Installation Directions

2014-09-04

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3M™ Cold Shrink QT-III Silicone Rubber
Indoor Termination Kits
With High-K Stress Relief
For Jacketed Concentric Neutral (JCN) Cable and
Concentric Neutral (CN) Cable
7653-T-150, 7655-T-150, 7656-T-150
Instructions
IEEE Std. No. 48
Class 1 Termination
25/28 kV Class
*35 kV Class
150 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.

Jacketed Concentric Neutral (JCN) Cable

Concentric Neutral (CN) Cable

January 2014
78-8126-0932-5 Rev F

3

1.0	Kit Contents
1 High-K, Tracking Resistant, Silicone Rubber Termination
2 Strips Scotch® Mastic Strip 2230 (black with white release liners, bagged)
1 Instruction Sheet

NOTE: Do not use knives to open plastic bags.

Kit Selection Table
NOTE: Final Determination Factor is cable insulation diameter.
Conductor Size Range (AWG & kcmil)
15 kV
25/28 kV
*35 kV

Kit Number

Primary Insulation
O.D. Range

Jacket O.D. Range

7653–T–150

0.72" – 1.29"
(18,3 – 32,8 mm)

1.04" – 1.60"
(26,4 – 40,6 mm)

2/0 – 300
(70 – 150 mm2)

2 – 4/0
(35 – 120 mm2)

2 – 2/0
(35 – 70 mm2)

7655–T–150

1.05" – 1.80"
(26,7 – 45,7 mm)

1.39" – 2.40"
(35,3 – 61,0 mm)

500 – 1000
(240 – 500 mm2)

250 – 800
(150 – 400 mm2)

3/0 – 600
(95 – 325 mm2)

7656–T–150

1.53" – 2.32"
(38,9 – 58,9 mm)

1.84" – 2.80"
(46,7 – 71,1 mm)

1250 – 2000
(625 – 1000 mm2)

900 – 1750
(500 – 800 mm2)

700 – 1500
(400 – 725 mm2)

*The 150 kV impulse level meets the impulse requirements for 35 kV class equipment where indoor terminations are used.

Table 1

	2	
78-8126-0932-5 Rev F

Instructions for Jacketed Concentric Neutral (JCN) 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	 Train cable into position and cut to length required for installation. Allow sufficient neutral wire length for
grounding connection.
2.3	 Prepare cable using dimensions shown in Figure 1. BE SURE TO ALLOW FOR DEPTH OF TERMINAL
LUG.
NOTE: Provide an additional exposed conductor distance to account for growth during crimping of ALUMINUM
lugs or connectors as follows:
Aluminum Lug and Connector
Growth Allowance

2 - 350
1/4” (6 mm)

400 - 650
1/2" (13 mm)

750 - 1000
3/4" (19 mm)

1250 - 2000
Field Determined

NOTE: It is imperative to remove all remnants of the semi-con layer, even if the semi-con layer comes off as one
layer. There should not be any remaining black areas, or particles, on the cable insulation layer.
Jacket Removal Length
Depth Of Terminal Lug + Growth Allowance
12"
(305mm)
2 1/2"
(64 mm)

Semi-Con
Neutral Wires
Cable Jacket

Figure 1

2.4	 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
Neutral Wires
1 ST Scotch® Mastic Strip 2230
Cable Jacket
Figure 2

