3M Cold Shrink Splice Kit QS-III...

3M™ColdShrinkSpliceKitQS-III5513AforUniShield®,WireShielded,LongitudinallyCorrugated(LC),andTapeShielded(RibbonShielded)CableorTransitionstoConcentricNeutral(CN)/JacketedConcentricNeutral(JCN)Cables

InstructionsIEEE Std. 40415 kV Class150 kV BIL

� CAUTION Working around energized systems may cause serious injury or death. Installation should

be performed by personnel familiar with good safety practice in handling electrical equipment. De-energize and ground all electrical systems before installing product.

Kit Selection TableKit Number Cable Insulation O.D. Range Conductor Size Range

5513A0.64" to 1.01"

(16,3 to 25,7 mm)2–4/0 AWG*(35–95 mm2)

* Splices (including size transitions) can be made to smaller or larger conductors (but larger conductors may require special neutral handling), provided both cables are within the Insulation O.D. Range and the connector meets the dimensional requirements shown below.

Connector Dimensional RequirementsMinimum Inches (mm) Maximum Inches (mm)

Outside Diameter 0.40" (10,2 mm) 1.10" (28 mm)

LengthAluminum (Al/Cu) Compression — 4.50" (114 mm)

LengthCopper Compression and 3M™ Shearbolt Connector QCI 2-250

— 5.00" (127 mm)

March 201178-8125-9950-0-C 3

2 78-8125-9950-0-C

1.0KitContentsa. 3M™ColdShrinkSpliceBody5415A(1ea.)

b.ColdShrinkJacketingTube(1ea.)

c. ColdShrinkAdapterTube(2ea.)

d. ShieldingSleeve,1/3NeutralMaximum(1ea.)

e. GroundStrap(1ea.)

f. ConstantForceSpringGroundConnectors(5ea.)

g.RedCompoundTubes(non-siliconegrease)(2ea.)

h. Scotch®MasticSealingStrips2230,6"length(6ea.)

i. Scotch®RubberMasticTape2228Rolls,2"x36"(2ea.)

j. CopperFoilTape,1/2"x10"(2ea.)

k. 3M™CableCleaningPadsCC-3(1ea.)

l. CablePreparationTemplate(1ea.)

m.InstructionBooklet(1ea.)

Note: Donotuseknivestoopenplasticbags.

Note: Connectornotshown,butifincluded,itisindicatedonthepackaginglabel.

Note: Kitcontains0,1or2ofitem“C,”ColdShrinkAdapterTube,asneededperconductorsize.

78-8125-9950-0-C 3

2.0PrepareCables

2.1 ForTape,LC,WireShieldorUniShield®Cable:

2.1.1 Preparecablesaccordingtostandardprocedures.Refertotemplateprovidedorillustrationbelowforproperdimensions.(Figure 1).

6 3/4"(171 mm)

13 1/4"(337 mm)

3 1/2"(89 mm)

Cable Jacket MetallicShield

Semi-con Insulation

6 3/4"(171 mm)

13 1/4"(337 mm)

3 1/2"(89 mm)

Cable Jacket Wire Shield Semi-con Insulation

6 3/4"(171 mm)

13 1/4"(337 mm)

InsulationShield Wires

3 1/2"(89 mm)

Tape & LC Shielded Cables

Wire Shielded Cable

UniShield® Cable

Figure 1

Note: CablesmustbewithintheinsulationO.D.rangeofthesplicekitandtheconnectormustmeetthedimensionalrequirementsshownonthefrontpage.

4 78-8125-9950-0-C

2.1.2 For Tape shield and LC shield: Secureendofeachmetallicshieldwithacoppertapestrip.For Wire shield and UniShield®:Carefullybendshieldwiresbackovercablejacketsandtemporarilysecurewithvinyltape.(Figure 2).


Wire Shielded Cable

UniShield® Cable

Foil Tape Semi-con

Semi-con

Metallic ShieldCable Jacket

Semi-con

Cable Jacket Vinyl Tape Shield Wires


Vinyl TapeNeutral Wires

Figure 2

Gotosection3.0“ParkSpliceComponents.”ifnottransitionsplicingtoJCNorCNcable.

