缆类型具有铜导体(Cu)、XLPE绝缘、铜丝屏蔽层以及专为工业环境中高机械应力和耐油性优化的特殊聚氨酯(PUR)外护套。
The Pfisterer Connex system represents a leading European separable connector solution for medium voltage applications, widely specified in transformer connections, switchgear interfaces, and cable distribution networks. According to Pfisterer technical documentation, the Connex plug range covers voltage classes from 12 kV to 42 kV with current ratings up to 630 A. Pfisterer Connex系统是欧洲领先的中压可分离连接器解决方案，广泛应用于变压器连接、开关设备接口和电缆配电网络。根据Pfisterer技术文档，Connex插头系列涵盖12kV至42kV电压等级，额定电流可达630A。
Technical Standard Reference 技术标准参考
This termination procedure follows IEC 60502-2 (Power cables with extruded insulation for rated voltages from 1 kV to 30 kV) and EN 50181 (Plug-in type bushings) interface specifications. 本端接程序遵循IEC 60502-2（额定电压1kV至30kV挤压绝缘电力电缆）和EN 50181（插入式套管）接口规范。
(N)TSCGEWÖU Cable Designation Breakdown — (N)TSCGEWÖU电缆型号解析
Understanding the cable designation is essential for proper connector selection and stripping dimension verification. The German cable nomenclature follows DIN VDE coding conventions. 了解电缆型号对于正确选择连接器和验证剥线尺寸至关重要。德国电缆命名遵循DIN VDE编码规范。
| Code 代码 | Element 元素 | Description 说明 |
|---|---|---|
| (N) | Standard Compliance 标准合规 | Conforms to German national standard (DIN VDE) / 符合德国国家标准 |
| T | Conductor Material 导体材料 | Copper conductor (Cu) / 铜导体 |
| SC | Screen Type 屏蔽类型 | Copper wire screen over each core / 每芯铜丝屏蔽 |
| GE | Outer Covering 外覆盖 | Embedded copper tape screen / 嵌入式铜带屏蔽 |
| W | Insulation Material 绝缘材料 | XLPE (Cross-linked polyethylene) / 交联聚乙烯 |
| Ö | Sheath Property 护套特性 | Oil-resistant sheath / 耐油护套 |
| U | Sheath Material 护套材料 | Polyurethane (PUR) outer sheath / 聚氨酯外护套 |
Voltage Class 电压等级
6/10 kV – 18/30 kV
Per VDE 0276-620
Conductor Temp. 导体温度
90°C (max)
Normal operation
Short-Circuit Temp. 短路温度
250°C (5s)
XLPE insulation limit
Min. Bend Radius 最小弯曲半径
15 × D
During installation
Flame Retardant 阻燃性
IEC 60332-1
Single cable test
Oil Resistance 耐油性
EN 60811-404
PUR sheath rated
Pfisterer Connex MV Plug System Overview — Pfisterer Connex中压插头系统概述
The Pfisterer Connex separable connector system is designed for reliable connections in medium voltage distribution networks. According to Pfisterer Connex catalog documentation, these connectors feature silicone rubber insulation bodies with geometric and resistive field control, meeting requirements of IEC 62271-209 for cable connections in metal-enclosed switchgear. Pfisterer Connex可分离连接器系统专为中压配电网络中的可靠连接而设计。根据Pfisterer Connex目录文档，这些连接器采用硅橡胶绝缘体，具有几何和电阻场控制功能，符合IEC 62271-209金属封闭开关设备电缆连接要求。
| Connex Model Connex型号 | Voltage Class 电压等级 | Current Rating 额定电流 | Interface 接口 | Cable Range (mm²) 电缆范围 |
|---|---|---|---|---|
| Connex 12 kV 250A | 12 kV | 250 A | Type A (EN 50181) | 25 – 95 |
| Connex 12 kV 630A | 12 kV | 630 A | Type B (EN 50181) | 95 – 300 |
| Connex 24 kV 250A | 24 kV | 250 A | Type A (EN 50181) | 25 – 95 |
| Connex 24 kV 630A | 24 kV | 630 A | Type B (EN 50181) | 95 – 400 |
| Connex 36 kV 630A | 36 kV | 630 A | Type C (EN 50181) | 150 – 630 |
Required Tools and Materials — 所需工具和材料
Proper termination requires specialized tools conforming to IEC safety standards. The following checklist ensures all necessary equipment is available before beginning the termination procedure. 正确的端接需要符合IEC安全标准的专用工具。以下清单确保在开始端接程序之前准备好所有必要设备。
Cable Preparation Tool Set
