3M 7625-T-95-3G Installation Manual

™

3M

Cold Shrink QT-III Silicone

Rubber Indoor Termination Kits

With High-K Stress Relief

For 3-Conductor Type “G” (Ground Wire) Copper Tape
Shield and Armored Cables

7600-T-3G Series

Instructions

IEEE Std. No. 48

Class 1 Termination

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.

August 2013

78-8127-6976-4 Rev D 3

Kit Contents

1 Cold Shrink Silicone Rubber Breakout Boot Assembly

1 Cold Shrink Silicone Rubber Jacket Seal Assembly

3 Silicone Rubber Phase Rejacketing Sleeve Assemblies

3 Cold Shrink Silicone Rubber Termination Assemblies

1 Tinned Copper Ground Braid Assembly

3 Constant-Force Springs (Small)

1 Constant-Force Spring (Large)

8 Strips Scotch® Mastic Strip 2230 (2 per termination bag & 2 per breakout boot bag)

1 Roll Scotch® Super 33+™ Vinyl Electrical Tape - 3/4"

1 Roll Scotch® Vinyl Electrical Tape Super 88 - 1-1/2"

1 Roll Scotch® Electrical Shielding Tape 24

1 3M™ Cable Cleaning Preparation Kit CC-2

1 Instruction Sheet

3 3M™ EMI Copper Foil Shielding Tape 1181 Strips, 1/2" x 10"

NOTE: Do Not use knives to open plastic bags.

Termination Application Ranges

(Final determining factor is cable insulation diameter. Listed insulation ranges allow + 0.10" (2,54 mm) for shielding.)

Kit Number BIL

(kV)

7620-T-95-3G 95

7621-T-95-3G 95

7623-T-95-3G 95

7624-T-95-3G 95

7625-T-95-3G 95

7621-T-110-3G 110

7622-T-110-3G 110

7624-T-110-3G 110

7625-T-110-3G 110

7693-T-150-3G 150

7694-T-150-3G 150

7695-T-150-3G 150

7696-T-150-3G 150

Insulation

Range

Min - Max

inch (mm)

0.33 - 0.50
(8,4-12,7)

0.50 - 0.70

(12,7-17,8)

0.70 - 0.92

(17,8-23,4)

0.92 - 1.18

(23,4-30,0)

1.18 - 1.52

(30,0-38,6)

0.50 - 0.70

(12,7-17,8)

0.70 - 0.92

(17,8-23,4)

0.92 - 1.18

(23,4-30,0)

1.18 - 1.52

(30,0-38,6)

0.70 - 0.92

(17,8-23,4)

0.92 - 1.18

(23,4-30,0)

1.18 - 1.52

(30,0-38,6)

1.53 - 1.81

(38,8-46,0)

Cable

O. D.
Max

2.20

(55,8)

2.80

(71,1)

3.30

(83,8)

3.90

(99,1)

4.50

(114,3)

2.80

(71,1)

3.30

(83,8)

3.90

(99,1)

4.50

(114,3)

3.30

(83,8)

3.90

(99,1)

4.50

(114,3)

5.40

(137,2)

5 kV 8 kV 15 kV 25/28 kV 35 kV

100% 133% 100% 133% 100% 133% 100% 133% 100% 133%

8-2 6- 4 6- 4 6- 4 — — — — — —

1-3/0 2-2/0 2-2/0 2-2/0 — — — — — —

4/0-350 3/0-350 3/0-350 3/0-350 — — — — — —

400-500 400-500 400-500 400-500 — — — — — —

700-1000 700-1000 700-1000 700-1000 — — — — — —

1-3/0 2-2/0 2-2/0 2-2/0 2-1 — — — — —

4/0-350 3/0-350 3/0-350 3/0-350 1/0-4/0 2-3/0 — — — —

400-500 400-500 400-500 400-500 250-350 4/0-350 — — — —

700-1000 700-1000 700-1000 700-1000 500-750 500-750 — — — —

4/0-350 3/0-350 3/0-350 3/0-350 1/0-4/0 2-3/0 1-1/0 — — —

400-500 400-500 400-500 400-500 250-350 4/0-350 2/0-250 1-4/0 1/0-3/0 —

700-1000 700-1000 700-1000 700-1000 500-750 500-750 350-500 250-500 4/0-500 1/0-350

— — — — — 1000 750 500-750 500-750 350-750

Conductor Size Range (AWG and kcmil)

Table 1

2 78-8127-6976-4 Rev D

1.0 Prepare Cable

ape Shield

1.1 Determine cable jacket removal length required for correct phase spacing and bolted terminal lug connections
([A] + [B] Figure 1; based on the longest phase to be connected). Allow for dimension [C] as needed.