78-8126-0932-5 Rev F	3

2.5	 Bend neutral wires back over applied sealing mastic and secure to cable jacket 4 1/2" (114 mm), below cable
semi-con edge using vinyl tape (Figure 3).
NOTE: Position vinyl tape with care, it also serves as a marker for positioning the termination.
2.6	 Select second Scotch® Mastic Strip 2230 from kit and remove white release liners. Apply a second SINGLE
WRAP of mastic over the neutral wires and previously applied mastic (Figure 3). Cut off excess.
2.7	 Compress neutral wires into Scotch® Mastic Strip 2230 by over-wrapping seal strips with two highly stretched
layers of electrical grade vinyl tape (Figure 3). Be sure to cover all exposed mastic.
NOTE: If using flat strap neutral cable, cover the flat strap neutral wires starting 1" (25 mm) from the Vinyl Tape
Marker (that was applied in Step 2.5) and proceed towards the edge of the semi-con layer where the flat strap
neutrals are bent back onto the jacket, using two half-lapped layers of electrical grade vinyl tape. The vinyl tape can
extend onto the semi-con layer up to 1/4" (6 mm).
4 1/2" (114 mm)
1/4"
(6 mm)

Semi-Con Edge
1 ST Scotch® Mastic Strip 2230
2 ND Scotch® Mastic Strip 2230
Two Highly Stretched Layers of Electrical Grade Vinyl Tape
Neutral Wires
Vinyl Tape Marker
Figure 3

3.0	Install Lug or Connector
Important Packaging Notice
In order to make sure that you receive an undamaged termination, this 3M™ Cold Shrink QT-III Termination is
packed with a RED SHIPPING CORE inside of the white core. Please remove the red shipping core BEFORE
you install the termination. This shipping core can be recycled with other polypropylene waste.

3.1	 Check to insure 3M™ Cold Shrink QT-lll Silicone Rubber Termination assembly fits over the selected lug or
connector. If lug or connector (Figure 4) will not fit through the termination core, clean the insulation (per Step
4.0) and slide termination on cable before installing lug or connector. Do not remove core at this
time.
Clearance

Connector/Lug

Figure 4

NOTE: Refer to pages 10 - 12 for 3M™ Lug and Connector crimping information.
NOTE: For Aluminum Conductors - Thoroughly wire brush conductor strands to remove aluminum oxide layer.
Immediately insert conductor into lug or connector barrel as far as it will go.

	4	
78-8126-0932-5 Rev F

3.2	 Position connector or lug and crimp according to manufacturer's directions. Remove excess oxide inhibitor and
sharp crimp flashings following crimping.

4.0	Clean Cable Insulation and Lug or Connector Barrel Using Standard Practice
4.1	 Wipe the cable insulation with an approved solvent (such as 3M™ Cable Cleaning Solvent CC Series).
DO NOT ALLOW SOLVENT TO TOUCH SEMI-CON INSULATION SHIELD!
4.2	
	
	
	

If abrasive must be used:
a. Use on insulation only. DO NOT USE ABRASIVE ON SEMI-CON INSULATION SHIELD!
b. Use only aluminum oxide abrasive; grit 120 or finer.
c. Be careful not to reduce the cable insulation diameter below that allowed by the kit.

5.0	Install Termination
5.1	 Slide the termination body onto the cable and remove core. Pull while unwinding counterclockwise starting
with the loose end (Figure 5). Make sure the termination body (not the core) is butted up to the edge of the
vinyl tape marker previously applied (Figure 5).
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.
Counterclockwise

Vinyl Tape Marker

NOTE: The material being removed at this step is mixed polymers
and can be recycled with other
waste.

Figure 5

5.2	 Collect all concentric neutral wires together (Figure 6) and connect to system ground according to standard
practice.

Concentric Neutral Wires

Figure 6

78-8126-0932-5 Rev F	5

Correct Installation of Termination on Jacketed Concentric Neutral (JCN) Cable

Vinyl Tape
Marker

Ridge at End of Cable
Insulation Shield (Semi-Con)

Ridge at End
of High-K Tube

Semi-Con Insulation Shield
Stress Controlling Compound

Environmental Top
Seal

Cable Insulation
Conductor

High-K Stress Relief Tube

Instructions for Concentric Neutral (CN) Cable
6.0	Prepare Cable
6.1	 Check to be sure cable size fits within kit range as shown in Table 1.
6.2	 Train cable into position and cut to length required for installation. Allow sufficient neutral wire length for
grounding connection.
6.3	 Prepare cable using dimensions shown in Figure 7. BE SURE TO ALLOW FOR DEPTH OF TERMINAL
LUG.
NOTE: Provide an additional exposed conductor distance to account for growth during crimping of ALUMINUM
lugs or connectors as follows:
Aluminum Lug and Connector
Growth Allowance

