3M Cold Shrink QS-III Silicone Rubber Splice Kit 5488A-TOW/WOT

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3M Cold Shrink QS-III Silicone Rubber Splice Kit 5488A-TOW/WOT For Tape Over Wire (TOW) and Wire-Over-Tape (WOT) Shielded Cable For 250 2000 kcmil cable with 650-mil primary insulation thickness Instructions IEEE Std. No. 404 69kV Class 350 kv BIL IEC 60840 72kV Class 325kV BIL F 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 5488A Primary Insulation O.D. Range 1.94 3.08" (49,3 75,4 mm) Table 1 Conductor Size Range 250 2000 kcmil (125 1000 mm 2 ) May 2013 3 78-8131-7604-3 Rev B

Kit Contents 1 Silicone Rubber Splice Body 2 Jacketing Tubes 1 Shielding Sleeve, 7' 1 Pre-formed Ground Braid Assembly 7 Constant Force Springs 6 3M Red Compound P55/R Tubes (non-silicone grease) 2 Rolls 3M Scotch-Seal Mastic Tape 2229, 1" x 3.5' 4 Rolls Scotch Rubber Mastic Tape 2228, 2" x 36" 1 Roll Scotch Electrical Shielding Tape 24, 1" x 15' 1 Pad Scotch Electrical Semi-conducting Tape 13, 18" x 35" 2 Rolls Scotch Vinyl Electrical Tape Super 88, 1½" x 44' 4 3M Cable Cleaning Pads CC-3 4 3M EMI Copper Foil Shielding Tape Strips 1811, 15" long 4 Rolls 3M Armorcast Structural Material 4560, 3" x 15' 1 Connector 1 Connector, Foil Pad 1 Connector, Instruction Sheet 3 Splice Instruction Booklets Note: Utility Colth (Aluminum Oxide) abrasive materials are required for cable preparation, but are NOT INCLUDED IN KIT. Required grits are P180, P240 and P320. Available 3M Utility Colth (Aluminum Oxide) Rolls UPC Codes are: P180: 51115-19788 P240: 51115-19786 P320: 51115-19784 Note: Do not use knives to open plastic bags. 2 78-8131-7604-3 Rev B

1.0 Prepare Cable I. Tape Over Wire Shield Cable 1.1 Check to be sure the cable fits within the kit ranges as shown in Table 1. 1.2 Prepare cables according to standard procedures. Refer to Figure 1 for proper dimensions. Copper foil tape strips are included to secure and cover the ends of the tape/lc shield. Approximately 30" (760 mm) additional distance is required on one cable to provide extra neutral wire length for connecting the neutrals. 1.3 Remove cable insulation for [B]. Insulation removal length shall not exceed 4 ½" (114 mm) from conductor end. Do not install connector now. 5.0" (127 mm) 5.0" (127 mm) [A] [B] Semi-Con Insulation Conductor Cable Jacket Corrugated Tape Shield Shield Wires Allow for extra neutral wire length Figure 1 Conductor Size Kcmil (mm 2 ) 250 600 (125 325) 700 1000 (400 500) 1100 1500 (600 800) 1600 2000 (850 1000) * Insulation OD is the final determining factor Primary Insulation O.D.* Inches (mm) 1.94 2.24 (49.3-56.9) 2.25 2.60 (57.0 66.0) 2.61 2.85 (66.1 72.4) 2.86 3.08 (72.5 75.4) Semi-con Cutback [A] Inches (cm) Insulation Cutback [B] Inches (mm) 13 ½ (34.3) 4 13 ¼ (102) (33.7) 13 (33.0) 4 ½ 12 ¾ (114) (32.4) 1.4 Clean or cover the cable jackets if necessary, 36" (915 mm) from the cable jacket cutback. 78-8131-7604-3 Rev B 3

2.0 Install Ground Braid Assembly (Optional) Note: If not grounding at this splice location, continue at step 3.0. 2.1 (Corrugated shielded cable only.) Fill the valleys on the corrugated shield with several wraps of Scotch Electrical Shielding Tape 24. Half-hitch to tie off. Repeat for both cables. (Figure 2) Scotch Electrical Shielding Tape 24 Corrugated Shield Figure 2 2.2 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 or corrugated shield and Scotch Electrical Shielding Tape 24 tape as shown. (Figure 3) Semi-Con Insulation Solder Block Ground Braid Assembly Corrugated Shield or Tape Shield Cable Jacket Edge Shield Wires Figure 3 4 78-8131-7604-3 Rev B

