3M Cold Shrink QS-III Splice Kit 5525A-750-CU, 25/28 kV, 750 kcmil, 1/case Operating instructions

3M
Brand
3M
Model
Cold Shrink QS-III Splice Kit 5525A-750-CU, 25/28 kV, 750 kcmil, 1/case
Category
Signal cables
Type
Operating instructions

This manual is also suitable for

3M
™
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
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 0.75" (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
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
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)Maximumaluminumconnectorcrimpedlengthallowedis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.
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.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(
)u
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-750-CU, 25/28 kV, 750 kcmil, 1/case Operating instructions

3M
Brand
3M
Model
Cold Shrink QS-III Splice Kit 5525A-750-CU, 25/28 kV, 750 kcmil, 1/case
Category
Signal cables
Type
Operating instructions
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