3M Cold Shrink QS-III Splice 5515A-350-AL, UniShield®, Longitudinally Corrugated, 15 kV, 350 kcmil, 1/case Operating instructions

3M
Brand
3M
Model
Cold Shrink QS-III Splice 5515A-350-AL, UniShield®, Longitudinally Corrugated, 15 kV, 350 kcmil, 1/case
Category
Signal cables
Type
Operating instructions

This manual is also suitable for

3M
™
Cold Shrink Splice Kit QS-III
5515A
for UniShield
®
, Wire Shielded, Longitudinally Corrugated (LC),
and Tape Shielded (Ribbon Shielded) Cable or Transitions to
Concentric Neutral (CN)/Jacketed Concentric Neutral (JCN) Cables
Instructions
IEEE Std. 404
15 kV Class
150 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 Table
Kit Number Cable Insulation O.D. Range Conductor Size Range
5515A
1.04"–1.70"
(26,4–43,2 mm)
350–750 kcmil*
(185–325 mm
2
)
* 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 Requirements
Minimum Inches (mm) Maximum Inches (mm)
Outside Diameter 0.80" (20,3 mm) 1.84" (46,7 mm)
Length
Aluminum (Al/Cu) Compression
—
6.75" (171 mm)
Length
Copper Compression and 3M
™
Shearbolt Connector
QCI 350-750
—
7.50" (191 mm)
March2011
78-8124-5934-1-E 3
2 78-8124-5934-1-E
1.0 Kit Contents
a. 3M
™
ColdShrinkSpliceBody5417A(1ea.)
b. ColdShrinkJacketingTube(1ea.)
c. ColdShrinkAdapterTube(1ea.)
d. ShieldingSleeve,1/3NeutralMaximum(1ea.)
e. GroundStrap(1ea.)
f. ConstantForceSpringGroundConnectors(5ea.)
g. RedCompoundTubes(non-siliconegrease)(2ea.)
h. Scotch
®
MasticSealingStrips2230,6"length(6ea.)
i. Scotch
®
RubberMasticTape2228Rolls,2"x36"(2ea.)
j. CopperFoilTape,1/2"x10"(2ea.)
k. 3M
™
CableCleaningPadsCC-3(1ea.)
l. CablePreparationTemplate(1ea.)
m.InstructionBooklet(1ea.)
Note: Donotuseknivestoopenplasticbags.
Note: Connectornotshown,butifincluded,itisindicatedonthepackaginglabel.
Note: Item“C,”ColdShrinkAdapterTube,maynotbeincludedinallkits.
78-8124-5934-1-E 3
2.0 Prepare Cables
2.1 For Tape, LC, Wire Shield or UniShield
®
Cable:
2.1.1 Preparecablesaccordingtostandardprocedures.Refertotemplateprovidedorillustrationbelowfor
properdimensions.(Figure1).
8 1/4"
(210 mm)
14 3/4"
(375 mm)
3 1/2"
(89 mm)
Cable Jacket
Metallic
Shield
Semi-con
Insulation
8 1/4"
(210 mm)
14 3/4"
(375 mm)
3 1/2"
(89 mm)
Cable Jacket
Wire Shield
Semi-con
Insulation
8 1/4"
(210 mm)
14 3/4"
(375 mm)
Insulation
Shield Wires
3 1/2"
(89 mm)
Tape & LC Shielded Cables
Wire Shielded Cable
UniShield
®
Cable
Figure1
Note: CablesmustbewithintheinsulationO.D.rangeofthesplicekitandtheconnectormustmeetthe
dimensionalrequirementsshownonthefrontpage.
4 78-8124-5934-1-E
2.1.2 For Tape shield and LC shield: Secureendofeachmetallicshieldwithacoppertapestrip.
For Wire shield and UniShield
®
:Carefullybendshieldwiresbackovercablejacketsandtemporarily
securewithvinyltape.(Figure2).
Tape & LC Shielded Cables
Wire Shielded Cable
UniShield
®
Cable
Foil Tape
Semi-con
Semi-con
Metallic Shield
Cable Jacket
Semi-con
Cable Jacket
Vinyl Tape Shield Wires
Cable Jacket
Vinyl Tape Shield Wires
Vinyl TapeNeutral Wires
Figure2
Gotosection3.0“ParkSpliceComponents.”ifnottransitionsplicingtoJCNorCNcable.
2.2 For Transitions to Jacketed Concentric Neutral (JCN) Cable:
2.2.1 Preparecablesaccordingtostandardprocedures.Refertotemplateprovidedorillustrationbelowfor
properdimensions(Figure3).
