3M 5786A-MT Cold Shrink QS-III Splice Kit Instructions

3M 5786A-MT Cold Shrink QS-III Splice Kit

Cable Range Requirements

Kit Number| Cable Insulation

O.D. Range

| Conductor Size Range
---|---|---
5786A- MT| 0.84″ to 1.36″

(21,3 mm to 34,5 mm)

| 1 AWG – 250 kcmil*

(50 – 120 mm2)

Splices (including size transitions) can be made to smaller or larger conductors, 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| 0.46″ (11,7 mm)| 1.36″ (34,5 mm)
Length

Aluminum (Al/Cu)

| ****

——

| ****

4.00″ (102 mm)

Length

Copper (Cu)

| ****

——

| ****

4.50″ (114 mm)

CAUTION: Working around energized high-voltage systems may cause serious injury or death. Installation should be performed by personnel familiar with good safety practice in handling high-voltage electrical equipment. De- energize and ground all electrical systems before installing product.

Prepare Cable

1. Prepare the cable according to your company’s standard procedures. Allow cable ends to overlap as much as 10″ (254 mm).

   • Remove 29″ (737 mm) of cable jacket, plus half of the overlap from Cable X.
   • Remove 24″ (610 mm) of cable jacket, plus half of the overlap from Cable Y.
   • Keep a 18″ (457 mm) piece of cable jacket removed from Cable X and a 13″ (330 mm) piece of jacket from Cable Y for use later in these instructions.

2. If cable is armored, remove cable armor leaving 1 1/2″ (37 mm) armor exposed beyond jacket end.

   • Remove cable binder , if present, at the end of the jacket or armor and discard.
   • Fold cable fillers and ground wire(s) back over cable jacket end. Do not cut off.
   • Temporarily hold the fillers and ground wire(s) back by banding them to the cable jacket using Scotch®
   • 33+ Vinyl Tape included in kit.

3. Cut the phase conductors to the appropriate length.

   • Conductors of Cable X should be 29″ (737 mm) when measured from the cable jacket end or 27 1/2″ (699 mm) when measured from end of the armor.
   • Conductors of Cable Y should be 24″ (610 mm) when measured from the cable jacket end or 22 1/2″ (572 mm) when measured from end of the armor.

4. Bind the metallic shields of both Cable X and Cable Y conductors with copper tape strip at a point 10 1/4″ (260 mm) from the end of each conductor.

   • Remove the metallic shields to copper tape binding .
   • If the conductors are individually jacketed, remove the individual jackets a distance of 13 3/4″ (349 mm) from the end of each conductor.

5. Remove cable semi-conductive insulation shields from conductors of both Cable X and Cable Y a distance of 7 1/4″ (185 mm) from the end of each conductor.
   Note: Cables must be within Insulation OD Range of splice kit.

6. Remove cable insulation from conductors ends of both Cable X and Cable Y.

   • 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 1/4″ (57 mm) from conductor end. Do not install connectors now.
     Note: This assumes that the installer has determined
     Aluminum Connector Size/Typical Growth allowance per end
     

   • AWG 1/8″ (3 mm)

   • 0 AWG 1/8″ (3 mm)

   • 0 AWG 1/8″ (3 mm)

   • 0 AWG 1/8″ (3 mm)

   • 0 AWG 1/4″ (6 mm)

   • 0 kcmil 1/4″ (6 mm)
     Notes

   • Copper connectors do not require a length change allowance.

   • Maximum aluminum connector crimped length allowed is 4.50″ (114 mm).

Place Components on Cable

1. Slide one large cold shrink jacket tube onto Cable X and one onto Cable Y with the loose core ribbon ends going on the cable last, extending toward the cable ends.

2. Slide a cold shrink splice body onto each conductor of Cable X with the loose core ribbon end going on the cable first, away from cable end.

3. Expand metallic shield sleeves and slide one onto each conductor of Cable Y. Compress the ends of each shield sleeve together next to the cable armor or jacket end, away from the prepared conductor ends.

4. For 1 and 1/0 AWG copper connectors or connectors with an O.D. between 0.46–0.60″
   (11,7–15,2 mm): Slide the cold shrink adapter tube with the RED CORE onto the insulation with the loose core ribbon end going on first, away from the cable end.

   • For 2/0 AWG through 250 kcmil copper connectors, 1 through 3/0 AWG aluminum connectors, or connectors with an O.D. between 0.53–0.84″ (13,5–21,3 mm): Slide the cold shrink adapter tube with the WHITE CORE onto the insulation with the loose core ribbon end going on first, away from the cable end.

Install Splice

1. Install connectors. See Table on front cover of this instruction for proper connector dimensions. Crimp connectors per recommendations from connector manufacturer. (For standard 3M™ Connectors, refer to table at the end of this instruction for crimping information).

2. Apply a tape marker to cable semi-con insulation shields on Cable Y (cable side which does not contain splice body) at a distance of 8 3/4″ (222 mm) measured from the CENTER of connectors.

