3M Cold Shrink QS-III Splice Kit 5458A, CN and JCN Cable, 25/28 kV, 500-1000 kcmil, Insul. O.D. Range 1.24-2.07 in, 1/case Operating instructions

™

Cold Shrink Splice Kit QS-III

5458A

for Jacketed Concentric Neutral (JCN) and

Concentric Neutral Cable

Instructions

IEEE Std. 404

25/28 kV Class

200 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

5458A

1.24" to 2.07"

(31,5 to 52,6 mm)

500–1000 kcmil*

(240–500 mm

)

* 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 1.05" (26,7 mm) 2.07" (52,6 mm)

Length

Aluminum (Al/Cu) Compression

—

7.50" (191 mm)

Length

Copper Compression and 3M

™

Shearbolt Connector

QCI 500-1000

—

8.25" (210 mm)

October2010

78-8125-9904-7-C 3

 2 78-8125-9904-7-C

1.0 Kit Contents

a. 3M

™

ColdShrinkSpliceBody5458A(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(2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.

Note: Kitscontaineither1or2ofitem“I,”CablePreparationTemplate,asneededperconductorsize.

78-8125-9904-7-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).

[B]

[A]

Cable Jacket

Semi-Con

Insulation

Neutral Wires

Allow for extra

neutral wire length

on one cable

[B]

[A]

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

Typical Conductor Size*

kcmil (mm

)

Insulation OD Range

Inches (mm)

Jacket Cutback [A]

Inches (mm)

Semi-Con Cutback [B]

Inches (mm)

500**–750

(240–400)

1.24–1.70

(31,5–43,2)

13 3/4

(349)

9 1/4

(235)

1000**

(500)

1.59–2.07

(40,4–52,6)

13 1/4

(337)

8 3/4

(222)

*For 100% and 133% insulation levels, insulation OD is the ﬁnal determining factor.

** 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 78-8125-9904-7-C

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

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

78-8125-9904-7-C 5

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

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.

 6 78-8125-9904-7-C

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 500-1000, 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8).

Refer to connector instructions for dimensions

Figure8

3.2 Install3M

™

ShearboltConnectorQCI500-1000accordingtotheinstructionsincludedwiththeconnector

(Figure9).

Connector

Shearbolt

Figure9

Gotosection4.0“InstallSplice.”

78-8125-9904-7-C 7

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41/8"(105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)

500 kcmil 1/4" (6 mm)

750–1000 kcmil 3/8" (10 mm)

Note: 1)Copperconnectorsdonotrequirealengthchangeallowance.

2)Maximumaluminumconnectorcrimpedlengthallowedis8.25"(210mm).

One-half connector length

+ growth allowance*

Figure10

3.4 For 500 kcmil copper connectors, or connectors with an O.D. between 1.05–1.24" (26,7–31,5 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

 8 78-8125-9904-7-C

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

4.0 Install Splice

4.1 Applyatapemarkertosemi-coninsulationshieldoncablewhichdoesnotcontainsplice.Measure111/2"



(292mm)fromcenterofconnector(Figure13).

Tape Marker

Semi-con

11 1/2"

(292 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

78-8125-9904-7-C 9

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1.24"(31,5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.

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 78-8125-9904-7-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

78-8125-9904-7-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 78-8125-9904-7-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

78-8125-9904-7-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 78-8125-9904-7-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.”

78-8125-9904-7-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 78-8125-9904-7-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

78-8125-9904-7-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 78-8125-9904-7-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

78-8125-9904-7-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 78-8125-9904-7-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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