3M Cold Shrink Silicone Rubber Skirted Termination Kit QT-III 7672-S-8-TOW/WOT (RW)

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1 3M Cold Shrink Silicone Rubber Skirted Termination Kit QT-III 7672-S-8-TOW/WOT (RW) for Tape Over Wire and Wire Over Tape Shielded Cable Instructions Class 1 Termination IEC ,5 kv 69 kv Class 325 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 Jacket O.D. Range Conductor Size Range 7672-S-8 (RW) 1.44" 2.58" ( mm) Table " 3.11" ( mm) AWG ( mm 2 ) October C

2 1.0 Kit Contents 1 Insulation Adapter Tube Assembly 1 Silicone Rubber Lug Seal Insulator Assembly 1 Hi-K Stress Control Assembly 1 Silicone Rubber Insulator Assembly 1 Silicone Rubber Skirted Insulator Assembly 1 Pre-formed Ground Braid Assembly 3 Constant Force Springs 1 Roll Scotch Electrical Shielding Tape 24 9 Tubes 3M Red Compound P55/R (Non-Silicone Grease) 1 Roll 3M Scotch-Seal Mastic Tape 2229, 1" (25 mm) wide 7 Strips, 2" 11" 1 Roll Scotch Silicone Rubber Tape 70 1 Roll Scotch Vinyl Electrical Tape Super 88, 1½" 44' 1 6" 22" Pad 1 3M Cable Cleaning Pads CC-3 1 3M EMI Copper Foil Shielding Tape Strip 1181, 15" long 4 Instruction Sheets Note: Do not use knives to open plastic bags C

3 2.0 Correct Installation of Termination Silicone Rubber Skirted Insulator Assembly A B C High-K Stress Control Mastic Semi-Con Insulation Shield Silicone Rubber Tubular Insulator High-K Stress Control Tube Silicone Rubber Lug Seal Tube A B C Semi-Con Insulation Shield High-K Stress Control Mastic High-K Stress Control Tube Silicone Rubber Tubular Insulator Silicone Rubber Skirted Insulator Assembly High-K Stress Control Mastic High-K Stress Control Tube Silicone Rubber Tubular Insulator Silicone Rubber Skirted Insulator Assembly *Shown without Insulation Adapter High-K Stress Control Mastic Silicone Rubber Lug Seal Tube Silicone Rubber Tubular Insulator Silicone Rubber Skirted Insulator Assembly Note: Check to insure all of the 3M Termination Assemblies QT-III will fit over the lug. If the lug will not fit through the assembly cores, this termination can not be installed using this lug. Do not remove any of the cores at this time C 3

4 I. Tape-Over-Wire Shield Cable (For Wire-Over-Tape Shield, go to section II on page 9.) 3.0 Prepare Cable 3.1 Check to be sure the cable fits within the kit ranges as shown in Table Prepare cable using dimensions shown in (Figure 1). Be sure to allow for depth of terminal lug plus 0.5" (13 mm) plus crimp growth. Note: Provide additional exposed conductor to allow for growth of aluminum lugs or connectors during crimping. Conductor Size Growth Allowance 0.25" (6 mm) 0.5" (13 mm) 0.75" (19 mm) Field Determined Table " (89 mm) 3.25" (82 mm) 47.25" (1200 mm) 43.75" (1110 mm) 40.50" (1030 mm) Depth of lug +0.5" (13 mm) +crimp growth Semi-Con Insulation Conductor Cable Jacket Corrugated Tape Shield Shield Wires Figure C

5 4.0 Install Ground Braid Assembly 4.1 Select the pre-formed ground braid assembly from the kit. Pass the end of the cable through the ground braid assembly loop, and position the ground braid assembly around the tape shield shown. (Figure 2) Semi-Con Insulation Solder Block Ground Braid Assembly Corrugated Tape Shield Cable Jacket Edge Shield Wires Figure Select the 3 constant force springs from the kit. Starting at the loop of the ground braid assembly nearest the cable jacket edge, install the 3 constant force springs, one around each ground braid loop. Cinch (tighten) the springs after wrapping the final turn. Extend the ground braid tails down the cable jacket. (Figure 3) Constant Force Spring Cable Jacket Edge Solder Block Ground Braid Assembly Figure C 5