2.2 ForTransitionstoJacketedConcentricNeutral(JCN)Cable:

2.2.1 Preparecablesaccordingtostandardprocedures.Refertotemplateprovidedorillustrationbelowforproperdimensions(Figure 3).

6 3/4"(171 mm)

13 1/4"(337 mm)

Neutral WiresSemi-conInsulation

6 3/4"(171 mm)

13 1/4"(337 mm)


Concentric Neutral (CN)

Jacketed Concentric Neutral (JCN)

Figure 3


78-8125-9950-0-C 5

2.2.2 Carefullybendneutralwiresbackoveredgeofcablejacketandtemporarilysecurewithvinyltape.


Wire Shielded Cable

UniShield® Cable

Foil Tape Semi-con

Semi-con

Metallic ShieldCable Jacket

Semi-con



Vinyl TapeNeutral Wires

Figure 4

Gotosection3.0“ParkSpliceComponents.”

2.3 ForTransitionstoConcentricNeutral(CN)Cable:

2.3.1 Preparecablesaccordingtostandardprocedures.Refertotemplateprovidedorillustrationbelowforproperdimensions(Figure 5).Do not cut neutral wires on CN cables.

6 3/4"(171 mm)

13 1/4"(337 mm)


6 3/4"(171 mm)

13 1/4"(337 mm)


Concentric Neutral (CN)

Jacketed Concentric Neutral (JCN)Figure 5


2.3.2 Cleancablesemi-conasshown(Figure 6).

Binder Wire Folded Back Neutral WiresSemi-Con

Clean

Figure 6

6 78-8125-9950-0-C

2.3.3 Placeastripofmasticaroundcablesemi-connexttoneutralbinder.Foldneutralsintomasticandplaceanotherbinderwireontheothersideofthemastic(Figure 7).

Binder Wire

Mastic Strip

Binder Wire

Figure 7

2.3.4 Wraptwoadditionalstripsofmasticoverthefirstoneandcoverwithtwohalflappedlayersofvinyltape(Figure 8).

2 additional mastic strips covered with 2 layers vinyl tape

Figure 8

2.3.5 Foldneutralsovermasticsealandtemporarilysecureendswithvinyltape(Figure 9).

Secure folded-back neutral wires with vinyl tape

Figure 9

78-8125-9950-0-C 7

3.0ParkSpliceComponents3.1 Cleanorcovercablejacketifnecessary,forcoldshrinkparkingposition.Slidejacketingtubeontoonecable

end.Slidesplicebodyontooppositecable,loosecoreendfirst.Forsizetransitions,parkspliceonsmallercable(Figure 10).

Note: Jacketingisnotoptional.Coldshrinkjacketingtubemustbeinstalled.

Loose Core End

Splice BodyJacketing Tube

Figure 10

Note: Ifspaceislimited,thejacketingtubeandsplicebodycanbeputonthecablestackedinsideeachother.

3.2 Positiontheexpandedshieldsleeveontoonecable.Theshieldsleeveisdesignedtocarryupto1/3neutralcurrent(Figure 11).

Expanded Shield Sleeve

Figure 11

8 78-8125-9950-0-C

4.0InstallConnectorNote: Ifusingacrimp-typeconnector,gotostep4.3.

4.1 If using a 3M™ Shearbolt Connector QCI 2-250, refertotheinstructionsincludedwiththeconnectorforinsulationcut-backdimension.Insulationremovallengthshallnotexceed21/2"(64mm)fromconductorend(Figure 12).

Refer to connector instructions for dimensions

Figure 12

4.2 Install3M™ShearboltConnectorQCI2-250accordingtotheinstructionsincludedwiththeconnector(Figure 13).

Connector

Shearbolt

Figure 13

Gotosection5.0“InstallSplice.”

78-8125-9950-0-C 9

4.3 If using a crimp type connector, removecableinsulationfor1/2connectorlengthplusanallowance*forincreasesinconnectorlengthduetocrimping.Insulationremovallengthshallnotexceed21/2"(64mm)fromconductorend.Do not install connector now (Figure 14).

