1

Corporate
2

Established since 1935, London-based CTL Components plc benefits from being part of CTL Components Group plc. As well as the manufacture of cable accessories, other Group activities include sub-contract precision sheet metalwork and finishing services and the distribution of electronic components. The entire Group is accredited to BS EN ISO 9001:2000 and has an impressive customer list of major international companies.

Cable accessories are a core CTL activity. Over half of production is exported and the CTL brand As a result, CTL holds approvals from many commands respect throughout the world. international oil, telecom, rail and utility companies and is the sole contracted supplier of cable accessories to the UK Governments Highways Agency.

As well as the given requirements of design, quality and price, it is the sheer breadth of CTLs range that provides customers with a reliable, authoritative and convenient one-stop-shop for all of their cable accessory needs. This catalogue alone lists nearly 100 variations of standard resin cable joints, almost all available immediately from stock. A specials service offers a further 400 variations to ensure that joints for almost any LV or MV cables can be supplied.

Jointer Training

CTL cable joints are good, but only as good as the people who install them! Thousands of jointers throughout the world have grown to appreciate the ease of working with CTL joints and often comment on the clear instructions, sensible designs with plenty of space and high quality components. For those less experienced, CTL offers a comprehensive jointer training programme run by highly-qualified trainers. Sessions are either held at CTLs London Head Office or at a clients location anywhere in the world. From Hong Kong to Azerbaijan, there are hundreds of jointers who proudly display their certificates of competence which have been issued to them following the successful completion of one of CTLs courses. These courses vary in duration from one to five days and cover the theory and practical skills required to safely install cable joints and terminations up to 33kV, utilising both resin and heatshrink technologies. CTL Components plc Falcon House, 19 Deer Park Rd, London, SW19 3UX. United Kingdom Tel: +44 (0) 20 8545 8700 Fax: +44 (0) 20 8540 0034 E-mail: [email protected] Web: www.ctl-components.com

Contents
Item
Jointer Training Contents Technical Information Certification LV Resin Cable Joints - Straight LV Resin Cable Joints - Branch LV Resin Cable Joints - Special Applications Cathodic Protection Joints Multicore Control & Pilot Cables Multipair Telecom Cables Mines & Quarries Oil & Petrochem 1.9/3.3 kV Joints LV Resin Cable Joints - Low Smoke Zero Halogen Joint Shell Dimensions CTL Cold-Pour Two-Part Resins Mechanical Connectors Cable Glands Cable Cleats Underground & Barrier Tapes Cable Clamps LV Heatshrink tubing LV Heatshrink Boxes LV Wraparound repair sleeves Anode Caps Cable End Caps Cable Breakouts LV Straight Joints LV Terminations MV Terminations for Polymeric Cables up to 36 kV MV Terminations for Paper Cables up to 12 kV MV (15kV) Heatshrink & Resin Cable Joints MV Heatshrink Cable Joints MV Tubing Stress Control Tubing Anti-tracking Tubing Semi-conductive Tubing Busbar Tubing MV Universal Boot Kits MV Accessories Heatshrink Boot Kits Stand-Off Insulators Gland Kits Constant Force Springs Self-amalgamating Tape Torch Kit Metallic Screens Compression Lugs & Ferrules Tools

CTL
Components plc

Page No
2 3 4 5 6 7 8 8 8 8 9 9 9 10 12 13 14 15 16 16 17 18 19 19 19 20 20 21 21 22 23 24 25 26 26 26 26 26 27 28 28 28 28 29 29 29 29 30 31

CTL operates a continuing product development programme and so reserves the right to alter specifications without prior notice. All text, images and drawings within this document are copyrighted and must not be reproduced in any form without prior written consent.

Contents
3

MV

Low Voltage

CTL
CLEARCAST

Technical Information
What goes into a good cable joint?
Injection Moulded Shells Rigid and very strong, their snap-lock design forms an excellent seal and prevents egress of resin. Mechanical Connectors Our MC1/0 to MC1/3 connectors have been especially designed to accept the same range of cable sizes as the CM0 to CM3 LV cable joints they are supplied with. Machined from solid brass, they are suitable for either copper or aluminium conductors. Two Allen screws for each core ensure a sound electrical performance and an Allen key is also provided with each kit to ensure that everything needed to join a cable is included in the one box (CM and CB +C ranges). The connector range is complemented with larger aluminium alloy connectors (see page 11). Earth Braid Offers significant advantages over single wire type earth continuity systems, which can fail if poorly positioned within wire armour cores that have spread. The flat, soft braid ensures good electrical contact and is insulated for extra protection. Constant Force Springs Cable joints move and expand due to earth shift and heat from electrical current. Constant force springs react to this movement and maintain a sound electrical connection between the steel wire armouring and the earth continuity braid. Core separators Provide safe separation of cores and connectors. Two-part resin CTLs long-proven resin formula is of such quality that it is equally suitable for both LV and MV applications and provides excellent adhesion to PVC, XLPE, polythene and paper cables. It is Breadth of range supplied in two-part easy-mix packaging, ensur- There are few, if any, combinations of power cables that CTL cannot join. We offer over 400 ing both convenience and safety. variations of resin cable joints including special Packaging versions for mines & quarries; oil & petrochem; CTL joints are supplied in especially robust and telecom & control; cathodic protection. These rigid boxes to withstand stacking both in ware- utilise both resin and heatshrink technologies and houses and in pallets. These boxes are also popu- are supplied for both LV and MV applications. lar with jointers since they can be used as mini Technical support workbenches. Call our technical help line on +44 (0) 20 8545 Instructions 8700 to be instantly put through to someone Detailed, clear and concise instruction sheets, who can answer your cable jointing question. mostly printed in full colour, ensure there is no CTL also offers specialist cable jointer training ambiguity about safe jointing procedures. courses - see inside cover.

Technical Info
4

Certification
MV Joints MV Terminations
CTL Medium Voltage joints are tested in accord- CTL Medium Voltage Terminations are tested in accordance with VDE0278 (CENELEC HD629.1S1) ance with Cenelec HD629.1S1. and IEC502.
Test Description Cable Type & System Voltages Polymeric 12 kV (Um) DC Withstand 15 min (kV) AC Withstand 5 min (kV) Partial Discharge <10pc (kV) Impulse Voltage (kVp)
Heat Cycling Air & Water (kV)

CTL
Components plc

Test Description

Cable Type & System Voltages Polymeric 17.5 kV (Um) 24 kV (Um) 76 57 51 22 125 32 16 36 kV (Um) 114 85 76 33 194 47.5 24 Paper 12 kV (Um) 38 28.5 25.5 95 9.5 8

38 28.5 11 95 16

Paper & Transition 12 kV (Um) 38 28.5 95 9.5

DC Withstand 15 min (kV) AC Withstand Dry 5 min (kV) AC Withstand Wet 1 min (kV) Partial Discharge <10pc (kV) Impulse Voltage (kVp) Heat Cycling Air (kV) Salt Fog 1000 hr (kV)

52 39 35 15 95 23 11

All CTL C-Shrink moulded shapes and heatshrink All CTL LV cable joints hold test certificate CENELEC HD 623.S1/DIN VDE 0278, now renamed tubing meet or exceed EA-1509-11. EN50393:2006. (BS6910 and BS7888 standards Properties Typical Results Test Method are now obsolete.)
Cont. Operating Temp. -55 to +110C Tensile Strength 15 MPa IEC 540 Ultimate Elongation 400% IEC 540 Heat Shock No Damage ASTM D2671 Dielectric Strength 15 kV/mm ASTM D2671 Water Absorption <0.1% ASTM D570 Flammability Self Extinguishing ASTM D635

LV Heatshrink Products

LV Cable Joints

All companies within CTL Components Group plc are fully acredited to BS EN ISO 9001:2000. CTL is a member of the British Standards Institution.

ISO 9001:2000

Certification
5

CTL
CLEARCAST

LV Resin Cable Joints - Straight

suitable for PVC or XLPE cable, 1kV

LV Straight

Armoured Cables
CM range
Max Cable Size 4 core (mm2) 1.5 - 6 10 - 16 25 35 - 95 120 150 185 - 240 300 - 400

Basic Joints Part No Earth Kit included

Basic Joints plus Mechanical Connectors Part No Connectors included

CM0 Braid & Constant Force Springs CM0+C 4 x MC1/0 & Allen Key CM1 Braid & Constant Force Springs CM1+C 4 x MC1/1 & Allen Key CM2 Braid & Constant Force Springs CM2+C 4 x MC1/2 & Allen Key CM3 Braid & Constant Force Springs CM3+C 4 x MC1/3 & Allen Key CM4 Braid & Constant Force Springs CM4+C 4 x MC1/3 & Allen Key CM5 Braid & Constant Force Springs CM5+C 4 x MC1/5 CM6 Braid & Constant Force Springs CM6+C 4 x MC1/6 CM7 Braid & Constant Force Springs CM7+C 4 x MC1/7 Basic joints with compression ferrules instead of mechanical connectors are also available

Quick S elec tion

No of cores 2 3 4 CM0 CM0 Cable size (mm2) 1.5 2.5 4 CM0 CM1 CM1 6 10 16 CM1 CM2 CM2 25 35 CM2 CM3 CM3 CM4 50 70 95 CM3 CM4 CM5 120 150 185 CM4 CM5 CM6 240 300 CM5 CM6 CM7 400

