3M Scotchcast Reenterable Signal and Control Cable Splicing Kits 78-R Series Instructions Voltage Rating: 1000 V, Temperature Rating: 90 C Kit Contents 78-R1 78-R2 78-R3 78-R4 78-R5 Sleeve Set 1 1 1 1 1 End Cap 2 2 2 2 2 Cap, Snap In 1 2 2 2 2 Strain Bar 1 1 2 2 2 Spacer Tube 1 1 2 2 2 Scotch Linerless Rubber Splicing Tape 130C 2 2 3 3 3 Shield Connector Kit 4 4 4 4 4 Hose Clamp 1 1/4" 2 2 Hose Clamp 1 3/4" 2 2 4 Hose Clamp 2 3/4" 4 4 Hose Clamp 3 1/4" 2 3 Hose Clamp 4 1/2" 3 Hose Clamp 5 1/3" 3 Hose Clamp 6 1/2" 3 Abrasive Cloth 1 1 1 1 1 3M Scotchcast Re-enterable Electrical Insulating Resin 2123 (C) / (D) 1 C / 1 D 1 C / 2 D 5 D 1C / 8 D 15 D Funnel 5" 1 1 1 Instruction Sheet 1 1 1 1 1 3M Scotchast Reenterable Signal and Control Cable Splicing Kits 78-R Series 78-R1 78-R2 78-R3 78-R4 78-R5 NUMBER OF PAGES: 6 Issue Date: 4/21/16 Scale: Not To Scale Revision C 78-8126-6770-3
Kit Selection Table 3M Scotchlok Connectors Cable Diameter Insulated Butt Connectors 18 22 AWG 14 16 AWG 10 12 AWG MV18BC MN18BC MV14BC MN14BC MV10BC MN10BC Kit No. Run Tap No. Cond. No. Pairs No. Cond. No. Pairs No. Cond. No. Pairs 78-R1 40 20 26 13 16 8 78-R2 66 33 45 22 26 13 78-R3 0.50" 1.50" (12,7 38,1 mm) 0.50" 1.00" (12,7 25,4 mm) 160 80 110 55 70 35 78-R4 0.50" 2.00" (12,7 50,8 mm) 0.50" 1.75" (12,7 44,4 mm) 300 150 180 90 110 55 78-R5 550 275 320 160 200 100 Pigtail Connectors Cable Diameter 6 10 AWG 8 18 AWG 12 22 AWG B/G R/Y O/B Kit No. Run Tap No. Cond. No. Pairs No. Cond. No. Pairs No. Cond. No. Pairs 78-R1 8 4 5 2 15 7 78-R2 20 10 10 5 30 15 78-R3 0.50" 1.50" (12,7 38,1 mm) 0.50" 1.00" (12,7 25,4 mm) 50 25 28 14 80 40 78-R4 0.50" 2.00" (12,7 50,8 mm) 0.50" 1.75" (12,7 44,4 mm) 84 42 60 30 142 71 78-R5 174 87 120 60 260 130 Tap (IDC) Connectors Cable Diameter 16 22 AWG 14 18 AWG 10 12 AWG 558 560 562 Kit No. Run Tap No. Cond. No. Pairs No. Cond. No. Pairs No. Cond. No. Pairs 78-R1 10 5 8 4 6 3 78-R2 20 10 16 8 12 6 78-R3 0.50" 1.50" (12,7 38,1 mm) 0.50" 1.00" (12,7 25,4 mm) 50 25 40 20 36 18 78-R4 0.50" 2.00" (12,7 50,8 mm) 0.50" 1.75" (12,7 44,4 mm) 100 50 80 40 68 34 78-R5 200 100 160 80 130 65 Table 1 Note: Above figures based on IMSA Cable Specifications. 2
Scotch Linerless Rubber Splicing Tape 130C End Cap Fill Port Strain Bar Snap-In-Cap Spacer Web Hose Clamp Splice Body Connectors Shield Connector Optional Jumper Not Supplied CABLE SPLICING A. Prepare End Caps 1. FOR CUT CABLES: trim end caps to appropriate diameter and slide onto cables (Figure 1). Inline Splice Using 3M Scotchlok Connectors: MU18BC, MN18BC, MN14BC, 557 MU14BC, MN10BC, MU10BC Scotch Linerless Rubber Splicing Tape 130C Figure 3 Cut Here Figure 1 2. FOR UNCUT CABLES (Figure 2): a. Slit end cap lengthwise. b. Flex cap over cable (a). c. Close seam with Scotch Linerless Rubber Splicing Tape 130C (b). d. Wrap front edge with 130C tape (c). Y Tap Splice Using 3M Scotchlok Connectors: 558, 560, 562 Figure 4 (a) Y Splice Using 3M Scotchlok Connectors: O/B, R/Y (b) (c) Kit No. Figure 2 B. Prepare Cable(s) 1. Train cable(s) in position for a splice opening of Dimension A. Remove cable jacket(s) for A. (Table 1 and Figure 3, 4, 5, or 6 of appropriate splice configuration.) Dimension A 78-R1 5 78-R2, 78-R3, 78-R4 17 78-R5 19 Table 1 X Splice Figure 5 Using 3M Scotchlok Connectors: O/B, R/Y Figure 6 3