8 1/4"
(210 mm)
14 3/4"
(375 mm)
Neutral Wires
Semi-con
Insulation
8 1/4"
(210 mm)
14 3/4"
(375 mm)
Neutral Wires
Semi-con
Insulation
Concentric Neutral (CN)
Jacketed Concentric Neutral (JCN)
Figure3
Note: CablesmustbewithintheinsulationO.D.rangeofthesplicekitandtheconnectormustmeetthe
dimensionalrequirementsshownonthefrontpage.
78-8124-5934-1-E 5
2.2.2 Carefullybendneutralwiresbackoveredgeofcablejacketandtemporarilysecurewithvinyltape.
Tape & LC Shielded Cables
Wire Shielded Cable
UniShield
®
Cable
Foil Tape
Semi-con
Semi-con
Metallic Shield
Cable Jacket
Semi-con
Cable Jacket
Vinyl Tape Shield Wires
Cable Jacket
Vinyl Tape Shield Wires
Vinyl TapeNeutral Wires
Figure4
Gotosection3.0“ParkSpliceComponents.”
2.3 For Transitions to Concentric Neutral (CN) Cable:
2.3.1 Preparecablesaccordingtostandardprocedures.Refertotemplateprovidedorillustrationbelowfor
properdimensions(Figure5).Do not cut neutral wires on CN cables.
8 1/4"
(210 mm)
14 3/4"
(375 mm)
Neutral Wires
Semi-con
Insulation
8 1/4"
(210 mm)
14 3/4"
(375 mm)
Neutral Wires
Semi-con
Insulation
Concentric Neutral (CN)
Jacketed Concentric Neutral (JCN)
Figure5
Note: CablesmustbewithintheinsulationO.D.rangeofthesplicekitandtheconnectormustmeetthe
dimensionalrequirementsshownonthefrontpage.
2.3.2 Cleancablesemi-conasshown(Figure6).
Binder Wire
Folded Back Neutral Wires
Semi-Con
Clean
Figure6
6 78-8124-5934-1-E
2.3.3 Placeastripofmasticaroundcablesemi-connexttoneutralbinder.Foldneutralsintomasticandplace
anotherbinderwireontheothersideofthemastic(Figure7).
Binder Wire
Mastic Strip
Binder Wire
Figure7
2.3.4 Wraptwoadditionalstripsofmasticoverthefirstoneandcoverwithtwohalflappedlayersofvinyl
tape(Figure8).
2 additional mastic strips covered with 2 layers vinyl tape
Figure8
2.3.5 Foldneutralsovermasticsealandtemporarilysecureendswithvinyltape(Figure9).
Secure folded-back neutral wires with vinyl tape
Figure9
78-8124-5934-1-E 7
3.0 Park Splice Components
3.1 Cleanorcovercablejacketifnecessary,forcoldshrinkparkingposition.Slidejacketingtubeontoonecable
end.Slidesplicebodyontooppositecable,loosecoreendfirst.Forsizetransitions,parkspliceonsmallercable
(Figure10).
Note: Jacketingisnotoptional.Coldshrinkjacketingtubemustbeinstalled.
Loose Core End
Splice Body
Jacketing Tube
Figure10
Note: Ifspaceislimited,thejacketingtubeandsplicebodycanbeputonthecablestackedinsideeachother.
3.2 Positiontheexpandedshieldsleeveontoonecable.Theshieldsleeveisdesignedtocarryupto1/3neutral
current(Figure11).
Expanded Shield Sleeve
Figure11
8 78-8124-5934-1-E
4.0 Install Connector
Note: Ifusingacrimp-typeconnector,gotostep4.3.
4.1 If using a 3M
™
Shearbolt Connector QCI 350-750, refertotheinstructionsincludedwiththeconnectorfor
insulationcut-backdimension.Insulationremovallengthshallnotexceed33/4"(95mm)fromconductorend
(Figure12).
Refer to connector instructions for dimensions
Figure12
4.2 Install3M
™
ShearboltConnectorQCI350-750accordingtotheinstructionsincludedwiththeconnector
(Figure13).
Connector
Shearbolt
Figure13
Gotosection5.0“InstallSplice.”
78-8124-5934-1-E 9
4.3 If using a crimp type connector, removecableinsulationfor1/2connectorlengthplusanallowance*for
increasesinconnectorlengthduetocrimping.Insulationremovallengthshallnotexceed33/4"(95mm)from
conductorend.Do not install connector now (Figure14).