电缆准备工具套装 — Stripping knife, rotary cutter
Torque Wrench
扭矩扳手 — Calibrated 5–50 Nm range
Hexagonal Crimping Tool
六角压接工具 — For conductor lug termination
Silicone Grease
硅脂润滑剂 — Pfisterer-specified lubricant
Abrasive Cloth (Fine)
细砂布 — For XLPE surface preparation
Insulation Resistance Tester
绝缘电阻测试仪 — 5 kV megohmmeter
Vernier Caliper
游标卡尺 — Dimension verification
Cleaning Solvent
清洁溶剂 — Isopropyl alcohol (IPA)
Safety Warning 安全警告
ALWAYS verify cable is de-energized and grounded before beginning termination work. Follow lockout/tagout (LOTO) procedures per OSHA 29 CFR 1910.147 or equivalent local regulations. Medium voltage work requires qualified personnel only. 务必在开始端接工作前确认电缆已断电并接地。遵循OSHA 29 CFR 1910.147或当地等效法规的上锁/挂牌(LOTO)程序。中压作业仅限合格人员操作。
Cable Stripping Dimensions — 电缆剥线尺寸
Accurate stripping dimensions are critical for proper connector interface and field control. The following table provides reference dimensions based on Pfisterer installation instructions. Always verify against the specific connector datasheet supplied with your Connex kit. 准确的剥线尺寸对于正确的连接器接口和场控制至关重要。下表根据Pfisterer安装说明提供参考尺寸。请务必根据Connex套件随附的具体连接器数据表进行验证。
Typical Stripping Sequence (Cable End View) 典型剥线顺序（电缆端部视图）
| Connex Type Connex类型 | L₁ Outer Sheath 外护套 (mm) | L₂ Screen 屏蔽层 (mm) | L₃ Semi-Con 半导层 (mm) | L₄ Insulation 绝缘层 (mm) | L₅ Conductor 导体 (mm) |
|---|---|---|---|---|---|
| 12 kV 250A | 250 ± 5 | 200 ± 3 | 155 ± 2 | 120 ± 2 | 30 ± 1 |
| 12 kV 630A | 280 ± 5 | 230 ± 3 | 175 ± 2 | 140 ± 2 | 35 ± 1 |
| 24 kV 250A | 320 ± 5 | 270 ± 3 | 210 ± 2 | 170 ± 2 | 32 ± 1 |
| 24 kV 630A | 350 ± 5 | 300 ± 3 | 235 ± 2 | 190 ± 2 | 38 ± 1 |
| 36 kV 630A | 420 ± 5 | 365 ± 3 | 290 ± 2 | 240 ± 2 | 42 ± 1 |
Dimension Note 尺寸说明
Dimensions shown are typical reference values. Always consult the specific installation instruction sheet (IIS) provided with each Pfisterer Connex connector kit, as dimensions may vary based on cable outer diameter and specific product variant. 所示尺寸为典型参考值。请务必查阅每个Pfisterer Connex连接器套件随附的具体安装说明书(IIS)，因为尺寸可能因电缆外径和特定产品变型而异。
Step-by-Step Termination Procedure — 分步端接程序
The following procedure outlines the critical steps for terminating (N)TSCGEWÖU cables into Pfisterer Connex plugs. This guide follows best practices referenced in industry technical resources and manufacturer specifications. 以下程序概述了将(N)TSCGEWÖU电缆端接到Pfisterer Connex插头的关键步骤。本指南遵循行业技术资源和制造商规范中的最佳实践。
Cable Preparation & Inspection 电缆准备与检查
Inspect the cable end for any damage, moisture ingress, or contamination. Cut the cable square using a fine-toothed saw or cable cutter. Verify the cable cross-section matches the Connex connector range. Mark all stripping dimensions (L₁ through L₅) using a permanent marker and measuring tape. 检查电缆端部是否有任何损坏、水分侵入或污染。使用细齿锯或电缆切割器将电缆切割成直角。确认电缆截面与Connex连接器范围匹配。使用永久性记号笔和卷尺标记所有剥线尺寸（L₁至L₅）。
Remove Outer Sheath (PUR) 移除外护套
Using a cable stripping tool or knife, carefully remove the polyurethane outer sheath to dimension L₁. Make a circumferential cut, then a longitudinal cut to peel away the sheath. Do not damage the underlying copper wire screen. Clean any residue from the screen surface. 使用电缆剥皮工具或刀具，小心地将聚氨酯外护套移除至尺寸L₁。进行环切，然后纵切以剥离护套。不要损坏下面的铜丝屏蔽层。清除屏蔽层表面的任何残留物。
Prepare Screen Connection 准备屏蔽连接