6 4.3 Select the roll of 1" ( 25 mm) wide 3M Scotch-Seal Mastic Tape 2229 from the kit. Cut a length of the tape long enough to wrap around the cable jacket. Remove the release liner from the mastic and, using light tension, apply a single wrap of mastic around the cable jacket, positioned under the ground braid solder blocks. (Figure 4) Solder Block 1st Mastic Strip (beneath solder blocks) Constant Force Springs Figure Cut four 1" (25 mm) lengths of 1" ( 25 mm) wide 3M Scotch-Seal Mastic Tape Remove the release liner and roll each mastic strip into a small roll. (Figure 5) Press the mastic rolls into place on either side of the ground braid solder blocks. (Figure 6) 1" (25 mm) Mastic Strip Figure 5 Mastic Rolled-Up Rolled Mastic (x4) Solder Block 1st Mastic Strip (beneath solder blocks) Figure C

7 4.5 Select the roll of 1" (25 mm) wide 3M Scotch-Seal Mastic Tape 2229 from the kit and cut a length of the mastic. Using light tension, apply a single wrap of mastic around the cable jacket over the ground braid solder blocks and the previously applied mastic. Bend wires back over applied sealing mastic. (Figure 7) 2nd Mastic Strip (over solder blocks & mastic rolls) Figure Cut a third length of sealing mastic long enough to wrap over applied mastic and solder blocks. Remove the release liner from the mastic and, using light tension, apply mastic over the shield wires and previously applied mastic. (Figure 8) 4.7 Secure the shield wires and the two tails of the ground braid assembly to the cable jacket approximately 6 inches (150 mm) from the cable jacket edge with several wraps of vinyl tape. (Figure 8) 6" (150 mm) (approx.) Vinyl Tape Wrap 3rd Mastic Strip (over shield wires & previous mastic) Figure C 7

8 4.8 Wrap two half-lapped layers of highly-tensioned Scotch Vinyl Electrical Tape Super 88 starting over the mastic seal and constant force springs to a dimension of 2.25" (57 mm) from the end of the cable semi-con, then returning to the mastic seal. The 2.25" (57 mm) dimension will be used as marker tape to install the insulation adapter tube. (Figure 9) 2.25" (57 mm) Cable Jacket Vinyl Tape Exposed Semi-Con Figure Clean Cable Insulation Using Standard Practice 5.1 Use only aluminum oxide abrasive to finish and polish insulation surface. 5.2 Use abrasive only on cable insulation. Do not use on semi-con. 5.3 When using abrasive, do not reduce the cable insulation diameter below that allowed by the kit. 5.4 Wipe the cable insulation clean with an approved solvent. Do not allow the solvent to touch semi-con insulation shield. Note: Remove any remaining solvent with 3M Cable Cleaning Pads CC-DRY (not supplied with kit) or lint-free cloth. Continue installation steps following Section C

9 II. Wire-Over-Tape Shield Cable 6.0 Prepare Cable 6.1 Check to be sure the cable fits within the kit ranges as shown in Table Prepare cable using dimensions shown in (Figure 10). Be sure to allow for depth of terminal lug plus 0.5" (13 mm) plus crimp growth. Note: Provide additional exposed conductor to allow for growth of aluminum lugs or connectors during crimping. Conductor Size Growth Allowance 0.25" (6 mm) 0.5" (13 mm) 0.75" (19 mm) Field Determined Table " (89 mm) 3.25" (82 mm) 47.25" (1200 mm) 43.75" (1110 mm) 40.50" (1030 mm) Depth of lug +0.5" (13 mm) +crimp growth Semi-Con Insulation Conductor Cable Jacket Tape Shield Shield Wires Figure C 9

10 7.0 Install Ground Braid Assembly 7.1 Fold the shield wires back along the cable jacket. Select the pre-formed ground braid assembly from the kit. Pass the end of the cable through the ground braid assembly loop, and position the ground braid assembly around the tape shield as shown. (Figure 11) Semi-Con Insulation Shield Wires Solder Block Ground Braid Assembly Tape Shield Cable Jacket Edge Figure Select the 3 constant force springs from the kit. Starting at the loop of the ground braid assembly nearest the cable jacket edge, install the 3 constant force springs, one around each ground braid loop. Cinch (tighten) the springs after wrapping the final turn. Extend the ground braid tails down the cable jacket. (Figure 12) Constant Force Spring Cable Jacket Edge Solder Block Ground Braid Assembly Figure C

