3M™ Cold Shrink QS-III Splicing Kit 5776A-MT

Cable Range Requirements

Kit Number: 5776A-MT

Cable Insulation O.D. Range: 0.84" to 1.38" (21,3 mm to 35,1 mm)

Conductor Size Range: 4/0 AWG - 500 kcmil* (95 - 240 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

⚠️ 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.

1.0 Kit Contents

• 3M™ Cold Shrink QS-III Splice Kit 5416A Silicone Rubber Splice Bodies
• Tubes, 3M™ Red Compound P55/R
• Metallic Shield Sleeves
• Constant Force Spring Shield Connectors (0.87" I.D.)
• Armor to Armor Continuity Braid
• Constant Force Spring Braid Connectors (1.54" I.D.)
• Cold Shrink Jacket Tubes
• 3M™ Cable Preparation Kit CC-2
• Roll, Scotch® Super 33+ Vinyl Electrical Tape (3/4" x 76')
• Rolls, Scotch® Vinyl Electrical Tape Super 88 (1 1/2" x 44')
• Rolls, 3M™ Scotch-Seal™ Mastic Tape 2229 (3 3/4" x 10')
• Roll, Scotch® Electrical Shielding Tape 24 (1" x 15')
• Roll, Scotch® Rubber Mastic Tape 2228 (2" x 10')
• Rolls, 3M™ Sheath Wrap (4" x 15')
• Instruction Sheet
• Cold Shrink Adapter Tubes
• Copper Foil Tape (1/2" x 10")
• Gloves

2.0 Prepare Cable

2.1 Prepare the cable

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

Remove 27 1/2" (699 mm) of cable jacket from Cable X, plus half of the overlap. Remove 22 1/2" (572 mm) of cable jacket from Cable Y, plus half of the overlap.

Keep a 17" (432 mm) piece of cable jacket removed from Cable X and a 12" (305 mm) piece of jacket from Cable Y for later use.

[Diagram Description: Shows Cable X with 27 1/2" (699 mm) jacket removed and Cable Y with 22 1/2" (572 mm) jacket removed.]

2.2 Armor and Binder Preparation

If cable is armored, remove cable armor leaving 1 1/2" (38,1 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 the 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® Super 33+ Vinyl Tape.

[Diagram Description: Shows cable end with binder removed, fillers and ground wires folded back and secured with tape.]

2.3 Cut Phase Conductors

Cut the phase conductors to the appropriate length.

Conductors of Cable X should be 27 1/2" (699 mm) from the cable jacket end or 26" (660 mm) from the armor end. Conductors of Cable Y should be 22 1/2" (572 mm) from the cable jacket end or 21" (533 mm) from the armor end.

[Diagram Description: Shows conductor lengths for Cable X (27 1/2" / 699 mm) and Cable Y (22 1/2" / 572 mm).]

2.4 Bind Metallic Shields

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 the copper tape binding.

If conductors are individually jacketed, remove the individual jackets a distance of 13 1/4" (337 mm) from the end of each conductor.

[Diagram Description: Shows copper tape strips binding metallic shields at 10 1/4" (260 mm) from conductor end.]

2.5 Remove Semi-Conductive Insulation Shields

Remove cable semi-conductive insulation shields from conductors of both Cable X and Cable Y a distance of 7 1/4" (184 mm) from the end of each conductor.

Note: Cables must be within Insulation OD Range of splice kit.

[Diagram Description: Shows removal of semi-conductive insulation shields to 7 1/4" (184 mm) from conductor end.]

2.6 Remove Cable Insulation

Remove cable insulation from conductor ends of both Cable X and Cable Y. Remove insulation for 1/2 connector length plus an allowance for increases in connector length due to crimping. Insulation removal length shall not exceed 2 7/8" (73 mm) from conductor end. Do not install connectors now.

Note: This assumes that the installer has determined the increased length of an aluminum connector crimped with a specific tool and die.

Notes: 1) Copper connectors do not require a length change allowance. 2) Maximum aluminum connector crimped length allowed is 5.75" (461 mm).

[Diagram Description: Shows conductor ends with insulation removed, indicating "field determine" for length.]