*Note: Thisassumesthattheinstallerhasdeterminedtheincreasedlengthofanaluminumconnectorcrimped
withaspecifictoolanddie.
Aluminum (Al/Cu) Crimp Connector Growth Chart
Conductor Size Typical growth allowance (per end)
350–500 kcmil 1/4" (6 mm)
750 kcmil 3/8" (10 mm)
Note: 1)Copperconnectorsdonotrequirealengthchangeallowance.
2)Maximumaluminumconnectorcrimpedlengthallowedis7.50"(191mm).
One-half connector length
+ growth allowance*
Figure14
4.4 For 350 and 500 kcmil copper connectors, or connectors with an O.D. between 0.80–1.04"
(20,3–26,4 mm): Slidethecoldshrinkadaptertubeontotheinsulationwiththeloosecoreribbonendgoingon
first,awayfromthecableend(Figure15).
Cold Shrink Adapter Tube
Loose Core End
Figure15
10 78-8124-5934-1-E
4.5 Installconnector.Seetable(oncover)forproperconnectordimensions.(Forstandard3M
™
Connectors,refer
totableattheendofthisinstructionforcrimpinginformation).Removeanyexcessoxidationinhibitorfrom
connectorendsifaluminumconnectorisused.Filesharpconnectorflashingifnecessary,takingcaretoremove
allmetalfilingsfromsplicearea(Figure16).
Connector
Figure16
5.0 Install Splice
5.1 Applyatapemarkertosemi-coninsulationshieldoncablewhichdoesnotcontainsplice.Measure10"
(254mm)fromcenterofconnector(Figure17).
Tape Marker
Semi-con
10"
(254 mm)
Figure17
5.2 If using cold shrink adapter tube:Positionadaptertubeovertheconnector.Shrinkadapternearcenterof
connectorbypullingandunwindingtheloosecoreendinacounter-clockwisedirection(Figure18).
Cold shrink adapter tube
Figure18
78-8124-5934-1-E 11
5.3 Cleancablesusingstandardpractice:
a.Donotallowsolventorabrasivetocontactthecablesemi-conductiveinsulationshield.
b.Donotreducecableinsulationdiameterbelow1.04"(26,4mm)specifiedforthesplice.
c.Theinsulationsurfacemustberound,smoothandfreeofcuts/voids.Sandingmaybenecessary,finish
sandingshouldbedonewitha300gritorhigherelectricalgradeabrasive.
d.Makecertainthatthecableinsulationissmooth,cleananddrybeforecontinuing.
5.4 Applyredcompoundoncableinsulations,makingcertaintofillinedgeofcablesemi-con.Do not use
silicone grease(Figure19).
Apply Red
Compound
Apply Red
Compound
Fill semi-con step Fill semi-con step
Figure19
5.5 Positionthesplicebodyoverconnectorarea,aligningendofthesplicebody(notthecore)atthecenter
ofthetapemarker.Slowlystarttoremovethesplicecorebypullingandunwindingtheloosecoreend
counterclockwise,allowingonly¼"(6mm)ofthesplicetoshrinkontothetapemarker.Carefullyslidethe
splicebodyoffthetapemarkerbypullingandtwistinguntiltheentiretapemarkerisexposed.Continue
removingthecoretocompletethesplicebodyinstallation(Figure20).
Note: Thesplicebodyendsmustoverlapontothesemi-conofeachcablebyatleast1/2"(13mm).
Note: Donotpushthesplicebodytowardthetapemarkerasthismaycausetheendtorollunder.Iftheend
doesrollunder,DONOTusesharp-edgedtoolstopullitoutasthiscouldcutanddamagethesplice.
Unwind Counter-clockwise
Align splice body with tape marker
Figure20
12 78-8124-5934-1-E
6.0 Connect Shield Sleeve
6.1 Centertheexpandedshieldsleeveoversplicebody.Hand-tightensleevefromsplicecenteroutwardin
bothdirections(Figure21).
Shield Sleeve
Hand-tighten sleeve from splice center outward
Figure21
6.2 For Tape Shielded and LC Shielded Cables:
6.2.1 Securesleevetocablemetallicshieldnexttoeachcablejacketusingtwowrapsofvinyltape
(Figure22).
Cable Jacket End
Vinyl Tape Shield Sleeve
Figure22
6.2.2 Bendendsofsleevebackovervinyltapeandsecurewithconstantforcespringsat11/2"(38mm)
and21/2"(64mm)fromjacketend.Trimoffexcesssleeve1/2"(13mm)fromsprings,ifnecessary
(Figure23).