2.3 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 4) Semi-con Cable Insulation Constant Force Spring Cable Jacket Edge Solder Block Ground Braid Assembly Figure 4 2.4 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 5) 2.5 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 5) 6" (150 mm) (approx.) Solder Block 1st Mastic Strip (beneath solder blocks) Vinyl Tape Wrap Constant Force Springs Figure 5 78-8131-7604-3 Rev B 5

2.6 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 6) Press the mastic rolls into place on either side of the ground braid solder blocks. (Figure 7) 1" (25 mm) Mastic Strip Mastic Rolled-Up Figure 6 Rolled Mastic (x4) Semi-con Cable Insulation Solder Block 1st Mastic Strip (beneath solder blocks) Figure 7 2.7 Select the roll of 1" (25 mm) 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 8) 2nd Mastic Strip (over solder blocks & mastic rolls) Figure 8 6 78-8131-7604-3 Rev B

2.8 Cover springs and mastic seal with two half-lapped layers of stretched vinyl tape. Do not cover exposed cable shield. (Figure 9) Vinyl tape Do not cover Figure 9 3.0 Park Splice Components 3.1 Carefully bend the neutral wires back over the edge of the corrugated shield and cable jacket. Keep wire profile low; do not fold wires square back but follow concentric turn of the cable and turn the wires in that direction. Press the wires against the cable jacket and secure the ends with vinyl tape. Repeat for both cables (Figure 10). Secure with vinyl tape Figure 10 78-8131-7604-3 Rev B 7

3.2 Slide the jacketing tubes onto one cable end (small tube inside larger tube with loose core ends opposite each other) (Figure 11). Slide splice body onto the opposite cable, loose core end first (Figure 12). Loose Core End Large Jacketing Tube Loose Core End Small Jacketing Tube Figure 11 Loose Core End Splice Body Figure 12 8 78-8131-7604-3 Rev B

3.3 Slide expanded shield sleeve over the splice body onto the cable (Figure 13). Expanded Shield Sleeve Splice Body Figure 13 4.0 Install Connector 4.1 Install connector according to connector instructions included with the connector. Shear bolt 5.0 Install Splice Connector Figure 14 5.1 Apply tape marker to semi-con insulation shield 1¾" (45 mm) from the cut back edge of the cable semi-con on the cable which does not contain splice (Figure 15). 1¾" (45 mm) Tape marker Corrugated Shield Foil Pad Figure 15 78-8131-7604-3 Rev B 9

5.2 Clean cables using standard practice: a. Do not allow solvent or abrasive to contact the cable semi-conductive insulation shield. b. Do not reduce cable insulation diameter below 1.94" (49,3 mm) specified for the splice. c. The insulation surface must be round, smooth and free of cuts/voids. Finish sanding must be done with a 300 grit or higher electrical grade abrasive. d. Make certain that the cable insulation is smooth, clean and dry before continuing. 5.3 Apply 3M Red Compound P55/R on cable insulations, making certain to fill in edge of cable semi-con. Do not use silicone grease (Figure 16). Fill semi-con step Fill semi-con step 3M Red Compound P55/R 3M Red Compound P55/R Figure 16 5.4 Position the splice body over connector area, aligning end of the splice body (not the core) at the center of the tape marker. Slowly start to remove the splice core by pulling and unwinding the loose core end counterclockwise, allowing only ¼" (6 mm) of the splice to shrink onto the tape marker. Carefully slide the splice body off the tape marker by pulling and twisting until the entire tape marker is exposed. Continue removing the core to complete the splice body installation (Figure 17). Unwind Counter-clockwise Align splice with tape marker Splice body Figure 17 10 78-8131-7604-3 Rev B

6.0 Connect the Wires and Corrugated/Tape Shields 6.1 Wrap the Scotch Electrical Semi-conducting Tape 13, 18" x 36" Pad over the shield sleeve (36" length following the cable), centered over the splice body. The pad can be trimmed to fit between the metallic shields. Secure with four bands of vinyl tape (Figure 18). Do not cover the entire pad with vinyl tape. Semi-Con Pad Secure with vinyl tape Figure 18 6.2 Take the temporary tape off neutral wires. Do not twist wires in to a single bundle. 6.3 Route the longer neutral wires straight across the previously installed pad. Secure to pad, over the splice body, with a band of vinyl tape (Figure 19). Long Neutral Wires Figure 19 6.4 Connect the longer neutral wires to the shorter wires using multiple connectors (3 or more). This is done to avoid damage to the splice body shoulders and end seals caused by large diameter wire/connectors being pressed in to them (Figure 20). Neutral Wire Connector (6 total; 3 on opposite side) Figure 20 78-8131-7604-3 Rev B 11

