3M Cold Shrink QS-III Splice Kit 5416A-250-AL, 250 kcmil, 1/case Operating instructions

3M
Brand
3M
Model
Cold Shrink QS-III Splice Kit 5416A-250-AL, 250 kcmil, 1/case
Category
Signal cables
Type
Operating instructions

This manual is also suitable for

3M
™
Cold Shrink Splice Kit QS-III
5416A
for Jacketed Concentric Neutral (JCN) and
Concentric Neutral Cable
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
5416A
0.84" to 1.38"
(21,3 to 35,1 mm)
4/0 AWG–350 kcmil*
(95–185 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 0.69" (17,5 mm) 1.49" (38 mm)
Length
Aluminum (Al/Cu) Compression
—
5.00" (127 mm)
Length
Copper Compression and 3M
™
Shearbolt Connector
QCI 4/0-600
—
5.75" (146 mm)
October2010
78-8124-5939-0-C 3
2 78-8124-5939-0-C
1.0 Kit Contents
a. 3M
™
ColdShrinkSpliceBody5416A(1ea.)
b. ColdShrinkJacketingTube(1ea.)
c. ColdShrinkAdapterTube(1ea.)
d. RedCompoundTubes(non-siliconegrease)(2ea.)
e. Scotch
®
MasticSealingStrips2230,6"length(6ea.)
f. Scotch
®
RubberMasticTape2228Rolls,2"x36"(2ea.)
g. NeutralPad(1ea.)
h. 3M
™
CableCleaningPadsCC-3(1ea.)
i. CablePreparationTemplate(1ea.)
j. 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.
78-8124-5939-0-C 3
2.0 Prepare Cables
2.1 Checktobesurethecablefitswithinthekitrangesasshownonthecoverpage.
2.2 Preparecablesaccordingtostandardprocedures.Refertotemplateprovidedorillustrationbelowforproper
dimensions.Additional distance is required on one cable to provide extra neutral wire length for
connecting the neutrals.(Figure1).
7 1/4"
(184 mm)
11 3/4"
(298 mm)
Cable Jacket
Semi-Con
Insulation
Neutral Wires
Allow for extra
neutral wire length
on one cable
7 1/4"
(184 mm)
11 3/4"
(298 mm)
Binding Wire
Semi-Con
Insulation
Neutral Wires
Allow for extra
neutral wire length
on one cable
Jacketed Concentric Neutral (JCN)
Concentric Neutral (CN)
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.
2.3 For JCN or CN splices with exposed neutral connections: Carefullybendtheneutralwiresbackoverthe
edgeofthecablejackets(JCN)orbindingwireortape(CN).Pressthemagainstthecableandtemporarily
secure/covertheendofthewireswithvinyltape(Figure2).
Secure with vinyl tape
Figure2
4 78-8124-5939-0-C
2.4 For CN to JCN transition splices or CN splices with covered neutral connections (as shown below):
2.4.1 Cleancablesemi-conasshown(Figure3).Do not use cable cleaning solvent.
Binding Wire
Folded Back
Neutral Wires
Semi-Con
Clean
Figure3
2.4.2 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4).
Binding Wire
Mastic Strip
Binding Wire
Figure4
2.4.3 Wraptwoadditionalstripsofmasticoverthefirstoneandcoverwithtwohalflappedlayersofvinyl
tape(Figure5).
2 additional Mastic Strips covered with
2 layers vinyl tape
Figure5
78-8124-5939-0-C 5
2.4.4 Foldneutralsovermasticsealandtemporarilysecureendswithvinyltape(Figure6).
Secure folded-back neutral
wires with vinyl tape
Figure6
Note: Jacketingisnotoptional.Coldshrinkjacketingtubemustbeinstalled.
2.5 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7).
Loose Core End
Splice Body
Jacketing Tube
Figure7
Note: Ifspaceislimited,thejacketingtubeandsplicebodycanbeputonthecablestackedinsideeachother.
3.0 Install Connector
Note: Ifusingacrimp-typeconnector,gotostep3.3.
3.1 If using a 3M
™
Shearbolt Connector QCI 4/0-600, refertotheinstructionsincludedwiththeconnectorfor
insulationcut-backdimension.Insulationremovallengthshallnotexceed3"(76mm)fromconductorend
(Figure8).
Refer to connector instructions for dimensions
Figure8
6 78-8124-5939-0-C
3.2 Install3M
™
ShearboltConnectorQCI4/0-600accordingtotheinstructionsincludedwiththeconnector
(Figure9).