2 - 350
1/4” (6 mm)

400 - 650
1/2" (13 mm)

750 - 1000
3/4" (19 mm)

1250 - 2000
Field Determined

NOTE: It is imperative to remove all remnants of the semi-con layer, even if the semi-con layer comes off as one
layer. There should not be any remaining black areas, or particles, on the cable insulation layer.
6.4	 Secure neutral wires to cable with several highly stretched layers of electrical grade vinyl tape around the cable
and neutral wires 2 3/4" (69,9 mm) from cut edge of cable semi-con (Figure 7).
6.5	 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 and neutral wires 2 3/4" (69,9 mm) from cut edge of cable semicon, directly on top of vinyl tape (Figure 7). Cut off excess.

	6	
78-8126-0932-5 Rev F

Depth Of Terminal Lug + Growth Allowance

2 3/4"
(69,9 mm)

12 1/4"
(311 mm)

Semi-Con
Neutral Wires
1 ST Scotch® Mastic Strip 2230 on top of Vinyl Tape

Figure 7

6.6	 Bend neutral wires back over applied sealing mastic and secure to cable 4 1/2" (114 mm), below cable semi-con
edge using vinyl tape (Figure 8).
NOTE: Position vinyl tape with care, it also serves as a marker for positioning the termination.
6.7	 Select second Scotch® Mastic Strip 2230 from kit and remove white release liners. Apply a second SINGLE
WRAP of mastic over the neutral wires and previously applied mastic (Figure 8). Cut off excess.
6.8	 Compress neutral wires into mastic by over-wrapping seal strips with two highly stretched layers of electrical
grade vinyl tape (Figure 8). Be sure to cover all exposed mastic.
4 1/2"
(114 mm)

Semi-Con Edge
Scotch® Mastic Strip 2230
2 ND Scotch® Mastic Strip 2230
Two Highly Stretched Layers of Electrical Grade Vinyl Tape
Neutral Wires
Vinyl Tape Marker
1 ST

Figure 8

78-8126-0932-5 Rev F	7

7.0	Install Lug or Connector
Important Packaging Notice
In order to make sure that you receive an undamaged termination, this 3M™ Cold Shrink QT-III Termination is
packed with a RED SHIPPING CORE inside of the white core. Please remove the red shipping core BEFORE
you install the termination. This shipping core can be recycled with other polypropylene waste.

7.1	 Check to insure 3M™ Cold Shrink QT-lll Silicone Rubber Termination assembly fits over the selected lug or
connector. If lug or connector (Figure 9) will not fit through the termination core, clean the insulation (per Step
8.0) and slide termination on cable before installing lug or connector. DO NOT REMOVE CORE AT THIS
TIME.
Clearance

Connector/Lug

Figure 9

NOTE: Refer to pages 10 - 12 for 3M Lug and Connector crimping information.
™

NOTE: For Aluminum Conductors - Thoroughly wire brush conductor strands to remove aluminum oxide layer.
Immediately insert conductor into lug or connector barrel as far as it will go.
7.2	 Position connector or lug and crimp according to manufacturer's directions. Remove excess oxide inhibitor and
sharp crimp flashings following crimping.

8.0	Clean Cable Insulation and Lug or Connector Barrel Using Standard Practice
8.1	 Wipe the cable insulation with an approved solvent (such as 3M™ Cable Cleaning Solvent CC Series).
DO NOT ALLOW SOLVENT TO TOUCH SEMI-CON INSULATION SHIELD!
8.2	
	
	
	

If abrasive must be used:
a. Use on insulation only. DO NOT USE ABRASIVE ON SEMI-CON INSULATION SHIELD!
b. Use only aluminum oxide abrasive; grit 120 or finer.
c. Be careful not to reduce the cable insulation diameter below that allowed by the kit.

