3M Cold Shrink Skirted Termination Kit QT-III 7672-S-8-TS (RW) for Tape Shielded Cable Instructions Class 1 Termination IEC 60840 72,5 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 O.D. Range Jacket O.D. Range Conductor Size Range 7672-S-8 (RW) 1.44" 2.58" (36.6 65.5 mm) Table 1 1.95" 3.11" (49.5 79.0 mm) 250 1750 AWG (120 850 mm 2 ) October 2011 3 78-8131-7388-3-C
1.0 Kit Contents 1 Insulation Adapter Tube Assembly 1 Lug Seal Insulator Assembly 1 Hi-K Stress Control Assembly 1 Insulator Assembly 1 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 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. 2 78-8131-7388-3-C
2.0 Correct Installation of Termination Skirted Insulator Assembly A B C High-K Stress Control Mastic Semi-Con Insulation Shield Tubular Insulator High-K Stress Control Tube Lug Seal Tube A B C Semi-Con Insulation Shield High-K Stress Control Mastic High-K Stress Control Tube Tubular Insulator Skirted Insulator Assembly High-K Stress Control Mastic High-K Stress Control Tube Tubular Insulator Skirted Insulator Assembly *Shown without Insulation Adapter High-K Stress Control Mastic Lug Seal Tube Tubular Insulator 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. 78-8131-7388-3-C 3
3.0 Prepare Cable 3.1 Check to be sure the cable fits within the kit ranges as shown in Table 1. 3.2 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 250 350 400 650 750 1000 1100 2000 Growth Allowance 0.25" (6 mm) 0.5" (13 mm) 0.75" (19 mm) Field Determined Table 2 3.50" (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 Cable Jacket Tape Shield Semi-Con Insulation Conductor Figure 1 4 78-8131-7388-3-C
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) Solder Block Ground Braid Assembly Insulation Semi-Con Tape Shield Cable Jacket Edge Figure 2 4.2 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) Semi-con Constant Force Spring Cable Jacket Edge Solder Block Ground Braid Assembly Figure 3 78-8131-7388-3-C 5
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) 4.4 Secure 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 4) 6" (150 mm) (approx.) Solder Block 1st Mastic Strip (beneath solder blocks) Vinyl Tape Wrap Figure 4 Constant Force Springs 4.5 Cut four 1" (25 mm) lengths of 1" ( 25 mm) wide 3M Scotch-Seal Mastic Tape 2229. 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) Semi-con Solder Block 1st Mastic Strip (beneath solder blocks) Figure 6 6 78-8131-7388-3-C
4.6 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. (Figure 7) 2nd Mastic Strip (over solder blocks & mastic rolls) Semi-Con Figure 7 4.7 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 8) 2.25" (57 mm) Cable Jacket Vinyl Tape Semi-Con Figure 8 5.0 Clean 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. 78-8131-7388-3-C 7
6.0 Install Insulation Adapter 6.1 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 9) Semi-Con Figure 9 6.2 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 10) 0.125" (3 mm) 0.125" (3 mm) Semi-Con Taper Edge of Vinyl Tape Taper Edge of Figure 10 6.3 Coat the cable insulation and vinyl tape/hi-k sealing mastic using 3 tubes of 3M Red Compound P55/R (nonsilicone grease). (Figure 11) Coat with 3M Red Compound P55/R Figure 11 8 78-8131-7388-3-C
6.4 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 12) 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 12 Insulation Adapter Tube Assembly Cable Insulation 78-8131-7388-3-C 9
7.0 Install Termination 7.1 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 13) Pad Insulation Adapter Tube Assembly 1.0" (25 mm) 5.0" (127 mm) Pad (2 Layers) Taper Edge Figure 13 7.2 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 14) 0.125" (3 mm) 0.125" (3 mm) Insulation Adapter Tube Assembly Taper Edge of Vinyl Tape Figure 14 Taper Edge of 10 78-8131-7388-3-C
7.3 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 15) Insulation Adapter Semi-Con Step Coat with 3M Red Compound P55/R 5.0" (127 mm) Figure 15 7.4 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 16) Align with step in semi-con portion of insulation adapter tube Unwind counter-clockwise Cable Jacket Stress Control Assembly Figure 16 7.5 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 17) Stress Control Assembly Tube Figure 17 78-8131-7388-3-C 11
7.6 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 18) 0.125" (3 mm) 0.125" (3 mm) Stress Control Assembly Tube Taper Edge of Vinyl Tape Taper Edge of 8.0 Install Lug or Connector Figure 18 8.1 Check to be sure the cable fits within the kit ranges as shown in Table 1. 8.2 Position lug/connector and crimp according to manufacturer s directions. Remove excess oxide inhibitor and sharp crimp flashing following crimping. 8.3 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 19) Remove Liner Mastic Folded Over Twice Figure 19 8.4 Wrap the mastic strip around the exposed conductor between the cable insulation and lug. Build the mastic up to the insulation O.D. (Figure 20) Doubled-Over Figure 20 12 78-8131-7388-3-C
8.5 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 20) 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 21) 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 21 8.6 Select the roll of Scotch 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 22) Insulation Adapter Tube Assembly 0.125" (3 mm) 0.125" (3 mm) Stress Control Assembly Tube Taper Edge of Taper Edge of Scotch Tape 70 Figure 22 8.7 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 23) Coat with 3M Red Compound P55/R Stress Control Assembly Tube Figure 23 4.0" (100 mm) 2.0" (50 mm) 78-8131-7388-3-C 13
8.8 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 24) Unwind counter-clockwise 2.0" (50 mm) Stress Control Assembly Tube Lug Seal Insulator Lug Figure 24 8.9 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 P55/R Red Compound. Do not apply P55/R Red Compound to the surface of the lug seal insulator tube. (Figure 25) 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 25 14 78-8131-7388-3-C
8.10 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 26) Unwind counter-clockwise Align with end of lug seal insulator tube Ground Braids Silicone Insulator Assembly Tube Figure 26 8.11 Clean the silicone insulator assembly tube with an approved cable cleaner and wipe dry. 8.12 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 27) Unwind counter-clockwise Align with end of Silicone Insulator Assembly Tube Ground Braids Skirted Insulator Assembly Tube Figure 27 8.13 Connect the completed termination to equipment/system following standard practice. 8.14 Connect the ground braid to the ground system following standard practice. 78-8131-7388-3-C 15
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