3M Cold Shrink QS-III Splice Kit 5525A, 25/28 kV, 250-750 kcmil (120-325 mm2), 1/case Operating instructions

Brand: 3M

Model: Cold Shrink QS-III Splice Kit 5525A, 25/28 kV, 250-750 kcmil (120-325 mm2), 1/case

Category: Signal cables

Type: Operating instructions

This manual is also suitable for

™

Cold Shrink Splice Kit QS-III

5525A

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

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

5525A

1.07"–1.70"

(27,2–43,2 mm)

250–750 kcmil*

(120–325 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 0.75" (19,1 mm) 1.70" (43,2 mm)

Length

Aluminum (Al/Cu) Compression

—

5.75" (146 mm)

Length

Copper Compression and 3M

™

Shearbolt Connector

QCI 350-750

—

6.69" (170 mm)

March2011

78-8125-9898-1-C 3

 2 78-8125-9898-1-C

1.0 Kit Contents

a. 3M

™

ColdShrinkSpliceBody5457A(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.

78-8125-9898-1-C 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 1/2"

(216 mm)

15"

(381 mm)

3 1/2"

(89 mm)

Cable Jacket

Metallic

Shield

Semi-con

Insulation

8 1/2"

(216 mm)

15"

(381 mm)

3 1/2"

(89 mm)

Cable Jacket

Wire Shield

Semi-con

Insulation

8 1/2"

(216 mm)

15"

(381 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 78-8125-9898-1-C

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

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 1/2"

(216 mm)

15"

(381 mm)

Neutral Wires

Semi-con

Insulation

8 1/2"

(216 mm)

15"

(381 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.

78-8125-9898-1-C 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

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 1/2"

(216 mm)

15"

(381 mm)

Neutral Wires

Semi-con

Insulation

8 1/2"

(216 mm)

15"

(381 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 78-8125-9898-1-C

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

78-8125-9898-1-C 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 78-8125-9898-1-C

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.”

78-8125-9898-1-C 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3/8"(86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)

250–500 kcmil 1/4" (6 mm)

750 kcmil 3/8" (10 mm)

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

2)Maximumaluminumconnectorcrimpedlengthallowedis6.69"(170mm).

One-half connector length

+ growth allowance*

Figure14

4.4 For 250, 350 and 500 kcmil copper connectors, or connectors with an O.D. between 0.75–1.07"

(19,1–27,2 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 78-8125-9898-1-C

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1/2"



(267mm)fromcenterofconnector(Figure17).

Tape Marker

Semi-con

10 1/2"

(267 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

78-8125-9898-1-C 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1.07"(27,2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 78-8125-9898-1-C

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

78-8125-9898-1-C 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 78-8125-9898-1-C

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

78-8125-9898-1-C 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 78-8125-9898-1-C

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

78-8125-9898-1-C 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 78-8125-9898-1-C

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

78-8125-9898-1-C 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.

 20 78-8125-9898-1-C

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

*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.

™M3

rotcennoC

rebmuN

rotcudnoC

eziS

)limck(

ydnruB . proCstteB&samohT

.oCDerauqS

.viDnosrednA

6DM 92YM A43Y

93Y,53Y

*64Y,*54Y

001Y **0 5MBT 8MBT 21MBT 51MBT

**3-6CV

F-6CV **T

8CV **C

)uC(90001 052 )3(661W )1(052 )2(R92A )2(TR92U — )2(wolleY )2(wolleY — )2(26 )2( —

)uC/lA(90002 052 )3(942W — )2(RA92A )2(TRA92U )1( — — )2(H17 )2(H17 )3( —

)uC(90011 052 )4(661W )2(052 )3(R92A )3(TR92U — )3(wolleY )3(wolleY — )3(26 )3( —

)uC/lA(052-IC 052 — — — )2(TRA13U — — — )2(H78 )2(H78 )2( —

)uC(01001 003 — — )3(R03A )2(TR03U — — )2(etihW — )2(66 )2( —

)uC/lA

(01002 003 — — )2(RA03A )2(TRA03U )1( — — )3(H67 )1(67 )2( —

)uC(01011 003 — — )3(R03A )3(TR03U — — )3(etihW — )3(66 )3( —

)uC/lA(003-IC 003 — — — )2(TRA13U — — — )2(H78 )2(H78 )2( —

)uC(11001 053 — — )2(R13A )2(TR13U — — )3(deR — )3(H17 )2( —

)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(

C(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(H041 )3( —

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3M Cold Shrink QS-III Splice Kit 5525A, 25/28 kV, 250-750 kcmil (120-325 mm2), 1/case Operating instructions

Brand: 3M

Model: Cold Shrink QS-III Splice Kit 5525A, 25/28 kV, 250-750 kcmil (120-325 mm2), 1/case

3M Cold Shrink QS-III Splice Kit 5525A, 25/28 kV, 250-750 kcmil (120-325 mm2), 1/case Operating instructions

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3M Cold Shrink QS-III Splice Kit 5525A, 25/28 kV, 250-750 kcmil (120-325 mm2), 1/case Operating instructions

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