3M™ Cold Shrink QS‑III Silicone Rubber Splice Kit 69 kV 5488A

3M™ Cold Shrink QS‑III Silicone
Rubber Splice Kit 69 kV
5488A, 5488A‑JCN-XB, and
5488A‑Shielded-XB
For Jacketed Concentric Neutral (JCN), Tape‑Shield, Longitudinally‑
Corrugated (LC) Shielded, Tape‑Over‑Wire (TOW) or Wire‑Over‑Tape (WOT)
Shielded Power Cables
Data Sheet
FCAUTION
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.
May 2014
78-8131-7603-5 Rev B
3
1. Product Description
Additional Kit Contents for 5488A‑JCN-XB Splice, and
5488A‑Shielded-XB:
• Silicone Rubber Tube Assembly
• Roll, Scotch® Linerless Rubber Splicing Tape 130C
• Roll, Scotch® Electrical Shielding Tape 24
Splice Features:
• Cold Shrink Design — for quick and easy
installation; excellent for cable size transitions
• Complete Kit — includes everything required to
make one splice
• Silicone Rubber Construction — for good high and
low temperature performance
• Production Tested — partial discharge and A.C.
withstand tests to provide reliability
• Computer Aided Design — for compact size and
optimal distribution of electrical field
• Special Electrode Design — minimizes electrical
stress at critical cable/splice interface
The 3M™ Cold Shrink QS-III Splice Kit 5488A is a
69 kV–class splice for joining jacketed concentric
neutral (JCN), tape-shield, longitudinally-corrugated
(LC) shielded, tape-over-wire (TOW) or wire-over-tape
(WOT) shielded power cables. It is a cold shrink design
sized to fit Type MV–90 or type MV-105 cables with
copper or aluminum conductor sizes ranging from 250
kcmil–2000 kcmil (120–1000 mm2). The cold shrink
splice body is a one–piece molded design made of
specially formulated silicone rubbers, while the cold
shrink jacketing is made of EPDM rubber for physical
protection. Each splice manufactured is factory tested to
provide reliability.
The splice kit contains a set-screw aluminum (Al/Cu)
inline connector, and can be used for size transitions
within the listed kit size range. It is designed to exceed
minimum industry test standards, and have a BIL rating
of 350 kV. The splice meets or exceeds the 69 kV
Voltage Class rating requirements of IEEE Std. 404.
2. Applications
For splicing 69 kV shielded power cables:
• For inline and crossbond/shield break splicing
• For transmission circuits
• For jacketed concentric neutral (JCN), tape-shield,
longitudinally-corrugated (LC) shielded, tape-overwire (TOW) or wire-over-tape (WOT) shielded
power cables
• For copper or aluminum conductors
• For direct burial installations
• For submerged locations
Kit Contents for 5488A Splice:
• Silicone Rubber Splice Body
• Jacketing Tubes
• Shielding Sleeve
• Pre-formed Braid Assembly (except JCN)
• Constant Force Springs
• 3M™ Red Compound P55/R Tubes
• (non-silicone grease)
• Roll 3M™ Scotch-Seal™ Mastic Tape 2229
• Rolls Scotch® Rubber Mastic Tape 2228
• Pad Scotch® Electrical Semi-conducting Tape 13
• Roll Scotch® Vinyl Electrical Tape Super 88
• 3M™ Cable Cleaning Pads CC-3
• 3M™ EMI Copper Foil Shielding Tape Strips 1181,
15" long
(except JCN)
• Rolls 3M™ Armorcast Structural Material 4560, 3" x
15'
• Shear Bolt Connector
• Instruction Booklets
2
78-8131-7603-5 Rev B
3. Data: Physical and Electrical Properties
The 3M™ Cold Shrink QS-III Splcie Kit 5488A can be used on cables with a rated operating temperature up to
105˚C, and an emergency overload rating of 140˚C. A splice constructed from this kit is rated for 69 kV and meets or
exceeds the requirements of IEEE Std. 404. The current rating of the splice meets or exceeds the current rating for the
cables on which it is installed. BIL rating is 350 kV.
