3M Cold Shrink QS-III Splice Kit 5526A, 25/28 kV, Standard, 1/case Operating instructions

3M
Brand
3M
Model
Cold Shrink QS-III Splice Kit 5526A, 25/28 kV, Standard, 1/case
Category
Signal cables
Type
Operating instructions

This manual is also suitable for

3M
™
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
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 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
2
)
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
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
2
)
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
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
2
)
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)Maximumaluminumconnectorcrimpedlengthallowedis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.
3
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.
© 3M 2011. All Rights Reserved.
78-8125-9899-9-C
Crimping Tool - Die Sets (number of crimps/end)
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ydnru .B proCstteB&samohT
.oCDerauqS
.viDnosrednA
A43Y
93Y,53Y
*64Y,*54Y
**0001Y 8MBT 21MBT 51MBT
**3-6CV
**TF-6CV
**C8CV
)uC(4100 01 05 )2(R43 )A 2(TR43U — )3(nworB — )3(H78 )2( —
)uC/lA(4100 02 05 — )4(TRA43 )U 1( — )3(H601 )4(H601 )2( )2(
)uC(4101 01 05 )4(R43 )A 3(TR43U — )4(nworB — )4(H78 )3( —
)uC/lA(005-I 0C 05 — )3(TRA43U — — — )3(H601 )3( —
)uC/lA(6100 02 06 — )4(TRA63 )U 1( — — )3(H511 )3( )3(
)uC(9100 01
57 — )3(TR93U — — — )3(H601 — —
)uC/lA(9100 02 57 — )4(TRA93U — — — )5(H521 )3( )3(
)uC(9101 01 57 — )5(TR93U — — — )4(H601 — —
)uC/lA(057-I 0C 57 — )3(TRA93S — — — )3(H041 )3( —
)uC(4200 01 00 )—1 4(TR44P,TR44 )———S 3(H521 — —
)uC/lA(4200 02 00 )—1 4(TRA44P,TRA44 )———S 4(H041 — —
)uC(4201 01 00 )—1 4(TR44P,TR44 )———S 4(H521 — —
*Y45 and Y46 accept all Y35 dies ("U Series"). For Y45, use PT6515 adapter. For Y46, use PUADP adapter.
**Anderson VC6-3, VC6-FT, VC8C and Burndy Y1000 require no die set.
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3M Cold Shrink QS-III Splice Kit 5526A, 25/28 kV, Standard, 1/case Operating instructions

3M
Brand
3M
Model
Cold Shrink QS-III Splice Kit 5526A, 25/28 kV, Standard, 1/case
Category
Signal cables
Type
Operating instructions
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