3M™ Cold Shrink QT-III Silicone Rubber Skirted Termination Kit With High-K Stress Relief For Tape Shielded, Wire Shielded and UniShield® Cable 7685-S-8 Instructions IEEE Std. No. 48 Class 1 Termination 35 kV Class 200 kV 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.
1.0 Kit Contents 3 High-K, Tracking Resistant, Silicone Rubber Terminations 3 Pre-formed Ground Braids 3 Constant Force Springs 3 3M™ EMI Copper Foil Shielding Tape 1181 Strips, 1/2" x 10" 6 Strips Scotch® Mastic Strip 2230 (black with white release liners, bagged) 1 3M™ Cable Cleaning Preparation Kit CC-2 1 Instruction Sheet NOTE: Do Not use knives to open plastic bags. Kit Selection Table NOTE: Final Determination Factor is cable insulation diameter. Kit Number 7685-S-8 Primary Insulation Jacket O.D.
Instructions For Tape Shielded Cable 2.0 Prepare Cable 2.1 Check to be sure cable size fits within kit size range as shown in Table 1. 2.2 Prepare cable using dimensions shown in Figure 1. Refer to Table 2 for semi-con cutback dimension. BE SURE TO ALLOW FOR DEPTH OF TERMINAL LUG. If necessary to prevent tape shield from unrolling, hold down edge with a single wrap of 3M™ EMI Copper Foil Shielding Tape 1181.
3.0 Install Ground Braid 3.1 Select a Scotch® Mastic Strip 2230 from kit and remove white release liners. Using light tension, apply a SINGLE WRAP of mastic around the cable jacket 1/4" (6 mm) from cut edge (Figure 2). Cut off excess. 1/4” (6 mm) Semi-Con Tape Shield 1ST Scotch® Mastic Strip 2230 Cable Jacket Figure 2 3.2 Position pre-formed ground braid with short tail over tape shield directly adjacent to cable jacket cut edge.
3.3 Wrap ground braid around cable tape shield one complete wrap, trim excess to prevent overlap and secure in place with constant force spring. Wrap spring in same direction as ground braid (Figure 4). Cinch (tighten) the spring after wrapping the final winding. 3.4 Select second Scotch® Mastic Strip 2230 from kit and remove white release liners. Apply a second SINGLE WRAP of mastic over solder block on ground braid and previously applied mastic (Figure 4). Cut off excess.
4.0 Install Lug or Connector 4.1 Check to insure 3M™ Cold Shrink QT-III Silicone Rubber Termination assembly fits over the selected lug or connector. If lug or connector (Figure 6) will not fit through the termination core, clean the insulation (per Step 5.0) and slide termination on cable before installing lug or connector. DO NOT REMOVE CORE AT THIS TIME. Clearance Connector/Lug Figure 6 NOTE: Refer to pages 19-21 for 3M™ Connector and Lug crimping information.
6.0 Install Termination 6.1 Slide the termination body onto the cable and remove core. Pull while unwinding, counter-clockwise, starting with the loose end (Figure 7). Make sure the termination body (not the core) is butted up to the edge of the vinyl tape marker previously applied (Figure 7). NOTE: Once the termination body makes contact over the mastic seal area, there is no need to continue supporting the assembly. DO NOT PUSH OR PULL ON THE TERMINATION ASSEMBLY WHILE UNWINDING THE CORE.
Instructions for Wire Shielded Cable 7.0 Prepare Cable 7.1 Check to be sure cable size fits within kit size range as shown in Table 1. 7.2 Prepare cable using dimensions shown in Figure 8 and 9. Refer to Table 3 for semi-con cutback dimension. BE SURE TO ALLOW FOR DEPTH OF TERMINAL LUG.
8.0 Install Ground Braid 8.1 Select a Scotch® Mastic Strip 2230 from kit and remove white release liners. Using light tension, apply a SINGLE WRAP of mastic around the cable jacket 1/4" (6 mm) from cut edge (Figure 10). Cut off excess. 1/4" (6 mm) Semi-Con 1ST Scotch® Mastic Strip 2230 Cable Jacket Figure 10 8.2 Position pre-formed ground braid with short tail over wire shield directly adjacent to cable jacket cut edge.
8.3 Wrap ground braid around cable shield wires one complete wrap, trim excess to prevent overlap and secure in place with constant force spring. Wrap spring in same direction as ground braid (Figure 12). Cinch (tighten) the spring after wrapping the final winding. 8.4 Select second Scotch® Mastic Strip 2230 from kit and remove white release liners. Apply a second SINGLE WRAP of mastic over solder block on ground braid and previously applied mastic (Figure 12). Cut off excess.
9.0 Install Lug or Connector 9.1 Check to insure 3M™ Cold Shrink QT-III Silicone Rubber Termination assembly fits over the selected lug or connector. If lug or connector (Figure 14) will not fit through the termination core, clean the insulation (per Step 10.0) and slide termination on cable before installing lug or connector. DO NOT REMOVE CORE AT THIS TIME. Figur e 14 Clearance Connector/Lug Figure 14 NOTE: Refer to pages 19 -21 for 3M™ connector and lug crimping information.