A. Splice Selection Table
Kit Number
5488A, 5488A-XB
Cable Insulation O.D. Range
Inches (mm)
Conductor Size Range
AWG or kcmil (mm2)
1.94–3.08"
(49,3–75,4 mm)
250–2000
(120–1000 mm2)
Table 1
B. Connector Dimensional Requirements Table
Conductor Size
250–600 kcmil
(125–325 mm2)
750–1000 kcmil
(400-500 mm2)
1250–1500 kcmil
(655-800 mm2)
1750–2000 kcmil
(875-1000 mm2)
Connector O.D.
Connector Length
1.94–2.50"
(49,3–63,5 mm)
8"±0.10"
(203 mm ± 2.54 mm)
2.51–3.08"
(63,6–75,4 mm)
9.25"±0.10"
(235 mm ± 2.54 mm)
Table 2
C. Typical Dimensions (Installed Splice)
62" (1575 mm)
5.8" (147 mm)
D. Parking Distance (Stacked)
92" (2.34 m)
Stacked Large Jacketing Tube
and Small Jacketing Tube
Expanded Shield Sleeve
Splice Body
48" (1.22 m)
78-8131-7603-5 Rev B
8" (0.2 m)
3
E. Typical Physical and Electrical Properties
Silicone Rubber (Splice Body — Insulation)
Physical Properties
Test Method
Typical Value*
Hardness – Shore A
(ASTM D 2240)
50
Elongation (%)
(ASTM D 412)
610
Tensile Strength (psi)
(ASTM D 412)
1090
(7,5 N/mm2)
Modulus @ 100% (psi)
(ASTM D 412)
340
(2,3 N/mm2)
Permanent Set (%)
(100%, 100˚C, 22 hrs)
(3M TM 86)
5
Thermal Conductivity (W/m K)
(ASTM D 518)
0.24
Silicone Rubber (Splice Body — Semi-Con Shell)
Physical Properties
Test Method
Typical Value*
Hardness – Shore A
(ASTM D 2240)
43
Elongation (%)
(ASTM D 412)
520
Tensile Strength (psi)
(ASTM D 412)
890
(6,1 N/mm2)
Modulus @ 100% (psi)
(ASTM D 412)
230
(1,6 N/mm2)
Permanent Set (%)
(100%, 100˚C, 22 hrs)
(3M TM 86)
5
Electrical Properties
Test Method
Typical Value*
Volume Resistivity (Ohm–cm)
(3M TM 80)
150
Electrical Properties
Test Method
Typical Value*
Dielectric Strength (V/mil)
(ASTM D 149)
370
(14,6 kV/mm)
Dielectric Strength, Wet (V/mil)
(ASTM D 149)
340
(13,4 kV/mm)
Ethylene Propylene Rubber (Jacketing Tubes)
Physical Properties
Typical Value*
Color
Black
48
Dielectric Constant
(ASTM D 150)
3.3
Hardness – Shore A
(ASTM D 2240)
Dielectric Loss
(ASTM D 150)
0.005
Ultimate Elongation, orig. (%)
(ASTM D 412)
635
Volume Resistivity (Ohm–cm)
(3M TM 80)
6x1014
Ultimate Tensile, orig. (psi)
(ASTM D 412)
1680
(11,6 MPa)
Modulus @ 100% (psi)
(ASTM D 412)
170
(1,17 MPa)
Fungus Resistance, 28 days
(ASTM G 21)
No Growth
Permanent Set (%)
8.8
Silicone Rubber (Splice Body — Inner Electrode)
Physical Properties
Test Method
Typical Value*
Hardness – Shore A
(ASTM D 2240)
43
Elongation (%)
(ASTM D 412)
510
Tensile Strength (psi)
(ASTM D 412)
880
(6,1 (N/mm2)
Modulus @ 100% (psi)
(ASTM D 412)
200
(1,4 N/mm2)
Permanent Set (%)
(100%, 100˚C, 22 hrs)
(3M TM 86)
4
Test Method
Typical Value*
Volume Resistivity (Ohm–cm)
(3M TM 80)
50
(250% Strain)
(5 min. recovery, @ 14.6
40˚F, 4.4˚C)
Electrical Properties
Electrical Properties
Test Method
Test Method
Typical Value*
Dielectric Strength, orig. (V/mil)
(ASTM D 149)
490
(19,1 kV/mm)
Dielectric Strength, wet (V/mil)
(ASTM D 149)
465
(18,1 kV/mm)
Dielectric Constant, orig.
