XAGA 550
I N S T A L L A T I O N
I N S T R U C T I O N
Joint closure system for telephone distribution
networks
XAGA-550 Kit Contents
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XAGA and encapsulant Installation
procedure
Shield (screen) continuity wire
assembly
Encapsulant mastic
Encapsulant containment sheet
Metal canister (2 half shells)
Self adhering aluminium closing strips
Mittens, PE pair
Cleaning tissues
Abrasive strip
Aluminium foil
Heat shrinkable reinforced sleeve
Flexible channels (+ under clip)
Note for branched joints
The standard XAGA-550 kit is designed for
maximum 1 cable entry at each end.
Note: Branched joints (more than 1 cable at
an end) require the use of one additional
branching kit (BOKT-5S or 5M) per added
cable.
Up to 4 cables, each end may be
accommodated.
Safety Rules
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Check manhole for presence of gas and
follow locally prescribed
precautions.
When working with open flame, use
standard safety equipment such as
gloves, safety glasses etc... as
required by local practices.
Recommended torches
Telstra approved soft Flame burner,
S414/130 or S414/107
Selection chart (dimensions in mm)
Telstra
Serial/item
Description
S513/00145
S513/00146
S513/00147
Branching kit
S513/00022
XAGA-550-43/8-100
XAGA-550-43/8-200
XAGA-550-75/15-250
S513/00148
Branching kit
S513/00097
XAGA-550-122/30-500
BOKT-5S
BOKT-5M
Max. Joint
bundle
diameter
Min cable
diameter
(O.D.)
Nominal
sheath
opening (L)
43
43
75
8
8
15
100
200
250
for use with S513/00145, S513/00146 &
S513/00147
122
30
500
Note
For joints with 2, 3 or 4 cables in one end the
overall cable diameter must be
determined.
Add 10 mm for every branch clip.
The total diameter must not exceed the joint
bundle diameter. See below.
20mm
15mm
15mm
for use with S513/00148
Effective diameter 70mm
BOKT Kit Content
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Branch off clip
Shield (screen) continuity clip +
connector
Cleaning tissue
Aluminium foil
Cable tie
Abrasive strip
Use kit S513/00147 with 2 x S513/00022
1 Remove cable sheath to the required
dimension (L), following locally prescribed
practices. Maximum 4 cables at each end.
Where applicable, remove sacrificial and
nylon oversheath(s). Using the kitted bond
line gauge, starting at the sheath cut, mark
the length of oversheath to be removed.
Remove the oversheath taking care not to
damage the cable sheath.
2 Where appropriate, install screen
continuity. Use tool to cut the cable sheath
over a length of 20 mm and a width of
10 mm.
3 Put cotton or PVC tape underneath
the cable sheath strip.
4 Install screen continuity clip with
standard pair of pliers.
5 For joints with three or more cables, install
continuity wire on screen continuity wire
assembly using crimp connector. Make the
joint according to normal practice.
6 Encapsulate joint in accordance with
attached TE Connectivity instruction.
7 Wrap the encapsulated joint with two
layers of craft paper, (S094/00002) with
50% overlap. Craft paper should NOT extend
beyond the encapsulant mastic.
8 Centre and fit metal canister over the
joint, and secure with tape. Seal canister
seam(s) with self adhering aluminium strip(s).
Smooth strip(s) with a blunt tool.
9 Tape the crowns, starting from 10 mm
onto the canister body down to the cable(s)
with 50% overlap, use PVC or heat resistant
tape. If applicable, use a branch clip
temporarily as an aid,
to spread cables prior to tape installation. DO
NOT over tension tape. Remove branch clip
for later installation.
10 Tape maximum 5 mm onto the cable(s).
Where applicable, re-check sacrificial and
nylon oversheath removal following
instruction 13. Remove additional oversheath
taking care not to damage the cable sheath.
11 Protect hands with mittens.
Using the cleaning tissue from the kit, clean
the cables over a distance of approximately
150 mm.
12 Using the abrasive strip from the kit,
abrade the cables circumferentially over the
cleaned length.
Note: Where applicable, install SCOP
(S433/00311) to lead-in, earth &
non-moisture barrier cables following Telstra
approved practices.
13 Use measuring strip (at bottom of
installation instruction) from the end of
canister and mark bondline length on each
cable.
14 Apply the aluminium foil to the cables,
positioning the blue line at the mark on the
cable and smooth foil with a blunt tool.
