How to use a cold-joint connector

Cold-joint connectors must be installed on de-energized cables following precise preparation, assembly, and insulation steps to ensure safe and reliable electrical connections. Safety PrecautionsDe-energize the cable and lock out/tag out all associated equipment before starting installation. Only trained electricians should perform the installation.

Wear appropriate personal protective equipment (PPE) and ensure the work area is clean and dry.

Required Tools

Cable stripping toolsTerminal crimping toolsFine sandpaper or polishing beltPVC tape and mastic tapesConstant-force springs (for securing shielding)Cable PreparationStrip the cable insulation according to the connector's specified dimensions, removing the semi-conductive shield at both ends. Polish the insulation with fine sandpaper to remove impurities or minor surface damage. Chamfer the insulated ends to ensure smooth insertion into the connector.

For connectors with copper shielding, slide the cable into the cold-shrink joint and the shorter cable into the copper shielding mesh, paying attention to the correct pulling direction.

Connector Assembly

Insert the cable conductor into the mechanical splicing connector and verify proper sizing. Wrap the copper shielding mesh over the joint body and secure it with PVC tape and constant-force springs, applying three layers for stability. Apply field control mastic on bolts or deep indent connectors as required, using only the specified mastic, not the one supplied with the connector.

Insulation and Sealing

Cover the connector and exposed conductor with two layers of semi-conductive tape, starting from the center of the connector. Wrap mastic tape over the polished outer jacket area (typically 200 mm) in a semi-lapped manner, stretching it to 200%. Apply armor tape in a semi-lapped manner over the mastic tape and secure with PVC tape.

Ensure the connector is not moved until the armor tape and mastic are fully set.

Final Checks

Verify that all semi-conductive screen edges are positioned correctly using the template provided with the connector. Apply reference marks and tape markers as instructed to maintain alignment and ensure proper stress control. Remove any grease or conductive residue from the crimped connector.

Dispose of installation waste responsibly and do not discard materials indiscriminately. NotesCold-joint connectors provide constant radial pressure and are suitable for medium-voltage cables, even in low-temperature or confined conditions. Follow the manufacturer's instructions for connector type, cable size, and voltage rating to ensure compliance with standards such as CENELEC HD 629.

1. Cold-shrink technology eliminates the need for heat, making it safer in environments where open flames are restricted. By carefully following these steps, cold-joint connectors can be installed safely, providing reliable electrical insulation, mechanical stability, and long-term performance.