Constant Force Springs
Folded over shield sleeve
Trim end of sleeve if necessary
1 1/2"
(38 mm)
2 1/2"
(64 mm)
Figure23
78-8124-5934-1-E 13
6.2.3 Wraptwolayersofstretchedvinyltapeoversprings(Figure24).
Vinyl Tape
Figure24
6.3 For Wire Shielded Cable:
6.3.1 Carefullyremovevinyltapefromdrainwires.Securesleevetocablesemi-conductinglayernexttoeach
cablejacketusingtwowrapsofvinyltape(Figure25).
Vinyl Tape
Drain Wires
Figure25
6.3.2 Bendendsofsleevebackovervinyltape.Positiondrainwiresovertheshieldsleeveandsecurewith
constantforcespringsat11/2"(38mm)and21/2"(64mm)fromjacketend.Trimoffexcesssleeve
1/2"(13mm)fromsprings,ifnecessary(Figure26).
Constant Force Springs
Drain wires over shield sleeve
Trim end of sleeve if necessary
1 1/2"
(38 mm)
2 1/2"
(64 mm)
Figure26
14 78-8124-5934-1-E
6.3.3 Wraptwolayersofstretchedvinyltapeoversprings(Figure27).
Vinyl Tape
Figure27
6.4 For UniShield
®
Cable:
6.4.1 Carefullyremovevinyltapefromdrainwires.Securesleevetocablesemi-conjacketnexttobent-back
shielddrainwiresusingtwowrapsofvinyltape(Figure28).
Vinyl Tape
Drain Wires
Figure28
6.4.2 Bendendsofsleevebackovervinyltape.Carefullypositiondrainwiresovertheshieldsleeve.Secure
withconstantforcesprings11/2"(38mm)and21/2"(64mm)ontodrainwires.Trimoffexcesssleeve
1/2"(13mm)fromsprings,ifnecessary(Figure29).
Constant Force Springs
Drain wires over shield sleeve
Trim end of sleeve if necessary
1 1/2"
(38 mm)
2 1/2"
(64 mm)
Figure29
78-8124-5934-1-E 15
6.4.3 Wraptwolayersofstretchedvinyltapeoversprings(Figure30).
Vinyl Tape
Figure30
6.5 For CN and JCN Cable:
6.5.1 Connectshieldsleevetometallic(LC,etc.)shieldfirst.Removevinyltapefromneutralwiresandroute
neutralwiresupwardnexttoendofcablejacket(orCNbinder)(Figure31).
Neutral Wires
Figure31
6.5.2 Securesleevetocablesemi-connexttoneutralwiresusingtwowrapsofvinyltape.Covertheendofthe
splicebody(asshownbelow)withtwohalf-lappedlayersofrubberorvinyltape(Figure32).
Neutral Wires Shield Sleeve (twisted)
Vinyl Tape
Rubber or Vinyl Tape
Figure32
16 78-8124-5934-1-E
6.5.3 Placea3-4"pieceofcablejacketovertherubberorvinyltapeandcablesemi-conasshownbelow.
Securewithvinyltape(Figure33).
Cable Jacket Piece
Figure33
6.5.4 Keepingtheconnectorascloseaspossibletothecable,connectshieldsleeveandneutralstogether,
usingasuitablecompressionconnector.(“INLINE,”“C,”or“H”type).Crimpconnectorfollowingthe
connectormanufacturer’srecommendation.Trimexcessneutralwiresandsleeveextendingbeyondthe
connector(Figure34).
Compression connector
Figure34
6.5.5 Foldconnectorovershieldsleeve,ensuringthattheconnectorisoverthecablejacketpiece,andsecure
withvinyltape(Figure35).
Vinyl Tape
Figure35
78-8124-5934-1-E 17
7.0 Grounding (Optional)
Note: Usetheseinstructionsifcircuitgroundingisrequiredatthislocation.
7.1 Onmetallicshielded(non-neutral)cable,wrapthegroundstraparoundtheshieldsleeve(betweenthecable
jacketandconstantforcespring)withthetailstowardsthecablejacket(Figure36).
Ground Strap
Figure36
7.2 Securegroundstraptotheshieldsleeveusingaconstantforcespring(Figure37).
Constant Force Spring
Figure37
7.3 Wraptwolayersofstretchedvinyltapeoverspring(Figure38).
Vinyl Tape
Figure38
18 78-8124-5934-1-E
7.4 Placeonemasticsealingstriponthecablejacketunderthesolderblocksofthegroundstrap(Figure39).
Solder Block
Mastic Strip
Figure39
7.5 Placeotherstripoverthesolderblocks.Pressthemasticstripsaroundthesolderblockandtothecablejacket.
Iftailsoverlapatthesolderblocks,placeapieceofmasticbetweenthem(Figure40).