9.0	Install Termination
9.1	 Slide the termination body onto the cable and remove core. Pull while unwinding, counterclockwise, starting
with the loose end (Figure 10). Make sure the termination body (not the core) is butted up to the edge of the
vinyl tape marker previously applied (Figure 10).
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.
Counterclockwise

Vinyl Tape Marker

NOTE: The material being removed at this step is mixed polymers
and can be recycled with other
waste.

Figure 10

9.2	 Collect all concentric neutral wires together (Figure 11) and connect to system ground according to standard
practice.
	8	
78-8126-0932-5 Rev F

Concentric Neutral Wires

Figure 11

Correct Installation of Termination on Concentric Neutral (CN) Cable

Vinyl Tape
Marker
Ridge at End
of High-K Tube

Semi-Con Insulation Shield
Stress Controlling Compound

Ridge at End of Cable
Insulation Shield (Semi-Con)

Cable Insulation
Conductor

Environmental Top
Seal
High-K Stress Relief Tube

78-8126-0932-5 Rev F	9

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

Square D Co.
Anderson Div.

Thomas & Betts Corporation

MD6

MY29

Y34A

Y35, Y39,
Y45*, Y46*

TBM 5

TBM 8

TBM 15

VC6–3,
VC6–FT**

30014
30015
30016

–

6AWG(1)

–

U5CRT(1)

Blue(1)

Blue(1)

–

(1)

10
1/4
3/8

30018
30019
30021

W161(1)

4AWG(1)

A4CR(1)

U4CRT(1)

Grey(1)

Grey(1)

–

(1)

2

1/4
5/16
3/8

30022
30023
30024

W162(2)

2AWG(1)

A2CR(1)

U2CRT(2)

Brown(1)

Brown(1)

33(1)

(2)

1

5/16
3/8

30027
30028

–

1AWG(1)

A1CR(1)

U1CRT(2)

Green(1)

Green(1)

37(1)

(2)

1/0

5/16
3/8

30031
30032

W163(2)

1/0(1)

A25R(1)

U25RT(1)

Pink(2)

Pink(2)

42H(2)

(1)

2/0

3/8
3/8

30036
31036

W241(2)
W241(3)

2/0(1)
2/0(2)

A26R(1)
A26R(2)

U26RT(2)
U26RT(3)

Black(2)
Black(3)

Black(2)
Black(3)

45(1)
45(2)

(1)
(2)

3/0

1/2
1/2

30041
31041

W243(2)
W243(3)

3/0(1)
3/0(2)

A27R(1)
A27R(2)

U27RT(2)
U27RT(3)

Orange(2)
Orange(3)

Orange(2)
Orange(3)

50(1)
50(2)

(2)
(3)

4/0

1/2
1/2
1/2

30045
31045
31145

BG(3)
BG(4)
BG(4)

4/0(1)
4/0(2)
4/0(2)

A28R(2)

U28RT(2)
U28RT(3)
U28RT(3)

Purple(2)
Purple(3)
Purple(3)

Purple(2)
Purple(3)
Purple(3)

54H(2)
54H(3)
54H(3)

(2)
(3)
(3)

250

1/2
1/2

31049
31149

W166(4)

250(2)

A29R(2)

U29RT(3)

Yellow(2)

Yellow(2)

62(2)

(2)

300

1/2
1/2

31053
31153

–

–

A30R(2)

U30RT(3)

–

White(3)

66(3)

(3)

350

1/2
1/2

31056
31156

–

–

A31R(2)

U31RT(3)

–

Red(4)

71H(4)

–

400

1/2
1/2

31060
31160

–

–

A32R(2)