Fold back the copper wire screen over the outer sheath, leaving sufficient length for the grounding connection as specified. Apply the screen connection clamp or spring from the Connex kit. Ensure 360° contact between the screen and grounding component. Cut excess screen wires cleanly. 将铜丝屏蔽层折叠在外护套上，按规定留出足够长度用于接地连接。安装Connex套件中的屏蔽连接夹或弹簧。确保屏蔽层与接地部件之间的360°接触。干净地切除多余的屏蔽丝。
Remove Semiconductive Layer 移除半导电层
Carefully remove the outer semiconductive layer to dimension L₃. Use a rotary stripping tool set to the correct depth to avoid damaging the XLPE insulation. The semi-con/insulation interface must be clean and smooth. Create a 45° chamfer at the semi-con cut edge to prevent field concentration. 小心地将外半导电层移除至尺寸L₃。使用设置为正确深度的旋转剥皮工具，以避免损坏XLPE绝缘层。半导层/绝缘层界面必须清洁光滑。在半导层切割边缘创建45°倒角以防止电场集中。
Prepare XLPE Insulation Surface XLPE绝缘表面处理
Lightly abrade the exposed XLPE insulation surface using fine abrasive cloth (provided in kit) to remove any oxidation and improve the silicone interface. Clean thoroughly with isopropyl alcohol and lint-free cloth. Allow to dry completely. The surface must be free of any semi-con residue, fingerprints, or contamination. 使用细砂布（套件中提供）轻轻打磨暴露的XLPE绝缘表面，以去除任何氧化并改善硅橡胶界面。用异丙醇和无绒布彻底清洁。待完全干燥。表面必须没有任何半导电层残留、指纹或污染。
Strip Insulation for Conductor 剥除绝缘露出导体
Remove the XLPE insulation to expose conductor length L₅. Use a semicircular blade knife or rotary tool. Remove any conductor screen layer if present. Verify conductor is undamaged—no nicked or cut strands. Clean conductor with solvent. 移除XLPE绝缘以露出导体长度L₅。使用半圆形刀片或旋转工具。如有导体屏蔽层，将其移除。确认导体未损坏——无划伤或切断的股线。用溶剂清洁导体。
Install Conductor Connector (Lug) 安装导体连接器（接线端子）
Select the appropriate compression lug from the Connex kit matching the conductor cross-section. Insert conductor fully into lug barrel. Crimp using calibrated hexagonal crimping tool with correct die size per DIN 46235 or manufacturer specification. Verify crimp quality—no voids, proper compression depth. 从Connex套件中选择与导体截面匹配的适当压接端子。将导体完全插入端子套筒。使用根据DIN 46235或制造商规范校准的六角压接工具和正确的模具尺寸进行压接。验证压接质量——无空隙，压缩深度正确。
Apply Silicone Lubricant 涂抹硅脂润滑剂
Apply a thin, even coat of Pfisterer-specified silicone grease to the entire prepared XLPE insulation surface and to the internal bore of the Connex silicone body. This ensures proper electrical interface and allows smooth assembly. Do not use petroleum-based lubricants. 在整个准备好的XLPE绝缘表面和Connex硅橡胶体的内孔上涂抹一层薄而均匀的Pfisterer指定硅脂。这确保了正确的电气界面并允许顺利组装。不要使用石油基润滑剂。
Assemble Connex Plug Body 组装Connex插头本体
Slide the Connex silicone plug body over the prepared cable end in a straight, continuous motion. Push firmly until the body seats against the screen connection point and the conductor lug extends through the plug contact area. Verify all internal components are properly positioned per the installation instruction diagram. 以直线、连续的动作将Connex硅橡胶插头本体滑过准备好的电缆端部。用力推动，直到本体抵靠屏蔽连接点，导体端子延伸穿过插头接触区域。根据安装说明图验证所有内部组件是否正确定位。
Secure Contact Assembly & Final Inspection 固定接触组件和最终检查
Tighten the contact bolt to the specified torque value (typically 20–30 Nm, verify per datasheet). Install any locking mechanisms, caps, or protective covers. Perform visual inspection for proper assembly. Conduct insulation resistance test (minimum 1000 MΩ at 5 kV DC) before energization per IEC 60060-1 recommendations. 将接触螺栓拧紧至规定扭矩值（通常为20-30 Nm，请根据数据表验证）。安装任何锁定机构、盖帽或保护盖。进行目视检查以确保正确组装。根据IEC 60060-1建议，在通电前进行绝缘电阻测试（5 kV DC下最小1000 MΩ）。
Quality Checkpoint 质量检查点
