3M Cold Shrink Splice Kit QS-III 5526A€¦ · 78-8125-9899-9-C 7 3.0 Park Splice Components 3.1...
Transcript of 3M Cold Shrink Splice Kit QS-III 5526A€¦ · 78-8125-9899-9-C 7 3.0 Park Splice Components 3.1...
3M™ColdShrinkSpliceKitQS-III5526AforUniShield®,WireShielded,LongitudinallyCorrugated(LC),andTapeShielded(RibbonShielded)CableorTransitionstoConcentricNeutral(CN)/JacketedConcentricNeutral(JCN)Cables
InstructionsIEEE Std. 40425/28 kV Class200 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 TableKit Number Cable Insulation O.D. Range Conductor Size Range
5526A1.24"–2.07"
(31,5–52,6 mm)500–1000 kcmil*(240–500 mm2)
* 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 RequirementsMinimum Inches (mm) Maximum Inches (mm)
Outside Diameter 1.05" (26,7 mm) 2.07" (52,6 mm)
LengthAluminum (Al/Cu) Compression — 7.50" (191 mm)
LengthCopper Compression and 3M™ Shearbolt Connector QCI 500-1000
— 8.25" (210 mm)
March 201178-8125-9899-9-C 3
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1.0KitContentsa. 3M™ColdShrinkSpliceBody5458A(1ea.)
b.ColdShrinkJacketingTube(1ea.)
c. ColdShrinkAdapterTube(1ea.)
d. ShieldingSleeve,1/3NeutralMaximum(1ea.)
e. GroundStrap(1ea.)
f. ConstantForceSpringGroundConnectors(5ea.)
g.RedCompoundTubes(non-siliconegrease)(2ea.)
h. Scotch®MasticSealingStrips2230,6"length(6ea.)
i. Scotch®RubberMasticTape2228Rolls,2"x36"(2ea.)
j. CopperFoilTape,1/2"x10"(2ea.)
k. 3M™CableCleaningPadsCC-3(1ea.)
l. CablePreparationTemplate(2ea.)
m.InstructionBooklet(1ea.)
Note: Donotuseknivestoopenplasticbags.
Note: Connectornotshown,butifincluded,itisindicatedonthepackaginglabel.
Note: Coldshrinkadaptertubemaynotbeincludedinallkits.
Note: Kitscontaineither1or2cut-backtemplatesasneededperconductorsize.
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2.0PrepareCables
2.1 ForTape,LC,WireShieldorUniShield®Cable:
2.1.1 Preparecablesaccordingtostandardprocedures.Refertotemplateprovidedorillustrationbelowforproperdimensions.(Figure 1).
“B”
“A”
3 1/2"(89 mm)
Cable Jacket MetallicShield
Semi-con Insulation
“B”
“A”
3 1/2"(89 mm)
Cable Jacket Wire Shield Semi-con Insulation
“B”
“A”
InsulationShield Wires
3 1/2"(89 mm)
Tape & LC Shielded Cables
Wire Shielded Cable
UniShield® Cable
Typical Conductor Size* kcmil (mm2)
Insulation OD RangeInches (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
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2.1.2 For Tape shield and LC shield: Secureendofeachmetallicshieldwithacoppertapestrip.For Wire shield and UniShield®:Carefullybendshieldwiresbackovercablejacketsandtemporarilysecurewithvinyltape.(Figure 2).
Tape & LC Shielded Cables
Wire Shielded Cable
UniShield® Cable
Foil Tape Semi-con
Semi-con
Metallic ShieldCable Jacket
Semi-con
Cable Jacket Vinyl Tape Shield Wires
Cable Jacket Vinyl Tape Shield Wires
Vinyl TapeNeutral Wires
Figure 2
Gotosection3.0“ParkSpliceComponents.”ifnottransitionsplicingtoJCNorCNcable.
2.2 ForTransitionstoJacketedConcentricNeutral(JCN)Cable:
2.2.1 Preparecablesaccordingtostandardprocedures.Refertotemplateprovidedorillustrationbelowforproperdimensions(Figure 3).
“B”
“A”
Neutral WiresSemi-conInsulation
“B”
“A”
Neutral WiresSemi-conInsulation
Concentric Neutral (CN)
Jacketed Concentric Neutral (JCN)
Typical Conductor Size* kcmil (mm2)
Insulation OD RangeInches (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
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2.2.2 Carefullybendneutralwiresbackoveredgeofcablejacketandtemporarilysecurewithvinyltape.
Tape & LC Shielded Cables
Wire Shielded Cable
UniShield® Cable
Foil Tape Semi-con
Semi-con
Metallic ShieldCable Jacket
Semi-con
Cable Jacket Vinyl Tape Shield Wires
Cable Jacket Vinyl Tape Shield Wires
Vinyl TapeNeutral Wires
Figure 4
Gotosection3.0“ParkSpliceComponents.”