(ASTM D 150)
5.0
Dielectric Constant, Wet
(ASTM D 150)
5.6
* All values are averages, based on several determinations and are not
intended for specification purposes.
4
78-8131-7603-5 Rev B
4. Specification
A. Product (Open Specification)
The jacketed concentric neutral (JCN), tape-shield, longitudinally-corrugated (LC) shielded, tape-over-wire (TOW)
or wire-over-tape (WOT) shielded power cable splice shall meet the requirements of IEEE Std. 404 for a 69 kV
rating, and must be rated by the manufacturer for use on 69 kV class cable systems. It must be rated for continuous
operation at 105˚C, with an emergency overload temperature rating of 140˚C. The splice shall be capable of splicing
cables with copper or aluminum conductors sized from 250–2000 kcmil (120–1000 mm2). The splice shall be of a
cold shrink design which does not require any additional heat source for installation. The cold shrink splice body
must be of a molded design made of silicone rubber. The splice jacketing shall be of a cold shrink tubing made of
EPDM rubber. The color of the splice body and outer jacket shall be black.
B. Engineering/Architectural (Closed Specification)
Splicing of all 69 kV rated cables, jacketed concentric neutral (JCN), tape-shield, longitudinally-corrugated (LC)
shielded, tape-over-wire (TOW) or wire-over-tape (WOT) shielded power cables, sized from 250–2000 kcmil (120–
1000 mm2) copper or aluminum, shall be performed in accordance with the instructions provided with the 3M™ Cold
Shrink QS-III Splice Kit 5488A, 5488A‑JCN-XB, or 5488A‑Shielded-XB.
5. Performance Tests
A. IEEE Std. 404 69/72 kV Voltage Rating
Design Test and Sequence
Test Requirement
Result
Minimum partial discharge (corona) level
60 kV–rms @ < 3 pC
Pass
Alternating-current 15 minute withstand
120 kV–rms
Pass
Direct-current 15 minute withstand
240 kV–dc
Pass
Impulse withstand (BIL) at 25˚C (77˚F)*
±350 kV–crest
Pass
Impulse withstand (BIL) at 130˚C (266˚F)*
±350 kV–crest
Pass
Minimum partial discharge (corona) level
60 kV–rms @ < 3 pC
Pass
Cyclic aging (in air and water)
80 kV–rms
Pass
Minimum partial discharge (corona) level
60 kV–rms @ < 3 pC
Pass
Alternating-current 6 hour withstand
100 kV–rms
Pass
Impulse withstand (BIL) at 25˚C (77˚F)
±350 kV–crest
Pass
Minimum partial discharge (corona) level
60 kV–rms @ < 3 p
Pass
Connector thermal and mechanical
ANSI C119.4
Pass
Production Test
Test Requirement
Production splices tested
100%
Minimum partial discharge (corona) level
60 kV–rms @ < 3 pC
Alternating-current 15 minute withstand
120 kV–rms
*Note: .
Impulse test wave is 1.2 x 50 μsec. (ANSI/IEEE Std. 4).
B. Operating Temperature
Reference: AEIC CS5 and AEIC CS6:
78-8131-7603-5 Rev B
Normal Operation
105˚C
5
Emergency Operation
140˚C
C. IEC 60840 69 kV Voltage Rating
Typical Results, IEC 60840 Test Sequence
3M™ Cold Shrink QS-III Splice Kit 5488A(RW) & 5488A-XB (RW)
72 kV
Insulation Class Test
Requirements
Result
PD at ambient CSV 63 kV for 10 sec CEV
54 kV
Pass
Load cycle for 20 cycles (8 hour loading to 95°C–100°C, at least 2 hours at
temperature, and 16 hours off-24 cycle)
72 kV
Pass
PD at ambient
54 kV
Pass
PD at elevated temperature (95°C–100°C)
54 kV
Pass
Impulse (10 impulses each polarity) at elevated temperature (95°C–100°C)
325 kV
Pass
15 Min AC withstand
90 kV
Pass
Water immersion and heat cycling
70˚
Pass
DC Voltage test
20 kV
Pass
DC Volt XB-20 kV
1 min.