2. Thoroughly scuff cable outer jackets for 63 with abrasive cloth provided to remove all dirt, wax, and extrusion marks (Figures 3 6). 3. Cable cutback a. SHIELDED CABLE: cut shield flush with cable jacket. Remove core wrapper, leaving 3/4 exposed beyond jacket (Figure 7). b. DOUBLE-JACKETED CABLE: remove shield flush with outer jacket. Remove inner jacket, leaving 1 1/2 exposed. Thoroughly scuff inner jacket with abrasive provided (Figure 7). Outer Jacket Fore Core Wrapper For Inner Jacket Figure 7 Core Wrapper Or Inner Jacket 3/4" 1 1/2" c. NON-SHIELDED CABLE: remove core wrapper flush with cable jacket. 4. Remove all filler materials. 5. Securely anchor cables into position to maintain Dimension A between cable jackets (Figure 3-6). b. KITS 78-R3, 78-R4, AND 78-R5: Y splice - install 1 each 4460-S on 2 adjacent cables and 2 each on opposite cable, 180 apart (Figure 10) REFER TO STEP D.3. Figure 10 X splice - install 1 each 4460-S on each cable REFER TO STEP D.3. 3. Install Scotchlok shield connector 4460-S a. Insert Plastic Shoe between shield and core wrapper (or inner jacket) until stops meet outer jacket. The Plastic Shoe can be easily inserted by gripping back end with pliers (Figure 11). (Not Included) Lock Nuts Top Optional Jumper Strain Bar Strain Bar Stud Insulation Install Connectors 1. Connector selection based on appropriate splice configuration (Figures 3 6). 2. Plan positioning of connectors for desired bundle. a. Observe color coding and select a center conductor from each cable. Hose Clamp Base Cable Jacket Shield Figure 11 Plastic Insert Shoe Core Wrapper Or Inner Jacket b. Cut to length and install connector(s). c. Continue connecting conductors, staggering individually or in pairs, as applicable (Figure 8). Figure 8 Shielded Cable Only 1. INLINE SPLICE (Figure 3) a. KITS 78-R1 and 78-R2: install 1 each 3M Shield Connector 4460-S on each cable REFER TO STEP D.3. b. KITS 78-R3, 78-R4, and 78-R5: install 2 each 4460-S shield connectors on each cable, 180 apart (Figure 9) REFER TO STEP D.3. NOTE: On smaller cables (13 O.D. and less), cut a 13 long slit in jacket opposite connector location to aid insertion of plastic shoe. b. Insert Base of connector between shield and Plastic Shoe. Tap cable jacket firmly over Base several times to drive teeth into shield (Figure 11). c. Install 4460-S Top, without nut, on stud of shield connector Base (Figure 11). d. Place Strain Bar Insulation on bar. Trim to length if necessary to clear mounting holes (Figure 11). e. Install Strain Bar and Lock Nuts; clamp to jacket with Hose Clamps supplied (Figures 11, 12, and 13). f. Attach any optional jumpers (not supplied) using second locknut where required (Figures 11, 12, and 13). 78-R1, 78-R2 78-R3, 78-R4, 78-R5 Figure 9 2. Y AND X SPLICES (Figures 4 6) a. KITS 78-R1 and 78-R2: install 1 each 4460-S shield connector on each cable REFER TO STEP D.3. Optional Jumper (Nor Supplied) Figure 12 Figure 13 4
E. Non-Shielded Cable Only 1. Place Strain Bar Insulation on bar(s). 2. Clamp bar(s) to cable jackets with hose clamps supplied (Figure 13). NOTE: Refer to Figures 12 and 13 for typical installations. F. Install Seals and Splice Body 1. Build sealing collars just beyond the ends of the Strain Bars. Each collar consists of 4 laps of highly elongated Scotch Linerless Rubber Splicing Tape 130C, stretched to 1/2 original width (Figure 14). Scotch Linerless Rubber Splicing Tape 130C Figure 14 2. For double-jacketed cable, scuff inner jacket with abrasive provided and install additional collars on inner jackets (Figure 15). G. Pour Compound 1. Slightly incline Splice Body 1/23 on one end. Support Splice Body not cable. 1/2 Figure 17 2. Kits 78-R3, 78-R4, and 78-R5: insert Funnel into fill port on lower end of Splice Body (Figure 17). 3. Mix Compound according to instructions on container. 