After completing termination, document the following: cable ID, connector serial number, stripping dimensions achieved, crimp tool calibration date, torque values applied, and insulation resistance test results. This documentation supports quality assurance per ISO 9001 requirements. 完成端接后，记录以下内容：电缆ID、连接器序列号、实际剥线尺寸、压接工具校准日期、施加的扭矩值和绝缘电阻测试结果。此文档支持ISO 9001要求的质量保证。
Common Issues and Troubleshooting — 常见问题与故障排除
| Issue 问题 | Possible Cause 可能原因 | Solution 解决方案 |
|---|---|---|
| Plug body won’t slide on 插头本体无法滑入 | Insufficient lubricant; XLPE surface not prepared; cable OD exceeds range | Apply more silicone grease; re-abrade and clean surface; verify cable compatibility |
| Low insulation resistance 绝缘电阻低 | Contamination on XLPE; moisture ingress; semi-con residue | Disassemble, re-clean with IPA, ensure dry environment; verify semi-con removal |
| Partial discharge detected 检测到局部放电 | Air voids at interface; improper semi-con chamfer; damaged insulation | Re-terminate with proper lubricant coverage; create proper 45° chamfer; inspect for cuts |
| Screen connection failure 屏蔽连接失效 | Incomplete 360° contact; corroded screen wires; clamp not tightened | Ensure full circumferential contact; clean or replace screen; verify clamp torque |
| Contact resistance high 接触电阻高 | Improper crimp; oxidized conductor; wrong lug size | Re-crimp with calibrated tool; clean conductor; verify lug cross-section match |
Authoritative Sources & References — 权威来源与参考文献
The technical specifications and procedures in this guide are derived from the following authoritative industry sources. We recommend consulting these resources for the most current standards and manufacturer-specific requirements. 本指南中的技术规格和程序来源于以下权威行业来源。建议查阅这些资源以获取最新标准和制造商特定要求。
-
Pfisterer Holding AG
Connex Separable Connector System — Product catalog and installation instructions
https://www.pfisterer.com/products/connectors -
VDE Verlag (German Electrotechnical Commission)
DIN VDE 0276-620 — Power cables with extruded insulation for rated voltages from 3.6/6 kV to 20.8/36 kV
https://www.vde-verlag.de/standards -
International Electrotechnical Commission (IEC)
IEC 60502-2 — Power cables with extruded insulation for rated voltages from 1 kV to 30 kV
https://webstore.iec.ch/publication/6364 -
International Electrotechnical Commission (IEC)
IEC 62271-209 — Cable connections for metal-enclosed switchgear and controlgear
https://webstore.iec.ch/publication/29115 -
CENELEC (European Committee for Electrotechnical Standardization)
EN 50181 — Plug-in type bushings above 1 kV up to 52 kV
https://www.cenelec.eu/ -
DIN (German Institute for Standardization)
DIN 46235 — Compression cable lugs and connectors for power cables
https://www.din.de/en -
OSHA (U.S. Occupational Safety and Health Administration)
29 CFR 1910.147 — Control of Hazardous Energy (Lockout/Tagout)
https://www.osha.gov/control-hazardous-energy -
ISO (International Organization for Standardization)
ISO 9001:2015 — Quality management systems requirements
https://www.iso.org/standard/62085.html
Contact Anhui Feichun Special Cable Co., Ltd. 联系安徽飞纯特种电缆有限公司
For technical consultation on (N)TSCGEWÖU cables, Pfisterer Connex compatible products, or custom medium voltage cable solutions, please contact our engineering and sales teams. 如需(N)TSCGEWÖU电缆、Pfisterer Connex兼容产品或定制中压电缆解决方案的技术咨询，请联系我们的工程和销售团队。
Technical Support 技术支持
Sales – Zihao Yang 销售-杨子豪
Sales – Ziyu Huang 销售-黄子瑜