6.5 Cover the connectors with two half-lapped layers of vinyl tape (Figure 21). 2 half-lapped layers vinyl tape Figure 21 6.6 Center the expanded shield sleeve over the semi-con pad (Figure 22). Center expanded shield sleeve over semi-con pad Figure 22 6.7 Hand tighten the sleeve outward while keeping it centered over the semi-con pad. Secure the centered shield sleeve to the cable metallic shield on both sides using two constant force springs on each end. Trim excess shield sleeve. (Figure 23). Secure with 2 constant force springs Trim excess shield sleeve Figure 23 12 78-8131-7604-3 Rev B

6.8 Wrap two half-lapped layers of highly-tensioned Scotch Vinyl Electrical Tape Super 88 over the constant force springs (Figure 24). Vinyl Tape Vinyl Tape Figure 24 7.0 Install Jacket Note: Jacketing is not optional. 7.1 Wrap a roll of slightly stretched Scotch Rubber Mastic Tape 2228, 2" x 36" around cable jacket ends (tacky side toward cable) (Figure 25). Stretch and tear off last 1 2" (25 50 mm) of mastic (Figure 26). If grounding was applied, apply tape centered over 3M Scotch-Seal Mastic Tape 2229. 2" rubber mastic 2" rubber mastic Figure 25 Stretch and tear off last 1 2" (25 50 mm) of rubber mastic Figure 26 78-8131-7604-3 Rev B 13

7.2 Install the smaller cold shrink tube by covering the rubber mastic, overlapping the cable jacket approximately 1/4 1/2" (6 12 mm), and unwinding toward the splice body, slowly pulling and unwinding the core counterclockwise (Figure 27). Unwind Counter-clockwise approx. 1/4 1/2" (6 12 mm) Figure 27 Jacketing tube 7.3 Wrap a single wrap of 3M Scotch-Seal Mastic Tape 2229, 1" x 10' around the smaller cold shrink tube ¼" from the end (over the splice body). Completely cover the sealing mastic with a wrap of vinyl tape (Figure 28). 1/4" (6 mm) 1" Mastic seal covered with vinyl tape Figure 28 14 78-8131-7604-3 Rev B

7.4 Install the larger cold shrink tube over the rubber mastic on the other cable in the same manner (Figure 29). Unwind Counter-clockwise Figure 29 Jacketing tube 7.5 Using the four rolls of 3M Armorcast Structural Material provided, wrap half-lapped layers over the entire splice extending 3" (76 mm) onto the cable jacket. Bind the final wrap in place with vinyl tape (Figure 300). Tear open the top end of the foil armorcast material 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. Note: Wear rubber gloves provided when handling armorcast material. The resin contains a black dye that will stain human skin. Armorcast 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. 3" (76 mm) 3" (76 mm) 4 rolls 3M Armorcast Structural Material Figure 30 7.6 Connect optional grounding. 78-8131-7604-3 Rev B 15

8.0 Prepare Cable II. Wire Over Tape Shield Cable 8.1 Check to be sure the cable fits within the kit ranges as shown in Table 1. 8.2 Prepare cables according to standard procedures. Refer to Figure 31 for proper dimensions. Copper foil tape strips are included to secure and cover the ends of the tape shield. Approximately 30" (760 mm) additional distance is required on one cable to provide extra neutral wire length for connecting the neutrals. 8.3 Remove cable insulation for [B]. Insulation removal length shall not exceed 4 ½" (114 mm) from conductor end. Do not install connector now. 5.0" (127 mm) 5.0" (127 mm) [A] [B] Semi-Con Insulation Conductor Cable Jacket Tape Shield Shield Wires Allow for extra neutral wire length Figure 31 Conductor Size Kcmil (mm 2 ) 250 600 (125 325) 700 1000 (400 500) 1100 1500 (600 800) 1600 2000 (850 1000) * Insulation OD is the final determining factor Primary Insulation O.D.* Inches (mm) 1.94 2.24 (49.3-56.9) 2.25 2.60 (57.0 66.0) 2.61 2.85 (66.1 72.4) 2.86 3.08 (72.5 75.4) Semi-con Cutback [A] Inches (cm) Insulation Cutback [B] Inches (mm) 13 ½ (34.3) 4 13 ¼ (102) (33.7) 13 (33.0) 4 ½ 12 ¾ (114) (32.4) 8.4 Clean or cover the cable jackets if necessary, 36" (915 mm) from the cable jacket cutback. 16 78-8131-7604-3 Rev B