Connector
Shearbolt
Figure9
Gotosection4.0“InstallSplice.”
3.3 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27/8"(73mm)from
conductorend.Do not install connector now (Figure10).
*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)
4/0 AWG–350 kcmil 1/4" (6 mm)
Note: 1)Copperconnectorsdonotrequirealengthchangeallowance.
2)Maximumaluminumconnectorcrimpedlengthallowedis5.75"(146mm).
One-half connector length
+ growth allowance*
Figure10
78-8124-5939-0-C 7
3.4 For 4/0 AWG through 350 kcmil copper connectors, or connectors with an O.D. between 0.69–0.84"
(17,5–21,3 mm): Slidethecoldshrinkadaptertubeontotheinsulationwiththeloosecoreribbonendgoingon
first,awayfromthecableend.
Cold Shrink Adapter Tube
Loose Core End
Figure11
3.5 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12).
Connector
Figure12
8 78-8124-5939-0-C
4.0 Install Splice
4.1 Applyatapemarkertosemi-coninsulationshieldoncablewhichdoesnotcontainsplice.Measure9"
(229mm)
fromcenterofconnector(Figure13).
Tape Marker
Semi-con
9"
(229 mm)
Figure13
4.2 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14).
Cold shrink adapter tube
Figure14
4.3 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0.84"(21,3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.
78-8124-5939-0-C 9
4.4 Applyredcompoundoncableinsulations,makingcertaintofillinedgeofcablesemi-con.Do not use
silicone grease(Figure15).
Apply Red
Compound
Apply Red
Compound
Fill semi-con step Fill semi-con step
Figure15
4.5 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16).
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16
10 78-8124-5939-0-C
For JCN to JCN Splices
5.0 Connect Neutral Wires for JCN Splices
5.1 For bundled neutrals using neutral pad:
5.1.1 Centerneutralpadonsplicebody.Removetemporaryvinyltapefromneutralwiresandconnectwith
aninlinecompressionconnector(crimpsleeve).Routeneutralsandconnectorovertheneutralpad
(Figure17).
Neutral Pad
Crimp Sleeve
Bundled Neutral Wires
Splice Body
Figure17
5.1.2 Applytwowrapsofvinyltapearoundeachendoftheneutralpadandovertheconnector(Figure18).
Vinyl Tape
Figure18
Gotostep6.0“Grounding(Optional)forJCNSplices.”
5.2 For neutrals evenly spaced around splice body:
5.2.1 Centerneutralpadonsplicebody.Routeneutralseitherstraightorconcentricallyaroundsplicebody
andsecureusingvinyltape(Figure19).
Vinyl Tape Vinyl Tape
Vinyl Tape
Splice Body
Neutral Wires
Neutral Pad
Figure19
78-8124-5939-0-C 11
For JCN to JCN Splices
5.2.2 Useapieceofcablejacket,removedduringcablepreparation,tocoverandprotectexposedcable
semi-conundertheareawheretheneutraland/orgroundconnectionwillbemade.Securewithtape.
Ensurethatthecablejacketpiecedoesnottouchthesplicebody(Figure20).
Note: Ifgroundingsplice,leavesufficientneutralwirelengthtoallowforagroundwireconnectionnextto
cablejacketormakebothneutralandgroundconnectionsusingasingleconnector.
5.2.3 Connectneutralsusingasuitablecompressionconnector("INLINE","C",or"H"type)between
jacketendandreducedsplicediameter.Keepconnectorprofileaslowaspossible.Crimpconnector
followingtheconnectormanufacturer'srecommendation(Figure20).
Splice Body
Neutral Connection
Area for ground connection
Piece of Cable Jacket
Figure20
6.0 Grounding (Optional) for JCN Splices
Note: Usetheseinstructionsifcircuitgroundingisrequiredatthislocation.
6.1 Connectagroundwiretotheneutrals,intheareawherethesplicediameterisreduced.Toprotectthecable
semicon,placeapieceofcablejacket(removedduringthecablepreparation)underthegroundconnector.
Ensurethatthecablejacketpiecedoesnottouchthesplicebody.Keepconnectorprofileaslowaspossible.
ForC-TaporH-Tapconnectors,positionflatagainstthecable(Figure21).
Ground Wire
Connector
Bundled Neutrals
Ground Wire
Connector
Neutral Connector
Piece of cable jacket Piece of cable jacket
Ground Wire Connection
for Bundled Neutrals
Ground Wire Connection
for Non-bundled Neutrals
Figure21
12 78-8124-5939-0-C
For JCN to JCN Splices
6.2 Cutonemasticsealingstripintotwoequalpieces.Placeonepieceonthecablejacketcenteredunderthe
groundwire,nearthejacketend.Rollthetworemainingfulllengthmasticstripsintosmallrolls.Placeone
rolloneachsideofthegroundwire(Figure22).