NOTE: Individual phase length and separation dimensions vary according to specific installation and equipment
design requirements. They must, therefore, be determined by the installer and must conform to accepted
engineering practices. Max phase length = 4 ft (121,9 cm)+ termination length (from table in Figure 18, page 13)

1.2 Remove cable jacket, armor, bedding (inner sheath) and core fillers according to Figure 1 dimensions. Secure
each copper tape shield end with a temporary band of vinyl tape (Figure 1).

Note: DO NOT DISCARD LEFTOVER JACKET MATERIAL.

[C]

Temporary Bands of

[B]

Vinyl Tape

Jacket

Removal

Length

[A] + [B]

[A]

Armor

Ground Wire

Copper T

2” (51 mm)

Figure 1

78-8127-6976-4 Rev D 3

2.0 Install Shield Grounding Braid Assembly & Re-route Cable Ground Wire(s)

Trim Here

Electrical Tape

2.1 Position ground braid assembly over cable with assembly connector aligned to edge of armor (Figure 2).

Note: For single ground wire cables, apply assembly to side opposite cable ground wire. Assembly connector
should not overlap armor.

Hint: Use temporary vinyl tape wraps as needed to assist in holding braid assembly to cable (Figure 2).

2.2 Attach Ground Braid Assembly Legs to Cable Phase Metallic Shields

(a.) Short (Center) Braid Tail – Position ground braid assembly as shown (Figure 2). Wrap short, center ground

braid tail around metallic shield of first cable core. Trim excess braid length to prevent overlap (Figure 2).
Secure ground braid to cable metallic shield using small constant-force spring (Figure 2). Spring and braid
leg should be wrapped in the same direction. Cinch (twist with hand) constant-force springs to tighten.

(b.) Install Second & Third Ground Braid Tails-Wrap the second and third ground braids around core legs to

adjust length . Position ground braid tails so all constant force springs are equal distance from the cable
armor.

®

2.3 Apply two highly-stretched half-lapped layers of Scotch
springs (Figure 2).

Super 33+™ Vinyl Electrical Tape over constant-force

Vinyl Tape

( typical )

Cable Armor

7.0"

(178 mm)

Connector

Braid Assembly Leg

Constant Force Spring

Metallic

Shield

Scotch® Super 33+™ Vinyl

Figure 2

4 78-8127-6976-4 Rev D

2.4 Measure distance [J] (Figure 3). Retrieve previously removed cable jacket material. Cut a straight piece to

dimension [J] and wrap it around cable phases beneath ground strap assembly and cable ground wire. Secure
jacket section in place using Scotch® Vinyl Electrical Tape Super 88 (wide vinyl tape) (Figure 3).

Note: Temporarily remove vinyl tape wrap on ground braid.

[J]

Side View

Bottom View

Scotch® Vinyl Electrical Tape Super 88 (Wide Vinyl Tape)

Ground Wire

Figure 3

78-8127-6976-4 Rev D 5

2.5 Fill one armor valley section with tightly-wrapped layers of Scotch® Electrical Shielding Tape 24 (Figure 4).

Scotch® Super 33+™ Vinyl Electrical Tape

Scotch® Electrical Shielding Tape 24:

2.6 Secure ground braid assembly to cable armor using large constant force spring (Figure 4). Once spring has been
applied, cinch (twist with hand) to tighten.

®

2.7 Apply one half-lapped layer of Scotch

Super 33+™ Vinyl Electrical Tape over large constant force spring and

cable armor (Figure 4).

Note: Apply Scotch®

Super 33+™ Vinyl Electrical Tape to hold down ground strap (Figure 4).

Fill To Level Of Armor High Points

Large Constant Force Spring

Figure 4

2.8 Bind cable ground wire with four half-lapped layers of Scotch® Vinyl Electrical Tape Super 88
(wide vinyl tape) (Figure 5). Limit width of tape wrapping to approximately 2-1/2” (63,5 mm).

