ASTM F1835-97(2007)

NOTICE: This standard has either been superseded and replaced by a new version or withdrawn.
Contact ASTM International (www.astm.org) for the latest information
Designation: F1835 − 97(Reapproved 2007) An American National Standard
Standard Guide for
Cable Splicing Installations
This standard is issued under the fixed designation F1835; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1. Scope Conductors, Hard, Medium-Hard, or Soft
D2671 Test Methods for Heat-Shrinkable Tubing for Elec-
1.1 This guide provides direction and recommends cable
trical Use
splicing materials and methods that would satisfy the require-
2.2 IEEE Standards:
ments of extensive cable splicing in modular ship construction
IEEE 45 Recommended Practice for Electrical Installations
and offers sufficient information and data to assist the ship-
on Shipboard
builder in evaluating this option of cable splicing for future
ship construction. 2.3 UL Standards:
UL STD 224 Extruded Insulating Tubing
1.2 This guide deals with cable splicing at a generic level
ULSTD 486A Wire Connectors and Soldering Lugs for Use
and details a method that will satisfy the vast majority of cable
with Copper Conductors
splicing applications.
2.4 IEC Standards:
1.3 This guide covers acceptable methods of cable splicing
IEC 228 Conductors of Insulated Cables
used in shipboard cable systems and provides information on
2.5 Federal Regulations:
current applicable technologies and additional information that
Title 46 Code of Federal Regulations (CFR), Shipping
the shipbuilder may use in decision making for the cost
2.6 Military Specifications:
effectiveness of splicing in electrical cable installations.
MIL-T-16366 Terminals, Electric Lug and Conductor
1.4 This guide is limited to applications of 2000 V or less,
Splices, Crimp-Style
but most of the materials and methods discussed are adaptable
MIL-T-7928 Terminals, Lug, Splices, Conductors, Crimp-
to higher voltages, such as 5-kV systems. The cables of this
Style, Copper
guide relate to all marine cables, domestic and foreign,
commercial or U.S. Navy.
3. Terminology
1.5 The values stated in SI units shall be regarded as
3.1 Definitions of Terms Specific to This Standard:
standard. The values given in parentheses are inch-pound units
3.1.1 adhesive, n—a wide range of materials used exten-
and are for information only.
sively for bonding and sealing; coating added to the inner wall
1.6 This standard does not purport to address all of the
of heat-shrinkable tubing to seal the enclosed area against
safety concerns, if any, associated with its use. It is the
moisture. Adhesive is for pressure retention and load-bearing
responsibility of the user of this standard to establish appro-
applications (see also sealant).
priate safety and health practices and determine the applica-
3.1.2 barrel, n—the portion of a terminal that is crimped;
tion of regulatory limitations prior to use.
designed to receive the conductor, it is called the wire barrel.
3.1.3 butt connector, n—a connector in which two conduc-
2. Referenced Documents
tors come together, end to end, but do not overlap and with
2.1 ASTM Standards:
their axes in line.
B8 Specification for Concentric-Lay-Stranded Copper
3.1.4 butt splice, n—device for joining conductors by butt-
ing them end to end.
This guide is under the jurisdiction of ASTM Committee F25 on Ships and
Marine Technology and is the direct responsibility of Subcommittee F25.10 on
Electrical. Available from Institute of Electrical and Electronics Engineers, Inc. (IEEE),
Current edition approved May 1, 2007. Published June 2007. Originally 445 Hoes Ln., P.O. Box 1331, Piscataway, NJ 08854-1331, http://www.ieee.org.
approved in 1997. Last previous edition approved in 2002 as F1835 - 97(2002). Available from Underwriters Laboratories (UL), 333 Pfingsten Rd.,
DOI: 10.1520/F1835-97R07. Northbrook, IL 60062-2096, http://www.ul.com.
2 5
For referenced ASTM standards, visit the ASTM website, www.astm.org, or Available from the International Electrotechnical Commission, 3 rue de
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM Varembe, Case Postale 131, CH-1211, Geneva 20, Switzerland.
Standards volume information, refer to the standard’s Document Summary page on AvailablefromStandardizationDocumentsOrderDesk,Bldg.4SectionD,700
the ASTM website. Robbins Ave., Philadelphia, PA 19111–5098, Attn: NPODS.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
F1835 − 97 (2007)
3.1.5 circumferential crimp, n—final configuration of a with multiple suppliers available; low-cost methods; and suit-
barrelmadewhencrimpingdiescompletelysurroundthebarrel able for marine, Navy, and IEC cables.
and form symmetrical indentations.