Second Mastic Strip
Figure40
8.0 Install Jacket
Note: Jacketingisnotoptional.
8.1 Applyonerollofslightlystretchedrubbermastictapearoundeachjacketend(tackysidetowardcable).Stretch
andtearofftheendoftherubbermasticasshownbelow.Ifgroundstrapwasapplied,tapeovermasticsealing
strips.ForCNcable,covermasticsealnexttobinder(Figure41).
Stretch and tear off last 1–2"
(25–50 mm) of rubber mastic
Rubber Mastic Rubber Mastic
Figure41
78-8124-5934-1-E 19
8.2 Begintoinstallthecoldshrinktubebycompletelycoveringtherubbermastic,andslowlypullingand
unwindingtheinnercorecounterclockwisetowardthesplicebody.Theoutercoreshouldremainrelatively
stationarywhileunwindingtheinnercore.Iftheoutercorebeginstomovetowardsthefirstmasticseal,gently
pulltheoutercoreandjacketingtubetowardsthesecondmasticsealandcontinueunwindingtheinnercore
(Figure42).
Unwind Counter-clockwise
Figure42
8.3 Continuetoinstallthecoldshrinktubeovertherubbermasticontheothercablebyslowlypullingand
unwindingtheoutercorecounterclockwise.Thisportionofthecoldshrinktubeinstallsdifferentlythantypical
coldshrinkproductsinthatasthetubeshrinks,theendrollsunder.Thetubemayneedaslightpushtogetover
thesecondmasticseal(Figure43).
Unwind Counter-clockwise
Figure43
Note: Inapplicationswherethespliceisregularlyexposedtohighlevelsofultra-violetradiation
(i.e.directsunlight),wraptwohalf-lappedlayersofScotch
®
Super33+
™
VinylElectricalTapeorScotch
®
VinylElectricalTapeSuper88overthere-jacketingtubes.
Note: Connectoptionalgrounding.
*Y45 and Y46 accept all Y35 dies (“U Series”). For Y45, use PT6515 adapter. For Y46, use PUADP adapter.
**Anderson VC6-3, VC6-FT and Burndy Y1000 require no die set.
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 Notice
All 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.
3
Electrical Markets Division
6801 River Place Blvd.
Austin, TX 78726-9000
800-245-3573
Fax 800-245-0329
www.3M.com/electrical
Please Recycle. Printed in USA.
© 3M 2011. All Rights Reserved.
78-8124-5934-1-E
Crimping Tool - Die Sets (number of crimps/end)
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)uC/lA(11002 053 — )2(TRA13U )1( — )3(H78 )3(H78 )2( —
)uC(11011 053 )3(R13A )3(TR13U — )4(deR — )4(H17 )3( —
)uC/lA(053-IC 053 — )2(TRA13U — — )2(H78 )2(H78 )3( —
)uC/lA(21002 004 — )4(TRA23U )1( — )4(H49 )4(H49 )2( )2(
)uC(41001 005 )2(R43A )2(TR43U — )
3(nworB — )3(H78 )2( —
)uC/lA(41002 005 — )4(TRA43U )1( — )3(
H601 )4(H601 )2( )2(
)uC(41011 005 )4(R43A )3(TR43U — )4(nworB — )4(H78 )3( —
)uC/lA(005-IC 005 — )3(TRA43U — — — )3(H601 )3( —
)uC/lA(61002 006 — )4(TRA63U )1( — — )3(H511 )3( )3(
)uC(91001 057 — )3(TR93U — — — )3(H601 — —
)uC/lA(91002 057 — )4(TRA93U — — — )5(H521 )3( )3(
)uC(91011 057 — )5(TR93U — — — )4(H601 — —
)uC/lA(057-IC 057 — )3(TRA93S — — — )3(140H (3) —
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3M Cold Shrink QS-III Splice 5515A-350-AL, UniShield®, Longitudinally Corrugated, 15 kV, 350 kcmil, 1/case Operating instructions

3M
Brand
3M
Model
Cold Shrink QS-III Splice 5515A-350-AL, UniShield®, Longitudinally Corrugated, 15 kV, 350 kcmil, 1/case
Category
Signal cables
Type
Operating instructions
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