2-1/2"

(63.5 mm)

Scotch® Vinyl Electrical Tape Super 88 (Wide Vinyl Tape)

Bottom View

Figure 5

6 78-8127-6976-4 Rev D

2.9 Loop cable ground wire back over armor (Figure 6). Adjust ground wire position over cable jacket to run

Scotch® Vinyl Electrical Tape Super 88 (Wide Vinyl Tape)

Under Ground Wire & Shield Braid Tail

parallel with tail of ground braid assembly.

Note: Do not make sharp or tight bends in ground wire. Ground wire loop should not extend beyond edge of
protective jacket section as shown.

Do not extend wire loop beyond this edge

Figure 6

Rotated View of Cable

2.10 Apply two half-lapped layers of Scotch® Vinyl Electrical Tape Super 88 (wide vinyl tape) over looped ground
wire area (Figure 7).

Figure 7

2.11 Wrap two strips of Scotch® Mastic Strip 2230 (one on top of the other) over cable jacket. Locate the mastic
strip directly under the shield braid solder block and ground wire (Figure 8).

Note: It will be necessary to temporarily remove vinyl tape over ground braid tail to complete this step.

Two Strips of Scotch® Mastic Strip 2230

Figure 8

78-8127-6976-4 Rev D 7

2.12 Separate ground wire strands over strips of Scotch® Mastic Strip 2230 as shown (Figure 9).

Two Strips of Scotch® Mastic Strip 2230

Separated Ground Wire Strands

Scotch® Mastic Strip 2230 Over Solder Block Section

Scotch® Mastic Strip 2230 Over Ground Wire Strands

Hint: Directly over the mastic seal strips, lift and bend the ground wire 90°. Reverse twist the ground conductor
to open strands. Use a screwdriver to aid in separating the strands. On 19 strand wire with reverse twist
innerconductors, twist ground wire in the opposite direction to aid in separating the inner-conductors. Flatten,
straighten and re-position the separated ground conductors. Be careful not to damage ground wire.

Wide Vinyl Tape

Figure 9

2.13 Apply one Strip of Scotch® Mastic Strip 2230 around ground wire strands (Figure 10). Apply one mastic seal
strip around solder block section of ground braid tail. Align mastic strip wraps with previously applied mastic
strip band around cable jacket.

Note: Avoid crossing individual wires at mastic seal location.

Wide Vinyl Tape

Figure 10

8 78-8127-6976-4 Rev D

2.14 Wrap two additional strips of Scotch® Mastic Strip 2230 directly over previously applied mastic. (Figure 11).

Two Strips of Scotch® Mastic Strip 2230 ( Final Layer )

Tape Super 88 Binding

2.15 Cover mastic seal area with two highly stretched half-lapped layers of Scotch® Vinyl Electrical Tape Super 88

(wide vinyl tape.)

Scotch® Vinyl Electrical Tape Super 88 (Wide Vinyl Tape)

Figure 11

2.16 Install cold shrink jacket extension assembly. Align the jacket seal tube (not the plastic support core) to overlap

ground wire seal area by approximately 1/4” (6 mm). To install, pull loose core end, while unwinding counter­clockwise around the cable. (Figure 12).

2.17 Bind cable ground wire and ground braid tail to cable jacket using Scotch® Vinyl Electrical Tape Super 88

(wide vinyl tape) (Figure 12). Apply at least eight tape layers and wrap only to width of tape roll.

1/4" (6 mm)

Scotch® Vinyl Electrical

Figure 12

78-8127-6976-4 Rev D 9

Pull Tab

3.0 Install Cold Shrink Silicone Rubber Breakout Boot Assembly

Loose Core Ends

Loose Core
End

3.1 Inspect breakout boot assembly and confirm that all loose plastic core ends are free as shown (Figure 13).

Neck Core

Boot Neck

Finger

Neck

Boot Finger

Loose Core End

Finger Core

Figure 13

3.2 To ensure that the breakout boot can be fully seated into the breakout area of the cable, it will be necessary to
unwind a few turns of each finger core.

Loose Core End

Caution: Do not unwind too far such that boot fingers begin to collapse.

3.3 Hold loose neck-end core ribbon to one side so that it can not become trapped between cable phases. Slide boot
assembly over cable end; guiding individual cable cores through boot assembly fingers.

Hint: View end of cable through finger cores to ease cable phase insertion.

