3MTM Cold Shrink Silicone Rubber Connector Insulators 8440 Series Data Sheet Product Description May 2014 3MTM Cold Shrink Connector Insulators 8440 Series are open-ended, silicone rubber, tubular sleeves. The sleeves are factory expanded and assembled on a removable supporting plastic core. Each rubber assembly is supplied for field installation in this pre-stretched condition. As the core is unwound, the insulating sleeve shrinks to form a tight seal. Three sizes of Cold Shrink Insulators cover terminal lug barrels and inline connectors. Collectively, the insulators have an application range of 0.35" (8,86 mm) to 0.95" (24,13 mm) for installations on #6 AWG to 3/0 AWG. Features Simple installation requires only workman's hands No tools required No heat required for installation Seals tight, retains its resiliency and pressure even after prolonged years of aging and exposure Resists moisture Wide range, size accommodation Resists acids and alkalies Resists ozone and ultraviolet light Resists fluid splashes Resists fire - will not support flame Operating temperature range -66F to 500F ( -55C to 260C) Applications Primary electrical insulation for all solid dielectric (rubber and plastic) insulated wire and cable splices rated to 1000 volts Electrical Aircraft cables For indoor and outdoor use, in cable tray or overhead applications Top moisture sealing for medium voltage, air insulated connectors and lugs Insulation of secondary splices, copper and aluminum conductors Sheath repairs Insulation of inline conductor transition connectors 1 of 5 3 3MTM Cold Shrink Silicone Rubber Connector Insulators 8440 Series Not for specifications. Values are typical, not to be considered minimum or maximum. Properties measured at room temperature 73F (23C) unless otherwise stated. Typical Physical Properties Typical Electrical Properties Physical Property (Test Method) Typical Value US unit (metric) Color Gray 100% Modulus (ASTM D 412) 180 psi (1,24 MPa) Ultimate Tensile (ASTM D 412) 1240 psi (8,55 MPa) Die B Tear (ASTM D 624B) 185 psi (1,28 MPa) Hardness (ASTM D 2240) 48 Shore A Specific Gravity 1.23 Electrical Property (Test Method) Dielectric Strength (ASTM D 149) @ 1,78 mm thickness Dielectric Strength 168 hours in H2O @ 194F (190C) Typical Value US unit (metric) 554 V/mil (21,8 mV/m) 543 V/mil (21,4 mV/m) Expanded Silicone Rubber Tube Loose Core End B Plastic Supporting Core Cable Range Part Number 8443-2 8443-6.5 8445-2.5 8445-7.5 8447-3.2 8447-8 A 3/8" (9,5 mm) min AWG 6-2 2 - 1/0 1/0 - 3/0 Application Range Inches (mm) Max. Dia. Min. Dia. Insulator for Seal Covers 0.560 0.30 (7,6) (14,22) 0.720 0.37 (9,4) (18,29) 0.950 0.49 (12,4) (24,13) Table 1 2 of 5 Dimensions Inches (mm) [A] Length 1.4 (36) 5.2 (132) 1.7 (43) 6.2 (158) 2.3 (57) 6.8 (172) [B] Core I.D. 0.68 (17,3) 0.84 (21,3) 1.07 (27,2) 3MTM Cold Shrink Silicone Rubber Connector Insulators 8440 Series Product Specifications Engineering and Architectural Specifications Performance Tests Exposed metallic connectors joining power cable conductors rated 1000 volts or less shall be covered with 3MTM Cold Shrink Silicone Tubular Rubber Insulation 8440 Series. The inline connections shall be insulated in accordance with the instructions provided with the 3MTM Cold Shrink Connector Insulator 8443-6, 8445-7.5, and 8447-8. The connecting barrel portion of terminal lugs shall be insulated in accordance with the instructions provided with the 3MTM Cold Shrink Connector Insulators 8443-2, 8445-2.5, and 8447-3.2. A silicone rubber cold shrink connector insulator must be capable of normal operation through a temperature range of 66F/ -55C to 500F/260C. It must be usable without additional covering or adhesive both indoors and outdoors, in cable tray or overhead applications on cables rated up to 1000V. It must be applied without additional heat or flame and, when applied according to manufacturer's directions, be immediately energizable. It must not support flame or be adversely affected by moisture, mild acids or alkalies, ozone or ultraviolet light. It must provide resistance to aircraft fluids and be compatible with all rubber and plastic insulated power cables. Flammability Test The test for flammability of the 3M Cold Shrink Insulators 8440 Series was conducted with specimens positioned both vertically and horizontally per specification BSS 7230. The silicone rubber insulation passed the Flammability Test of BSS 7230 without supporting a flame. In addition, these insulators were also subjected to a gas flame test as outlined in paragraph 4.4.15 of MIL-C24643A and met the passing criteria as specified. No fuse was blown during the one hour flame exposure. Humid Environment Tests to verify electrical integrity through conditions of high humidity were run per Mil Standard 202- Method B. The test duration was 10 days at 104F/40C and 95% RH. Typical test values are found in Table 2. Test Before After Insulation Resistance 3.0 x 1012 2.5 x 1012 Withstand 2500 V-rms 2500 V-rms Table 2 Result Pass Pass Ultraviolet Resistance After 1000 hours of testing in a Weather-O-Meter according to Specifications ASTM D750 and ASTM G23, the silicone rubber insulation did not exhibit crazing, cracking or change in surface appearance. Thermal Shock Assembled units from the fluid resistance test were used for the thermal shock evaluation. The units were subjected to 15 cycles of the following thermal shock sequence: 1. 