U32RT(3)

–

Blue(4)

76H(4)

–

500

1/2
5/8
1/2

31066
31067
31166

–

–

A34R(2)

U34RT(3)

–

Brown(4)

87H(4)

–

600

1/2
1/2

31068
31168

–

–

–

U36RT(3)

–

Green(4)

94H(4)

–

750

1/2

31172

–

–

–

Y39, Y45,
Y46
U39RT(5)

–

–

106H(4)

–

–

Y45:
S44RT(6)
Y46:
P44RT(6)

–

–

125H(4)

–

1000

1/2

31178

–

–

* Y45 and Y46 accept all Y35 dies (“U” series). For Y45 use PT6515 adapter. For Y46 use PUADP adapter.
** Anderson VC6–3 and VC6–FT require no die set.

	10	

78-8126-0932-5 Rev F

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.)

3M™Scotchlok™
Lug Number

Crimping Tool-Die Sets (Minimum Number Of Crimps)

6

5/16

40016

W161(1)

6AWG(1)

A6CAB(1)

U6CABT(1)

(1)

Grey(1)

Grey(1)

–

29(1)

(1)

–

BY19(3)

J(3)

4

5/16

40020

W162(3)

4AWG(1)

A4CAB(1)

U4CABT(1)

(1)

Green(2)

Green(2)

–

37(1)

(1)

–

BY53(3)

P(3)

3/8

40024

W163(3)

2AWG(1)

A2CAB(1)

U2CABT(1)

(1)

Pink(2)

Pink(2)

42H(2)

(1)

BY23(3)

1/2(3)

1/2

40025

W163(3)

2AWG(1)

A2CAB(1)

U2CABT(1)

(1)

Pink(2)

Pink(2)

42H(2)

(1)

BY23(3)

1/2(3)

3/8

40028

W163(3)

1AWG(1)

A1CAR(1)

U1CART(1)

(1)

Gold(2)

Gold(2)

45(1)

(1)

BY23(3)

1/2(3)

1/2

40029

W163(3)

1AWG(1)

A1CAR(1)

U1CART(1)

(1)

Gold(2)

Gold(2)

45(1)

(1)

BY23(3)

1/2(3)

3/8

40032

W241(3)

1/0(1)

A25AR(1)

U25ART(1)

(1)

Tan(2)

Tan(2)

50(1)

(1)

BY25(3)

5/8–1(3)

1/2

40033

W241(3)

1/0(1)

A25AR(1)

U25ART(1)

(1)

Tan(2)

Tan(2)

50(1)

(1)

BY25(3)

5/8–1(3)

3/8

40132

W241(3)

1/0(1)

A25AR(1)

U25ART(1)

(1)

Tan(2)

Tan(2)

50(1)

(1)

BY25(3)

5/8–1(3)

1/2

40037

BG(4)

2/0(1)

A26AR(2)

U26ART(2)

(1)

Olive(2)

Olive(2)

54H(2)

(2)

BY31C(3)

5/8–1(3)

1/2

40137

BG(4)

2/0(1)

A26AR(2)

U26ART(2)

(1)

Olive(2)

Olive(2)

54H(2)

(2)

BY31C(3)

5/8–1(3)

1/2

40041

W166(4)

3/0(1)

A27AR(2)

U27ART(2)

(1)

Ruby(2)

Ruby(2)

60(2)

(2)

1/2

40141

W166(4)

3/0(1)

A27AR(2)

U27ART(2)

(1)

Ruby(2)

Ruby(2)

60(2)

(2)

1/2

40045

W660(4)

4/0 (2)

A28AR(2)

U28ART(2)

(1)

66(4)

(2)

5/8

40046

W660(4)

4/0 (2)

A28AR(2)

U28ART(2)

(1)

66(4)

(2)

1/2

40145

W660(4)

4/0 (2)

A28AR(2)

U28ART(2)

(1)

66(4)