Unarmoured Cables
CM EX range
Max Cable Size 4 core (mm2) 1.5 - 10 16 25 - 35 50 - 95 120 150 - 185 240 - 300 400

Basic Joints Part No

Basic Joints plus Mechanical Connectors Part No Connectors included

CM0EX CM0EX+C 4 x MC1/0 & Allen Key CM1EX CM1EX+C 4 x MC1/1 & Allen Key CM2EX CM2EX+C 4 x MC1/2 & Allen Key CM3EX CM3EX+C 4 x MC1/3 & Allen Key CM4EX CM4EX+C 4 x MC1/3 & Allen Key CM5EX CM5EX+C 4 x MC1/5 CM6EX CM6EX+C 4 x MC1/6 CM7EX CM7EX+C 4 x MC1/7 Basic joints with compression ferrules instead of mechanical connectors are also available

Quick S elec tion

No of cores 2 3 4 Cable size (mm2) 1.5 2.5 4 CM0EX CM0EX CM0EX 6 10 16 25 35 50 70 95 CM3EX CM3EX CM3EX CM4EX CM4EX CM5EX 120 150 185 CM4EX CM5EX CM6EX 240 300 400 CM1EX CM1EX CM2EX CM1EX CM2EX CM2EX CM5EX CM6EX CM7EX

LV Resin Cable Joints - Branch

suitable for PVC or XLPE cable, 1kV

CTL
CLEARCAST

CU range Universal joints for branch & straight jointing

Main Cable Size 2,3 & 4 core (mm2) Max Branch Cable 2,3 & 4 core (mm2) Basic Joints Part No Basic Joints plus Mech. Connectors Part No Connectors included

Armoured & Unarmoured Cable - Uncut Main 1.5 - 2.5 1 x 2.5 CU0 CU0+C 4 x MC3 4-6 2x6 CU1 CU1+C 4 x MC3 10 - 25 2 x 25 CU2 CU2+C 4 X MC2 35 - 50 2 x 35 CU3 CU3+C 4 x MC3/3 70 - 95 2 x 35 CU4 CU4+C 4 x MC4/1 120 - 185 2 x 35 CU5 CU5+C 4 x MC4/2

CB range

CB ring connector range

Main Cable Size 2,3 & 4 core (mm2)

Max Branch Cable 2,3 & 4 core (mm2)

Basic Joints Part No

Basic Joints plus Mech. Connectors Part No Connectors included

Main Cable Size 4 core (mm2)

Max Branch Cable 2,3 & 4 core (mm2)

Part No Inc ring connector

Armoured & Unarmoured Cable - Uncut Main 1.5 - 16 16 CB1 CB1+C 4 x MC3/1 25 - 35 35 CB2 CB2+C 4 x MC2 50 - 70 35 CB2.5 CB2.5+C 4 x MC4/1

Armoured & Unarmoured Cable - Uncut Main 25 - 70 50 CB1.5+MCRC1 70 - 150 70 CB2.5+MCRC2 95 - 185 70 CB2.5+MCRC3

Mains Branch Joints

CBM range
Part No Inc mechanical connectors Uncut Main Cable 2, 3 & 4 core (mm2) Max Branch Cable 2,3 & 4 core (mm2) Part No Inc mechanical connectors

Armoured & Unarmoured Cable 50 - 70 70 CBM0+C 95 - 120 120 CBM1+C 150 - 185 185 CBM2+C 240 - 300 300 CBM3+C

Cut Main Cable 2, 3 & 4 core (mm2)

Max Branch Cable 2,3 & 4 core (mm2)

Armoured & Unarmoured Cable 1.5 - 35 35 CBM1.5+C 50 - 150 150 CBM2.5+C 185 - 300 300 CBM3.5+C

LV Branch
7

Service Branch Joints

CTL
CLEARCAST

LV Resin Cable Joints - Special Applications

suitable for PVC or XLPE cable, 1kV

LV Specials

Cathodic Protection Joints

Approved by many oil and utility companies throughout the world, the main applications for these joints include:Jointing of single core DC feeder to anode cable for cathodic protection of pipelines, jetties, tanks and buried structures. Two variants of CP joints are offered:CPJ - the classic cathodic protection joint for use when upright branch joints are required. CB0 - a Y-shaped joint for horizontal branch jointing applications.

Max Cable Size single core (mm2) 120 95

Max Branch single core (mm2) 95 95

Basic Kit no connector Part No CPJ120 CB0

Kit with Split-Bolt Line-Tap Part No Kit includes

CPJ120+C Joint+ 1 x MC3/4 Please enquire

Multicore Control & Pilot Cables CML Range

Especially designed for Control/Telemetry applications and for joining Pilot cables. Suitable for multi-core cables 600/1000V, PVC insulated, armoured or unarmoured. Nylon spacer tapes are included for easy bundling of cores and to ensure even penetration of resin.
No of cores Core size 1.5 - 2.5 mm2 Armoured 2-4 5 7-8 10 - 11 16 - 27 30 - 48 Unarmoured Core size 4 - 6 mm2 Armoured Unarmoured

CM0L CM0LEX CM0L CM0LEX CM0L CM0LEX CM1L CM1LEX CM1L CM1LEX CM2L CM2LEX CM2L CM2LEX CM2L CM2LEX CM3L CM3LEX CM3L CM3LEX CM4L CM4LEX Insulated ferrules for CML range should be ordered separately (one ferrule per core). 0.5 - 1.0 mm2 - use Part No KX670; 1.5 - 2.5 mm2 - use Part No KX680; 4.0 - 6.0 mm2 - use Part No KX700.

Multipair Telecom Cables CML Range

No of pairs 2 5 10 15 Armoured

For multipair cables, PVC insulated / PVC oversheathed, conductor 0.9 mm, armoured or unarmoured.
Unarmoured No of pairs Armoured Unarmoured

CM0L CM0LEX 25 CM2L CM1LEX CM1L CM0LEX 40 CM3L CM2LEX CM1L CM1LEX 50 CM4L CM2LEX CM2L CM1LEX 100 CM4L CM3LEX Insulation-displacement connectors (Part No MCT) should be ordered separately (2 per pair).

LV Resin Cable Joints - Special Applications

suitable for PVC or XLPE cable, 1kV

CTL
CLEARCAST

Supplied with required accessories including: Self-amalgamating tape to insulate ferrules. Special spiral spacers for core separation. Stainless steel mesh sleeve. 11 kV version also available.
Cable No of Part No (mm2) cores 1.5 2 3 4 2 3 4 2 3 4 CM1MQ CM1MQ CM1MQ CM1MQ CM1MQ CM1MQ CM1MQ CM1MQ CM1MQ Cable No of Part No (mm2) cores 6 2 3 4 2 3 4 2 3 4 CM1MQ CM1MQ CM1MQ CM1MQ CM2MQ CM2MQ CM2MQ CM2MQ CM2MQ Cable No of Part No (mm2) cores 25 2 3 4 2 3 4 2 3 4 CM2MQ CM3MQ CM3MQ CM3MQ CM3MQ CM3MQ CM3MQ CM4MQ CM4MQ Cable No of Part No (mm2) cores 70 2 3 4 2 3 4 2 3 4 CM4MQ CM4MQ CM4MQ CM4MQ CM4MQ CM5MQ CM5MQ CM5MQ CM5MQ Cable No of (mm2) cores 150 185 240 300 2 3 4 2,3,4 2,3,4 2,3,4

CMMQ Range

Part No CM5MQ CM5MQ CM6MQ CM6MQ CM6MQ CM6MQ

2.5

10

35

95

16

50

120

Oil & Petrochem

CMOP Range
Cable No of (mm2) cores 150 2 3 4 2 3 4 Part No CM5OP CM5OP CM6OP CM5OP CM6OP CM6OP

Supplied with required accessories inc: Earth continuity components for lead covered (LV) cables.
Cable No of Part No (mm2) cores 1.5 2 3 4 2 3 4 2 3 4 CM1OP CM1OP CM1OP CM1OP CM1OP CM1OP CM1OP CM2OP CM2OP Cable No of Part No (mm2) cores 6 2 3 4 2 3 4 2 3 4 CM2OP CM2OP CM2OP CM2OP CM2OP CM2OP CM2OP CM2OP CM2OP Cable No of Part No (mm2) cores 25 2 3 4 2 3 4 2 3 4 CM2OP CM3OP CM3OP CM3OP CM3OP CM3OP CM3OP CM4OP CM4OP Cable No of Part No (mm2) cores 70 2 3 4 2 3 4 2 3 4 CM4OP CM4OP CM4OP CM4OP CM4OP CM5OP CM5OP CM5OP CM5OP

2.5

10

35

95

185

16

50

120

1.9/3.3 kV Joints
Suitable for PVC or XLPE/SWA/PVC oversheathed, 1900/3300V cables, with stranded copper or aluminium conductors, to BS5467 and 6346.