3.0 Place Components on Cable

3.1 Install Jacket Tubes

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.

[Diagram Description: Shows a large cold shrink jacket tube with its loose core ribbon end.]

3.2 Install Splice Bodies

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 the cable end.

[Diagram Description: Shows a cold shrink splice body with its loose core ribbon end.]

3.3 Install Shield Sleeves

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.

[Diagram Description: Shows shield sleeves installed on conductors.]

3.4 Install Adapter Tubes (for 4/0 AWG through 350 kcmil copper connectors or connectors with O.D. 0.69 - 0.84")

Slide a cold shrink adapter tube onto each conductor of Cable Y with the loose core ribbon end going on first, away from the cable end.

[Diagram Description: Shows a cold shrink adapter tube on a conductor.]

4.0 Install Splice

4.1 Install Connectors

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

4.2 Apply Tape Marker

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 9" (229 mm) measured from the CENTER of connectors.

[Diagram Description: Shows a tape marker applied at 9" (229 mm) from the connector center.]

4.3 Shrink Adapter Tube

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

4.4 Clean Connector Ends

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.

4.5 Apply Red Compound

Apply 3M™ Red Compound P55/R on cable insulation, making certain to fill in the edges of the cable semi-con.

Note: DO NOT use silicone grease.

[Diagram Description: Shows application of 3M™ Red Compound P55/R.]

4.6 Install Splice Body

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 counter-clockwise 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.

[Diagram Description: Shows splice body aligned to marker tape.]

4.7 Center and Secure Shield Sleeves

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

[Diagram Description: Shows Scotch® Super 33+ Vinyl Tape securing shield sleeves.]

4.8 Connect Sleeve Ends

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.

[Diagram Description: Shows constant force spring installation and trimming excess sleeve.]

4.9 Connect Ground Wires

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

[Diagram Description: Shows connected ground wires.]

4.10 Reestablish Cable Fillers

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.

[Diagram Description: Shows cable fillers secured with Scotch® Super 33+ Vinyl Tape.]

5.0 Install Armor Continuity (If Cable is Armored)

5.1 Apply Shielding Tape to Armor

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.

[Diagram Description: Shows Scotch® Electrical Shielding Tape 24 applied to armor.]

5.2 Wrap Ground Continuity Braid

Wrap an end of the ground continuity braid around exposed armor and applied Scotch® Electrical Shielding 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+ Vinyl Tape.

[Diagram Description: Shows constant force spring installed over braid.]

6.0 Install Splice Jacket

6.1 Overwrap with Jacket Pieces

Overwrap the exposed conductors on each side of splice bodies with jacket pieces saved from step 2.1. Bind the cable jacket pieces in place with one half-lapped layer of Scotch® Vinyl Electrical Tape Super 88 1 1/2" wide tape.

[Diagram Description: Shows jacket piece overwrapped with vinyl tape.]

6.2 Apply Rubber Mastic Tape

At both ends of splice, apply four wraps of Scotch® Rubber Mastic Tape 2228, around the cable jacket 1/2" from jacket ends. Stretch the rubber mastic to three-fourth original width when applying.

[Diagram Description: Shows application of Scotch® Rubber Mastic Tape 2228.]

6.3 Install Cold Shrink Jacket Tubes

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 counter-clockwise direction to install jacket tubes.

[Diagram Description: Shows cold shrink jacket tube installation.]

6.4 Apply Vinyl Tape in Splice Center

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

[Diagram Description: Shows Scotch® Vinyl Electrical Tape Super 88 applied in splice center.]

6.5 Apply Mastic Tape

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).

[Diagram Description: Shows application of 3M™ Scotch-Seal™ Mastic Tape 2229.]

6.6 Cover with Vinyl Tape

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

[Diagram Description: Shows Scotch® Vinyl Electrical Tape Super 88 covering mastic tape.]

6.7 Overwrap with Sheath Wrap

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 dye 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.

[Diagram Description: Shows 3M™ Sheath Wrap application.]

6.8 Splice is Complete

Splice is complete.

[Diagram Description: Shows the completed splice.]

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

*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.

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