3M 5458A-IJ User manual

3M™ Cold Shrink Integrated Splice
Kit QS-III 5458A-IJ
for Jacketed Concentric Neutral (JCN) Cable
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
5458A-IJ 1.24"–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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)
September2010
78-8127-8872-3-B3

 2 78-8127-8872-3-B
1.0 Kit Contents
a. 3M™ColdShrinkIntegratedSpliceBody5458A-IJ(1ea.)
b. ConstantForceSprings(4ea.)
c. RedCompoundTubes(non-siliconegrease)(2ea.)
d. Scotch®RubberMasticTape2228Rolls,2"x48"(2ea.)
e. Scotch®MasticSealingStrips2230,6"length(8ea.)
f. ColdShrinkAdapterTube(1ea.*)
g. 3M™CableCleaningPadsCC-3(1ea.)
h. Scotch®ElectricalShieldingTape24,1"x15'(1ea.)
i. 3M™AluminumFoilTapeStrips1115B,10"length(2ea.)
j. Cut-backTemplate(2ea.**)
k. InstructionBooklet(1ea.)
*Cold shrink adapter tube may not be included in all kits.
**Kits contain either 1 or 2 cut-back templates as needed per conductor size.
Note: Do not use knives to open plastic bags.
Note: Connector not shown, but if included, it is indicated on the packaging label.

78-8127-8872-3-B 3
2.0 Prepare Cables
2.1 Checktobesurethecablefitswithinthekitrangesasshownonthecoverpage.
2.2 Preparecablesaccordingtostandardprocedures.Refertotemplateprovidedorillustrationbelowforproper
dimensions(Figure1).
“A”
“B”
3 1/2"
(89 mm)
Insulation
Semi-Con
Neutral Wires
Cable Jacket
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 mm)
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
2.3 Carefullybendthecutneutralwiresupandawayfromthecablesemi-conasshown.FoldoneScotch®Mastic
SealingStrip2230inhalflengthwiseandapplyonewraponlyatcablejacketedgeundertheneutralwires
(Figure2).
Insulation
Semi-Con
Neutral Wires
Scotch® Mastic Sealing Strip 2230
Fold mastic strip in half lengthwise
Figure2

 4 78-8127-8872-3-B
2.4 Markthecablesemi-con4"(102mm)fromthecablejacketedge.Applytwohalf-lappedlayersofScotch®
ElectricalShieldingTape24overthecablesemi-con,startingfromthemasticedgeouttothemarkonthe
semi-conandback.Half-hitchtotieoff(Figure3).
Insulation
Semi-Con
Neutral Wires
Scotch® Mastic Sealing Strip 2230
4"
(102 mm)
Scotch® Electrical Shielding Tape 24
Figure3
2.5 Carefullylayneutralwiresbackdownontopoftheshieldingtapeandpressintomastic.Keepwireprofilelow
byfollowingtheconcentricturninthecable(Figure4).
2.6 Removethelinerfromone3M™AluminumFoilTapeStrip1115Bandsecuretheendsoftheneutralwires.
Wrapthealuminumtapeontopofitselfandtightlypressdownontheedgeofthetapetowardtheendofthe
electricalshieldingtape(Figure4).
Insulation
Semi-Con
Neutral Wires
3M™ Aluminum Foil Tape Strip 1115B
Scotch® Electrical Shielding Tape 24
Press down edge tightly
Figure4

78-8127-8872-3-B 5
2.7 ApplyaScotch®MasticSealingStrip2230overthepreviouslyappliedmasticstripandoverlappingontothe
cablejacket.Kneadmasticaroundneutralwires.Overwrapmasticwithvinyltape,takingcarenottoextend
tapealongneutralwires(Figure5).
Scotch® Mastic Sealing Strip 2230
Overwrap with vinyl tape
Cable Jacket
Figure5
2.8 Cleanorcovercablejacket30"(760mm)fromjacketedgeonsidewheresplicebodywillbeparked.
2.9 Slideintegratedsplicebodyontocleancablejacket,loosecoreendfirst(Figure6).
Loose core end
Integrated splice body
Cleaned cable jacket
Figure6
3.0 Install Connector
Note: If using a crimp-type connector, go to step (3.3).
3.1 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7).
Refer to connector instructions for dimensions
Figure7

 6 78-8127-8872-3-B
3.2 Install3M™ShearboltConnectorQCI500-1000accordingtotheinstructionsincludedwiththeconnector
(Figure8).
Connector
Shearbolt
Figure8
Go to section 4.0 “Install Splice.”
3.3 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9).
*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9

78-8127-8872-3-B 7
3.4 For500kcmilcopperconnectors,orconnectorswithanO.D.between1.05–1.24"(26,7–31,5mm):
Parkcoldshrinkadaptertubeoncableinsulation(Figure10).
Cold shrink adapter tube
Figure10
3.5 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(Figure11).
Connector
Figure11
4.0 Install Splice
4.1 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12).
Tape Marker
Semi-con
11 1/2"
(292 mm)
Figure12

 8 78-8127-8872-3-B
4.2 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13).
Cold shrink adapter tube
Figure13
4.3 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.
4.4 Applyredcompoundoncableinsulations,makingcertaintofillinedgeofcablesemi-con.Donotuse
siliconegrease(Figure14).
Apply Red
Compound
Apply Red
Compound
Fill semi-con step Fill semi-con step
Figure14

78-8127-8872-3-B 9
4.5 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15).
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15
5.0 Connect Shielding
5.1 Removethevinyltapeholdingtheshieldsleeveontherejacketingtube,andspreadtheshieldsleeveouttoward
thecablejacket.
Note: The 3M™ Cold Shrink Integrated Splice Body includes a pre-installed ground braid for external
grounding on either side of the splice body. If not using the ground braid, it may be tied into the ground
system with the shield sleeve using constant force springs as shown below.
5.2 Hand-tightentheshieldsleeveoutwardandsecureit(alongwiththegroundbraidifnotgroundingexternally)
totheneutralwiresoneithersideofthespliceusingtwoconstantforcespringsoneachendbetweenthe
vinlytapeatthejacketedgeandthealuminumfoiltapeasshown.Trimexcessgroundbraidifneeded.Cinch
(tighten)thespringafterwrappingthefinalwinding(Figure16).
Ground Braid
Aluminum Foil Tape beneath Shield Sleeve
Constant Force Springs
Cable Jacket
Rejacketing Tube
Vinyl Tape
Figure16

 10 78-8127-8872-3-B
5.3 Wraptwohalf-lappedlayersofvinyltapeovertheconstantforcesprings(Figure17).
Vinyl Tape
Figure17
6.0 External Grounding (Optional)
Note: Use these instructions if circuit grounding is required at this location.
6.1 Connectagroundwiretothepre-installedgroundbraidontheintegratedspliceusinganappropriateconnector.
Keepconnectorprofileaslowaspossible.ForC-taporH-tapconnectors,positionflatagainstthecable.Crimp
connectorfollowingtheconnectormanufacturer’srecommendations(Figure18).
Ground Wire
Connector
Ground Braid
Figure18