4. Fill splice with Compound; continue pouring until Splice Body is completely filled. Close fill ports with Snap-in Cap(s) (Figure 18). H. Position Splice 1. Immediately position splice in its final mounting arrangement: either direct buried or on support arms (Figure 18). NOTE: Locate support arms under splice near center and ends, and band or tie into place (center support not necessary for 78-R1) (Figure 18) Scotch Linerless Rubber Splicing Tape 130C Figure 15 NOTE: Sealing Collars must be within area to be covered by Splice Body. 3. Install Splice Mold Body a. Center lower Splice Body half (with Spacer Web) on splice bundle; attach upper half (with fill ports) matching tongue and groove (Figure 16). Figure 16 b. Place one large hose clamp around center of Splice Body and moderately tighten, except on Kit 78-R1 where no center clamp is provided for. c. Slide End Caps over splice ends, setting them firmly in grooves. d. Fasten End Caps to Splice Body with large hose clamps and moderately tighten. NOTE: Refer to Figure 2 for field split end caps. e. Wrap cable exit from End Cap with 4 laps of highly elongated Scotch Linerless Rubber Splicing Tape 130C to seal. Tie Or Band Figure 18 2. Splice may be immediately energized (while compound is curing. II. SPLICE RE-ENTRY A. Remove Splice Body and Compound 1. Remove hose clamps from Splice Body and End Caps; remove Scotch Linerless Rubber Splicing Tape 130C used to seal the end cap ports to the cable jackets. 2. Slide End Caps from Splice Body. 3. Part Splice Body halves by slowly pulling apart at one end with even pressure (Figure 19). Figure 19 4. Remove Spacer Web from splice and discard. Note: DO NOT REUSE SPACER WEB. 5. Remove as much compound as possible. 5
B. Perform Splicing Work Required C. Splice Re-Encapsulation 1. Spirally wrap new Spacer Web 7820 around splice bundle, leaving gaps at the fill port locations (for faster compound penetration); DO NOT overlap web (Figure 20). Figure 20 2. Reassemble Splice Body according to procedures outlined in I. CABLE SPLICING. End Caps and Splice Body can be reused. NOTE: Be sure that new spacer web does not block fill ports. 3. Fill Splice Body with new 3M Scotchcast Reenterable Electrical Insulating Resin 2123 as outlined in Pour Compound procedure. NOTE: THIS PROCEDURE DOES NOT INCLUDE THE 12 INCH 78-R1 KIT. A. Position Splice Body as shown in Figure 22 with a hose clamp. Saw the splice body top (with fill ports) in half at the center cut mark provided. Use opposite splice body half as a guide for cutting (Figure 22). NOTE: New compound will bond to old compound left in splice. SPLICE EXTENSION (For Extended Jacket Opening) BY CUTTING ONE ADDITIONAL SPLICE BODY IN HALF, ANY DESIRED LENGTH MAY BE OBTAINED BY ADDING STANDARD SECTIONS STAGGERED IN SERIES (BRICK-LAYING EFFECT). REMAINING SPLICE BODY HALF MAY BE SAVED FOR FUTURE USE (Figure 21). 1/2 Closure Length Figure 22 B. Assemble the splice by staggering the 2 cut sections with standard splice body sections, as required for desired length. Tape seams with Scotch Linerless Rubber Splicing Tape 130C (Figure 23). Complete splicing according to produce outlined in I. CABLE SPLICING. Figure 22 3M, Scotch, Scotchast and Scotchlok are trademarks of 3M Company. Important Notice Warranty; Limited Remedy; Limited Liability 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. 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. Electrical Markets Division 6801 River Place Blvd. Austin, TX 78726-9000 800.245.3573 FAX: 800.245.0329 www.3m.com/electrical Please recycle 3M 2016 All rights reserved 78-8126-6770-3 Rev C 6