3. If using cold shrink adapter tube:

   • Position cold shrink adapter tube over center of connector. Shrink the adapter near center of connector by pulling and unwinding the loose core ribbon end in a counter-clockwise direction.

4. Remove any excess oxidation inhibitor from  connector ends if aluminum connectors are used.
   Clean cable using standard practice:

   • a. Do not use solvent or abrasive on cable semi-conductive insulation shield.
   • b. If abrasive is used on cable insulation, do not reduce diameter below the 0.84″ (21,3 mm) minimum specified for the splice.

5. Apply red compound on cable insulation, making certain to fill in edge of cable semi-cons.
   Note: DO NOT use silicone grease.

6. Individually, position each splice body over the connector area and align the leading end of the rubber with the center of the marker tape.

   • Slowly begin to remove the inner support core by pulling while unwinding the loose ribbon end in a counterclockwise direction, allowing only 1/4″
     (6 mm) of the splice to shrink onto the marker tape.

   • Carefully slide the splice body off the marker tape by pulling and twisting until the entire marker tape is exposed. Continue removing the core to complete splice body installation.
     Note: The splice body ends must overlap onto the semi-conducting layer of each cable by at least 1/2″ (12,7 mm).
     Note: DO NOT push the splice body towards 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.

7. Center the metallic shield sleeves over the splice bodies. Hand tighten sleeves from center of splices outward in both directions. Secure sleeves by applying Scotch® Super 33+ Vinyl Tape bands at splice center and at each end.

8. Connect sleeve ends to the cable metallic shield with a small constant force spring.

   • Install each spring by unwrapping and rewrapping the spring around itself over the shield sleeve end and cable metallic shield.
   • Trim off excess shield sleeve braid material.
   • Cover springs and trimmed shield sleeve ends with one half-lapped layer of vinyl tape.

9. Connect the ground wire(s) from Cable X to the ground wire(s) from Cable Y. Make the connection away from the splice bodies.

10. Unfold the cable fillers and reestablish their lay between the cable conductors. Hold the fillers in place with a band of Scotch® Super 33+ Vinyl Tape.

5.0 Install Armor Continuity (If Cable is Armored)

1. Apply multiple wraps of Scotch® Electrical Shielding Tape 24 around the exposed armor on both Cable X and Cable Y to fill a valley in the corrugated armor. Half hitch to tie off.
   • Wrap an end of the ground continuity braid around exposed armor and applied Tape 24 on one cable end.
   • Wrap one wrap only and fold the braid at 90° with the long braid end extending toward splice opening.
   • Install a large constant force spring around the braid wrapped on the armor. Spiral wrap the braid around the splice opening to the other cable armor.
   • Fold the braid 90° and wrap braid end around armor. Wrap braid end for one wrap only. Cut off and discard excess braid.
   • Connect braid by installing other constant force
   • spring. Overwrap each spring with Scotch®
   • Super 33+ Tape.

Install Splice Jacket

1. Over wrap the exposed conductors on each side of splice bodies with jacket pieces saved from step.

   • Bind the cable jacket pieces in place with one half-lapped layer of Scotch® Vinyl Electrical Tape Super 88, 1 1/2″ wide tape.
   • At both ends of splice, apply four wraps of Scotch® Rubber Mastic Tape 2228.rubber mastic, around the cable jacket 1/2″ from jacket ends.
   • Stretch the rubber mastic to three-fourth original width when applying.

2. Install a cold shrink jacket tube on each cable with the leading end just covering the Scotch® Rubber

   • Mastic Tape 2228. and the tube extending toward the splice bodies.
   • Pull while unwinding the loose core ribbon end in a counterclockwise direction to install jacket tube.

3. Apply one half lapped layer of Scotch® Vinyl Electrical Tape Super 88 over the unjacketed area in splice center.

4. Apply two half-lapped layers of 4″ wide 3M™ Scotch-Seal™ Mastic Tape 2229 over applied vinyl tape in splice center. Overlap ends of Cold Shrink jacket tubes 2″ (51 mm).

5. Cover the applied 3M™ Scotch-Seal™ Mastic Tape 2229 with two half lapped layers of Scotch® Vinyl Electrical Tape Super 88.

6. Overwrap the entire splice with a minimum of two half lapped layers of 3M™ Sheath Wrap.

   • Tear open the top end of the foil 3M™ Sheath Wrap container and fill foil container half full with water.
   • Squeeze the container four or five times allowing the water to penetrate the roll. Pour out water, remove roll from foil container and immediately apply to splice area.
   • Bind the final wrap in place with vinyl tape.
     Note: Wear rubber gloves provided when handling 3M™ Sheath Wrap. The resin contains a black die that will stain human skin. 3M™ Sheath Wrap can be applied first and then sprayed with water to activate the curing system It will also cure from moisture in the air in humid conditions.