*Note: Thisassumesthattheinstallerhasdeterminedtheincreasedlengthofanaluminumconnectorcrimpedwithaspecifictoolanddie.

Aluminum(Al/Cu)CrimpConnectorGrowthChartConductor Size Typical growth allowance (per end)

2–3/0 AWG 1/8" (3 mm)

4/0 AWG 1/4" (6 mm)

Note: 1)Copperconnectorsdonotrequirealengthchangeallowance.2)Maximumaluminumconnectorcrimpedlengthallowedis5.00"(127mm).

One-half connector length+ growth allowance*

Figure 14

4.4 For 2 through 1/0 AWG copper connectors, 2 and 1 AWG aluminum connectors, or connectors with an O.D. between 0.40–0.55" (10,2–14,0 mm): SlidethecoldshrinkadaptertubewiththeWHITE CORE ontotheinsulationwiththeloosecoreribbonendgoingonfirst,awayfromthecableend.

For 2/0 through 4/0 AWG copper connectors or connectors with an O.D. between 0.50–0.64" (12,7–16,3 mm): SlidethecoldshrinkadaptertubewiththeRED CORE ontotheinsulationwiththeloosecoreribbonendgoingonfirst,awayfromthecableend(Figure 15).

Cold Shrink Adapter Tube

Loose Core End

Figure 15

10 78-8125-9950-0-C

4.5 Installconnector.Seetable(oncover)forproperconnectordimensions.(Forstandard3M™Connectors,refertotableattheendofthisinstructionforcrimpinginformation).Removeanyexcessoxidationinhibitorfromconnectorendsifaluminumconnectorisused.Filesharpconnectorflashingifnecessary,takingcaretoremoveallmetalfilingsfromsplicearea(Figure 16).

Connector

Figure 16

5.0InstallSplice5.1 Applyatapemarkertosemi-coninsulationshieldoncablewhichdoesnotcontainsplice.Measure81/2"

(216mm)fromcenterofconnector(Figure 17).

Tape Marker

Semi-con

8 1/2"(216 mm)

Figure 17

5.2 If using cold shrink adapter tube:Positionadaptertubeovertheconnector.Shrinkadapternearcenterofconnectorbypullingandunwindingtheloosecoreendinacounter-clockwisedirection(Figure 18).

Cold shrink adapter tube

Figure 18

78-8125-9950-0-C 11

5.3 Cleancablesusingstandardpractice:

a.Donotallowsolventorabrasivetocontactthecablesemi-conductiveinsulationshield.

b.Donotreducecableinsulationdiameterbelow0.64"(16,3mm)specifiedforthesplice.

c.Theinsulationsurfacemustberound,smoothandfreeofcuts/voids.Sandingmaybenecessary,finishsandingshouldbedonewitha300gritorhigherelectricalgradeabrasive.

d.Makecertainthatthecableinsulationissmooth,cleananddrybeforecontinuing.

5.4 Applyredcompoundoncableinsulations,makingcertaintofillinedgeofcablesemi-con.Do not use silicone grease(Figure 19).

Apply RedCompound

Apply RedCompound

Fill semi-con step Fill semi-con step

Figure 19

5.5 Positionthesplicebodyoverconnectorarea,aligningendofthesplicebody(notthecore)atthecenterofthetapemarker.Slowlystarttoremovethesplicecorebypullingandunwindingtheloosecoreendcounterclockwise,allowingonly¼"(6mm)ofthesplicetoshrinkontothetapemarker.Carefullyslidethesplicebodyoffthetapemarkerbypullingandtwistinguntiltheentiretapemarkerisexposed.Continueremovingthecoretocompletethesplicebodyinstallation(Figure 20).

Note: Thesplicebodyendsmustoverlapontothesemi-conofeachcablebyatleast1/2"(13mm).

Note: Donotpushthesplicebodytowardthetapemarkerasthismaycausetheendtorollunder.Iftheenddoesrollunder,DONOTusesharp-edgedtoolstopullitoutasthiscouldcutanddamagethesplice.

Unwind Counter-clockwise

Align splice body with tape marker

Figure 20

12 78-8125-9950-0-C

6.0ConnectShieldSleeve6.1 Centertheexpandedshieldsleeveoversplicebody.Hand-tightensleevefromsplicecenteroutwardin

bothdirections(Figure 21).