Cable No of Part No (mm2) cores 16 25 35 50 50 3 3 3 1 3 CM2M CM3M CM3M CM2M CM3M

Cable No of Part No (mm2) cores 70 70 95 95 120 1 3 1 3 1 CM2M CM3M CM2M CM4M CM2M

Cable No of Part No (mm2) cores 120 150 150 185 185 3 1 3 1 3 CM4M CM3M CM5M CM3M CM5M

Cable No of Part No (mm2) cores 240 240 300 300 400 1 3 1 3 1 CM3M CM6M CM3M CM6M CM4M

Cable No of (mm2) cores 400 500 630 800 1000 3 1 1 1 1

Part No CM6M CM4M CM4M CM4M CM4M

LV Specials
9

Mines & Quarries

CTL
CLEARCAST

LV Resin Cable Joints - Low Smoke Zero Halogen

suitable for PVC or XLPE cable, 1kV

Low Smoke

Distinguished by its yellowtinted injection-moulded shells, CTLs range of Low Smoke Zero Halogen cable joints has been especially developed to meet the increasing demand for joints that match the characteristics of modern flame retardant, fire resistant and low smoke cables. To reflect the specialist application, these joints can be installed without the need for dedicated tools or the application of heat. All of the popular and wellestablished features of standard CTL joints have been retained. Internationally, there are several standards that regulate fire behaviour. CTL products conform to the following national standards:-

UK:- BS 476 Part 7, Class 1Y rating. Germany:- DIN 4102/part 1, B1 rating. France:- NFP 92 501, 5 & 16, M2 rating. A typical kit consists of an outer shell manufactured from UV stable , low smoke, zero halogen, flame retardant material that matches or exceeds the relevant properties of similarly specified cable. For the majority of applications it is only the shell that requires specialist fire-sensitive properties. In these cases CTLs standard two-part polyurethane resin is supplied in easy-mix pouches. When specifications call for the resin to also be flame retardant,

halogen-free and low smoke, joints are shipped with CTLs CR171H resin which is flame retardent to V0 rating of UL94.

10

LV Resin Cable Joints - Low Smoke Zero Halogen

suitable for PVC or XLPE cable, 1kV
Specifications - CTL Low Smoke Zero Halogen cable joints Properties of shell Flammability Flame retardant Flame class rating: 3mm Flame class rating: 1mm Glow wire test, 1 mm, 850 C Low Smoke Smoke density 4 min Halogens Mechanical Tensile strength at yield (speed 50mm/min) Impact Charpy Impact, notched Thermal Thermal conductivity Electrical Dielectric strength Volume resistivity Surface resistivity Properties of resin type CR171H Flammability - Flame class rating: 6mm Physical properties Operating temperature Thermal conductivity Shrinkage Coefficient of linear expansion Electrical properties Volume resistivity Surface resistivity Electric strength Permittivity Main Cable 2, 3 & 4 core (mm2) Straight Joints 1.5, 2.5, 4, 6 10, 16 25 35, 50, 70 95, 120 150, 185 240, 300 400 Branch Joints 1.5, 2.5, 4, 6, 10 16, 25, 35 Rating Relevant standard

CTL
CLEARCAST

V-0 V-2 Pass Dm < 200 Free 63 Mpa 30 kJ/m2 0.20 W/m C 17kV/mm 1015 Ohm.m 1015 Ohm V-0 -40 C to +105 C 0.75 W/mK Low Low 11 - 13 log Ohm 12 - 14 log Ohm > 16 MV/m 3.2 @ 1 KHz Branch Cable 2,3 & 4 core (mm2)

UL94 UL94 IEC 695-2-1 AIRBUS Standard ABD 0031 DIN VDE 472 part 815 ISO 527, DIN 53455 ISO 179/2C DIN 52612 IEC 243, ASTMD 149 IEC 93, DIN53482 IEC 93, DIN53482 UL94

Part No

CM0LSHF CM1LSHF CM2LSHF CM3LSHF CM4LSHF CM6-07LSHF CM6-08LSHF CM7-08LSHF 1.5, 2.5, 4, 6, 10 16, 25, 35 CB1LSHF CB2LSHF

Accessories a) Brass connectors with Allen head screws for Cu or Al conductors. b) Aluminium alloy connectors with shear-head bolts & brass gauze for Cu or Al conductors c) Copper or aluminium crimp ferrules

See page 15 for Hazardous Area Cable Glands.

See page 17 for cable clamps, troughs and J hooks especially designed for the rail industry.

Zero Halogen
11

CTL
CLEARCAST

Joint Shell Dimensions

Straight-through Joints Type CM0 range CM1 range CM2 range CM3 range CM4 range CM5 range CM6 range CM7 range A 200 250 320 450 550 660 1290 1345 B min 35 45 60 75 100 140 140 155 5 8 10 30 40 50 45 70 C max 20 30 34 48 66 85 95 105
A

Joint Shells

CM0 - CM7
B C

CB0 - CB2
C2

B
C1 C1

Branch Joints Type CB0 range CB1 range CB1.5 range CB2 range CB2.5 range CB3.5 range CBM0/1.5 CBM1 CBM2/2.5 CBM3/3.5 CPJ120 A 190 335 300 420 420 500 710 770 910 1010 160 B min 60 110 130 125 150 150 120 140 170 200 92 10 10 25 10 42 57 C1 max 20 23 50 32 60 65 45 53 60 73 25 min 10 10 22 10 30 34 C2 max 20 23 32 32 45 50 45 53 60 73 20

CB1.5 - CB3.5
C2

C1

10

10

CBM
Universal Joints Type CU0 range CU1 range CU2 range CU3 range CU4 range CU5 range A 175 220 300 400 500 500 B min 40 65 80 95 110 160 8 13 19 23 26 38 C1 max 20 22 29 35 50 65 min 8 13 18 21 25 39 C2 max 15 21 22 25 30 50
A B

CPJ
B
C1

C2

C1

All shells apart from CM6, CM7 & CBM are injection-moulded from high-impact polycarbonate to form clear, rigid and strong pairs which clip together easily and provide a robust seal to prevent resin leakage. Many are also available in Low Smoke Zero Halogen variants which can be identified by their yellow tint (see pages 10 & 11). CM6, CM7 & CBM shells share a similar design but are manufactured using a vacuum-forming process.

CU0 - CU5
C2

B
C1

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CTL Cold-Pour Two-Part Resins

Specifications
Features
Two-part Polyurethane resin in protective aluminium foil. Mixing is performed in sealed conditions - no need for skin contact but safety gloves are provided. Controlled curing temperature designed to be compatible with PVC, XLPE, EPR, Polythene and PILC cables. Clear mixing instructions on every pack. Full Health & Safety labelling. Batch number & use-by-date on every pack. Designed to meet the requirements of BS 6910, BS7888, CENELEC HD623 S1 and EN50393:2006. The same well-proven high quality resin formula is used as standard throughout both the LV & MV ranges. Specification
Mixed properties Specific gravity Density (g/ml) Colour Gel Time Peak Exotherm Complete cure time Shelf life Operating temperature Thermal Conductivity Tensile strength Electrical strength Health & safety Pack designed to contain factory dispensed quantities of resin & hardener 1.40 Resin, 1.22 Hardener 1.36 mixed system Cream (standard) 20-30 minutes at 21 C for 200g mass 54-75 C depending upon volume and ambient temperature. at 23 C - 24 hours at 80 C - 1 hour 24 months when stored at 5C - 15 C. -40 C to +100 C continuous, for cured product >0.4w/mK 45 MPa 20kV/mm Each pack contains mixing instructions and carries health and safety warnings. H&S (COSHH) Information Sheet available upon request No special labelling required for shipments by air, sea or road (UN No 2489, packaging group III)

CTL
CLEARCAST

Transportation

Also available

Flame retardant, halogen-free resin to VO rating of UL94. Traffic systems resin - Two-part, fast-curing toughened polyurethane resin designed for the encapsulation of speed sensors, junction boxes and the bases of control cabinets. Re-enterable resin - Two-part polyurethane resin that can be removed after curing. Ideal for encapsulating expensive components or multicore and multipair cables where subsequent repair may be required.
Part No Useable volume of pack

CR0 CR1 CR2 CR4 CR6

180 ml 350 ml 825 ml 1850 ml 3000 ml

Resin Packs
13

CTL
CLEARCAST

Mechanical Connectors
Straight-through Type - MC1 Range
Brass Connectors (set of 4) with Allen Key Core sizes mm 1.5 - 10 16 - 25 35 - 50 70 - 120 Core sizes mm 50 - 95 120 - 185 240 - 300 400 - 500
2

Connec tors
14

To max 10mm2 MC1/0 MC1/1 MC1/2 MC1/3 To max 95mm2 MC1/4 MC1/5 MC1/6 MC1/7

To max 25mm2 MC1/1 MC1/2 MC1/2 MC1/3 To max 185mm2 MC1/5 MC1/5 MC1/6 MC1/7

To max 50mm2 MC1/2 MC1/2 MC1/2 MC1/3 To max 300mm2 MC1/6 MC1/6 MC1/6 MC1/7

To max 120mm2 MC1/3 MC1/3 MC1/3 MC1/3 To max 500mm2 MC1/7 MC1/7 MC1/7 MC1/7

Aluminium Connectors with shear-head screws

2

Service Branch Type, Uncut Main - MC2 Range

Aluminium Alloy
Main cable to max 35mm2 Branch cable to max 35mm2

Plain Brass or Tin Plated

Main cable mm2 1.5 - 6 10 16 25 - 35 50 - 70 95 - 120 6mm MC3 MC3/0 MC3/1 MC3/2 MC3/3 MC3/4
2

Service Branch Type, Uncut Main - MC3 Range

Max Branch Cable:10mm MC3/0 MC3/0 MC3/1 MC3/2 MC3/3 MC3/4
2

16mm2 MC3/1 MC3/1 MC3/1 MC3/2 MC3/3 MC3/4

35mm2 MC3/2 MC3/2 MC3/2 MC3/2 MC3/3 MC3/4

70mm2 MC3/3 MC3/3 MC3/3 MC3/3 MC3/3 MC3/4

120mm2 MC3/4 MC3/4 MC3/4 MC3/4 MC3/4 MC3/4

Service Branch Type, Uncut Main - MC4 Range

Aluminium Alloy
Main cable mm2 50 - 95 120 - 185 240 - 300 Branch to max 35mm2 MC4/ 1 MC4/ 2 MC4/ 3 Notes Fitted with shear-head screws. Brass gauze is supplied for use on Cu conductors.