5. General Requirements for Cable Splicing
3.1.6 compression connector, n—connector crimped by an
5.1 Cable splicing requires that cable joints be insulated and
externally applied force; the conductor is also crimped by such
sealed with an insulation equal in electrical and mechanical
force inside the tube-like connector body.
properties to the original cable. Cable splicing shall consist of
3.1.7 cold-shrink tubing, n—tubular rubber sleeves that are
a conductor connector, replacement of conductor insulation,
factory expanded and assembled onto a removable core. No
replacement of the overall cable jacket, and where applicable,
heat is used in installation. Also known as prestretched tubing
reestablishment of shielding in shielded cables and electric
(PST).
continuity in the armor of armored cables.
3.1.8 crimp connectors, n—tubular copper connectors made
5.2 NonspliceApplications—The only unacceptable area for
to match various wire sizes and fastened to the conductor ends
a cable splice is established by regulations and concerns the
by means of a crimping tool.
restrictionofbeingunabletosplicecablesindefinedhazardous
3.1.9 crimping die, n—portion of the crimping tool that areas. Hazardous areas are locations in which fire or explosion
shapes the crimp. hazards may exist as a result of flammable gases or vapors,
flammable liquids, combustible dust, or ignitable fibers or
3.1.10 crimping tool, n—amechanicaldevice,whichisused
flyings.
tofastenelectricalconnectorstocableconductorsbyforcefully
compressing the connector onto the conductor. This tool may
6. Cable Splicing
have interchangeable dies or “jaws” to fit various size connec-
6.1 Cable splicing presented in this guide uses a system of
tors.
compression-crimp, tubular-metal connectors for butt connec-
3.1.11 heat-shrink tubing, n—electrical insulation tubing of
tion of cable conductors and insulating systems of shrinkable
a polyolefin material, which shrink in diameter from an
tubing to reinsulate the individual conductors and replace the
expanded size to a predetermined size by the application of
overall cable jacket.
heat. It is available in various diameter sizes.
6.2 Crimp Connectors—For splice connection of
3.1.12 primary insulation, n—the layer of material that is
conductors, compression-crimped connectors shall be used for
designedtodotheelectricalinsulating,usuallythefirstlayerof
joininganelectricalconductor(wire)toanotherconductor.The
material applied over the conductor.
joint requires proper compression to achieve good electrical
3.1.13 sealant, n—inner-wall coating optional to shrinkable performance while not overcompressing and mechanically
damaging the conductor. Compression connections are accom-
tubing to prevent ingress of moisture to the enclosed area (see
also adhesive). plished by applying a controlled force on a barrel sleeve to the
conductor with special tools and precision dies.
3.1.14 splice, n—a joint connecting conductors with good
mechanical strength and good conductivity. 6.3 Conductor Reinsulation—Thin-wall shrinkable tubing
shall be used to reinsulate the conductor and the installed
3.1.15 tensile, n—amount of axial load required to break or
connector. The insulation tubing, when shrunk or recovered,
pull wire from the crimped barrel of a terminal or splice.
shall be equal in electrical and mechanical properties to the
original conductor insulation. Tubing used for conductor rein-
4. Significance and Use
sulation does not require an interior adhesive sealant coating.
4.1 Splicing of cables in the shipbuilding industry, both in
6.4 Cable Jacket Reinsulation—Shrinkable tubing shall be
Navy and commercial undertakings, has been concentrated in
used to envelop the overall splice. To satisfy more abusive
repair, conversion, or overhaul programs. However, many
conditions that cable jackets are exposed to, a flame-retardant,
commercial industries, including aerospace and nuclear power,
thick-wall tubing construction with factory applied sealant
have standards defining cable splicing methods and materials
shall be used.
that establish the quality of the splice to prevent loss of power
or signal, ensure circuit continuity, and avoid potential cata-
7. Cable Preparation
strophic failures. This guide presents cable splicing techniques
7.1 Cables to be spliced shall be prepared to the dimensions
and hardware for application to commercial and Navy ship-
specified in Fig. 1 and Fig. 2. Fig. 1 provides cable preparation
building to support the concept of modular ship construction.
for power cables from single to four conductor sizes. Dimen-
4.2 This guide resulted from a study that evaluated the
sions for multiple conductor cables (conductor size of No. 14
various methods of cable splicing, current technologies, prior
or less) are shown in Fig. 2.
studies and recommendations, performance testing, and the
7.2 Care must be exercised when preparing the cable ends
expertise of manufacturers and shipbuilders in actual cabling
so that conductor insulation is not cut when removing the
splicing techniques and procedures.
overall cable jacket, shield, or cable armor, where applicable.
4.3 The use of this guide by a shipbuilder will establish Similarcareisrequiredwhenremovingtheindividualshieldor
cabling splicing systems that are: simple and safe to install; insulation protecting the conductor to prevent cuts or nicks on
waterproof, corrosion, and impact resistant; industry accepted the individual conductor strands.