Shield Sleeve

Hand-tighten sleeve from splice center outward

Figure 21

6.2 ForTapeShieldedandLCShieldedCables:

6.2.1 Securesleevetocablemetallicshieldnexttoeachcablejacketusingtwowrapsofvinyltape(Figure 22).

Cable Jacket End

Vinyl Tape Shield Sleeve

Figure 22

6.2.2 Bendendsofsleevebackovervinyltapeandsecurewithconstantforcespringsat11/2"(38mm)and21/2"(64mm)fromjacketend.Trimoffexcesssleeve1/2"(13mm)fromsprings,ifnecessary(Figure 23).

Constant Force Springs

Folded over shield sleeve

Trim end of sleeve if necessary1 1/2"(38 mm)

2 1/2"(64 mm)

Figure 23

78-8125-9950-0-C 13

6.2.3 Wraptwolayersofstretchedvinyltapeoversprings(Figure 24).

Vinyl Tape

Figure 24

6.3 ForWireShieldedCable:

6.3.1 Carefullyremovevinyltapefromdrainwires.Securesleevetocablesemi-conductinglayernexttoeachcablejacketusingtwowrapsofvinyltape(Figure 25).

Vinyl TapeDrain Wires

Figure 25

6.3.2 Bendendsofsleevebackovervinyltape.Positiondrainwiresovertheshieldsleeveandsecurewithconstantforcespringsat11/2"(38mm)and21/2"(64mm)fromjacketend.Trimoffexcesssleeve1/2"(13mm)fromsprings,ifnecessary(Figure 26).


Drain wires over shield sleeve


2 1/2"(64 mm)

Figure 26

14 78-8125-9950-0-C


Vinyl Tape

Figure 27

6.4 ForUniShield®Cable:

6.4.1 Carefullyremovevinyltapefromdrainwires.Securesleevetocablesemi-conjacketnexttobent-backshielddrainwiresusingtwowrapsofvinyltape(Figure 28).

Vinyl TapeDrain Wires

Figure 28

6.4.2 Bendendsofsleevebackovervinyltape.Carefullypositiondrainwiresovertheshieldsleeve.Securewithconstantforcesprings11/2"(38mm)and21/2"(64mm)ontodrainwires.Trimoffexcesssleeve1/2"(13mm)fromsprings,ifnecessary(Figure 29).


Drain wires over shield sleeve


2 1/2"(64 mm)

Figure 29

78-8125-9950-0-C 15


Vinyl Tape

Figure 30

6.5 ForCNandJCNCable:

6.5.1 Connectshieldsleevetometallic(LC,etc.)shieldfirst.Removevinyltapefromneutralwiresandrouteneutralwiresupwardnexttoendofcablejacket(orCNbinder)(Figure 31).

Neutral Wires

Figure 31

6.5.2 Securesleevetocablesemi-connexttoneutralwiresusingtwowrapsofvinyltape.Covertheendofthesplicebody(asshownbelow)withtwohalf-lappedlayersofrubberorvinyltape(Figure 32).

Neutral Wires Shield Sleeve (twisted)

Vinyl Tape Rubber or Vinyl Tape

Figure 32

16 78-8125-9950-0-C

6.5.3 Placea3-4"pieceofcablejacketovertherubberorvinyltapeandcablesemi-conasshownbelow.Securewithvinyltape(Figure 33).

Cable Jacket Piece

Figure 33

6.5.4 Keepingtheconnectorascloseaspossibletothecable,connectshieldsleeveandneutralstogether,usingasuitablecompressionconnector.(“INLINE,”“C,”or“H”type).Crimpconnectorfollowingtheconnectormanufacturer’srecommendation.Trimexcessneutralwiresandsleeveextendingbeyondtheconnector(Figure 34).

Compression connector

Figure 34

6.5.5 Foldconnectorovershieldsleeve,ensuringthattheconnectorisoverthecablejacketpiece,andsecurewithvinyltape(Figure 35).

Vinyl Tape

Figure 35

78-8125-9950-0-C 17

7.0Grounding(Optional)Note: Usetheseinstructionsifcircuitgroundingisrequiredatthislocation.

