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

(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

78-8127-8872-3-B 11

6.2 Cutonemasticsealingstripintotwoequalpieces.Placeonepieceonthecablejacketcenteredunderthe

groundwirenearthejacketend.Rolltwomasticstripsintosmallrolls.Placeonerolloneithersideofthe

groundwire.(Figure19).

Ground Wire

Ground Wire Rolled Mastic

Half Mastic Strip

Cable Jacket

Rolled Mastic

Half Mastic Strip

Figure19

6.3 Placetheotherhalfmasticstripoverthepreviouslyappliedmasticandgroundwire.Pressthemasticaround

thegroundwireandtothecablejacket(Figure20).

Second Half Mastic Strip

Ground Wire

Figure20

6.4 Wraptwohalf-lappedlayersofvinyltapeoverthegroundconnector(Figure21).

Vinyl Tape

Ground Wire

Mastic Seal for Ground Wire

Figure21

 12 78-8127-8872-3-B

7.0 Install Jacket

Note: Jacketing is not optional.

7.1 WraparollofslightlystretchedScotch®RubberMasticTape2228,2"x36"aroundcablejacketends(tacky

sidetowardcable)(Figure22).Stretchandtearofflast1–2"(25–50mm)ofmastic(Figure23).Ifgrounding

wasapplied,applytapeovermasticstrips.

2" rubber mastic 2" rubber mastic

Figure22

Stretch and tear off last 1–2"

(25–50 mm) of rubber mastic

Figure23

7.2 Installthelargerrejacketingtubebyslowlypullingandunwindingthecorecounterclockwise.Thetubemay

needaslightpushtokeepitfromfoldingbackonitself(Figure24).

Unwind Counter-clockwise

Figure24

78-8127-8872-3-B 13

7.3 Installthesmallerrejacketingtubebyslowlypullingandunwindingthecorecounterclockwise.Thetubemay

needaslightpushtokeepitfromfoldingbackonitself(Figure25).

Unwind Counter-clockwise

Figure25

7.4 Connectoptionalgrounding.

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.

 14 78-8127-8872-3-B

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

™M3

rotcennoC

rebmuN

rotcudnoC

eziS

)limck(

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.

78-8127-8872-3-B 15

3M and Super 33+ are trademarks of 3M Company. Scotch is a registered trademark of 3M Company.

All other trademarks are property of their respective owners.

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