3.4 Slide breakout boot assembly onto cable as far as it will go. Large neck-end should fully extend over
previously-installed jacket sealing assembly tube.

Hint: Spreading cable phases while sliding the boot assembly can ease the installation.

3.5 Remove large neck-end core. Grasping loose core ribbon end , pull and unwind counter-clockwise around cable.

3.6 Remove each finger core. Grasping loose core ribbon end , pull and unwind counter-clockwise around each
cable phase leg.

4.0 Install Silicone Rubber Rejacketing Sleeves

4.1 From the chart below, determine the correct [A] (Figure 14) dimension for the termination being installed.

Kit Number Dimension [A]

7620-T-95-3G 6.75" (171 mm)

7621-T-95-3G
7623-T-95-3G
7624-T-95-3G
7625-T-95-3G

7621-T-110-3G
7622-T-110-3G
7624-T-110-3G
7625-T-110-3G

7693-T-150-3G
7694-T-150-3G
7695-T-150-3G
7696-T-150-3G

5.50" (140 mm)

8.5" (216 mm)

12.0" (305 mm)

10 78-8127-6976-4 Rev D

4.2 Place a vinyl tape marker on each cable phase leg at dimension [X] (Figure 14).

[S]

[X]

Trim Line

3.0” (76 mm)

Note: [X] = [A](From chart above) + [B](Lug barrel depth). Allow for crimp growth when using aluminum lugs.

4.3 Determine required rejacketing sleeve length for each phase leg (Distance [S], Figure 14). Be sure to include

1.0" (25 mm) breakout boot finger overlap in measurement.

1.0" (25 mm) Overlap

[A]

Marker Tape

[B]

Figure 14

4.4 Using scissors, trim rejacketing sleeve assembly to length required (Figure 15). Cut tubing and inner braid

together.

Note: Inner polyester braid should extend approximately 3.0” (76 mm) beyond rejacketing tube end before cutting.
There is no need for termination-end braid exposure.

Breakout Boot End Rejacketing Sleeve

Termination End

Expose
Approximately

[S]

Figure 15

4.5 Guide one rejacketing sleeve assembly over each cable phase leg (Figure 16). Push sleeve assembly from

above. Continuously guide the free end, maintaining sleeve-to-cable-core alignment.

Right

Wrong

Figure 16

78-8127-6976-4 Rev D 11

4.6 Slide rejacketing sleeve until inner polyester braid is adjacent to breakout boot finger (Figure 17).

4.7 Fold outer silicone tubing back on itself for 1.0" (25 mm) (Figure 17) and trim off exposed polyester braid.

Note: Do not damage silicone tubing while cutting. Sleeve assembly may be rotated to ease trimming. When doing
so, rotate in the direction of the cable copper tape shield wrap.

1.0" (25 mm)

Silicone Tube Fold-back

Polyester Braid

Step 4.6

Step 4.7

Figure 17

Rejacketing Sleeve

over Marker Tape

4.8 Slide rejacketing sleeve assembly down until folded tube contacts edge of breakout boot finger (Figure 17).

4.9 Pull folded silicone tube section down onto breakout boot finger (Figure 17).

Note: Rejacketing tube end should align with upper edge of installed marker tape (Figure 17). Minor tube
adjustments can be made as needed.

12 78-8127-6976-4 Rev D

5.0 Install 3M™ Cold Shrink QT-III Silicone Rubber Termination Assemblies

A

B

C

D

Rejacketing Sleeve

Rejacketing Sleeve

0.75" (19 mm)

Rejacketing Sleeve

5.1 Prepare cable phase legs according to dimensions shown (Figure 18).

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.

Kit Number Dimension A Dimension B Dimension C Dimension D

7620-T-95-3G 6.75" (171 mm) Lug Depth* 2.0" (51 mm) 1.0" (25 mm)

7621-T-95-3G
7623-T-95-3G
7624-T-95-3G
7625-T-95-3G

7621-T-110-3G
7622-T-110-3G
7624-T-110-3G
7625-T-110-3G

7693-T-150-3G
7694-T-150-3G
7695-T-150-3G
7696-T-150-3G

*Allow for crimp growth when using aluminum lugs and connectors.