11 7.3 Select the roll of 1" ( 25 mm) wide 3M Scotch-Seal Mastic Tape 2229 from the kit. Cut a length of the tape long enough to wrap around the cable jacket. Lift the ground braid tails and shield wires. Remove the release liner from the mastic and using light tension, apply a single wrap of mastic around the cable jacket positioned under the ground braid solder blocks and shield wires. (Figure 13) Shield Wires Constant Force Springs Solder Block 1st Mastic Strip (beneath solder blocks & shield wires) Figure Select the roll of 1" ( 25 mm) wide 3M Scotch-Seal Mastic Tape 2229 from the kit. Cut a length of the tape long enough to wrap around the cable jacket and previously applied mastic. Fold the ground braid tails out of the way. Remove the release liner from the mastic and, using light tension, apply a single wrap of mastic around the cable jacket, positioned over the shield wires and previously applied mastic. (Figure 14) Constant Force Springs Shield Wires 2nd Mastic Strip (over shield wires & previously applied mastic) Figure C 11

12 7.5 Cut four 1" (25 mm) lengths of 1" ( 25 mm) wide 3M Scotch-Seal Mastic Tape Remove the release liner and roll each mastic strip into a small roll. (Figure 15) Press the mastic rolls into place on either side of the ground braid solder blocks. (Figure 16) 2" (50 mm) Mastic Strip Mastic Rolled-Up Figure 15 Rolled Mastic (x4) Solder Block 2nd Mastic Strip (beneath solder blocks) Figure Cut a third length of sealing mastic long enough to wrap over applied mastic and solder blocks. Remove the release liner from the mastic and, using light tension, apply mastic over the shield wires and previously applied mastic. (Figure 17) 7.7 Secure the shield wires and the two tails of the ground braid assembly to the cable jacket approximately 6 inches (150 mm) from the cable jacket edge with several wraps of vinyl tape. (Figure 17) 6" (150 mm) (approx.) Vinyl Tape Wrap 3rd Mastic Strip (over solder blocks & previous mastic) Figure C

13 7.8 Wrap two half-lapped layers of highly-tensioned Scotch Vinyl Electrical Tape Super 88 starting over the mastic seal and constant force springs to a dimension of 2.25" (57 mm) from the end of the cable semi-con, then returning to the mastic seal. The 2.25" (57 mm) dimension will be used as marker tape to install the insulation adapter tube. (Figure 18) 2.25" (57 mm) Cable Jacket Vinyl Tape Exposed Semi-Con Figure Clean Cable Insulation Using Standard Practice 8.1 Use only aluminum oxide abrasive to finish and polish insulation surface. 8.2 Use abrasive only on cable insulation. Do not use on semi-con. 8.3 When using abrasive, do not reduce the cable insulation diameter below that allowed by the kit. 8.4 Wipe the cable insulation clean with an approved solvent. Do not allow the solvent to touch semi-con insulation shield. Note: Remove any remaining solvent with 3M Cable Cleaning Pads CC-DRY (not supplied with kit) or lint-free cloth. 9.0 Install Insulation Adapter 9.1 Select one 2" x 11" (50.8 mm x 280 mm) Hi-K mastic strip from the kit. Remove the liners and wrap around the end of the cable semi-con and cable insulation. Position the Hi-K sealing mastic so that half covers the cable semi-con and half covers the cable insulation. (Figure 19) Semi-Con Cable Insulation Figure C 13

14 9.2 Wrap two half-lapped layers of highly-tensioned Scotch Vinyl Electrical Tape Super 88 over the hi-k mastic, leaving approximately 0.125" (3 mm) of mastic exposed at each end. Taper the exposed edges of the hi-k mastic onto the cable by gently pressing along the edge with your finger. (Figure 20) 0.125" (3 mm) 0.125" (3 mm) Cable Insulation Semi-Con Taper Edge of Vinyl Tape Taper Edge of Figure Coat the cable insulation and vinyl tape/hi-k sealing mastic using 3 tubes of 3M Red Compound P55/R (nonsilicone grease). (Figure 21) Coat with 3M Red Compound P55/R Figure C

