Motor Lead Pigtail Splice for 1000 volts (or less) cables with one-hole lugs For two-hole lug connections, use 3MTM Motor Lead Pigtail Splice Kits 5316 thru 5319 Instructions CSA Certified for 600V or Less Kit Contents (kit contains 3 splices): 3 3 3 3 Lug Covers Locking Pins Tubes Silicone Grease Mastic Sealing Strips Kit Selection Table Kit Number Cable Size Range AWG/kcmil (mm2) Feeder Motor Lead Cable Insulation O.D. Range in. (mm) Lug Cover* I.D. in. (mm) Maximum Bolt Length in. (mm) 5302 2 - 1/0 (35 -60) 4 - 1/0 (25 - 50) 0.34 - 0.54 (9 - 14) 0.95 (24) 3/4 (19) 5303 1/0 - 250 (70 - 120) 2 - 250 (35 - 120) 0.40 - 0.80 (10 - 20) 1.20 (30) 1-1/4 (32) 5304 250 - 500 (150 - 240) 4/0 - 500 (120 - 240) 0.67 - 1.05 (17 - 27) 1.70 (43) 1-1/2 (38) * Lug cover I.D. - use when calculating kit sizing for a connection of more than two conductors (e.g. 3-way, 4-way, etc. Use of one-hole stacking lugs is recommended.) Table 1 Technical Information: For use on Non-Shielded Cables 1000 Volts (or less) with one-hole lugs. Cable Size Range: Feeder: 2 AWG-500 kcmil Motor Lead: 4 AWG-500 kcmil Copper Conductors 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. 3MTM Motor Lead Pigtail Splice Kits for 1000 Volts (or less) 5302, 5303, 5304 78-8126-5500-5-C A. Prepare Cables According to Standard Procedures B. Install Lugs 1. Install and crimp lugs per manufacturer's direction. (See back page if 3MTM ScotchlokTM Copper Lugs are used.) 1. Check to be sure cable sizes fit within the kit range as shown in Table 1. 2. Clean insulation (or jacket as applicable) for approximately 6" (152 mm). 2. Remove cable insulation for length recommended by terminal lug manufacturer; if no information is available, remove for depth of lug barrel. 3. Bolt lugs together. See Table 1 for maximum bolt length, and Figure 1 for proper bolt/lug arrangement. Note: If a split bolt connector is used, refer to Table 2 below for maximum split bolt size for each kit. C. Installation Kit No. Max. Split Bolt Size 5302 4 AWG 5303 2 AWG 5304 250 kcmil Note:If moisture resistance is not required, proceed to Step 4. 1. To gauge mastic build up in next step, temporarily install lug cover over bolted lugs, leaving 1/2" (13 mm) of lug exposed. Table 2 Note:Position lug cover so punched holes are positioned between the two conductors (Figure 3). 2. Separate the cables and apply mastic strip around insulation and between them at a position just onto insulation (Figure 3). For jacketed feeder cable, see note below. Build thickness so the overall diameter is slightly larger than the observed inside diameter of the lug cover. Press cables together and be sure that no MASTIC STRIP OVERWRAPPED WITH VINYL TAPE LUG COVER Figure 1 For Jacketed Feeder Cable Only: HOLE FOR LOCKING PIN I f jacketed feeder cable is used, remove an additional 1/2" (13 mm) of jacket, leaving 1/2" (13 mm) of cable insulation exposed (Figure 2). Jacket " APPLY SILICONE GREASE Figure 3 Insulation For Jacketed Feeder Cable Only: or jacketed feeder cable, center mastic strip over cutF back edge of cable jacket, so that it seals onto both the cable jacket and insulation (Figure 4). JACKET EDGE INSULATION LUG COVER Figure 2 HOLE FOR LOCKING PIN MASTIC STRIP OVERWRAPPED WITH VINYL TAPE APPLY SILICONE GREASE Figure 4 78-8126-5500-5-B void exists between them. 3. Overwrap the mastic with 1 or 2 wraps of vinyl tape. 4. Install lug cover. Note:The kit contains a small tube of silicone grease. Use it to lightly lubricate the mastic-vinyl wrap. This will aid in installng the lug cover (Figure 3 or 4, as