Ground Wire
Rolled Mastic
Half Mastic Strip
Cable Jacket
Ground Wire
Rolled Mastic
Half Mastic Strip
Figure22
6.3 Placetheotherhalfmasticstripovergroundwireandtworolls.Pressthemasticaroundthegroundwireand
tothecablejacket.Overwraptheconnectorswithvinyltape(Figure23).
Second Half Mastic Strip
Vinyl tape over connector
Figure23
7.0 Install Jacket for JCN Splices
Note: Jacketingisnotoptional.
7.1 Applyonerollofslightlystretchedrubbermastictapearoundeachjacketend(tackysidetowardcable).If
groundwireisconnected,applytapeovermasticsealingstrips.Stretchandtearofftheendoftherubber
masticasshown.
Stretch and tear off last 1–2"
(25–50 mm) of rubber mastic
Rubber Mastic Rubber Mastic
Figure24
78-8124-5939-0-C 13
For JCN to JCN Splices
7.2 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25).
Unwind Counter-clockwise
Figure25
7.3 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26).
Unwind Counter-clockwise
Figure26
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.
14 78-8124-5939-0-C
For CN to CN Splices
8.0 Connect Neutral Wires for CN Splices
8.1 For splices with exposed neutral connections:
8.1.1 Applyamasticstriparoundthesemi-conjacketofeachcableatthelocationwhereneutralwiresare
bentback(Figure27).
Binding Wire
Folded Back
Neutral Wires
Semi-Con
Mastic Strip
Figure27
8.1.2 Runtwosolidbarewiresacrossthespliceandpressthemintothemasticonbothcables.Leave
10"–12"(250–300mm)ofextrawirepasteachmastic(Figure28).
Press wires into mastic
Leave 10–12" (250–300 mm) of extra wire
Figure28
8.1.3 Applyonerollofslightlystretchedrubbermastictapeovereachmasticstrip(tackyside
towardscable).Stretchandtearofftheendoftherubbermasticasshown(Figure29).
Stretch and tear off last 1–2"
(25–50 mm) of rubber mastic
Rubber Mastic Rubber Mastic
Figure29
Gotosection9.0“InstallJacketforCNSplices.”
78-8124-5939-0-C 15
For CN to CN Splices
8.2 For splices with covered neutral connections:
8.2.1 Centerneutralpadonsplicebody.Removetemporaryvinyltapefromneutralwiresandconnectwith
aninlinecompressionconnector(crimpsleeve).Routeneutralsandconnectorovertheneutralpad
(Figure30).
Neutral Pad
Crimp Sleeve
Bundled Neutral Wires
Splice Body
Figure30
8.2.2 Applytwowrapsofvinyltapearoundeachendoftheneutralpadandovertheconnector(Figure31).
Vinyl Tape
Figure31
Gotostep8.3.
8.2.3 For neutrals evenly spaced around splice body:
Centerneutralpadonsplicebody.Routeneutralseitherstraightorconcentricallyaroundsplicebody
andsecureusingvinyltape(Figure32).
Vinyl Tape Vinyl Tape
Vinyl Tape
Splice Body
Neutral Wires
Neutral Pad
Figure32
16 78-8124-5939-0-C
For CN to CN Splices
8.2.4 Useapieceofcablejacket,removedduringcablepreparation,tocoverandprotectexposedcable
semi-conundertheareawheretheneutraland/orgroundconnectionwillbemade.Securewithtape.
Ensurethatthecablejacketpiecedoesnottouchthesplicebody(Figure33).
8.2.5 Connectneutralsusingasuitablecompressionconnector(“INLINE,”“C,”or“H”type)between
jacketendandreducedsplicediameter.Keepconnectorprofileaslowaspossible.Crimpconnector
followingtheconnectormanufacturer’srecommendation(Figure33).
Splice Body
Neutral Connection
Piece of Cable Jacket
Figure33
8.3 Applyonerollofslightlystretchedrubbermasticovereachmasticseal(tackysidetowardcable).Stretch
andtearofftheendoftherubbermasticasshown(Figure34).
Stretch and tear off last 1–2"
(25–50 mm) of rubber mastic
Rubber Mastic Rubber Mastic
Figure34
78-8124-5939-0-C 17
For CN to CN Splices
9.0 Install Jacket for CN Splices
Note: Jacketingisnotoptional.