F1835 − 97 (2007)
FIG. 1 Splice Dimensions for Power Cables
F1835 − 97 (2007)
FIG. 2 Splice Dimensions for Control-Multiple Conductor Cables
7.2.1 Insulation cutting tools that limit depth of cut should 7.2.2 Cable preparation shall result in stripping the indi-
be used to prepare cable ends so that underlying insulation is vidual conductors so that the bare copper is long enough to
not cut. Similar care is required when removing the individual
reach the full depth of the butt connector plus 3.2 mm ( ⁄8 in.).
conductor insulation to protect the conductor copper strands
from nicks and cuts.
F1835 − 97 (2007)
7.3 Match the geometrical arrangement between cables to 8.1.2 Conductor Reinsulating Material—To reinsulate the
be spliced using conductor color code identification to elimi- conductor and the installed connector, heat-shrink tubing shall
nate crossovers or mismatch when splicing.
be used. (see Table 3).
8.1.2.1 When recovered or shrink, the tubing used shall be
7.4 Cable ends shall be in or near their final position before
being spliced. equal to or greater than the thickness of the original conductor
insulation.
8. Materials and Tools
8.1.2.2 Shrink tubing used for conductor reinsulation shall
be heat-shrink tubing. The tubing shall be thin-wall cross-
8.1 Cable Splicing Materials—The following sections pro-
vide an overview of the various splice materials. In addition, linked polyolefin tubing, flame-retardant (FR-1) construction
specific recommendations and suggested guidelines are offered
in accordance with UL STD 224 requirements. Performance
that would enhance the cable splicing process.
requirements shall include:
8.1.1 Crimp-Type Connectors—Splice connectors shall be
Shrink ratio 2:1
compression-type, butt connectors conforming to the require- Operating temperature range –55 to +135°C
Minimum shrinkage temperature +121°C
ments of UL STD 486A and shall be satisfactory to Section
Longitudinal shrinkage ±5 %
20.11 of IEEE 45.
Electrical rating 600-V continuous operation
8.1.1.1 Connector shall be seamless, tin-plated copper. Dielectric strength in accordance with 19.7 kV/mm (500 V/mil) min
Test Methods D2671
8.1.1.2 Butt connector shall have positive center wire stops
for proper depth of conductor insertion.
8.1.2.3 Shrink tubing to cover the connection of individual
8.1.1.3 Connectors shall be marked with wire size for easy
conductors does not require an interior coating of adhesive
identification.
(mastic) sealant.
8.1.1.4 Connector shall have inspection holes to allow
8.1.3 Cable Jacket Replacement Materials—Several meth-
visual inspection for proper wire insertion.
odsandavarietyofmaterialsareavailablethatwillprovidethe
8.1.1.5 Butt connector for wire sizes No. 10 (AWG) or
mechanical protection, moisture-sealing properties, and elec-
larger shall be the “long barrel” type to permit multiple crimps
trical performance characteristics needed in a cable splice. For
on each side of the connector for greater tensile strength. The
a splice reliability and ease of installation replacement of cable
conductorendsshallbefullyinsertedtothe“stop”atthecenter
jacket and to envelop the splice area, however, either the
of the connector. For smaller conductor sizes (No. 10AWG or
heat-shrink or the cold-shrink (prestretched) type shall be used.
less), a single crimp should be spaced half way between the
end of the connector and the center wire stop. 8.1.3.1 The tubing used, when recovered or shrunk, shall be
8.1.1.6 Connector shall be color-coded in accordance with equal to or greater than the thickness of the original conductor
Table 1 or Table 2. insulation (see Table 3).
TABLE 1 Connector Data (English Units)
Conductor Size AWG or Connector Overall Depth of Each Side of Overall Diameter of Conductor Nominal Number of Crimps/
A
Color Code
B
MCM Designation Length (min) Barrel (min) Barrel (Approximate) Diameter, in. End
5 1
22 ⁄8 ⁄4 0.150 – 0.025 1
5 1
20 ⁄8 ⁄4 0.150 – 0.039 1
5 1
18 ⁄8 ⁄4 0.150 – 0.049 1
5 1
16 ⁄8 ⁄4 0.150 – 0.061 1
5 1
14 ⁄8 ⁄4 0.150 – 0.077 1
3 5
12 ⁄4 ⁄16 0.212 – 0.092 1
3 5
10 ⁄4 ⁄16 0.212 – 0.108 1
3 13 1
81 ⁄4 ⁄16 ⁄4 red 0.146 2
3 1 5
62 ⁄8 1 ⁄8 ⁄16 blue 0.184 2
3 1 5
42 ⁄8 1 ⁄8 ⁄16 gray 0.226 2
5 1 3
32 ⁄8 1 ⁄4 ⁄8 white 0.254 2
5 1 7
22 ⁄8 1 ⁄4 ⁄16 brown 0.282 2
...