7.1 Onmetallicshielded(non-neutral)cable,wrapthegroundstraparoundtheshieldsleeve(betweenthecablejacketandconstantforcespring)withthetailstowardsthecablejacket(Figure 36).

Ground Strap

Figure 36

7.2 Securegroundstraptotheshieldsleeveusingaconstantforcespring(Figure 37).

Constant Force Spring

Figure 37

7.3 Wraptwolayersofstretchedvinyltapeoverspring(Figure 38).

Vinyl Tape

Figure 38

18 78-8125-9950-0-C

7.4 Placeonemasticsealingstriponthecablejacketunderthesolderblocksofthegroundstrap(Figure 39).

Solder Block

Mastic Strip

Figure 39

7.5 Placeotherstripoverthesolderblocks.Pressthemasticstripsaroundthesolderblockandtothecablejacket.Iftailsoverlapatthesolderblocks,placeapieceofmasticbetweenthem(Figure 40).

Second Mastic Strip

Figure 40

8.0InstallJacketNote: Jacketingisnotoptional.

8.1 Applyonerollofslightlystretchedrubbermastictapearoundeachjacketend(tackysidetowardcable).Stretchandtearofftheendoftherubbermasticasshownbelow.Ifgroundstrapwasapplied,tapeovermasticsealingstrips.ForCNcable,covermasticsealnexttobinder(Figure 41).

Stretch and tear off last 1–2" (25–50 mm) of rubber mastic

Rubber Mastic Rubber Mastic

Figure 41

78-8125-9950-0-C 19

8.2 Begintoinstallthecoldshrinktubebycompletelycoveringtherubbermastic,andslowlypullingandunwindingtheinnercorecounterclockwisetowardthesplicebody.Theoutercoreshouldremainrelativelystationarywhileunwindingtheinnercore.Iftheoutercorebeginstomovetowardsthefirstmasticseal,gentlypulltheoutercoreandjacketingtubetowardsthesecondmasticsealandcontinueunwindingtheinnercore(Figure 42).


Figure 42

8.3 Continuetoinstallthecoldshrinktubeovertherubbermasticontheothercablebyslowlypullingandunwindingtheoutercorecounterclockwise.Thisportionofthecoldshrinktubeinstallsdifferentlythantypicalcoldshrinkproductsinthatasthetubeshrinks,theendrollsunder.Thetubemayneedaslightpushtogetoverthesecondmasticseal(Figure 43).


Figure 43

Note: Inapplicationswherethespliceisregularlyexposedtohighlevelsofultra-violetradiation(i.e.directsunlight),wraptwohalf-lappedlayersofScotch®Super33+™VinylElectricalTapeorScotch®VinylElectricalTapeSuper88overthere-jacketingtubes.

Note: Connectoptionalgrounding.

Crimping Tool - Die Sets (number of crimps/end)

Square D Co. 3M™ Conductor Burndy Corporation Thomas & Betts Corp. Anderson Div. Kearney Connector Size No. (AWG or MD6 MY29 Y34A Y35, Y39 Y1000** TBM 5 TBM 8 TBM 15 VC6-3** Type O kcmil) Y45*, Y46* VC6-FT**

CI-22(Al/Cu) 2sol. BG(3) --- U243(1) U25ART(1) --- --- Olive(2) 50(1) (1) 5/8-1(3)

10003(Cu) 2str. W162(2) 2AWG(1) A2CR(1) U2CRT(2) --- Brown(1) Brown(1) 33(1) (1) ---

20003(Al/Cu) 2str. W163(3) 2AWG(1) A2CAB(1) UTCABT(1) (1) Pink(2) Pink(2) 42H(2) (1) 1/2(3)

CI-21(Al/Cu) 2str. BG(3) --- U243(1) U25ART(1) --- --- Olive(2) 50(1) (1) 5/8-1(3)

10004(Cu) 1 --- 1AWG(1) A1CR(1) U1CRT(2) --- Green(1) Green(1) 37(1) (1) ---

20004(Al/Cu) 1 W163(3) 1AWG(1) A1CAB(1) U1CART(1) (1) Gold(2) Gold(2) 45(1) (1) 1/2(3)