2. 3. 4. 30 minutes at -66F/ -55C 5 minutes at 74F/23C 30 minutes at 500F/260C 5 minutes at 74F/23C The insulation resistance values and results of test are found in Table 3. 3 of 5 3MTM Cold Shrink Silicone Rubber Connector Insulators 8440 Series Performance Tests (continued) Fluid Monsanto L.D. Jet A MIL-L-7808 MIL-L-23699 5% Saline Insulation Resistance 1.5 x 1013 ohms 1.0 x 1012 ohms 7.0 x 1012 ohms 1.7 x 1012 ohms 3.5 x 1012 ohms 6.5 x 1012 ohms 8.0 x 1012 ohms 3.5 x 1012 ohms 9.0 x 1012 ohms 6.5 x 1012 ohms Test Before After Before After Before After Before After Before After Withstand Result 2500 V-rms 2500 V-rms 2500 V-rms 2500 V-rms 2500 V-rms 2500 V-rms 2500 V-rms 2500 V-rms 2500 V-rms 2500 V-rms Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Altitude Electrical integrity at high at high altitudes was determined by testing to Mil Standard 1344A, Test method 1004.1. Typical test values are found in Table 4. Altitude 50,000 70,000 Insulation Resistance 1.0 x 1011 ohms 1.8 x 1012 ohms Withstand 2500 V-rms 2500 V-rms Table 4 Result Pass Pass Heat Aging Installed silicone rubber insulators were subjected to an eight hour heat aging test at 500F/260C. Other units were subjected to 401F/205C for 30 days. The silicone rubber remained resilient and showed no sign of deterioration. Fluid Resistance To determine the effect of a fluid splash on insulated connected assemblies, the units were subjected to ten cycles of the following test sequence: 1. One minute fluid soak 2. 24 hour, 74F/23C ambient dry 3. Insulation resistance measurement 4. 2.4 kV-rms withstand Results from the fluid resistance test are found in table 5. Fluid Splash Test Insulation Resistance/2500 V-rms Withstand Fluid Monsanto L.D. Jet A MIL-L-7808 MIL-L-23699 5% Saline Initial 1.5 x 1013/Pass 1 2 3.0 x 109 ohms 1.2 x 109 ohms 2.0 x 1012 ohms 1.2 x 1012 ohms 8.0 x 1012 ohms 2.5 x 1012 ohms 3.5 x 1012 ohms 2.0 x 1012 ohms 5.0 x 1012 ohms 5.0 x 1012 ohms 3 4 4.0 x 107 ohms 1.8 x 107 ohms 1.2 x 1012 ohms 8.0 x 1011 ohms 2.5 x 1012 ohms 4.0 x 1012 ohms 3.5 x 1012 ohms 3.0 x 1012 ohms 3.0 x 1012 ohms 4.0 x 1012 ohms 5 6 8.0 x 106 ohms 6.0 x 106 ohms 3.0 x 1011 ohms 2.0 x 1011 ohms 2.0 x 1012 ohms 2.5 x 1012 ohms 6.0 x 1012 ohms 1.8 x 1012 ohms 2.0 x 1012 ohms 7.0 x 1012 ohms 7 8 5.0 x 106 ohms 4.0 x 106 ohms 1.8 x 1011 ohms 1.0 x 1011 ohms 1.0 x 1012 ohms 2.5 x 1012 ohms 9.0 x 1012 ohms 1.0 x 1011 ohms 1.4 x 1012 ohms 3.0 x 1012 ohms 9 10 4.0 x 106 ohms 3.5 x 106 ohms 1.0 x 1011 ohms 7.0 x 1010 ohms 6.5 x 1011 ohms 1.0 x 1012 ohms 3.0 x 1012 ohms 5.0 x 1011 ohms 1.2 x 1012 ohms 5.0 x 1012 ohms 7.2 x 1012/Pass 3.5 x 1012/Pass 8.0 x 1012/Pass 9.0 x 1012/Pass Table 5 4 of 5 3MTM Cold Shrink Silicone Rubber Connector Insulators 8440 Series Maintenance Components of 3MTM Cold Shrink Silicone Rubber Connector Insulators are stable under normal storage conditions for a period of three years from the date of manufacture. The cold shrink insulators are not impaired by freezing or overheating due to the ambient temperatures found in storage or shipping. Normal storage and stock rotation are recommended. Approximate Installed Weight Terminal Lug Insulators Inline Connector Insulators 8443-2 Weight oz. (gm) 0.123 (3.5) 8443-6.5 Weight oz. (gm) 0.388 (11.0) 8445-2.5 0.190 (.54) 8445-7.5 0.564 (16.0) 8447-3.2 0.335 (9.5) 8447-8 0.776 (22.0) Part No. Part No. Table 6 Shelf Life & Storage 3MTM Cold Shrink Silicone Rubber Connector Insulators 8440 Series have a 3-year shelf life from date of manufacture when stored in a humidity controlled storage (10C/50F to 27C/80F and <75% relative humidity). Availability Please contact your local distributor; available from 3M.com/electrical [Where to Buy] or call 1.800.245.3573. 3M is a trademark of 3M Company. 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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 3M product or refund the purchase price of the 3M product. Except where prohibited by law, 3M will not be liable for any indirect, special, incidental or consequential loss or damage arising from this 3M product, regardless of the legal theory asserted. 3M Electrical Markets Division 6801 River Place Blvd. Austin, TX 78726-9000 800.245.3573 FAX: 800.245.0329 www.3M.com/electrical Please recycle (c) 3M 2014 All rights reserved 78-8124-5813-7 Rev C 5 of 5