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3M
Cold Shrink Integrated Splice
™
Kit QS-III 5415A-IJ
for Jacketed Concentric Neutral (JCN) Cable
Instructions
IEEE Std. 404
15 kV Class
150 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 Number
5415A-IJ
* 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.
Outside Diameter
Length
Aluminum (Al/Cu) Compression
Length
Copper Compression and 3M
™
QCI 2-250
September 2010
78-8127-8867-3-B
Kit Selection Table
Cable Insulation O.D. Range
0.64" to 1.01"
(16,3 to 25,7 mm)
Connector Dimensional Requirements
Minimum Inches (mm)
Shearbolt Connector
0.40" (10,2 mm)
—
—
Conductor Size Range
2 - 4/0 AWG*
(35–95 mm
)
2
Maximum Inches (mm)
1.10" (28 mm)
4.50" (114 mm)
5.00" (127 mm)
3
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Summary of Contents for 3M 5415A-IJ
- Page 1 Connector Dimensional Requirements Minimum Inches (mm) Maximum Inches (mm) Outside Diameter 0.40" (10,2 mm) 1.10" (28 mm) Length — 4.50" (114 mm) Aluminum (Al/Cu) Compression Length — Copper Compression and 3M Shearbolt Connector 5.00" (127 mm) ™ QCI 2-250 September 2010 78-8127-8867-3-B...
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Page 2: Kit Contents
1.0 Kit Contents a. 3M Cold Shrink Integrated Splice Body 5415A-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 36" (2 ea.) ® e. Scotch Mastic Sealing Strips 2230, 6" length (8 ea.) ® f. Cold Shrink Adapter Tube (2 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 (1 ea.) k. Instruction Booklet (1 ea.) *Cold shrink adapter tube may not be included in all kits. - Page 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). 13 1/4" (337 mm) 3 1/2" 6 3/4" (89 mm) (171 mm) Neutral Wires Cable Jacket Semi-Con Insulation 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). Fold mastic strip in half lengthwise Semi-Con Insulation Scotch® Mastic Sealing Strip 2230 Neutral Wires Figure 2 78-8127-8867-3-B...
- Page 4 4" (102 mm) Semi-Con Insulation Scotch® Electrical Shielding Tape 24 Scotch® Mastic Sealing Strip 2230 Neutral Wires 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). Press down edge tightly Neutral Wires Semi-Con Insulation Scotch® Electrical Shielding Tape 24 Aluminum Foil Tape Strip 1115B ™...
- Page 5 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 2-250, refer to the instructions included with the connector for ™ insulation cut-back dimension. Insulation removal length shall not exceed 2 1/2" (64 mm) from conductor end (Figure 7). Refer to connector instructions for dimensions Figure 7 78-8127-8867-3-B...
- Page 6 3.2 Install 3M Shearbolt Connector QCI 2-250 according to the instructions included with the connector ™ (Figure 8). Shearbolt Connector 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 2 1/2" (64 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.
- Page 7 3.4 For 2 through 1/0 AWG copper connectors, 2 and 1 AWG aluminum connectors, or connectors with an O.D. between 0.40–0.55" (10,2–14,0 mm): Park the cold shrink adapter tube with the WHITE CORE on the insulation. For 2/0 through 4/0 AWG copper connectors or connectors with an O.D. between 0.50–0.64" (12,7–16,3 mm): Park the cold shrink adapter tube with the RED CORE on the 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 infrmation). 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 8 1/2" (216 mm) from center of connector (Figure 12). 8 3/4" 8 1/2" (222 mm) (216 mm) Tape Marker Semi-con Figure 12 78-8127-8867-3-B...
- Page 8 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 0.64" (16,3 mm) specified for the splice. c. T he 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. M ake 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). Fill semi-con step Fill semi-con step Apply Red Apply Red Compound Compound Figure 14 78-8127-8867-3-B...
- Page 9 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.
- Page 10 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). Connector Ground Wire Ground Braid Figure 18 78-8127-8867-3-B...
- Page 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 Rolled Mastic Half Mastic Strip Cable Jacket 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). Ground Wire Second Half Mastic Strip Figure 20 6.4 Wrap two half-lapped layers of vinyl tape over the ground connector (Figure 21). Ground Wire Mastic Seal for Ground Wire Vinyl Tape Figure 21 78-8127-8867-3-B...
- Page 12 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 78-8127-8867-3-B...
- Page 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. 78-8127-8867-3-B...
- Page 14 Crimping Tool - Die Sets (number of crimps/end) Square Conductor D Co. 3M™ Burndy Corporation Thomas & Betts Corp. Kearney Anderson Size Connector (AWG or Div. kcmil) Y35, Y39, VC6-3** MY29 Y34A Y1000** TBM 5 TBM 8 TBM 15 Type O Y45*, Y46* VC6-FT** CI-22 (Al/Cu) 2 sol.
- Page 15 78-8127-8867-3-B...
- Page 16 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 consequential loss or damage arising from this 3M product, regardless of the legal theory asserted.
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