Mains Branch Type, Uncut Main - MCM Range

Aluminium Alloy
Main Cable mm2 50 - 95 120 - 185 240 - 300 95mm2 MCM1 MCM2 MCM3 Max Branch Cable:185mm2 MCM2 MCM2 MCM3 300mm2 MCM3 MCM3 MCM3

Mains Branch Type, Cut Main - MCM Range

Aluminium Alloy
Main Cable mm2 50 - 185 120 - 300 Branch to max 185mm2 MCM6 MCM7 Branch to max 300mm2 MCM7 MCM7

Insulation-Piercing Ring Connector - MCRC Range

Uncut Main
Main Cable mm2 25 - 50 70 - 150 95 - 185 Max Branch Cable:50mm MCRC1 MCRC2 MCRC3
2

70mm2 MCRC2 MCRC3

95mm2 MCRC3

Live Cable Connector - MC5 Range

Service Branch Type, Uncut Main
Insulated Main mm2 16 - 150 Uninsulated Branch to max 50mm2 MC5

Cable Glands Indoor & Outdoor Glands

Selection chart for 600/1000 V copper conductor PVC insulated SWA cable Conductor Area mm2 1.5 2.5 4 6 10 16 25 35 50 70 95 120 150 185 240 300 300 400 Neu1 tral 2 3 31/2 4 No of Cores 5 7 10 12 19 27 37 48

CTL
Components plc

Supplied complete with PVC Shrouds, galvanised locknut & brass earthtag.

Indoor & Outdoor Glands BW Indoor Gland Part No CG20SBW CG20BW CG25BW CG32BW CG40BW CG50BW CG63BW CG75BW CW Outdoor Gland Part No CG20SCW CG20CW CG25CW CG32CW CG40CW CG50CW CG63CW CG75CW Size Pack Qty

20s 20 25 32 40 50 63 75

2 2 2 2 1 1 1 1

16 16 25 35 50 70 70 95 120 150 185 185

25 25 25 25 32 32 40 40 50

20s 20s 20s 20s 20s 20s 20s 20s 25 25 25 25 25 25 25 32 32 32 32 40 40 40 40 50 40 50 50 50 50 63 63 63

32 32 32 40 50 50 50 63 63 75 75 63 75 75 75

20s 20s 20s 20 20 25 25 32 32 20s 20s 20 25 25 25 32 32 40 20 20 25 25 25 32 40 40 50 20 25 25 32 32 40 40 50 50 50 63 63 75

Hazardous Area Glands

See www.ctl-components.com for size selection tables.

Type E1EX:- Captive Cone gland for steel wire, braid and tape armoured cable. Patented disconnect system allows inspection of armour clamp and inner seal after assembly. Seals on the cable sheath to IP68 if fitted with a sealing gasket. IP Ratings:- IP66/67/68, Standards:- CENELEC/Atex Zones 1, 2, 21 EExde IIC.

Manufactured from brass or nickel-plated brass. Type A2F:- Compression gland for unarmoured cable, fitted with an elastomeric displacement seal, giving superior cable retention, explosion protection and IP rating. Supplied with a polypropylene or neoprene sealing gasket. IP Ratings:IP66/67/68, Standards:- CENELEC/Atex Category 2, Category 3 EExde IIC 2 GD. Type A2EX:- Compression gland for unarmoured elastometric and plastic cables in areas requiring a flameproof EExde IIC seal on the outer sheath. Fitted with an inner seal on the cable sheath and a harder outer seal to grip the cable, giving superior cable retention and IP rating. Seals on the cable sheath to IP68 if fitted with a sealing gasket. IP Ratings:- IP66/67/68, Standards:- CENELEC/Atex Zones 1, 2, 21 EExde IIC.

Nylon Cable Glands

Metric Part No CG12M CG16M CG20M CG25M CG32M CG40M CG50M CG63M Size M12x1.5 M16x1.5 M20x1.5 M25x1.5 M32x1.5 M40x1.5 M50x1.5 M63x1.5 Imperial Pack Qty Part No Size 100 CG7PG PG7 100 CG9PG PG9 100 CG11PG PG11 50 CG13.5PG PG13.5 24 CG16PG PG16 12 CG21PG PG21 6 CG29PG PG29 4 CG36PG PG36 CG42PG PG42 CG48PG PG48 Pack Qty 100 100 100 100 100 50 24 12 6 6

Manufactured from grey polyamid, these glands are rated IP67, supplied with lock nuts and are available in metric or imperial sizes. Different colours are available upon request.

Cable Glands
15

CTL
Components plc

Cable Cleats Single & dual fixing cleats

A comprehensive range that provides a simple yet strong means of securing cables. The two hole version is designed to easily stack, thus saving space and time. Manufactured from highly UV resistant polypropylene - Low Smoke Zero Halogen variants are also available.
Single hole fixing for cables or pipes up to 50.8 mm Part No CC5 CC6 CC7 CC8 CC9 CC10 CC11 CC12 CC14 CC16 CC18 CC20 Size 5 6 7 8 9 10 11 12 14 16 18 20 Cable (mm) Min 10.1 12.6 15.1 17.7 20.2 22.7 25.3 27.6 30.4 35.4 40.5 45.6 Max 12.7 15.2 17.8 20.3 22.8 25.4 27.7 30.5 35.5 40.6 45.7 50.8 Stud Hole Size M6 M6 M6 M6 M6 M6 M10 M10 M10 M10 M10 M10 Two hole fixing cables or pipes 50-135 mm Part No CCT8 CCT9 CCT10 CCT11 CCT12 CCT14 CCT15 CCT16 CCT17 CCT18 CCT19 Size 8 9 10 11 12 14 15 16 17 18 19 Cable (mm) Min 46 50 57 64 70 76 75 105 112 120 128 Max 51 57 64 70 76 85 105 112 120 128 135 Stud Hole Size M10 M10 M10 M10 M10 M10 M10 M10 M10 M10 M10

Tapes & Cleats

Underground & Barrier Tapes

Barrier Tapes
Barrier Tape Self-adhesive Hazard Tape

For use around cable trenches and on building sites. Available in Red/White or Black/Yellow. 70mm wide supplied in 500m dispenser box or on a 100m reel.

Hazard Tapes

A statutory requirement for safety in the workplace, these self-adhesive tapes can be used to warn people of dangerous areas. Available in Black/Yellow or Red/White, the tapes are 50mm wide on 33m rolls.

Standard Warning Tapes

Specified by most utility companies, these are laid during the back-filling of trenches and act as a warning device for future excavations. Supplied 150mm wide on 365M rolls with a choice of nine messages and ten appropriate colours.

Detectable Warning Mesh

Conforming to BS EN 12613:2001, this warning plyage material is specified by the major utilities. It should be laid 0.3m above the cable/pipe and is designed to fragment when disturbed in such a way as to give the operator best chance of prior warning of an underground hazard. It has a stainless steel detection wire running along its length for easy detection using a metal detector. Choice of five messages in five appropriate colours, 200mm wide on 100m reels.

Cable Covers

Available in a variety of formats/thicknesses, these help protect cables and pipes from penetration by stopping picks, spades and even digger shovels.

Standard Warning Tape Wording/Colours Electric Cable Below Street Lighting Cable Below Gas Main Below Sewer Pipe Below Fibre Optic Cable Below Water Pipe Below Sewer Pipe Below Telephone Cable Below Communications Cable Below

Detectable Warning Mesh Wording/Colours Electric Cable Below Gas Pipe Below Water Pipe Below Sewer Pipe Below Fire Mains Below

16

Cable Clamps
CTLs ranges of single-bolt fixing cable clamps, counterbeds and fixing accessories are manufactured from either galvanised steel, non-magnetic aluminium or Grade 1 stainless steel. Special variants, including troughs and J hooks have been designed to address the specific needs of the rail industry. These extensive ranges are detailed in a separate CTL catalogue which is available upon request.

CTL
Components plc

Type S

Cable Hangers

Type MKD

Type AC

For 1, 2 or 3 cables of 6 - 175 mm, all types.