15 9.4 Select the insulation adapter tube assembly from the kit. Slide the insulation adapter tube assembly over the lug and cable with the loose core end toward the lug. Align the insulation adapter tube assembly (not the core) with the end of tape (at 2.25" over the cable semi-con) and remove the core by pulling the loose core end while unwinding counter-clockwise. (Figure 22) Note: The insulation adapter will be shorter than the exposed cable insulation by 0.1" (2 mm) to 4.0" (102 mm) depending on the cable insulation diameter. Align with tape marker Unwind counter-clockwise Figure 22 Insulation Adapter Tube Assembly Cable Insulation C 15

16 10.0 Install Termination 10.1 Select the large Hi-K mastic pad from the kit. Remove the liners and align the pad with 1" (25 mm) covering the black semi-con portion of the insulation adapter tube assembly, and 5" (127 mm) covering the grey insulation portion of the insulation adapter tube assembly. Using light tension, wrap the pad around the cable insulation two times. Trim the pad to overlap the start by approximately 0.25" (6 mm). Taper the pad edge by gently pressing along the edge with your finger. (Figure 23) Pad Insulation Adapter Tube Assembly 1.0" (25 mm) 5.0" (127 mm) Pad (2 Layers) Cable Insulation Taper Edge Cable Insulation Figure Wrap two half-lapped layers of highly-tensioned Scotch Vinyl Electrical Tape Super 88 over the hi-k mastic pad, leaving approximately 0.125" (3 mm) of mastic exposed at each end. Taper the exposed edges of the hi-k mastic onto the cable by gently pressing along the edge with your finger. (Figure 24) 0.125" (3 mm) 0.125" (3 mm) Insulation Adapter Tube Assembly Taper Edge of Vinyl Tape Taper Edge of Figure C

17 10.3 Starting 5" (127 mm) from the cut end of the insulation, apply 2 tubes of 3M Red Compound P55/R (nonsilicone grease) over exposed insulation and vinyl tape-wrapped mastic pad. (Figure 25) Insulation Adapter Semi-Con Step Coat with 3M Red Compound P55/R 5.0" (127 mm) Figure Select the stress control assembly (medium length tubular assembly on white core) from the kit. Slide the stress control assembly over the lug and cable with the loose core end toward the lug. Align the stress control assembly tube (not the core) with the step on the black semi-con portion of the insulation adapter tube assembly, and remove the core by pulling the loose end while unwinding counter-clockwise. Clean exposed cable insulation after installation. (Figure 26) Align with end of metallic shield Unwind counter-clockwise Cable Jacket Stress Control Assembly Figure Select one 2' x 11" (50 mm x 280 mm) hi-k mastic strip from the kit. Remove the liners and wrap around the end of the stress control assembly tube and cable insulation. Position the hi-k mastic so that half covers the stress control assembly tube, and half covers the cable insulation. (Figure 27) Stress Control Assembly Tube Cable Insulation Insulation Adapter Tube Assembly Figure C 17

18 10.6 Wrap two half-lapped layers of highly-tensioned Scotch Vinyl Electrical Tape Super 88 over the hi-k mastic, leaving approximately 0.125" (3 mm) of mastic exposed at each end. Taper the exposed edges of the hi-k mastic onto the cable by gently pressing along the edge with your finger. (Figure 28) 0.125" (3 mm) 0.125" (3 mm) Insulation Adapter Tube Assembly Stress Control Assembly Tube Taper Edge of Taper Edge of Cable Insulation Vinyl Tape 11.0 Install Lug or Connector Figure Check to be sure the cable fits within the kit ranges as shown in Table Position lug/connector and crimp according to manufacturer s directions. Remove excess oxide inhibitor and sharp crimp flashing following crimping Select one or more of the 2" x 11" (50 mm x 280 mm) hi-k mastic strips from the kit. Remove the liner and fold the mastic strip twice lengthwise to form a 0.5" (12 mm) wide strip. (Figure 29) Remove Liner Mastic Folded Over Twice Figure Wrap the mastic strip around the exposed conductor between the cable insulation and lug. Build the mastic up to the insulation O.D. (Figure 30) Doubled-Over Figure C

