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Page 1 of 4 78-8124-5813-7

Silicone Rubber Cold ShrinkConnector Insulators 8440 Series

Data Sheet

1.0 Product Description

3M Cold Shrink Connector Insulators 8440 Series are openended, 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 thispre-stretched condition. As the core is unwound, the insulatingsleeve shrinks to form a tight seal. Three sizes of Cold ShrinkInsulators cover terminal lug barrels and three sizes of ColdShrink Insulators cover inline connectors. Each insulator type,collectively has an application range of 0.35" (8,86 mm) to 0.95"(24,13 mm) for installations on #6 AWG to 3/0 AWG.

Simple installation, requires only workman's hands. No tools required. No heat required for installation. Seals tight, retains its resiliency and pressure even after

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 - 66 F/ - 55 C to

500F/260C.

2.0 Applications

Primary electrical insulation for all solid dielectric(rubber and plastic) insulated wire and cable splicesrated to 1000 volts.

Electrical Aircraft cables. For indoor, outdoor, in cable tray for overhead use. Physical protection and moisture sealing for high voltage,

air insulated connectors and lugs. Insulation of secondary splices, copper and aluminum

conductors. Sheath repairs. Insulation for inline conductor transition connector.

3.0 Data: Physical & Electrical Properties

High Stretch Silicone Rubber

Typical Physical Properties

Test Method Typical Values

Color Grey

100% Modulus 180 psiASTM D412-75 (1.24MPa)

Ultimate Tensile 1240 psiASTM D412-75 (8.55 MPa)

Die B Tear 185 psiASTM D624B-73 (1.28 MPa)

Shore A Hardness 48ASTM D2240-75

Specific Gravity 1.23

Permanent Set 7.1%100% Strain - 22 hours@ 212 F/100 C

Dielectric Strength 554 Volts/milASTM D149-75 (21.8 MV/m)@1.78 mm thickness

Dielectric Strength 543 Volts/mil168 hours in H2O (21.4 MV/m)@194F/90C

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78-8124-5813-7 Page 2 of 4

4.0 Specifications Product

Exposed metallic connectors joining power cableconductors rated 1000 volts or less shall be coveredwith 3M 8440 Series Silicone Cold Shrink tubularrubber insulation.

The inline connections shall be insulated in accordancewith the instructions provided with the 3M ColdShrink Connector Insulator 8443-6, 8445-7.5, and8447-8. The connecting barrel portion of terminal lugsshall be insulated in accordance with the instructions

provided with the 3M

Cold Shrink ConnectorInsulators 8443-2, 8445-2.5, and 8447-3.2.

Engineering/Architectural

A silicone Cold Shrink Connector Insulators must becapable of normal operation through a temperaturerange of -66F/ -55C to 500F/260C. It must beusable without additional covering or adhesive bothindoors and outdoors, in cable tray or overheadapplications on cables rated up to 1000V. It must beapplied without additional heat or flame and, whenapplied according to manufacturer's directions, beimmediately energizable. It must not support flame or

be adversely affected by moisture, mild acids oralkalies, ozone or ultraviolet light. It must provideresistance to aircraft fluids and be compatible with allrubber and plastic insulated power cables.

5.0 Performance Tests

A. Flammability Test

The test for flammability of the 3M Cold ShrinkInsulators 8440 Series was conducted with specimenspositioned both vertically and horizontally perspecification BSS 7230. The silicone rubber insulationpassed the Flammability Test of BSS 7230 withoutsupporting a flame. In addition, these insulators werealso subjected to a gas flame test as outlined inparagraph 4.4.15 of MIL-C-24643A and met thepassing criteria as specified. No fuse was blownduring the one hour flame exposure.

B. Humid Environment

Tests to verify electrical integrity through conditionsof high humidity were run per Mil Standard 202-Method B. The test duration was for 10 days at104F/40C and 95% RH. Typical test values are foundin Table 2.

C. Ultraviolet Resistance

After 1000 hours of testing in a Weather-O-Meteraccording to Specifications ASTM D750 and ASTM

G23, the silicone rubber insulation exhibited nocrazing, cracking or change in surface appearance.

Expanded Silicone Rubber Tube

3/8"(9,5 mm)min.

A

BLoose Core End

Plastic supporting core

Table 2

Table 1

traPrebmuN

egnaRelbaC egnaRnoitacilppA

)mm(sehcnI

snoisnemiD

)mm(sehcnI

GWA*.aiD.niM

laeSrof

**.aiD.xaM

srevoCrotalusnI

BA

)eroC(.D.IhtgneL

2-3448 2-6 )68.8(053. )22.41(065. )63(4.1 )3.71(86.0

5.6-3448 2-6 )68.8(053. )22.41(065. )231(2.5 )3.71(86.0

5.2-5448 0/1-2 )7.01(024. )92.81(027. )34(7.1 )3.12(48.0

5.7-5448 0/1-2 )7.01(024. )92.81(027. )851(2.6 )3.12(48.0

2.3-7448 0/3-0/1 )41(055. )31.42(059. )75(3.2 )2.72(70.1

8-7448 0/3-0/1 )41(055. )31.42(059. )271(8.6 )2.72(70.1

tseTnoitalusnIecnatsiseR

dnatshtiW tluseR

erofeB 01x0.3 21 smr-V0052 ssaP

retfA 01x5.2 21 smr-V0052 ssaP

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Page 3 of 4 78-8124-5813-7

D. Thermal Shock

Assembled units from the fluid resistance test were usedfor the thermal shock evaluation. The units were subjectedto 15 cycles of the following thermal shock sequence:

1. 30 minutes at -66F/ -55C.2. 5 minutes at 74F/23C.3. 30 minutes at 500F/260C.4. 5 minutes at 74F/23C.