2.3 ForTransitionstoConcentricNeutral(CN)Cable:
2.3.1 Preparecablesaccordingtostandardprocedures.Refertotemplateprovidedorillustrationbelowforproperdimensions(Figure 5).Do not cut neutral wires on CN cables.
“B”
“A”
Neutral WiresSemi-conInsulation
“B”
“A”
Neutral WiresSemi-conInsulation
Concentric Neutral (CN)
Jacketed Concentric Neutral (JCN)Typical Conductor Size*
kcmil (mm2)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 Cleancablesemi-conasshown(Figure 6).
Binder Wire Folded Back Neutral WiresSemi-Con
Clean
Figure 6
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2.3.3 Placeastripofmasticaroundcablesemi-connexttoneutralbinder.Foldneutralsintomasticandplaceanotherbinderwireontheothersideofthemastic(Figure 7).
Binder Wire
Mastic Strip
Binder Wire
Figure 7
2.3.4 Wraptwoadditionalstripsofmasticoverthefirstoneandcoverwithtwohalflappedlayersofvinyltape(Figure 8).
2 additional mastic strips covered with 2 layers vinyl tape
Figure 8
2.3.5 Foldneutralsovermasticsealandtemporarilysecureendswithvinyltape(Figure 9).
Secure folded-back neutral wires with vinyl tape
Figure 9
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3.0ParkSpliceComponents3.1 Cleanorcovercablejacketifnecessary,forcoldshrinkparkingposition.Slidejacketingtubeontoonecable
end.Slidesplicebodyontooppositecable,loosecoreendfirst.Forsizetransitions,parkspliceonsmallercable(Figure 10).
Note: Jacketingisnotoptional.Coldshrinkjacketingtubemustbeinstalled.
Loose Core End
Splice BodyJacketing Tube
Figure 10
Note: Ifspaceislimited,thejacketingtubeandsplicebodycanbeputonthecablestackedinsideeachother.
3.2 Positiontheexpandedshieldsleeveontoonecable.Theshieldsleeveisdesignedtocarryupto1/3neutralcurrent(Figure 11).
Expanded Shield Sleeve
Figure 11
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4.0InstallConnectorNote: Ifusingacrimp-typeconnector,gotostep4.3.
4.1 If using a 3M™ Shearbolt Connector QCI 500-1000, refertotheinstructionsincludedwiththeconnectorforinsulationcut-backdimension.Insulationremovallengthshallnotexceed33/4"(95mm)fromconductorend(Figure 12).
Refer to connector instructions for dimensions
Figure 12
4.2 Install3M™ShearboltConnectorQCI500-1000accordingtotheinstructionsincludedwiththeconnector(Figure 13).
Connector
Shearbolt
Figure 13
Gotosection5.0“InstallSplice.”
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4.3 If using a crimp type connector, removecableinsulationfor1/2connectorlengthplusanallowance*forincreasesinconnectorlengthduetocrimping.Insulationremovallengthshallnotexceed41/8"(105mm)fromconductorend.Do not install connector now (Figure 14).
*Note: Thisassumesthattheinstallerhasdeterminedtheincreasedlengthofanaluminumconnectorcrimpedwithaspecifictoolanddie.
Aluminum(Al/Cu)CrimpConnectorGrowthChartConductor Size Typical growth allowance (per end)
500 kcmil 1/4" (6 mm)
750–1000 kcmil 3/8" (10 mm)
Note: 1)Copperconnectorsdonotrequirealengthchangeallowance.2)Maximumaluminumconnectorcrimpedlengthallowedis8.25"(210mm).
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): Slidethecoldshrinkadaptertubeontotheinsulationwiththeloosecoreribbonendgoingonfirst,awayfromthecableend(Figure 15).
Cold Shrink Adapter Tube
Loose Core End
Figure 15
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4.5 Installconnector.Seetable(oncover)forproperconnectordimensions.(Forstandard3M™Connectors,refertotableattheendofthisinstructionforcrimpinginformation).Removeanyexcessoxidationinhibitorfromconnectorendsifaluminumconnectorisused.Filesharpconnectorflashingifnecessary,takingcaretoremoveallmetalfilingsfromsplicearea(Figure 16).
Connector
Figure 16
5.0InstallSplice5.1 Applyatapemarkertosemi-coninsulationshieldoncablewhichdoesnotcontainsplice.Measure111/2"
(292mm)fromcenterofconnector(Figure 17).
Tape Marker
Semi-con
11 1/2"(292 mm)
Figure 17
5.2 If using cold shrink adapter tube:Positionadaptertubeovertheconnector.Shrinkadapternearcenterofconnectorbypullingandunwindingtheloosecoreendinacounter-clockwisedirection(Figure 18).