Type U

Cable Clamps
17

CTL
C-SHRINK

LV Heatshrink tubing Thin Wall

CTLs H range of thin wall heatshrink tubes is made of cross-linked semi-flexible polyolefin which shrinks uniformly to form a permanent insulating covering. Upon recovery, thin wall tube will conform to the shape it is applied over. Ideal for low voltage electrical insulation up to 1000V.
Basic Properties - Thin Wall Operating Temp Shrink Ratio Standard Colours Options -40 to +125C 2:1 Black; Blue; Red; Yellow; Transparent. (0thers on request). Supplied on reel or cut to any length. Flame retardent. Self-extinguishing. Thin dual wall with adhesive lining. 3:1 shrink ratio. Special types to MIL STD 23053/5

W d

LV Heatshrink

Dimensions - Thin Wall Part No Inner as supplied D min (mm) 1.2 1.6 2.4 3.2 4.8 6.4 9.5 12.7 16.0 19.0 25.4 32.0 38.0 51.0 76.0 102.0 Inner recovered d max (mm) 0.6 0.8 1.2 1.6 2.4 3.2 4.8 6.4 8.0 9.5 12.7 16.0 19.0 25.4 38.0 51.0 Wall thickness fully recovered W (mm) 0.45 0.45 0.45 0.45 0.45 0.55 0.55 0.55 0.60 0.70 0.75 0.90 0.90 1.00 1.30 1.40

H12 H16 H24 H32 H48 H64 H95 H127 H160 H190 H254 H320 H380 H510 H760 H1020

See also CTLs LV heatshrink boxes on page 19.

Medium Wall
CTLs HM range is a cross-linked medium wall heatshrink polyolefin tubing with a shrink ratio 3:1 to 4:1. The medium wall thickness provides a tough and semi-flexible insulation making the product ideal for the protection of underground cable joints, crimped terminal ends and cable terminations. The HMA range has a hot-melt adhesive lining which ensures an environmental seal that prevents the ingress of water.

Dimensions - Medium Wall Part No With Adhesive Part No Without Adhesive HM12-3 HM19-6 HM30-10 HM40-12 HM50-16 HM63-19 HM70-25 HM90-30 HM115-35 HM140-42 HM170-58 Inner as supplied D min (mm) 12.0 19.0 30.0 40.0 50.0 63.0 70.0 90.0 115.0 140.0 170.0 Inner recovered d max (mm) 3.0 6.0 10.0 12.0 16.0 19.0 25.0 30.0 35.0 42.0 58.0 Wall thickness fully recovered W (mm) 1.5 2.0 2.0 2.0 2.0 2.5 2.5 2.5 3.0 3.0 3.0

HMA12-3 HMA19-6 HMA30-10 HMA40-12 HMA50-16 HMA63-19 HMA70-25 HMA90-30 HMA115-35 HMA140-42 HMA170-58

Thick Wall
CTLs HTH range is a cross-linked heavy-wall heatshrink polyolefin tubing with a shrink ratio 3:1 to 4:1. The toughness and weatherability of the tubes makes them well-suited for exposed applications for the protection of cable joints. The HTHA range contains hot-melt adhesive coating.
Basic Properties - Medium & Thick Wall Operating Temp Dielectric strength Shrink Ratio Standard Colour Options -55 to +125C In excess of 15kV/mm 3:1 to 4:1 Black Standard lengths of 1m, 1.2m, 1.5 m or cut to any length. Flame retardent. Selfextinguishing.

Dimensions - Thick Wall Part No With Adhesive Part No Without Adhesive Inner as supplied D min (mm) 13.0 19.0 28.0 38.0 50.0 68.0 90.0 120.0 130.0 160.0 185.0 240.0 Inner recovered d max (mm) 4.0 6.0 9.0 12.0 16.0 22.0 30.0 40.0 36.0 50.0 50.0 54.0 Wall thickness fully recovered W (mm) 2.5 2.5 3.0 4.0 4.0 4.0 4.1 4.2 4.2 4.2 4.5 5.0

HTHA13-4 HTHA19-6 HTHA28-9 HTHA38-12 HTHA50-16 HTHA68-22 HTHA90-30 HTHA120-40 HTHA130-36 HTHA160-50 HTHA185-50 -

HTH13-4 HTH19-6 HTH28-9 HTH38-12 HTH50-16 HTH68-22 HTH90-30 HTH120-40 HTH130-36 HTH160-50 HTH240-54

18

LV Heatshrink Boxes
Ten size and nine colour variations of thin-walled heatshrink tubing in easy to dispense display cartons - ideal for wholesalers shelves.

CTL
C-SHRINK

Heatshrink boxes - Thin wall tubing dimensions Part No Inner as supplied (mm) 1.2 1.6 2.4 3.2 4.8 6.4 9.5 12.7 19.1 25.4 Inner recovered (mm) 0.6 0.8 1.2 1.6 2.4 3.2 4.7 6.4 9.5 12.7 Wall thickness recovered (mm) 0.45 0.45 0.45 0.45 0.45 0.55 0.55 0.55 0.70 0.75 Length per box (m)

For colour:Red Yellow Black Brown White

Part No Suffix:For colour:Part No Suffix:R Clear C Y Blue BL BLK Green/Yellow GY BR Grey GY W

HSB1206 HSB1608 HSB2412 HSB3216 HSB4824 HSB7030 HSB10050 HSB13060 HSB190100 HSB260120

15 15 15 15 10 10 10 8 7 4

LV Wraparound repair sleeves

CTLs HWS range of heatshrinkable wraparound repair sleeves is manufactured from a highly crosslinked polyolefin compound. The sleeves are coated with hot-melt adhesive and are supplied with a metallic channel for closure.
Dimensions - Wraparound Repair Sleeve Inner as Inner Wall thicksupplied recovered ness fully D1 min D2 max recovered (mm) (mm) W (mm) HWS36-10 36 10 3 HWS50-15 50 15 3 HWS60-18 60 18 3 HWS70-22 70 22 3 HWS80-25 80 25 3 HWS100-30 100 30 3 HWS135-38 135 38 3 HWS188-55 188 55 3 HWS200-60 200 60 3 Length L available from 0.25m to 1.5m. Part No

Basic Properties - Wraparound repair sleeves Operating Temp -40 to +90C Dielectric strength > 15kV/mm Shrinking temperature 120C

W D1 D2

Adhesive coating

Anode Caps
T F N L

H W

Coating

Dimensions (mm) - Anode caps Part No HAN8240 HAN10840 Supplied H 80 108 Recovered W 4 4 T 4 4 F H F L M N 14 40 6.5 170 115 67 14 40 6.5 170 115 67 Tolerances:- 2%, except W & T 10%

LV Heatshrink
19

CTL
C-SHRINK

Cable End Caps

CTLs HE range of heat-shrinkable End Caps offers an economical means of sealing power and control cable ends to ensure a water-tight seal. They are resistant to oxidation, ozone and UV radiation. Their internal surface has a layer of hotmelt adhesive, which retains its flexible properties after recovery. Heat-shrinkable End Caps are recommended for use both in open air and on underground power distribution cables with PVC, lead or XLPE sheaths, aluminium or steel armoured. They can be combined to form a live cable end kit (as shown in the bottom left of the photo).
Basic Properties - Cable End Caps Shrink Temperature Shrink Ratio Colour Options 130C >2:1 Black Cable end caps with white flash for live cables; black mastic sealant for use on paper insulated cables; with built-in air valves for pressurised cables.
M N W

LV Heatshrink

Part No

Expanded (mm) H M 45 63 70 102 118 130 164 155 155 N 40 58 65 92 105 107 138 133 133 R 5 11 20 23 25 31 48 48 46

Recovered (mm) H R W 4.0 3 2.0 4.5 4 2.3 6.0 7.5 3.1 8.5 8 3.0 14.5 12 3.2 24.0 16 3.7 38.0 20 4 45.0 22 4.5 57.0 25 4 57.0 25 5

Cable Diam (mm) 4-8 5-12 7-17 10-22 17-34 28-55 43-70 65-90 75-110 80-135

HE10-4 HE15-5 HE20-6 HE25-10 HE40-15 HE65-25 HE80-40 HE110-45 HE120-60 HE145-60

Cable Breakouts
CTLs HB range of heat-shrinkable breakouts is ideal for insulating and sealing cable crutches, providing resistance to abrasion and weathering. The standard range is lined with hot-melt adhesive. Black mastic sealant is also available if required.
Approx. Conductor Size (mm2) 2.5 - 10 25 - 50 4-50 185 - 400 4 - 16 16 - 35 50 - 150 150 - 240 150 - 300 150 - 400 400 400-500 2.5 - 10 4 - 35 35 - 70 35 - 70 35 - 70 35 - 120 70 - 120 70 - 120 120 - 400 300 - 400 35 - 185 4 - 35 4 - 70 70 - 120

Tolerances:- M & N 2%, H & R 3%, W 10%

10.0 15.0 20.0 25.0 40.0 63.0 78.0 106.0 120.0 145.0

No of Cores

Part No

Expanded (min) H J
9.0 14.0 24.0 43.0 9.0 15.0 26.0 36.0 35.0 48.0 55.0 62.0 9.0 15.0 20.0 21.5 15.0 20.0 25.0 25.0 35.0 45.0 30.0 8.2 12.0 20.3

Fully recovered dimensions (max) H

9.4 10.0 22.0 38.1 9.1 14.0 22.0 33.0 34.0 47.0 47.0 54.0 9.0 14.0 24.9 22.9 14.0 25.0 25.0 22.0 33.0 47.0 24.5 16.0 16.0 36.8