15 Flame brush the cable area between the
indicated arrows. Flame brush PE cable for
5 seconds, moisture barrier (MB)
10 seconds. Preheat lead cable over the
bond line area for 5-10 seconds.
16 Wear protective gloves. Wrap the
sleeve around the canister. Place the
underclip over the rails at the centre of the
sleeve.
17 Pull flexible channels over the sleeve rails
until they butt on top of the underclip. Centre
the sleeve over the joint, such that the sleeve
length matches the blue lines on the
aluminium foils.
18 For branch joints, position the
wraparound sleeve such that the adhesive
flap and sleeve rails are over the largest
cable, see drawing. Avoid pinching the
adhesive flap between sleeve rails.
20 Notes for heating
21 Start heating in the centre of the
sleeve 180 degrees from the channel.
Continuously heat circumferentially (heating
equally on both sides) until
arrival at the channel area. Recovery in the
channel area should take place towards the
end of heating. Continue heating until all the
thermochromic paint has changed colour
from green to black.
BOKT-5L 160/42-200/50
19 Insert the branch off clip(s) fully
between cables. Proportion the sleeve
on each side of the branch off clip(s)
according to the cable size. Secure the
cables together with the cable tie from the
branching kit.
Regulate flame to a total length of
approximately 350mm with a yellow tip of
approximately 150mm
• During shrinkage, move flame
continuously to avoid local overheating
• Apply heat until the thermochromic paint
has changed colour completely with the
exception of the immediate vicinity of the
clips and channels where a green area of
about 2 mm may remain.
23 Press the channel gently down with a
blunt tool to give the channel the shape of
the canister transition.
Note for branched joints
• Pull branched cables together by
tightening the cable tie from the branch off
kit. Repeat operations 21 and 22, starting in
the centre.
Note for lead cable
• On completion of sleeve recovery, apply
additional heat over the bond line for 5-10
seconds, moving the torch at all times.
Leave the closure undisturbed until
cool to the touch.
24 When all thermochromic paint has
changed colour two separate lines should be
visible in the slots of the channel. If the lines
are not visible within 2-3 minutes of
completion of shrinking, apply more heat
around the sleeve at that point to re-flow the
adhesive. Take care not to overheat the
sleeve. Check if the clip adhesive is seen to
flow. If not apply additional heat all around
the clip area until the clip
adhesive appears at the sleeve end.
Leave the closure undisturbed until
cool to the touch.
BOKT-5S 43/8-75/15
22 Progressively move towards the end of
the sleeve converting all paint. A green area
of about 2 mm may remain in the immediate
vicinity of the clips and
channels.
BOKT-5M 92/25-125/30
XAGA-550 Re-entry
Safety rules
When working with open flame, use standard safety equipment such as gloves, safety glasses etc… as required by local practices.
1 Use pliers and a hacksaw or locally
approved tool to lift the channel and cut
it from the sleeve while cold. Avoid
damaging the cable(s).
2 Ring cut the heat shrink sleeve material
onto the metal canister shoulder at both
ends.
3 Heat the sleeve circumference at one
end from the ring cut to sleeve end,
including branch off clips if present, as
shown.
4 While the adhesive is still hot, remove
the clip with a pair of pliers.
5 Remove the sleeve end with a pair of
pliers by pulling the sleeve gently off the
cables. Apply more heat if necessary.
6 Remove the aluminium flap of the sleeve
with a pair of pliers.
7 Remove the PVC tape from the crown of
the canister.
8 While the adhesive is still hot,
separate the cables with an appropriate tool
to assist clip insertion when reclosing.
9 Repeat steps 3 through 8 on the
opposite end. Locate one of the canister
seams. Make a cut through the sleeve along
the seam and separate the canister. Remove
the canister and re-work the joint.
Re-closing
Use a new XAGA-550 kit and repeat the
installation procedure.
The remaining adhesive does not have to be
removed from the cables.
Ensure any remaining adhesive is clean and
free of grease or dirt before
re-closing.
Tyco Electronics Raychem bvba
Diestsesteenweg 692
3010 Kessel-Lo, Belgium
Tel.: 32-16 351 011
Fax: 32-16 351 697
www.te.com
www.telecomnetworks.com
XAGA, TE (logo) and TE Connectivity are trademarks of the
TE Connectivity group of companies and its licensors.
TC 205/SIP/AU/4 01/00