Cold shrink adapter tube
Figure 18
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5.3 Cleancablesusingstandardpractice:
a.Donotallowsolventorabrasivetocontactthecablesemi-conductiveinsulationshield.
b.Donotreducecableinsulationdiameterbelow1.24"(31,5mm)specifiedforthesplice.
c.Theinsulationsurfacemustberound,smoothandfreeofcuts/voids.Sandingmaybenecessary,finishsandingshouldbedonewitha300gritorhigherelectricalgradeabrasive.
d.Makecertainthatthecableinsulationissmooth,cleananddrybeforecontinuing.
5.4 Applyredcompoundoncableinsulations,makingcertaintofillinedgeofcablesemi-con.Do not use silicone grease(Figure 19).
Apply RedCompound
Apply RedCompound
Fill semi-con step Fill semi-con step
Figure 19
5.5 Positionthesplicebodyoverconnectorarea,aligningendofthesplicebody(notthecore)atthecenterofthetapemarker.Slowlystarttoremovethesplicecorebypullingandunwindingtheloosecoreendcounterclockwise,allowingonly¼"(6mm)ofthesplicetoshrinkontothetapemarker.Carefullyslidethesplicebodyoffthetapemarkerbypullingandtwistinguntiltheentiretapemarkerisexposed.Continueremovingthecoretocompletethesplicebodyinstallation(Figure 20).
Note: Thesplicebodyendsmustoverlapontothesemi-conofeachcablebyatleast1/2"(13mm).
Note: Donotpushthesplicebodytowardthetapemarkerasthismaycausetheendtorollunder.Iftheenddoesrollunder,DONOTusesharp-edgedtoolstopullitoutasthiscouldcutanddamagethesplice.
Unwind Counter-clockwise
Align splice body with tape marker
Figure 20
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6.0ConnectShieldSleeve6.1 Centertheexpandedshieldsleeveoversplicebody.Hand-tightensleevefromsplicecenteroutwardin
bothdirections(Figure 21).
Shield Sleeve
Hand-tighten sleeve from splice center outward
Figure 21
6.2 ForTapeShieldedandLCShieldedCables:
6.2.1 Securesleevetocablemetallicshieldnexttoeachcablejacketusingtwowrapsofvinyltape(Figure 22).
Cable Jacket End
Vinyl Tape Shield Sleeve
Figure 22
6.2.2 Bendendsofsleevebackovervinyltapeandsecurewithconstantforcespringsat11/2"(38mm)and21/2"(64mm)fromjacketend.Trimoffexcesssleeve1/2"(13mm)fromsprings,ifnecessary(Figure 23).
Constant Force Springs
Folded over shield sleeve
Trim end of sleeve if necessary1 1/2"(38 mm)
2 1/2"(64 mm)
Figure 23
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6.2.3 Wraptwolayersofstretchedvinyltapeoversprings(Figure 24).
Vinyl Tape
Figure 24
6.3 ForWireShieldedCable:
6.3.1 Carefullyremovevinyltapefromdrainwires.Securesleevetocablesemi-conductinglayernexttoeachcablejacketusingtwowrapsofvinyltape(Figure 25).
Vinyl TapeDrain Wires
Figure 25
6.3.2 Bendendsofsleevebackovervinyltape.Positiondrainwiresovertheshieldsleeveandsecurewithconstantforcespringsat11/2"(38mm)and21/2"(64mm)fromjacketend.Trimoffexcesssleeve1/2"(13mm)fromsprings,ifnecessary(Figure 26).
Constant Force Springs
Drain wires over shield sleeve
Trim end of sleeve if necessary1 1/2"(38 mm)
2 1/2"(64 mm)
Figure 26
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6.3.3 Wraptwolayersofstretchedvinyltapeoversprings(Figure 27).
Vinyl Tape
Figure 27
6.4 ForUniShield®Cable:
6.4.1 Carefullyremovevinyltapefromdrainwires.Securesleevetocablesemi-conjacketnexttobent-backshielddrainwiresusingtwowrapsofvinyltape(Figure 28).
Vinyl TapeDrain Wires
Figure 28
6.4.2 Bendendsofsleevebackovervinyltape.Carefullypositiondrainwiresovertheshieldsleeve.Securewithconstantforcesprings11/2"(38mm)and21/2"(64mm)ontodrainwires.Trimoffexcesssleeve1/2"(13mm)fromsprings,ifnecessary(Figure 29).
Constant Force Springs
Drain wires over shield sleeve
Trim end of sleeve if necessary1 1/2"(38 mm)
2 1/2"(64 mm)
Figure 29
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6.4.3 Wraptwolayersofstretchedvinyltapeoversprings(Figure 30).