(2)

1/2

40049

W249(3)

A29AR(2)

U29ART(2)

(1)

71H(4)

71H(2)

(3)

5/8

40050

W249(3)

A29AR(2)

U29ART(2)

(1)

71H(4)

71H(2)

(3)

1/2

40149

W249(3)

A29AR(2)

U29ART(2)

(1)

71H(4)

71H(2)

(3)

1/2

40053

A30AR(2)

U30ART(2)

(1)

76H(4)

76H(2)

(3)

1/2

40153

A30AR(2)

U30ART(2)

(1)

76H(4)

76H(2)

(3)

1/2

40056

U31ART(2)

(1)

87H(4)

87H(3)

(3)

5/8

40057

U31ART(2)

(1)

87H(4)

87H(3)

(3)

1/2

40156

U31ART(2)

(1)

87H(4)

87H(3)

(3)

1/2

40160

U32ART(4)

(1)

94H(4)

94H(4)

–

5/8

40067

U34ART(4)

(1)

106H(4)

106H(3)

1/2

40166

U34ART(4)

(1)

106H(4)

106H(3)

1/2

40170

U36ART(4)

(1)

115H(3)

5/8

40073

U39ART(4)

(1)

1/2

40172

U39ART(4)

(1)

5/8

40079

S44ART(4)

(1)

1/2

40178

S44ART(4)

(1)

2

1

1/0

2/0

3/0

4/0

250

300

350

400
500
600
750

1000

Burndy Corporation
MD6

MY29

Y34A

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

Thomas & Betts Corporation

Y35, Y39,
Y1000** TBM 5
Y45*, Y46*

TBM 8 TBM 12 TBM 15

–

–

–

–

–

White(4)
–

White(4)

–

White(4)

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

125H(4)
125H(4)
140H(4)
140H(4)

* 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.

78-8126-0932-5 Rev F	11

Square D Co.
Anderson Div.

ITT
Blackburn
Co.

Kearny
Nat’l
Div.

VC6–3**
VC8C**
VC6–FT**

OD58

TYPE O

–
–
–

–

–

–

–

–

–

–

737(3)
737(3)

BY35C(4)

840(4)

BY35C(4)

840(4)

BY35C(4)

840(4)

–

–

–

–

–

–

–

–

–

(2)

–

–

–

–

–

–

–

–

–

–

–

(2)
(2)
(3)
(3)
(3)
(3)
(3)

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

Crimping Table For 3M™ Stem Type Connector
3M Connector
Number

Recommended Crimping Tools

™

1, 1/0
2
2/0

3/0
4/0
–

SC0001
SC0002
SC0010

SC0020
SC0030
SC0040

Manufacturer

Mech. Tool

Die (Minimum No.
Crimps)

Hydraulic

Die (Minimum No.
Crimps)

Burndy

MD6

BG(4), W241(3)

Y35, Y39, Y45*,
Y46*

U25ART(2),
U243(2)

Kearny

0–51, 0–52

5/8–1 (4)

WH–1, WH–2

5/8–1(4)

T&B

TBM 5

Tan(2)

–

–

T&B

TBM 8

Olive(2), Tan(2)

TBM 15

50(2)

Anderson

–

–

VC6**

(2)

Burndy

MD6

W249(3)

Y35, Y39, Y45*,
Y46*

U28ART(2)

Kearny

0–51, 0–52

840(5)

WH–1, WH–2

840(2)

T&B

TBM 8

Red(4)

TBM 15

71H(3)

Anderson

–

–

VC6**

(2)

* Y45 and Y46 accept all Y35 dies (“U” series). For Y45 use PT6515 adapter. For Y46 use PUADP adapter.
** Anderson VC6 is dieless and does not require a die set.

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3
Electrical Markets Division
6801 River Place Blvd.
Austin, TX 78726-9000
800 245 3573
Fax 800 245 0329
www.3M.com/electrical

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