J
2.8 3.0 6.7 12.7 3.0 4.0 8.0 16.0 14.0 20.0 20.0 27.0 1.8 3.2 7.1 6.4 3.2 6.0 6.0 8.5 14.0 20.0 7.5 4.0 4.0 8.9

P
76.5 90.0 120.0 141.5 76.5 110.0 185.0 210.0 200.0 225.0 250.0 240.0 78.0 105.0 99.0 165.1 90 180.0 160.0 190.0 215.0 245.0 180.0 75.0 75.0 137.2

R
20.0 20.0 35.0 42.5 20.0 20.0 45.0 50.0 50.0 75.0 75.0 65.0 17.0 25.0 34.0 38.1 25 45.0 45.0 45.0 50.0 72.0 30.0 20.0 20.0 50.8

HW
1.6 2.0 3.2 3.8 2.5 2.3 3.8 4.0 3.0 3.8 4.2 4.0 2.7 2.5 4.5 4.1 2.5 4.0 4.0 4.0 4.0 4.5 3.5 2.5 2.5 2.5

JW
1.6 2.3 3.0 3.8 2.5 1.5 3.0 3.2 2.0 3.0 3.5 2.5 2.0 1.5 4.5 3.3 1.5 3.0 3.0 3.0 3.0 3.0 3.0 1.5 1.5 2.5

5 6

HB2/21-9 HB2/33-10 HB2/60-22 HB2/87-38 HB3/25-9 HB3/38-14 HB3/60-22 HB3/80-33 HB3/90-34 HB3/110-47 HB3/125-47 HB3/140-54 HB4/28-9 HB4/38-14 HB4/45-25 HB4/47-23 HB4/50-14 HB4/55-25 HB4/65-25 HB4/72-22 HB4/100-33 HB4/125-47 HB5/60-25 HB6/30-16 HB6/40-16 HB6/60-37

21.0 33.0 60.0 87.0 25.0 38.0 60.0 80.0 90.0 110.0 125.0 140.0 28.0 38.0 45.0 47.4 50.0 55.0 60.0 72.0 100.0 125.0 60.0 30.0 40.0 60.7

P JW J H

HW

S 2 Core 3 Core

S 4 Core

All Dimensions mm.

20

LV Straight Joints
A comprehensive range of heatshrink joints offering the following features: Simple, fast installation allowing immediate backfill of the trench. Excellent electrical insulation Outstanding environmental resistance. Proven mechanical strength. Slim profile. Mechanical or crimp connectors available upon request. Joints to customer specification also available ( eg HJ1/3/6 for 3 x 6 mm2, HJ3/3/120 for 3 x 120 mm2 etc). Special kits for lead covered (LC) cables. Typical kit content: Adhesive-lined medium wall tubing for connector insulation, outer sealing and protection tube. For armoured cable we include a special aluminium cage and constant force springs for mechanical protection and earth continuity.
Cable or Joint Type CTL Joint Kit Approx Joint Size (mm) 19 19 19 30 12 30

CTL
C-SHRINK

Conductor CTL Joint Approx Joint Size (mm) Size 2 3 or 4 Kit Length core (mm2) Polymeric Insulated Armoured Cable 1.5 - 6 HJ1 400 40 10 - 50 HJ2 800 60 70 - 150 HJ3 1000 100 185 - 300 HJ4 1200 120 Polymeric Insulated Unarmoured Cable 1.5 - 10 HJ1EX 300 30 16 - 70 HJ2EX 600 50 95 - 185 HJ3EX 800 80 240 - 400 HJ4EX 1000 100 Paper Insulated Armoured Cable 16 - 25 HJP1 400 40 35 - 50 HJP2 800 60 70 - 150 HJP3 1000 100 185 - 300 HJP4 1200 120 Transition Joints (Paper/Polymeric) 16 - 25 HJT1 400 40 35 - 50 HJT2 800 60 70 - 150 HJT3 1000 100 185 - 300 HJT4 1200 120 Underwater Joint Kits for Flexible Cable 1.5 - 2.5 HUJK1 400 40 4 -6 HUJK2 800 60 10 HUJK3 1000 100 16 HUJK4 1200 120 25 HUJK5 1200 120

Length Airfield Lighting Kits Primary 6 mm2 HALK1 200 HALK2 200 Secondary 4mm2 Braided Primary HALK3 200 Traffic Light Kits Loop - Armour HTLK1 300 Loop - Loop HTLK5 50 Feeder - Feeder HTLK7 300

LV Terminations
No of Cores Cable range (mm2) 4 - 16 25 - 50 70 - 150 185 - 400 4 - 16 25 - 35 50 - 150 185 - 400 4 - 35 50 - 70 95 - 120 150 - 400 Indoor HT16-2 HT50-2 HT150-2 HT400-2 HT16-3 HT35-3 HT150-3 HT400-3 HT35-4 HT70-4 HT120-4 HT400-4 Part No Outdoor HTO16-2 HTO50-2 HTO150-2 HTO400-2 HTO16-3 HTO35-3 HTO150-3 HTO400-3 HTO35-4 HTO70-4 HTO120-4 HTO400-4 2

Typical kit content: Adhesive-lined medium wall tubing for core sealing; cable breakout; non-adhesive-lined tubes for lug sealing; phase colour-coded thin wall tubes; constant force springs for earth connection. Cable lugs are also available if required.

The same kit may be used for armoured or unarmoured cable. Generous tail lengths - 1200mm for outdoor and 300mm for indoor terminations (special tail lengths are also available).

LV Heatshrink
21

CTL
C-SHRINK

MV Heatshrink Terminations for Polymeric Cables

3.3 kV to 36kV Terminations certified to: DIN VDE 0278 up to 24 kV IEC 502 1994 for 36 kV.
Manufactured from heatshrinkable material. Terminations and tail lengths can be designed for individual needs. Optional crimping lugs for both indoor and outdoor terminations are available - see page 30. A range of bushing kits for indoor terminations is also available (see page 28 for heatshrink types and page 27 for cold push-on types). Stand-off insulators with pole mounting brackets for outdoor terminations are also available (see page 28).
For Single Core Polymeric Cable Each kit contains one set of three single-core terminations Max kV Part No Indoor HSK3001 HSK3002 HSK3003 HSK3004 HSK3005 HSK3006 HSK3007 HSK3008 HSK3009 HSK3010 HSK3011 HSK3012 HSK3014 HSK3016 HSK3018 HSK3020 HSK3022 HSK3024 HSK3026 HSK3028 HSK3030 HSK3032 Cable Size (mm2) Std. tail Lengths (mm) Outdoor 450 450 450 450 650 650 650 650 650 650 650 650 650 650 900 900 900 900 900 900 900 900 Max kV For Three Core Polymeric Cable Each kit contains one three-core termination Part No Outdoor HSK3/1014 HSK3/1016 HSK3/1018 HSK3/1022 HSK3/1024 HSK3/1026 HSK3/1028 HSK3/1030 HSK3/1032 HSK3/1034 HSK3/1036 HSK3/1038 HSK3/1040 HSK3/1042 HSK3/1044 HSK3/1046 HSK3/1048 HSK3/1050 HSK3/1052 HSK3/1054 HSK3/1056 Cable Size
(mm2)

MVTerminations

Std. tail Lengths (mm) Indoor 550 550 550 650 650 650 650 650 650 650 650 650 650 850 850 850 850 850 850 850 850 Outdoor 550 550 550 650 650 650 650 650 650 650 650 650 650 1200 1200 1200 1200 1200 1200 1200 1200

3.6

7.2

17.5

24

36

Screen Earthing Kits - Polymeric Cables

Solderless Screen Earthing Kits are used for earthing the copper screen layer within polymeric insulated cables. The kit consists of three constant force springs and three solder blocked earth braids.
Part No 1 core system MVAA1CSE MVAB1CSE MVAC1CSE MVAD1CSE MVAE1CSE 3 core 7.2 kV system MVAA3CSE 16 - 70 MVAB3CSE 95 - 150 MVAC3CSE 185 - 300 MVAD3CSE 400 - 630 MVAE3CSE 800 - 1000 Cable Size (mm2) 17.5 kV 24 kV 36 kV 16 - 25 35 - 95 25 - 70 120 - 240 95 - 185 300 - 500 240 - 500 630 - 1000 630 - 1000

Outdoor Indoor HSK1014 16 - 35 450 HSK1016 50 - 95 450 HSK1018 120 - 300 450 HSK1020 400 - 500 450 HSK1022 16 - 35 650 HSK1024 50 - 120 650 HSK1026 150 - 185 650 HSK1028 240 - 400 650 HSK1030 500 - 630 650 HSK1032 25 - 70 650 HSK1034 95 - 185 650 HSK1036 240 - 300 650 HSK1038 400 - 630 650 HSK1040 800 - 1000 650 HSK1042 35 - 70 750 HSK1044 95 - 185 750 HSK1046 240 - 400 750 HSK1048 500 - 1000 750 HSK1050 50 - 95 750 HSK1052 120 - 300 750 HSK1054 400 - 630 750 HSK1056 800 - 1000 750

Indoor HSK3/3001 3.6 HSK3/3002 HSK3/3003 HSK3/3005 HSK3/3006 7.2 HSK3/3007 HSK3/3008 HSK3/3009 HSK3/3010 HSK3/3011 17.5 HSK3/3012 HSK3/3014 HSK3/3016 HSK3/3018 HSK3/3020 24 HSK3/3022 HSK3/3024 HSK3/3026 HSK3/3028 36 HSK3/3030 HSK3/3032

16 - 35 50 - 95 120 - 300 16 - 35 50 - 120 150 - 185 240 - 400 500 - 630 25 - 70 95 - 185 240 - 300 400 - 630 800-1000 35 - 70 95 - 185 240 - 400 500- 1000 50 - 95 120 - 300 400 - 630 800-1000

25 - 70 95 - 300 400 - 1000

22

MV Heatshrink Terminations for Paper Cables

For use up to 17.5 kV. Suitable for single or three core paper insulated, belted or screened cables.