5.50" (140 mm) Lug Depth* 2.5" (64 mm) 1.25" (32 mm)

8.5" (216 mm) Lug Depth* 2.5" (64 mm) 1.25" (32 mm)

12.0" (305 mm) Lug Depth* 2.5" (64 mm) 1.25" (32 mm)

Figure 18

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

5.2 Secure cable copper tape shield ends with 3M™ EMI Copper Foil Shielding Tape 1181 Strips. (Figure 19).

3M™ EMI Copper Foil Shielding

Figure 19

Tape 1181 Strips

5.3 Secure rejacketing sleeve with two half-lapped layers of Scotch® Super 33+™ Vinyl Electrical Tape (Figure 20).

Start taping 0.75" (19 mm) over rejacketing sleeve, extend 0.25" (6 mm) over cable metallic shield and return to
starting point.

™

Note: Do not cover 3M

EMI Copper Foil Shielding Tape 1181 Strips.

0.25" (6 mm)

78-8127-6976-4 Rev D 13

Scotch® Super 33+™ Vinyl
Electrical Tape

Figure 20

5.4 Place a termination installation marker tape at position [M] (Figure 21).

[M]

Marker Tape

Last Crimp

First Crimp

Figure 21

Kit Number Dimension M

7620-T-95-3G 4.0" (102 mm)

7621-T-95-3G
7623-T-95-3G
7624-T-95-3G
7625-T-95-3G

7621-T-110-3G
7622-T-110-3G
7624-T-110-3G
7625-T-110-3G

7693-T-150-3G
7694-T-150-3G
7695-T-150-3G
7696-T-150-3G

5.0" (127 mm)

5.0" (127 mm)

5.0" (127 mm)

5.5 Install terminal lugs.

Note: Special Case – When lug spade dimension is larger than inside diameter of white plastic
termination core, position termination assemblies over cable phase legs prior to installing lugs.

Remove inner red shipping core from each termination assembly by pulling and unwinding the loose red core
ribbon. Position one termination over each cable phase leg. Each termination assembly must be positioned with
its loose white core ribbon end directed toward the open (cut) end of the cable. DO NOT REMOVE CORE
AT THIS TIME. Continue with lug installations.

(a.) For Aluminum Conductors - Thoroughly wire brush conductor strands to remove aluminum oxide

layer. Immediately insert conductor into terminal lug barrel as far as it will go.

(b.) Ensure that each lug face is parallel to equipment bushing or lug connection interface (Figure 22).

Figure 22

(c.) Crimp terminal lug according to manufacturer's recommendations. Start at the upper end as shown

(Figure 22). Remove all traces of oxide inhibitor that may have come out of lug barrel during crimping.

(d) If abrasive must be used:

1. Use on insulation only. DO NOT USE ABRASIVE ON SEMI-CON INSULATION SHIELD!

2. Use only aluminum oxide abrasive; grit 120 or finer.

14 78-8127-6976-4 Rev D

3. Be careful not to reduce the cable insulation diameter below that allowed by the kit.

™

(e.) Thoroughly clean primary insulation and lug barrel area using solvent wipe from supplied 3M

Cable

Cleaning Preparation Kit CC-2.

Note: DO NOT ALLOW SOLVENT TO TOUCH SEMI-CON INSULATION SHIELD.

™

5.6 Install 3M

Cold Shrink QT-III Silicone Rubber Termination assemblies.

(a.) Remove the inner red shipping core from the termination assembly by pulling and unwinding the loose red

core end.

(b.) Position the termination assembly with the loose white core ribbon directed toward the terminal lug.

(c.) Align the base of the termination (not the plastic core) with the installation marker tape as shown

(Figure 23).

(d.) Grasp the loose white core ribbon. Pull and unwind counter-clockwise around cable end (Figure 23).

Note: Once the termination body makes contact, there is no need to continue supporting the assembly. DO NOT
PULL OR PUSH ON THE TERMINATION ASSEMBLY WHILE UNWINDING THE CORE.

(e.) Remove the installation marker tape.

Termination Base Aligned With Marker Tape Edge

Rejacketing Sleeve

Marker Tape

Figure 23

5.7 Connect shield braid tail and cable ground wire to system ground (earth) according to normal practice.

78-8127-6976-4 Rev D 15

3M, Super 33+ and Scotch are trademarks of 3M Company.

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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.

Warranty; Limited Remedy; Limited Liability.

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
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special, incidental or consequential loss or damage arising from this 3M product, regardless of the legal theory asserted.

3

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Fax [phone]
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78-8127-6976-4 Rev D