19 11.5 Apply additional wrap(s) of hi-k mastic (not folded) onto the insulation adapter tube assembly for 1" (25 mm) and taper the hi-k mastic 2" (50 mm) onto the lug barrel. (Figure 30) When using a tapered barrel lug, extend the hi-k mastic onto the barrel 2" (50 mm) past the tapered part of the barrel. (Figure 31) 1.0" (25 mm) 2.0" (50 mm) 1.0" (25 mm) 2.0" (50 mm) Insulation Adapter Tube Assembly Typical Lug Cable Insulation Insulation Adapter Tube Assembly Tapered Lug Cable Insulation Figure Select the roll of Scotch Silicone Rubber Tape 70 from the kit. Using moderate tension, wrap 2 half-lapped layers of tape over the hi-k mastic, leaving approximately 0.125" (3 mm) of mastic exposed at each end. Taper the exposed edges of the hi-k mastic onto the cable by gently pressing along the edge with your finger. (Figure 32) Insulation Adapter Tube Assembly 0.125" (3 mm) 0.125" (3 mm) Stress Control Assembly Tube Taper Edge of Taper Edge of Scotch Silicone Rubber Tape 70 Figure Apply 1 tube of 3M Red Compound P55/R (non-silicone grease) 2" (50 mm) over the lug seal area and onto the cable insulation for approximately 4 inches (100 mm). (Figure 33) Coat with 3M Red Compound P55/R Stress Control Assembly Tube Figure " (100 mm) 2.0" (50 mm) C 19

20 11.8 Select the silicone rubber lug seal insulator from the kit. Slide the lug seal insulator onto the cable insulation with the loose core end toward the cable insulation. Position the lug seal insulator tube (not the core) 2" (50 mm) onto the lug barrel. Remove the core by pulling the loose core end while unwinding counter-clockwise. (Figure 34) Unwind counter-clockwise 2.0" (50 mm) Stress Control Assembly Tube Silicone Rubber Lug Seal Insulator Lug Figure Apply 3 tubes of 3M Red Compound P55/R to the exposed cable insulation and hi-k stress control assembly tube. Fill the bottom edge of the silicone rubber lug seal the 3M Red Compound P55/R. Do not apply 3M Red Compound P55/R to the surface of the lug seal insulator tube. (Figure 35) Coat with 3M Red Compound P55/R Stress Control Assembly Tube Fill step with 3M Red Compound P55/R Lug Seal Assembly Tube DO NOT GREASE Figure C

21 11.10 Select the silicone insulator assembly (long tubular assembly) from the kit. Slide the silicone insulator assembly over the lug and cable with the loose core end toward the cable jacket. Overlap the lug seal insulator, and align the silicone insulator assembly tube (not the core) with the end of the lug seal. Remove the core by pulling the loose end while unwinding counter-clockwise. (Figure 36) Unwind counter-clockwise Align with end of lug seal insulator Ground Braids Silicone Insulator Assembly Tube Figure Clean the silicone insulator assembly tube with an approved cable cleaner and wipe dry Select the skirted insulator assembly from the kit. Carefully remove the red shipping core by pulling the loose end while unwinding counter-clockwise and discard. Slide the skirted insulator assembly over the lug and cable with the loose core end toward the cable jacket. Align the skirted insulator assembly tube (not the core) with the leading edge of the previously installed silicone insulator assembly tube. Remove the core by pulling the loose end while unwinding counter-clockwise. (Figure 37) Unwind counter-clockwise Align with end of Silicone Insulator Assembly Tube Ground Braids Skirted Insulator Assembly Tube Figure Connect the completed termination to equipment/system following standard practice Connect the ground braid to the ground system following standard practice C 21

22 3M, Scotch-Seal and Scotch 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. 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 consequential loss or damage arising from this 3M product, regardless of the legal theory asserted. 3 Electrical Markets Division 6801 River Place Blvd. Austin, TX Fax Please Recycle. Printed in USA. 3M All Rights Reserved C

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