9.0 Install Ground Braid Assembly (Optional) Note: If not grounding at this splice location, continue at step 10.0 Park Splice Componets. 9.1 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 32) Semi-Con Insulation Shield Wires Solder Block Ground Braid Assembly Tape Shield Cable Jacket Edge Figure 32 9.2 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 33) Constant Force Spring Cable Jacket Edge Solder Block Ground Braid Assembly Figure 33 78-8131-7604-3 Rev B 17

9.3 Bend shield wires up, away from cable jacket, spacing them evenly around the ground braid tails. (Figure 34) Shield Wires Figure 34 9.4 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 35) 9.5 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 35) 6" (150 mm) (approx.) Vinyl Tape Wrap Solder Block 1st Mastic Strip (beneath solder blocks) Shield Wires Figure 35 18 78-8131-7604-3 Rev B

9.6 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 36) Press the mastic rolls into place on either side of the ground braid solder blocks. (Figure 37) 1" (25 mm) Mastic Strip Mastic Rolled-Up Figure 36 Rolled Mastic (x4) Solder Block 1st Mastic Strip (beneath solder blocks) Figure 37 9.7 Select the roll of 1" (25 mm) wide 3M Scotch-Seal Mastic Tape 2229 from the kit. 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 38) 2nd Mastic Strip (over solder blocks & mastic rolls) Figure 38 78-8131-7604-3 Rev B 19

9.8 Cover springs and mastic seal with two half-lapped layers of stretched vinyl tape. Do not cover shield wires or exposed cable shield. (Figure 39) Vinyl tape Vinyl tape Do not cover 10.0 Park Splice Components Figure 39 10.1 Carefully bend the neutral wires back over the edge of the cable jacket. Keep wire profile low; do not fold wires square back but follow concentric turn of the cable and turn the wires in that direction. Press the wires against the cable jacket and secure the ends with vinyl tape. Repeat for both cables (Figure 40). Secure with vinyl tape Figure 40 20 78-8131-7604-3 Rev B

10.2 Slide the jacketing tubes onto one cable end (small tube inside larger tube with loose core ends opposite each other) (Figure 41). Slide splice body onto the opposite cable, loose core end first (Figure 42). Loose Core End Large Jacketing Tube Loose Core End Small Jacketing Tube Figure 41 Loose Core End Splice Body Figure 42 78-8131-7604-3 Rev B 21

10.3 Slide expanded shield sleeve over the splice body onto the cable (Figure 43). Expanded Shield Sleeve Splice Body Figure 43 11.0 Install Connector 11.1 Install connector according to instructions included with the connector. Shear bolt 12.0 Install Splice Connector Figure 44 12.1 Apply tape marker to semi-con insulation shield 1¾" (45 mm) from the cut back edge of the cable semi-con on the cable which does not contain splice (Figure 45). 1¾" (45 mm) Tape marker Foil Pad Tape Shield Figure 45 22 78-8131-7604-3 Rev B

12.2 Clean cables using standard practice: a. Do not allow solvent or abrasive to contact the cable semi-conductive insulation shield. b. Do not reduce cable insulation diameter below 1.94" (49,3 mm) specified for the splice. c. The insulation surface must be round, smooth and free of cuts/voids. Sanding may be necessary, finish sanding should be done with a 300 grit or higher electrical grade abrasive. d. Make certain that the cable insulation is smooth, clean and dry before continuing. 12.3 Apply 3M Red Compound P55/R on cable insulations, making certain to fill in edge of cable semi-con. Do not use silicone grease (Figure 46). Fill semi-con step Fill semi-con step 3M Red Compound P55/R 3M Red Compound P55/R Figure 46 12.4 Position the splice body over connector area, aligning end of the splice body (not the core) at the center of the tape marker. Slowly start to remove the splice core by pulling and unwinding the loose core end counterclockwise, allowing only ¼" (6 mm) of the splice to shrink onto the tape marker. Carefully slide the splice body off the tape marker by pulling and twisting until the entire tape marker is exposed. Continue removing the core to complete the splice body installation (Figure 47). Unwind Counter-clockwise Align splice with tape marker Splice body Figure 47 78-8131-7604-3 Rev B 23

