3M Cold Shrink QS-III Splice Kit 5526A-1000-CU, 1000 kcmil, Insulation O.D. Range 1.24"-2.07" (31,5-52,6 mm), 1 per case Operating instructions

™

Cold Shrink Splice Kit QS-III

5526A

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

5526A

1.24"–2.07"

(31,5–52,6 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)

March2011

78-8125-9899-9-C 3

 2 78-8125-9899-9-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. 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(2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: Coldshrinkadaptertubemaynotbeincludedinallkits.

Note: Kitscontaineither1or2cut-backtemplatesasneededperconductorsize.

78-8125-9899-9-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).

“B”

“A”

3 1/2"

(89 mm)

Cable Jacket

Metallic

Shield

Semi-con

Insulation

“B”

“A”

3 1/2"

(89 mm)

Cable Jacket

Wire Shield

Semi-con

Insulation

“B”

“A”

Insulation

Shield Wires

3 1/2"

(89 mm)

Tape & LC Shielded Cables

Wire Shielded Cable

UniShield

Cable

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)

15 3/4

(400)

9 1/4

(235)

1000**

(500)

1.59–2.07

(40,4–52,6)

15 1/4

(387)

8 3/4

(222)

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

**Cables must be within the Insulation OD Range of the splice kit and the connector must meet the dimensional requirements shown on the front page.

Figure1

 4 78-8125-9899-9-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).

“B”

“A”

Neutral Wires

Semi-con

Insulation

“B”

“A”

Neutral Wires

Semi-con

Insulation

Concentric Neutral (CN)

Jacketed Concentric Neutral (JCN)

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)

15 3/4

(400)

9 1/4

(235)

1000**

(500)

1.59–2.07

(40,4–52,6)

15 1/4

(387)

8 3/4

(222)

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

**Cables must be within the Insulation OD Range of the splice kit and the connector must meet the dimensional requirements shown on the front page.

Figure3

78-8125-9899-9-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.

“B”

“A”

Neutral Wires

Semi-con

Insulation

“B”

“A”

Neutral Wires

Semi-con

Insulation

Concentric Neutral (CN)

Jacketed Concentric Neutral (JCN)

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)

15 3/4

(400)

9 1/4

(235)

1000**

(500)

1.59–2.07

(40,4–52,6)

15 1/4

(387)

8 3/4

(222)

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

**Cables must be within the Insulation OD Range of the splice kit and the connector must meet the dimensional requirements shown on the front page.

Figure5

2.3.2 Cleancablesemi-conasshown(Figure6).

Binder Wire

Folded Back Neutral Wires

Semi-Con

Clean

Figure6

 6 78-8125-9899-9-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

78-8125-9899-9-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 78-8125-9899-9-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 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12).

Refer to connector instructions for dimensions

Figure12

4.2 Install3M

™

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

(Figure13).

Connector

Shearbolt

Figure13

Gotosection5.0“InstallSplice.”

78-8125-9899-9-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41/8"(105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)

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14

4.4  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(Figure15).

Cold Shrink Adapter Tube

Loose Core End

Figure15

 10 78-8125-9899-9-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111/2"



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

Tape Marker

Semi-con

11 1/2"

(292 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

78-8125-9899-9-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1.24"(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.

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 78-8125-9899-9-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

78-8125-9899-9-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 78-8125-9899-9-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

78-8125-9899-9-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 78-8125-9899-9-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

78-8125-9899-9-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 78-8125-9899-9-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

78-8125-9899-9-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.

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.

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.

78-8125-9899-9-C

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