Pass
Lightning Impulse XB
60/30 kV
Pass
Cable and accessory examination
Pass
(No evidence of electrical activity)
D. Partial Discharge (Corona) Tests
The purpose of partial discharge testing is to determine that all properly installed splices operate corona-free at
a minimum of 150% of their operating voltage. For the test, the applied test voltage is gradually increased until
discharges appear on the test set oscilloscope display. The voltage at which these discharges reach a magnitude
greater than 3 picocoulombs is recorded as the corona starting voltage (CSV). The applied voltage is then
lowered until the the discharge level drops below 3 picocoulombs, and this is recorded as the corona extinction
voltage (CEV).
E. Lightning Impulse Tests
The QS-III splice 5488A was evaluated to IEEE Standard 404 Basic Impulse Levels. For this test, a 1.2 x
50-microsecond voltage wave is applied to the termination lug. The test consists of both positive and negative
polarity surges per the specified standard. The QS-III splice 5488A meets or exceeds the requirements of IEEE
Standard 404.
F. Ground Braid
3M™ Cold Shrink QS-III Splice Kit 5488A
Series Ground Braids
6
78-8131-7603-5 Rev B
6. Installation Techniques for
5488A Kit
7. Install splice over connector area, aligning end
with tape marker, and removing core by pulling and
unwinding counterclockwise.
Detailed instructions for installing the 3M™ Cold Shrink
QS-III Rubber Splice Kit 5488A are included with each
kit.
8. Complete shield break installation.
9. Connect wire to neutral wires.
10. Mark and connect wires as required.
1. Prepare cable according to standard procedure.
2. Slide cold shrink jacketing tube and cold shrink splice
body onto prepared cables.
11.Maintenance
3. Install connector.
6. Install splice over connector area, aligning end
with tape marker, and removing core by pulling and
unwinding counterclockwise.
Components of the 3M™ Cold Shrink QS-III Splice Kits
QS-III 5488A, 5488A‑JCN-XB and 5488A‑ShieldedXB are stable under normal storage conditions. Normal
stock rotation procedures are recommended. As
provided, in the expanded state, the QS-III splice kits
have an on-shelf storage life of one year from the date
of manufacture. The installed splices can be field tested
using standard field cable testing procedures (reference
ANSI/IEEE Std. 400, “Guide for Making High–Direct–
Voltage Tests on Power Cable Systems in the Field”).
7. Connect neutral wires (JCN cable), route neutral wires
over the neutral pad which is centered on splice body.
12.Availability
4. Apply a tape marker on one cable.
5. Apply 3M™ Red Compound P55/R on cable insulation
and fill in edge of cable semi–con. DO NOT use silicone
grease.
8. Connect ground wire if circuit grounding is required at
this location. Apply mastic sealing strips to seal ground
wire at end of cable jacket.
11. Cover splice with 3M Armorcast Structural Material.
3M™ Cold Shrink QS-III Splice Kits QS-III 5488A,
5488A‑JCN-XB and 5488A‑Shielded-XB are available
to splice 69 kV jacketed concentric neutral (JCN), tapeshield, longitudinally-corrugated (LC) shielded, tapeover-wire (TOW) or wire-over-tape (WOT) shielded
power cables. The connectors can be either ordered with
the kit or provided separately. These kits are available
from your local authorized 3M electrical distributor.
12. Connect ground wire to ground if splice is to be
grounded.
13.Connectors for 69 kV QS-III Splices
7. Installation Techniques for 3M™
Cold QS-III Shrink Rubber Splice
Kit 5488A 5488A‑JCN-XB or 3M™
Cold Shrink QS-III Rubber Splice Kit
5488A 5488A‑Shielded-XB
The QS-III splice kits 5488A series are designed to be
used with 3M shear bolt connectors. Connector sizes and
dimensional information are shown in Table 2.
9. Apply rubber mastic tape around the end of both cable
jackets.
10. Install cold shrink jacketing tube over splice.
Detailed instructions for installing the 5488A‑JCN-XB
or 5488A‑Shielded-XB QS–III kits are included with
each kit.
1. Prepare cable according to standard procedure.
2. Install silicone rubber tube assembly.
3. Slide cold shrink splice body onto prepared cables.
4. Install connector.
5. Apply a tape marker on silicone rubber tube.
6. Apply red compound P/55R on cable insulation and
silicone tube; fill in edge of cable semi–con. DO NOT
use silicone grease.
78-8131-7603-5 Rev B
7
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3
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78-8131-7603-5 Rev B