7. Splice is complete.

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

3M™ Connector Number

| ****

Conductor Size (AWG or kcmil)

| Burndy| Thomas & Betts Corp.| Square D Co. Anderson Div.| Kearney
---|---|---|---|---|---
MD6| MY29| Y34A| Y35, Y39 Y45, Y46| Y1000**| TBM 5| TBM 8| TBM 12| TBM 15| VC6-3** VC6- FT**| Type O
10004 (Cu)| 1| —| 1 AWG (1)| A1CR (1)| U1CRT (2)| —| Green (1)| Green (1)| —| 37 (1)| (1)| —
20004 (Al/Cu)| 1| W163 (3)| 1 AWG (1)| A1CAB (1)| U1CART (1)| 1| Gold (2)| Gold (2)| —| 45 (1)| (1)| 1/2 (3)
CI-21 (Al/Cu)| 1| BG (3)| —| U243 (1)| U25ART (1)| —| —| Olive (2)| —| 50 (1)| (1)| 5/8-1 (3)
10005 (Cu)| 1/0| W163 (2)| 1/0 (1)| A25R (1)| U25RT (1)| —| Pink (2)| Pink (2)| —| 42 (2)| (1)| —
20005 (Al/Cu)| 1/0| W241 (2)| 1/0 (1)| A25AR (1)| U25ART (1)| (1)| Tan (2)| Tan (2)| —| 50 (1)| (1)| 5/8-1 (3)
CI-1/0 (Al/Cu)| 1/0| BG (3)| —| U243 (1)| U25ART (1)| —| —| Olive (2)| —| 50 (1)| (1)| 5/8-1 (3)
10006 (Cu)| 2/0| W241 (2)| 2/0 (1)| A26R (1)| U26RT (2)| —| Black (2)| Black (2)| —| 45 (1)| (1)| —
20006 (Al/Cu)| 2/0| BG (4)| 2/0 (1)| A26AR (2)| U26ART (2)| (1)| Olive (2)| Olive (2)| —| 54H (2)| (2)| 5/8-1 (3)
11006 (Cu)| 2/0| W241 (3)| 2/0 (2)| A26R (2)| U26RT (2)| —| Black (3)| Black (3)| —| 45 (2)| (2)| —
CI-2/0 (Al/Cu)| 2/0| W249 (3)| —| —| U28ART (2)| —| —| Blue (4)| —| 76 (2)| (2)| 840 (4)
10007 (Cu)| 3/0| W243 (2)| 3/0 (1)| A27R (1)| U27RT (2)| —| Orange (2)| Orange (2)| —| 50 (1)| (1)| —
20007 (Al/Cu)| 3/0| W166 (4)| 3/0 (1)| —| U27ART (2)| (1)| Ruby (2)| Ruby (2)| —| 60 (2)| (2)| 737 (3)
11007 (Cu)| 3/0| W243 (3)| 3/0 (2)| A27R (2)| U27RT (3)| —| Orange (3)| Orange (3)| —| 50 (2)| (2)| —
CI-3/0 (Al/Cu)| 3/0| W249 (3)| —| —| U28ART (2)| —| —| Blue (4)| —| 76 (2)| (2)| 840 (4)
10008 (Cu)| 4/0| BG (3)| 4/0 (1)| A28R (2)| U28RT (2)| —| Purple (2)| Purple (2)| —| 54H (2)| (2)| —
20008 (Al/Cu)| 4/0| W660 (4)| 4/0 (2)| A28AR (2)| U28ART (2)| (1)| —| White (4)| —| 66 (4)| (2)| 840 (4)
11008 (Cu)| 4/0| BG (4)| 4/0 (2)| A28R (3)| U28RT (3)| —| Purple (3)| Purple (3)| —| 54H (3)| (3)| —
CI-4/0 (Al/Cu)| 4/0| W249 (3)| —| —| U28ART (2)| —| —| Blue (4)| —| 76 (2)| (2)| 840 (4)
10009 (Cu)| 250| W166 (3)| 250 (1)| A29R (2)| U29RT (2)| —| Yellow (2)| Yellow (2)| —| 62 (2)| (2)| —
20009 (Al/Cu)| 250| W249 (3)| —| A29AR (2)| U29ART (2)| (1)| —| —| 71H (2)| 71H (2)| (3)| —
11009 (Cu)| 250| W166 (4)| 250 (2)| A29R (3)| U29RT (3)| —| Yellow (3)| Yellow (3)| —| 62 (3)| (3)| —
CI-250 (Al/Cu)| 250| —| —| —| U31ART (2)| —| —| —| 87H (2)| 87H (2)| (2)| —

Y45 and Y46 accept all Y35 dies (“U Series”). For Y45, use PT6515 adapter. For Y46, use PUADP adapter. Anderson VC6-3, VC6-FT and Burndy Y1000 require no die set.
3M, Scotch, Super 33+ and Scotch-Seal are trademarks of 3M Company.

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.

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This product will be free from defects in material and manufacture at 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 direct, indirect, special, incidental or consequential loss or damage arising from this 3M product, regardless of the legal theory asserted.

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• phone: 800-245-3573
• Fax 800-245-0329
• www.3M.com/electrical

References

• 3M Electrical Products for Electrical Construction & Maintenance

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