CTL
C-SHRINK

Manufactured from heatshrinkable material. Terminations and tail lengths can be designed for individual needs. Optional crimping lugs for both indoor and outdoor terminations are available - see page 30. A range of bushing kits for indoor terminations is also available (see page 28 for heatshrink types and page 2 for cold push-on types). Stand off insulators with pole mounting brackets for outdoor terminations are also available (see page 28).
For Single Core Paper Insulated, Belted or Screened Cable Each kit contains one set of three single-core terminations Max kV 3.6 Part No Indoor HSP3001 HSP3002 HSP3003 HSP3005 HSP3007 HSP3008 HSP3010 HSP3011 HSP3012 HSP3014 Outdoor HSP1014 HSP1016 HSP1018 HSP1022 HSP1026 HSP1028 HSP1032 HSP1034 HSP1036 HSP1038 Cable Size (mm2) 16-50 70-185 240-300 16-50 70-150 185-400 16-35 50-95 120-300 400 Std. tail Lengths (mm) Indoor 450 450 450 650 650 650 650 650 650 650 Outdoor 550 550 550 650 650 650 650 650 650 650 Max kV For Three Core Paper Insulated, Belted or Screened Cable Each kit contains all components required for a 3-core termination Part No Outdoor HSP3/1014 HSP3/1016 HSP3/1018 HSP3/1022 HSP3/1026 HSP3/1028 HSP3/1032 HSP3/1034 HSP3/1036 HSP3/1038 Cable Size
(mm2)

Std. tail Lengths (mm) Indoor 450 450 450 650 650 650 650 650 650 650 Outdoor 550 550 550 650 650 650 650 650 650 650

7.2

17.5

Indoor HSP3/3001 3.6 HSP3/3002 HSP3/3003 HSP3/3005 7.2 HSP3/3007 HSP3/3008 HSP3/3010 HSP3/3011 17.5 HSP3/3012 HSP3/3014

16-50 70-185 240-300 16-50 70-150 185-300 16-35 50-95 120-300 400

Screen Earthing Kits - PILC & PICAS Cables

Part No MVA12ASEC MVA12BSEC Cable Size (mm2) up to 185 240 - 300

Sheath Earth Connectors provide a simple and effective method of earthing lead or aluminium sheaths of PILC and PICAS 12 kV cables. They are fully tested and compliant to C93. Short circuit rating: PILCAS 13.1 kA for 3 seconds PILC6 kA for 3 seconds

See page 31 for ranges of crimping, cable cutting and cable preparation tools.

MVTerminations
23

CTL
C-SHRINK

MV (15kV) Heatshrink & Resin Cable Joints

Heatshrink joint, resin protected to prevent water ingress

MV Joints

An innovative, highly effective and fully-tested design of joint that combines CTLs two core competencies in resin and heatshrink joint technologies. Features include: Resin encapsulation provides mechanical protection and prevents water ingress. Simple design easy to install. Suitable cable types include:- XLPE. - Paper. - XLPE/Paper transition. - Trifurcating joints 3-core to 3 single cores. Optional core connectors - choice of:- mechanical connectors with shear-head bolts. - compression ferrules with conical ends. High quality two-part polyurethane resin in easy-mix bag system. Unique mould design. - Clear shell for easy inspection. - Interlocking, non-reversible halves. - Superior resin-seal system. No taping of core conductors.

Earth continuity kit with constant force spring system. Strong aluminium wrap-around cage - rubber spacers ensure correct positioning . All components and resin packed together in one sturdy box. Tested to:- CENELEC HD 629.1S1:1996. - DIN VDE 0278 Pt 629-1. Short circuit and current test (armour continuity & complete joint):- 18.5 kA for 1 second. - 22kA for 0.5 second.

A range of Pilot cable joints is available to accompany this range see page 6

Unique Full Faraday Cage Solution

(Transition joint shown.)
Dual wall tube Insulating tube Conductive tube (Faraday Cage) Coloured phase marker over end of screen treatment

Polymeric cable
Part No

Paper cable
Cable type

Conductive tube
Cable Size

CM6HX3N XLPE 3 core 35 - 150 mm2 CM7HX3N XLPE 3 core 185 - 300 mm2 CM6HXP3N XLPE/Paper (Transition) 3 core 35 - 150 mm2 CM7HXP3N XLPE/Paper (Transition) 3 core 185 - 300 mm2 CM6HP3N Paper/Paper 3 core 35 - 150 mm2 CM7HP3N Paper/Paper 3 core 185 - 300 mm2 To ensure correct selection of the joints, full cable specifications should be provided at time of order.

24

MV Heatshrink Cable Joints

6.6 - 36 kV
CTLs C-Shrink Medium Voltage Heatshrink Jointing System for single and three core cables up to 36 kV features: Simple design easy to install. Suitable cable types include:- XLPE, Paper & XLPE/Paper transition. Optional core connectors (see below). Outer protection either:- Thick wall heatshrink tubing. - or Reinforced wrap-around sealing sleeve for maximum mechanical strength and minimum installation space. 3.3kV non-shielded Joints also available. Tested to CENELEC HD629.1S1:1996 (DIN VDE 0278 Pt 629-1).
Ordering Codes Specification Basic Part No Code HJMV A U 7 12 17 24 36 Description

CTL
C-SHRINK

Heatshrink Joint Medium Voltage Armoured Cable Armouring Unarmoured Cable 6.6 kV 12 kV Voltage 15 kV - 17 kV 24 kV 36 kV 6.6 kV 11 - 12 kV 15 - 17 kV 24 kV 36 kV A 35 - 150 16 - 70 16 - 70 25 - 95 Cable Size (mm2) & B 185 - 240 95 - 185 95 - 185 35 - 95 120 - 240 Voltage C 300 - 400 240 - 400 240 - 400 120 - 240 300 - 630 D 500 - 630 500 - 630 300 - 500 PL Polymeric to Polymeric PB Paper to Paper Insulation Type TR Polymeric to Paper - Transition TT Three core Paper to three single core Polymeric - Trifurcating 11 Single to Single Core Core 31 Three Core to Three single Cores Configuration 33 Three to Three Core Ordering example:HJMVA12BPL33 = Heatshrink joint, armoured cable,12kV, 185 mm2 polymeric insulation, 3 core to 3 core.

MV Connectors
To complement its range of MV joints, CTL can supply either shear-head mechanical connectors or compression ferrules. All are available with barrier for use with transition XLPE/paper cable joints.

MV Joints
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C-SHRINK

MV Tubing Stress Control Tubing Semi-conductive Tubing

Heat-shrinkable tubing used exclusively as stress Semi-conductive heat-shrinkable tubing used to control relief in medium voltage cable joints and rebuild the shield in medium voltage cable joint terminations, up to 36kV. The product features a applications. very high dielectric constant. Basic Properties
Basic Properties Operating Temperature Shrinking Temperature Dielectric constant (permitivity) Standard Colour Part No Inner as supplied (mm) 26 30 45 50 65 95 -40 to +100C 110C 20 - 35 Black Inner recovered (mm) 12 15 20 25 30 45 Wall thickness nominal (mm) 2.5 2.7 2.8 2.9 3.1 3.2 HCON44-16 HCON70-25 HCON95-35 HCON110-40 Operating Temperature Shrinking Temperature Standard Colour Part No Inner as supplied (mm) 44 70 95 110 -40 to +90C 120C Black Inner recovered (mm) 16 25 35 40 Wall thickness nominal (mm) 2.8 3.0 3.0 3.0

MV Tubing

The HBM range of heat shrinkable tubing is particularly suited for insulating medium voltage busbars up to 36kV. It is available in Medium Wall (reduces distance between bus bars to half ) and Thick Wall (reduces Anti-tracking red heat-shrinkable tubing for use distance to one third the distance between two phases in medium voltage switchboards). in MV joints and terminations up to 36kV.