applicable). LUG COVER 5. Be sure the locking pin (punched) holes are beyond the cable end of the mastic-vinyl wrap. Insert plastic locking pin through holes. HINT: Inserting pin from the blind (back) side of lug cover will aid in visually seeing the pinpoint for proper alignment through the second hole (Figure 5). LOCKING PIN 6. Cut off excess pin length, if desired. Must leave 1/4" (6 mm) extended out of cap. Figure 5 Lug and Crimping Information for 3MTM ScotchlokTM Copper Lugs 30018 thru 31067 One hole 5.0 Copper Lugs Cable Size 4 2 1 Stud Size 10 1/4 3/8 1/4 5/16 3/8 5/16 3/8 1/0 3/8 2/0 3/0 4/0 250 300 350 400 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 5/8 500 CRIMPING TOOL-DIE SETS (NO. OF CRIMPS) ScotchlokTM Copper Lug Number 30018 30019 30021 30022 30023 30024 30027 30028 30031 30032 30036 30041 30045 31049 31053 31056 31060 31066 31067 Thomas & Betts Corporation Burndy Corporation MD6 MY29 Y34A Y35,Y39, Y45*,Y46* T BM 5 T BM 8 T BM 1 5 W161(1) 4 AWG(1) A4CR(1) U4CRT(1) Blue(1) Grey(1) -- Universal(1) W162(2) 2 AWG(1) A2CR(1) U2CRT(2) Grey(1) Brown(1) 33(1) Universal(2) -- 1 AWG(1) A1CR(1) U1CRT(2) Green(1) Green(1) 37(1) Universal(2) W163(2) 1/0(1) A25R(1) U25RT(1) Pink(2) Pink(2) 42H(2) Universal(1) W241(2) W243(2) BG(3) W166(4) ---- 2/0(1) 3/0(1) 4/0(1) 250(2) ---- A26R(1) A27R(1) A28R(2) A29R(2) A30R(2) A31R(2) A32R(2) U26RT(2) U27RT(2) U28RT(2) U29RT(3) U30RT(3) U31RT(3) U32RT(3) Black(2) Orange(2) Purple(2) Yellow(2) ---- Black(2) Orange(2) Purple(2) Yellow(2) White(3) Red(4) Blue(4) 45(1) 50(1) 54H(2) 62(2) 66(3) 71H(4) 76H(4) Universal(1) Universal(2) Universal(2) Universal(2) Universal(3) --- -- -- A34R(2) U34RT(3) -- Brown(4) 87H(4) -- *Y45 and Y46 accept all Y35 dies ("U" Series). ForY45 use PT6515 adapter. For Y46 use PUADP adapter. **Anderson VC6-3 and VC6-FT and Burndy Y1000 require no die set. 78-8126-5500-5-B Square D Co. Anderson Div. VC6-3, VC6-FT** Appendix A Appendix B Splice Removal Splice Reusability 1. Remove Locking Pin from Lug Cover. 2. Slide Lug Cover off of lugged or split-bolt connection. 1. First inspect the removed Lug Cover and Locking Pin for damage or wear. Replace with a new splice if evidence of damage or wear is found. 3. If splice was sealed for moisture resistance: Remove Mastic and Vinyl Tape Seal from cables. 2. Obtain material to replace the non-reusable splice components. 4. Remove nut and bolt (or split-bolt) to separate the motor lead from the feeder cable(s). 3. Re-Install the splice according to the standard kit instructions. Caution Reusable Components Be careful not to damage cables. * Lug Cover * Locking Pin Replacement Components These are standard 3M products, available from 3M Electrical Markets Division. * 3MTM Scotch-SealTM Mastic Strip 2230 (UPC 054007-41813), 5/8" x 6", 40/case * SIL-5cc Silicone Grease (UPC 054007-41814), 5ccTube * Scotch(R) Super 33+TM Vinyl Electrical Tape (UPC 054007-06132), 3/4" x 66' * 3M Pin-Lug Cover, 2" Lg. (78-8041-7208-4, special order) 3M, Scotchlok, Super 33+ and Scotch-Seal are trademarks of 3M Company. Scotch is a registered trademark of 3M Company. 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. 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 for a period of one (1) year from 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 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. 3 Electrical Markets Division 6801 River Place Blvd. Austin, TX 78726-9000 800-245-3573 Fax 800-245-0329 www.3M.com/electrical Please recycle. Printed in USA. (c) 3M 2007. All rights reserved. 78-8126-5500-5-C