13.0 Connect the Tape Shields/LC Shields 13.1 Wrap the Scotch Electrical Semi-conducting Tape 13, 18" x 36" Pad over the shield sleeve (36" length following the cable), centered over the splice body. The pad can be trimmed to fit between the metallic shields. Secure with four bands of vinyl tape (Figure 48). Do not cover the entire pad with vinyl tape. Semi-Con Pad Secure with vinyl tape Figure 48 13.2 Center the expanded shield sleeve over the semi-con pad (Figure 49). Center expanded shield sleeve over semi-con pad Figure 49 13.3 Hand tighten the sleeve outward while keeping it centered over the semi-con pad. Secure the centered shield sleeve to the cable metallic shield on both sides using two constant force springs on each end. Trim excess shield sleeve. (Figure 50). Secure with 2 constant force springs Trim excess shield sleeve Figure 50 24 78-8131-7604-3 Rev B

13.4 Wrap two half-lapped layers of highly-tensioned Scotch Vinyl Electrical Tape Super 88 over the constant force springs (Figure 51). Vinyl Tape Vinyl Tape Figure 51 13.5 Take the temporary tape off neutral wires. Do not twist wires in to a single bundle. 13.6 Route the longer neutral wires straight across the previously installed pad. Secure to pad, over the splice body, with a band of vinyl tape (Figure 52). Figure 52 Long Neutral Wires 13.7 Connect the longer neutral wires to the shorter wires using multiple connectors (3 or more). This is done to avoid damage to the splice body shoulders and end seals caused by large diameter wire/connectors being pressed in to them (Figure 53). Neutral Wire Connector (6 total; 3 on opposite side) Figure 53 78-8131-7604-3 Rev B 25

13.8 Cover the connectors with two half-lapped layers of vinyl tape (Figure 54). 2 half-lapped layers vinyl tape 14.0 Install Jacket Note: Jacketing is not optional. Figure 54 14.1 Wrap a roll of slightly stretched Scotch Rubber Mastic Tape 2228, 2" x 36" around cable jacket ends (tacky side toward cable) (Figure 55). Stretch and tear off last 1 2" (25 50 mm) of mastic (Figure 56). If grounding was applied, apply tape centered over 3M Scotch-Seal Mastic Tape 2229. 2" rubber mastic 2" rubber mastic Figure 55 Stretch and tear off last 1 2" (25 50 mm) of rubber mastic Figure 56 26 78-8131-7604-3 Rev B

14.2 Install the smaller cold shrink tube by covering the rubber mastic, overlapping the cable jacket approximately 1/4 1/2" (6 12 mm), and unwinding toward the splice body, slowly pulling and unwinding the core counterclockwise (Figure 57). Unwind Counter-clockwise approx. 1/4 1/2" (6 12 mm) Figure 57 Jacketing tube 14.3 Wrap a single wrap of 3M Scotch-Seal Mastic Tape 2229, 1" x 10' around the smaller cold shrink tube ¼" from the end (over the splice body). Completely cover the sealing mastic with a wrap of vinyl tape (Figure 58). 1/4" (6 mm) 1" Mastic seal covered with vinyl tape Figure 58 78-8131-7604-3 Rev B 27

14.4 Install the larger cold shrink tube over the rubber mastic on the other cable in the same manner (Figure 59). Unwind Counter-clockwise Figure 59 Jacketing tube 14.5 Using the four rolls of 3M Armorcast Structural Material provided, wrap half-lapped layers over the entire splice extending 3" (76 mm) onto the cable jacket. Bind the final wrap in place with vinyl tape (Figure 60). Tear open the top end of the foil armorcast material 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. Note: Wear rubber gloves provided when handling armorcast material. The resin contains a black dye that will stain human skin. Armorcast 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. 3" (76 mm) 3" (76 mm) 4 rolls 3M Armorcast Structural Material Figure 60 14.6 Connect optional grounding. 28 78-8131-7604-3 Rev B

78-8131-7604-3 Rev B 29

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