11.0 Install Termination 11.1 Slide the termination body onto the cable and remove core. Pull while unwinding, counter-clockwise, starting with the loose end (Figure 15). Make sure the termination body (not the core) is butted up to the edge of the vinyl tape marker previously applied (Figure 15). NOTE: Once the termination body makes contact over the mastic seal area, there is no need to continue supporting the assembly. DO NOT PUSH OR PULL ON THE TERMINATION ASSEMBLY WHILE UNWINDING THE CORE.
Instructions for UniShield® Shielded Cable 12.0 Prepare Cable 12.1 Check to be sure cable size fits within kit size range as shown in Table 1. 12.2 Prepare cable using dimensions shown in Figure 16, 17 and 18. Refer to Table 4 for dimension [A]. BE SURE TO ALLOW FOR DEPTH OF TERMINAL LUG. NOTE: Provide additional exposed conductor distance to account for growth during crimping of ALUMINUM lugs or connectors as follows: Aluminum Connector Growth Allowance Kit Number Insulation 0.D. 7685-S-8 1.05" -1.
12.4 Remove constant force spring. Carefully bend shield wires back upon cable jacket 1 1/2" (38 mm). Cut excess shield wire and discard (Figure 17). Depth Of Terminal Lug + Growth Allowance [A] + 3” (76 mm) 1 1/2 (38 mm) Semi-Conductive Jacket Fold Back Shield Wires Figure 17 12.5 Remove semi-conductive jacket to dimension shown in Figure 18. NOTE: To ease jacket removal, install constant force spring as shown in Figure 18 and ring cut 80% through jacket.
13.0 Install Ground Braid 13.1 Select a Scotch® Mastic Strip 2230 from kit and remove white release liners. Using light tension, apply a SINGLE WRAP of mastic around the cable semi-conductive jacket 1/4" (6 mm) from shield wires (Figure 19). Cut off excess. 1/4 (6 mm) Semi-Con Shield Wires 1 ST Scotch® Mastic Strip 2230 Figure 19 13.2 Position pre-formed ground braid with short tail directly over cut edge of folded back shield wires.
13.3 Wrap ground braid around cable shield wires one complete wrap, trim excess to prevent overlap and secure in place with constant force spring. Wrap spring in same direction as ground braid (Figure 21). Cinch (tighten) the spring after wrapping the final winding. 13.4 Select second Scotch® Mastic Strip 2230 from kit and remove white release liners. Apply a second SINGLE WRAP of mastic over solder block on ground braid and previously applied mastic (Figure 21). Cut off excess.
14.0 Install Lug or Connector 14.1 Check to insure 3M™ Cold Shrink QT-III Silicone Rubber Termination assembly fits over the selected lug or connector. If lug or connector (Figure 23) will not fit through the termination core, clean the insulation (per Step 15.0) and slide termination on cable before installing lug or connector. DO NOT REMOVE CORE AT THIS TIME. Clearance Connector/Lug Figure 23 NOTE: Refer to pages 19 - 21 for 3M™ connector and lug crimping information.
16.0 Install Termination 16.1 Slide the termination body onto the cable and remove core. Pull while unwinding, counter-clockwise, starting with the loose end (Figure 24). Make sure the termination body (not the core) is butted up to the edge of the vinyl tape marker previously applied (Figure 24). NOTE: Once the termination body makes contact over the mastic seal area, there is no need to continue supporting the assembly. DO NOT PUSH OR PULL ON THE TERMINATION ASSEMBLY WHILE UNWINDING THE CORE.
Tooling Index Lug and Crimping Information for 3M™ Scotchlok™ Copper Lugs 30014 thru 30045 One hole 31145 thru 31178 Two hole — long barrel 31036 thru 31068 One hole-long barrel Cable Size AWG/ kcmil Stud Size (in.) 3M™ Scotchlok™ Copper Lug Number 6 10 1/4 5/16 4 Crimping Tool-Die Sets (Minimum Number Of Crimps) Burndy Corporation Thomas & Betts Corporation Square D Co. Anderson Div.
Tooling Index Lug and Crimping Information for 3M™ Scotchlok™ Copper/Aluminum Lugs 40016 thru 40079 One hole 40132 thru 40178 Two hole Cable Size AWG/ kcmil Stud Size (in.
Tooling Index Crimping Information for 3M™ Stem Connectors Copper/Aluminum Conductor Size AWG & kcmil Stranded 2, 1 4 1/0 2/0 3/0 4/0 Solid 1, 1/0 2 2/0 3/0 4/0 – 3M™ Connector Number SC0001 SC0002 SC0010 SC0020 SC0030 SC0040 Crimping Table For 3M™ Stem Type Connector Recommended Crimping Tools Manufacturer Mech. Tool Die (Minimum No. Crimps) Hydraulic Die (Minimum No.
3M, Scotch and Scotchlok are trademarks of 3M Company. UniShield is a registered trademark of General Cable Technologies Corporation. Important Notice 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.