Vinyl Tape
Figure 30
6.5 ForCNandJCNCable:
6.5.1 Connectshieldsleevetometallic(LC,etc.)shieldfirst.Removevinyltapefromneutralwiresandrouteneutralwiresupwardnexttoendofcablejacket(orCNbinder)(Figure 31).
Neutral Wires
Figure 31
6.5.2 Securesleevetocablesemi-connexttoneutralwiresusingtwowrapsofvinyltape.Covertheendofthesplicebody(asshownbelow)withtwohalf-lappedlayersofrubberorvinyltape(Figure 32).
Neutral Wires Shield Sleeve (twisted)
Vinyl Tape Rubber or Vinyl Tape
Figure 32
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6.5.3 Placea3-4"pieceofcablejacketovertherubberorvinyltapeandcablesemi-conasshownbelow.Securewithvinyltape(Figure 33).
Cable Jacket Piece
Figure 33
6.5.4 Keepingtheconnectorascloseaspossibletothecable,connectshieldsleeveandneutralstogether,usingasuitablecompressionconnector.(“INLINE,”“C,”or“H”type).Crimpconnectorfollowingtheconnectormanufacturer’srecommendation.Trimexcessneutralwiresandsleeveextendingbeyondtheconnector(Figure 34).
Compression connector
Figure 34
6.5.5 Foldconnectorovershieldsleeve,ensuringthattheconnectorisoverthecablejacketpiece,andsecurewithvinyltape(Figure 35).
Vinyl Tape
Figure 35
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7.0Grounding(Optional)Note: Usetheseinstructionsifcircuitgroundingisrequiredatthislocation.
7.1 Onmetallicshielded(non-neutral)cable,wrapthegroundstraparoundtheshieldsleeve(betweenthecablejacketandconstantforcespring)withthetailstowardsthecablejacket(Figure 36).
Ground Strap
Figure 36
7.2 Securegroundstraptotheshieldsleeveusingaconstantforcespring(Figure 37).
Constant Force Spring
Figure 37
7.3 Wraptwolayersofstretchedvinyltapeoverspring(Figure 38).
Vinyl Tape
Figure 38
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7.4 Placeonemasticsealingstriponthecablejacketunderthesolderblocksofthegroundstrap(Figure 39).
Solder Block
Mastic Strip
Figure 39
7.5 Placeotherstripoverthesolderblocks.Pressthemasticstripsaroundthesolderblockandtothecablejacket.Iftailsoverlapatthesolderblocks,placeapieceofmasticbetweenthem(Figure 40).
Second Mastic Strip
Figure 40
8.0InstallJacketNote: Jacketingisnotoptional.
8.1 Applyonerollofslightlystretchedrubbermastictapearoundeachjacketend(tackysidetowardcable).Stretchandtearofftheendoftherubbermasticasshownbelow.Ifgroundstrapwasapplied,tapeovermasticsealingstrips.ForCNcable,covermasticsealnexttobinder(Figure 41).
Stretch and tear off last 1–2" (25–50 mm) of rubber mastic
Rubber Mastic Rubber Mastic
Figure 41
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8.2 Begintoinstallthecoldshrinktubebycompletelycoveringtherubbermastic,andslowlypullingandunwindingtheinnercorecounterclockwisetowardthesplicebody.Theoutercoreshouldremainrelativelystationarywhileunwindingtheinnercore.Iftheoutercorebeginstomovetowardsthefirstmasticseal,gentlypulltheoutercoreandjacketingtubetowardsthesecondmasticsealandcontinueunwindingtheinnercore(Figure 42).
Unwind Counter-clockwise
Figure 42
8.3 Continuetoinstallthecoldshrinktubeovertherubbermasticontheothercablebyslowlypullingandunwindingtheoutercorecounterclockwise.Thisportionofthecoldshrinktubeinstallsdifferentlythantypicalcoldshrinkproductsinthatasthetubeshrinks,theendrollsunder.Thetubemayneedaslightpushtogetoverthesecondmasticseal(Figure 43).
Unwind Counter-clockwise
Figure 43
Note: Inapplicationswherethespliceisregularlyexposedtohighlevelsofultra-violetradiation(i.e.directsunlight),wraptwohalf-lappedlayersofScotch®Super33+™VinylElectricalTapeorScotch®VinylElectricalTapeSuper88overthere-jacketingtubes.
Note: Connectoptionalgrounding.
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 NoticeAll 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.
3Electrical Markets Division6801 River Place Blvd. Austin, TX 78726-9000 800-245-3573Fax 800-245-0329www.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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)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(
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)uC(4200 01 00 )—1 4(TR44P,TR44 )———S 3(H521 — —
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)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.