HSC26-12 HSC30-15 HSC45-20 HSC50-25 HSC65-30 HSC95-45

Busbar Tubing

Anti-tracking Tubing
Basic Properties Operating Temperature Shrinking Temperature Dielectric strength Comparative tracking index Flammability Standard Colour Part No Inner as supplied (mm) 30 35 49 56 70 100 -40 to +100C 120C > 15 kV/mm KA1 (IEC 112)

Basic Properties Continuous temperature range Shrinking Temperature Dielectric strength Part No Self extinguishing/ halogen free Black Inner recovered (mm) 10 12 16 21 26 40 Wall thickness nominal (mm) 2.4 2.6 2.9 3.0 3.1 3.8 HBM30-12 HBM50-12 HBM75-30 HBM100-40 HBM120-50 HBT36-10 HBT46-14 HBT54-16 HBT66-20 HBT95-30 -40 to +100C 120C > 15 kV/mm Wall thickness nominal (mm) 2.3 2.5 2.5 2.5 3.0 4.0 4.5 5.0 5.0 7.0

HAT30-10 HAT35-12 HAT49-16 HAT56-21 HAT70-26 HAT100-40

Inner Inner as supplied recovered (mm) (mm) Medium Wall 30 12 50 20 75 30 100 40 120 50 Thick Wall 36 10 46 14 54 16 66 20 95 30

MV Breakouts
CTLs range extends to both anti-tracking and semi-conductive breakouts for use in 3-core terminations and 3-core cable joints up to 36kV. See web for specifications and sizes.

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MV Universal Boot Kits

These Universal Boot Kits are designed for indoor use with Polymeric or Paper cables at voltages between 6.6kV and 24kV. Providing screw-on connection using standard bushing, they are equally suitable for round or sector-shaped cable. Features include: Manufactured from heavy-duty EPDM rubber. Re-usable. Suitable for use in oil-filled transformer boxes when Paper cables are upgraded to XLPE. Universal design - same kit can be used for straight, right-angled, or parallel (piggy-back) installation. Easy to install - no heat or tools required. Easily removable cover for voltage testing. An ideal complement to indoor terminations. Sold in sets of 3.

CTL
Components plc

Above:- Illustration of a parallel installation. (extension bolts can be provided.) Below:- Illustration of universal straight or rightangle installation.

Recommended Minimum Air Gaps (mm) U (kV) Insulation A B C D E Level (kV) 12 75 50 10 90 20 470 24 125 110 50 130 50 570 The recommended minimum distances quoted apply in general. However, in cases where type testing has been carried out, other minimum distances may apply. The distances shown above are for gas-insulated Ring Main Units (RMU).

Cable size (mm2) 25 - 300

Part No IBK300

Rating (A) 600

MV Accessories
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Components plc

MV Accessories Heatshrink Boot Kits

Cable size (mm2) 50 - 400 Part No HKS HKR

MV Accessories
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Each kit consists of three boots made of nontracking material along with sufficient mastic tape to cover the bushing nuts.
Description Set of 3 straight boots Set of 3 right-angle boots

Stand-Off Insulators
Voltage kV 12 24 33 36 Creepage Path (mm) 465 615 845 1160

Designed for outdoor terminations, each kit consists of a pole mounting bracket with three polymeric insulators.
Part No SO12 SO24 SO33 SO36

Gland Kits
Top Hat style, for three-core paper or polymeric cable. Manufactured from zinc-plated steel. Suitable for Indoor Terminations up to 36kV.
Cable size (mm2) 16 - 95 120 - 300 Part No HSGA/3 HSGB/3

Top Hat style, for single-core aluminium wire armoured cable. Manufactured from aluminium. Suitable for Indoor Terminations up to 36kV.
Cable size (mm2) Part No 16 - 630 HSGB/1 Supplied in sets of three

Brass cone style, for paper or polymeric cable. Suitable for earthing of cable entry for Indoor Terminations up to 36kV.
Cable size (mm2) 16 - 300 16 - 300 Part No CG16-300 CG16-300/INS Description Kit for 3 x single-core cable Kit for 1 x 3 core cable c/w insulating cork gasket

MV Accessories Constant Force Springs

CTLs range of Constant Force Springs is manufactured from BS5770 302S25 Stainless Steel which has been heat-treated and coiled. The springs feature chamfered and raised leading edges for easy use. Principal applications are: Earth continuity systems for LV joints. Screen attachment in MV joints and terminations.
Constant Force Springs (Dimensions in mm - special sizes available upon request.) Part No RF059 RF060 RF0 RF1 RF2 Inner 3.6 7.5 11 15 17 Width 6.35 9.5 16 19 19 Thickness 0.05 0.10 0.15 0.20 0.20 Application range 4 - 10 9 - 15 12 - 19 17 - 22 19 - 29 Part No RF3 RF4 RF5 RF6 RF7 Inner 23 23 32 42 45 Width 19 19 19 19 19 Thickness 0.24 0.35 0.45 0.45 0.60 Application range 25 - 37 31 - 50 44 - 70 58 - 94 60 - 130

CTL
Components plc

This self-amalgamating tape is manufactured from a tough EPR based elastic material that completely self-fuses to form a water, ozone and corona resistant mass at cable terminations or splices. It has a high dielectric strength and forms stable, long-lasting joints.
Standard Sizes (mm) Part No Width Thickness Length CT691975 19 0.75 10 m CT692575 25 0.75 10 m Special sizes available upon request

Self-amalgamating Tape

Basic Properties Volume resistivity 1015 ohms/cm Dielectric strength 28 kV/mm Dielectric constant 2.8

Tensile strength Elongation at break Peak operating temp.

3.5 Mpa 700% 130C

Propane torch burner with piezo ignition, regulator and soft flame nozzle.
Part No HA076 Nozzle (mm) 50 Hose length (m) 2

Torch Kit

CTLs specialist sheet metalwork plant can manufacture any sizes of earthing and protective cages in either aluminium or galvanised steel.

Metallic Screens

MV Accessories
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Compression Lugs & Ferrules

An especially comprehensive range of lugs and ferrules that is manufactured to the very highest standards. Matching mechanical, battery and hydraulic compression tools complement the range. Range highlights are shown below and a detailed 300 page catalogue is available upon request.

Compression
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R range Tin plated copper cable lugs, available with or without inspection holes in size range 6 mm2 to 400 mm2. Insulated, 45 and 90 angled variants also available. Ferrules include Butt, T and Cross connector types. DIN range As above, with the added benefit of meeting DIN Standard 46235.

Aluminium cable lugs and ferrules Aluminium lugs 16 mm2 to 500 mm2 with solid palm (suitable for outdoor terminations). DIN Standard 46329. Aluminium lugs 10 mm2 to 400 mm2 suitable for indoor terminations. DIN Standard 48201. Aluminium ferrules 10mm2 to 500 mm2. DIN Standard 48201.

Bi-metallic cable lugs and ferrules Bi-metallic lugs 16 mm2 to 300 mm2 with solid copper palm. DIN Standard 48201. Bi-metallic lugs10 mm2 to 400 mm2 with copper insert. DIN Standard 48201. Bi-metallic ferrules 10mm2 to 300 mm2 including copper connecting bolt option.

Insulated and uninsulated solderless terminals and cable end sleeves Ring, fork, tab and pin types with matching receptacles and butt connectors. Available both in packs and assortment boxes.

Tools
Mechanical crimping tools K2:- Indent ratchet crimping tool covering sizes 0.75 - 16 mm2. K507:- Hand ratchet crimping tool with 3 quickchange die sets stored in the handle. For preinsulated terminals 0.75 - 6mm, endsleeves and copper tube terminals up to 10mm. K05/06/09:- Hexagonal crimping tool with integral revolving dies. Size range K05 6 - 50 mm2, K06 10 - 120 mm2, K09 25 - 150 mm2. K22:- Crimping tool for interchangeable dies 6 300 mm2. Flip-top style crimping head rotates 360. Telescopic handles. Hydraulic crimping tools HK60/22:- For interchangeable dies 6 - 300 mm2. Two-stage hydraulics with auto-retraction. Flip-top style crimping head rotates 360. HK120/42:- For interchangeable dies 16 - 400 mm2. Two-stage hydraulics with auto-retraction. C-shape crimping head rotates 360. HK120/42 Battery crimping tools EK15 range:- Battery-powered mini tools designed for one-handed crimping of lugs, connectors, terminals, end sleeves etc. Auto-retract and interchangeable dies. EK22PLUS:- Battery-powered crimping tool for interchangeable dies. Two-stage hydraulics, auto-retract. Flip-top style closed crimping head rotates 360.

CTL
Components plc

K2

K507

K05 & 6 & 9

K22

HK60/22

EK15/50,15/50G, 35/4UK

EK22PLUS

K1031

K1041

ESG45PLUS

Cable cutting tools K1031:- Ratchet design - cuts cable in steps. For cable up to 60 mm . K1041:- Ratchet design - cuts cable in steps. For cable up to 100 mm . ESG45PLUS:- Battery-powered cutting tool for steel armoured, copper or aluminium cable up to 45 mm . Cutting head (with flip-open jaws) rotates 360. A 230 V mains-powered version is also available (part no KNSG45). Cable preparation tools for polymeric cables GB-PM20-SET:- The ultimate cable preparation kit for the professional cable jointer. Consists of:GB-M20:- Removes outer insulation and XLPE inner insulation. For cables 35-500 mm2, 15-50 mm . GB-P20:- Peeling/shaving tool removes the cables bonded semi-conducting layer. For cables 10-50 mm . GB-KG05-3:- Chamfers edges of XLPE insulation. Tools for larger cables up to 630 mm2 (70 mm ) are also available.

GB-PM20-SET

GB-M20

GB-P20 Issue 6a

GB-KG05-3

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