CI-21(Al/Cu) 1 BG(3) --- U243(1) U25ART(1) --- --- Olive(2) 50(1) (1) 5/8-1(3)

10005(Cu) 1/0 W163(2) 1/0(1) A25R(1) U25RT(1) --- Pink(2) Pink(2) 42(2) (1) ---

20005(Al/Cu) 1/0 W241(2) 1/0(1) A25AR(1) U25ART(1) (1) Tan(2) Tan(2) 50(1) (1) 5/8-1(3)

CI-1/0(Al/Cu) 1/0 BG(3) --- U243(1) U25ART(1) --- --- Olive(2) 50(1) (1) 5/8-1(3)

10006(Cu) 2/0 W241(2) 2/0(1) A26R(1) U26RT(2) --- Black(2) Black(2) 45(1) (1) ---

20006(Al/Cu) 2/0 BG(4) 2/0(1) A26AR(2) U26ART(2) (1) Olive(2) Olive(2) 54H(2) (2) 5/8-1(3)

11006(Cu) 2/0 W241(3) 2/0(2) A26R(2) U26RT(2) --- Black(3) Black(3) 45(2) (2) ---

CI-2/0(Al/Cu) 2/0 W249(3) --- --- U28ART(2) --- --- Blue(4) 76(2) (2) 840(4)

10007(Cu) 3/0 W243(2) 3/0(1) A27R(1) U27RT(2) --- Orange(2) Orange(2) 50(1) (1) ---

20007(Al/Cu) 3/0 W166(4) 3/0(1) --- U27ART(2) (1) Ruby(2) Ruby(2) 60(2) (2) 737(3)

11007(Cu) 3/0 W243(3) 3/0(2) A27R(2) U27RT(3) --- Orange(3) Orange(3) 50(2) (2) ---


10008(Cu) 4/0 BG(3) 4/0(1) A28R(2) U28RT(2) --- Purple(2) Purple(2) 54H(2) (2) ---

20008(Al/Cu) 4/0 W660(4) 4/0(2) A26AR(2) U28ART(2) (1) --- White(4) 66(4) (2) 840(4)

11008(Cu) 4/0 BG(4) 4/0(2) A28R(3) U28RT(3) --- Purple(3) Purple(3) 54H(3) (3) ---


*Y45andY46acceptallY35dies(“USeries”).ForY45,usePT6515adapter.ForY46,usePUADPadapter.**AndersonVC6-3,VC6-FTandBurndyY1000requirenodieset.

3M and Super 33+ are trademarks of 3M Company. Scotch is a registered trademark of 3M Company. UniShield is a registered trademark of General Cable Technologies Corporation.

Important NoticeAll statements, technical information, and recommendations related to 3M’s products are based on information believed to be reliable, but the accuracy or completeness is not guaranteed. Before using this product, you must evaluate it and determine if it is suitable for your intended application. You assume all risks and liability associated with such use. Any statements related to the product which are not contained in 3M’s current publications, or any contrary statements contained on your purchase order shall have no force or effect unless expressly agreed upon, in writing, by an authorized officer of 3M.

Warranty; Limited Remedy; Limited Liability. This product will be free from defects in material and manufacture for a period of one (1) year from the time of purchase. 3M MAKES NO OTHER WARRANTIES INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

If this product is defective within the warranty period stated above, your exclusive remedy shall be, at 3M’s option, to replace or repair the 3M product or refund the purchase price of the 3M product. Except where prohibited by law, 3M will not be liable for any indirect, special, incidental or con-sequential loss or damage arising from this 3M product, regardless of the legal theory asserted.

3Electrical Markets Division6801 River Place Blvd. Austin, TX 78726-9000 800-245-3573Fax 800-245-0329www.3M.com/electrical

Please Recycle. Printed in USA.© 3M 2011. All Rights Reserved.78-8125-9950-0-C

3M Cold Shrink Splice Kit QS-III...

Documents

Transcript of 3M Cold Shrink Splice Kit QS-III...