9.1 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35).
Unwind Counter-clockwise
Figure35
9.2 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36).
Unwind Counter-clockwise
Figure36
18 78-8124-5939-0-C
For CN to CN Splices
9.3 For exposed neutral connection: Routeneutralsoverspliceandconnect.Includetwowiresroutedunder
splicejacket(Figure37).
Crimp Sleeve
Bundled Neutral Wires
Figure37
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: Ifcircuitgroundingisrequiredatthissplicelocation,connecttoexposedneutralwires.
For CN to JCN Transition Splices
10.0 Connect Neutral Wires for Transition Splices
10.1 For bundled neutrals using neutral pad:
10.1.1Centerneutralpadonsplicebody.Removetemporaryvinyltapefromneutralwiresandconnectwith
aninlinecompressionconnector(crimpsleeve).Routeneutralsandconnectorovertheneutralpad
(Figure38).
Neutral Pad
Crimp Sleeve
Bundled Neutral Wires
Splice Body
Figure38
78-8124-5939-0-C 19
For CN to JCN Transition Splices
10.1.2Applytwowrapsofvinyltapearoundeachendoftheneutralpadandovertheconnector(Figure39).
Vinyl Tape
Figure39
Gotosection11.0“Grounding(Optional)forTransitionSplices.”
10.2 For neutrals evenly spaced around splice body:
10.2.1Centerneutralpadonsplicebody.Routeneutralseitherstraightorconcentricallyaroundsplicebody
andsecureusingvinyltape(Figure40).
Vinyl Tape Vinyl Tape
Vinyl Tape
Splice Body
Neutral Wires
Neutral Pad
Figure40
10.2.2Useapieceofcablejacket,removedduringcablepreparation,tocoverandprotectexposedcable
semi-conundertheareawheretheneutraland/orgroundconnectionwillbemade.Securewithtape.
Ensurethatthecablejacketpiecedoesnottouchthesplicebody(Figure41).
Note: Ifgroundingsplice,leavesufficientneutralwirelengthtoallowforagroundwireconnectionnextto
cablejacketormakebothneutralandgroundconnectionsusingasingleconnector.
10.2.3Connectneutralsusingasuitablecompressionconnector("INLINE","C",or"H"type)between
jacketendandreducedsplicediameter.Keepconnectorprofileaslowaspossible.Crimpconnector
followingtheconnectormanufacturer'srecommendation(Figure41).
Splice Body
Neutral Connection
Piece of Cable Jacket
Area for ground connection
Figure41
20 78-8124-5939-0-C
For CN to JCN Transition Splices
11.0 Grounding (Optional) for Transition Splices
Note: Usetheseinstructionsifcircuitgroundingisrequiredatthislocation.
11.1 Connectagroundwiretotheneutrals,intheareawherethesplicediameterisreduced.Toprotectthecable
semicon,placeapieceofcablejacket(removedduringthecablepreparation)underthegroundconnector.
Ensurethatthecablejacketpiecedoesnottouchthesplicebody.Keepconnectorprofileaslowaspossible.
ForC-TaporH-Tapconnectors,positionflatagainstthecable(Figure42).
Ground Wire
Connector
Bundled Neutrals
Ground Wire
Connector
Neutral Connector
Piece of cable jacket Piece of cable jacket
Ground Wire Connection
for Bundled Neutrals
Ground Wire Connection
for Non-bundled Neutrals
Figure42
11.2 Cutonemasticsealingstripintotwoequalpieces.Placeonepieceonthecablejacketcenteredunderthe
groundwire,nearthejacketend.Rollthetworemainingfulllengthmasticstripsintosmallrolls.Placeone
rolloneachsideofthegroundwire(Figure43).
Ground Wire
Rolled Mastic
Half Mastic Strip
Cable Jacket
Ground Wire
Rolled Mastic
Half Mastic Strip
Figure43
11.3 Placetheotherhalfmasticstripovergroundwireandtworolls.Pressthemasticaroundthegroundwireand
tothecablejacket.Overwraptheconnectorswithvinyltape(Figure44).
Second Half Mastic Strip
Vinyl tape over connector
Figure44
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3M Cold Shrink QS-III Splice Kit 5416A-250-AL, 250 kcmil, 1/case Operating instructions

3M
Brand
3M
Model
Cold Shrink QS-III Splice Kit 5416A-250-AL, 250 kcmil, 1/case
Category
Signal cables
Type
Operating instructions
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