The insulation resistance values and results of test arefound in Table 3.

E. Altitude

Electrical integrity at high altitudes was determined bytesting to Mil Standard 1344A, Test method 1004.1.Typical test values are found in Table 4.

F. Heat Aging

Installed silicone rubber insulators were subjected to an

eight hour heat aging test at 500F/260C. Other units weresubjected to 401F/205C for 30 days. The silicone rubberremained resilient and showed no sign of deterioration.

Table 3

Table 4

diulF tseTnoitalusnI

ecnatsiseRdnatshtiW tluseR

.D.LotnasnoMerofeB

retfA01x5.1 31 smho01x0.1 21 smho

smr-V0052smr-V0052

ssaPssaP

AteJerofeB

retfA

01x0.7 21 smho

01x7.1 21 smho

smr-V0052

smr-V0052

ssaP

ssaP

8087-L-LIMerofeB

retfA

01x5.3 21 smho

01x5.6 21 smho

smr-V0052

smr-V0052

ssaP

ssaP

99632-L-LIM

erofeB

retfA

01x0.8 21 smho

01x5.3 21 smho

smr-V0052

smr-V0052

ssaP

ssaP

enilaS%5erofeB

retfA

01x0.9 21 smho

01x5.6 21 smho

smr-V0052

smr-V0052

ssaP

ssaP

edutitlAnoitalusnIecnatsiseR

dnatshtiW tluseR

000,05 01x0.1 11 smho smr-V0052 ssaP

000,07 01x8.1 21 smho smr-V0052 ssaP

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G. Fluid Resistance

To determine the affect of a fluid splash on insulatedconnected assemblies, the units were subjected to tencycles 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 foundin table 5.

6.0 Maintenance

Components of 3M Silicone PST Cold ShrinkConnector Insulators are stable under normal storageconditions for a period of three years from the date ofmanufacture. The Cold Shrink Insulators are notimpaired by freezing or overheating due to the ambienttemperatures found in storage or shipping. Normalstorage and stock rotation are recommended.

7.0 Availability

3M Silicone PST Cold Shrink Connector Insulators8440 Series are available through your localauthorized 3M electrical distributor.

Electrical Products Division

6801 River Place Blvd.Austin, TX 78726-9000800/245-3573 Printed on 50% recycled paper Litho in USAwww.3M.com/elpd with 10% post-consumer 3M 2003 78-8124-5813-7 Rev. B

IMPORTANT NOTICE

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.

Warranty; Limited Remedy; Limited Liability. This product will be free from defects in material and manufacture as of the date ofpurchase. 3M MAKES NO OTHER WARRANTIES INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OFMERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. If this product is defective within the warranty period stated above,your exclusive remedy shall be, at 3Ms option, to replace or repair the 3M product or refund the purchase price of the 3M product. Exceptwhere prohibited by law, 3M will not be liable for any loss or damage arising from this 3M product, whether direct, indirect, special,incidental or consequential regardless of the legal theory asserted.

Fluid Splash Test Insulation Resistance/2500 V-rms Withstand

Table 5

Table 6

diulF .D.LotnasnoM AteJ 8087-L-LIM 99632-L-LIM enilaS%5

laitinI 01x5.1 31 ssaP/ 01x2.7 21 ssaP/ 01x5.3 21 ssaP/ 01x0.8 21 ssaP/ 01x0.9 21 ssaP/

1

2

01x0.3 9 smho

01x2.1 9 smho

01x0.2 21 smho

01x2.1 21 smho

01x0.8 21 smho

01x0.2 21 smho

01x5.2 21 smho

01x0.5 21 smho

01x5.3 21 smho

01x0.5 21 smho

34

01x0.4 7 smho01x8.1 7 smho

01x2.1 21 smho01x0.8 11 smho

01x5.2 21 smho01x0.3 21 smho

01x0.4 21 smho01x0.3 21 smho

01x5.3 21 smho01x0.4 21 smho

5

6

01x0.8 6 smho

0.6 x 01 6 smho

01x0.3 11 smho

01x0.2 11 smho

01x0.2 21 smho

01x8.1 21 smho

01x5.2 21 smho

01x0.2 21 smho

01x0.6 21 smho

01x0.7 21 smho

7

8

0.5 x 01 6 smho

0.4 x 01 6 smho

01x8.1 11 smho

01x0.1 11 smho

01x0.1 21 smho

01x0.1 11 smho

01x5.2 21 smho

01x4.1 21 smho

01x0.9 21 smho

01x0.3 21 smho

901

0.4 x 01 6 smho5.3 x 01 6 smho

01x0.1 11 smho01x0.7 01 smho

01x5.6 11 smho01x0.5 11 smho

01x0.1 21 smho01x2.1 21 smho

01x0.3 21 smho01x0.5 21 smho

thgieWdellatsnIetamixorppA

srotalusnIrotcennoCenilnIsrotalusnIguLlanimreT

.oNtraPthgieW

)mg(.zo.oNtraP

thgieW

)mg(.zo

2-3448 )5.3(321.0 5.6-3448 )0.11(883.0

5.2-5448 )45.(091.0 5.7-5448 )0.61(465.0

2.3-7448 )5.9(533.0 8-7448 )0.22(677.0