connector installation guide compression and mechanical … · 2018. 5. 8. · • 75°c - use the...
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Connector Installation Guide
Compression and Mechanical
Connectors
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Typical Cross Section of a
Compression Connector Before
Installation
Before compression, a
typical cross section of
cable consists of 75%
metal and 25% air
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Typical Cross Section of a
Compression Connector After
Installation
After compression, little air is left.
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1 - 2 hole lug
H-Taps
C-Taps Narrow Tongue Single & Dual
Mounting holes
Grid Grounding Splices
Compression
Connector Types
Flared-End
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1. Determine Proper Connector For Cable • Conductor size and CU = Copper conductors only
• Conductor size and “AL9” = Aluminum conductors only
• Conductor size and “AL9CU” = Aluminum or Copper
conductors
• Match size and type of conductor to proper lug
Note: Consult manufacturers instructions on whether fine stranded conductors
or welding cable conductor types may be used.
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• Manufacturer
• Wire Size
• Wire material- CU, AL, or AL9CU (indicates
Dual Rating and 90° C)
• Optional Crimp Indicator Bands
• Listing Information
Marking Information on Connectors:
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2. Strip and Properly Prepare Cable
• Strip insulation carefully to avoid nicking strands.
• Strip to proper length so conductor can be fully inserted.
• Refer to manufacturer’s instructions for strip length.
• Most connectors are suitable for one conductor. Never
install more than one conductor unless specifically
allowed by the manufacturer’s instructions.
Aluminum Conductor –
• Brush the stripped portion of the conductor to
remove oxide film using a stainless steel wire brush.
• Apply oxide inhibitor compound and wire brush into
the stranding. Do not remove pre-filled inhibitor from
the barrel.
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Installation Guide for
Compression
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3. Select proper installing die tool • Always refer to the connector manufacturer’s instructions for the
proper compression die that is intended for the connector.
• Manufacturer’s may use colored bands or dots that correspond
to color markings on dies.
• Manufacturer’s may use die code number marked or stamped on
the connector.
• Knurls may be used in place of colored bands.
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4. Locate tool with correct die in proper position on connector
and activate tool • Connectors that are banded with colored stripes to indicate
number and location of each crimp.
• Connectors may also be marked with the die code number at
each compression location.
• Follow manufacturers instructions whether to crimp on the
colored bands or between the colored bands.
1st Crimps
2nd Crimps
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4. Continued….
When crimped, the die code number or other marking will be
embossed on connector for easy inspection to determine if
correct die and connector combination were used.
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Select proper installing dieless tool • Crimp as directed by the manufacturer’s instructions.
Dieless Tools
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Use a 2-hole connector if there is a
concern for twisting the connection.
5. Connector Securement
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Installation Guide
for Mechanical
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Overhead
Transformer
Single
Conductor
Lug
Stud Type Transformer
Double
Conductor
Lug
Double
Conductor
Lug, NEMA
Pad
Copper
Single
Conductor
Lug
Mechanical
Connector Types
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• Manufacturer’s name or Symbol
• Wire Size or range
• Wire material- CU, AL, or Both
• Temperature Rating if applicable
• AL9CU Shows Dual Rating (Al & Cu) and 90°C
• UL and/or CSA if it is a listed connector
Marking Information on Connectors:
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1. Unlike Compression connectors, mechanical connectors
typically take a range of conductors. It is important to check
that the cable falls within the cable range listed on the
connector.
2. If the connector is intended to be used on a bus, pad or
equipment, mount the connector and tighten the mounting
hardware per the manufacturer’s specifications.
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3.Strip and Properly Prepare Cable • Strip insulation carefully to avoid nicking strands
• Strip to proper length so conductors can be fully
inserted
• Refer to manufacturers instructions for strip length
• Aluminum Conductor –
• Brush the stripped portion of the conductor to
remove oxide film with a stainless steel wire brush.
Apply oxide inhibitor compound and wire brush into
the stranding
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4. Insert the conductor(s) and tighten all set screws per the manufacturer’s recommendations.
• Do not retighten after properly torqued.
• Most connectors are suitable for one conductor. Never
install more than one conductor unless specifically
allowed by the manufacturers instructions.
• Use the mounting bolt size as recommended by the
manufacturer.
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Split Bolts
• Generally used as taps.
• If conductors are different materials, a spacer bar is included. Aluminum conductor should always be positioned on top.
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• Voltage Rating (Insulated Only)
• 300 volts
• 600 volts
• 1000 volts signs/luminaires
• Note: NOT MARKED
• Non-insulated listed connectors are suitable for 2,000 volts. They may be used over 2,000 volts up to 35,000 volts where the effects of corona have been investigated.
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• Non-insulated Temperature Rating
• 75°C - Use the connector at 75°C ampacity
• 90°C - Use the connector at 90°C ampacity
• Higher temp rated conductors at higher ambient
temperatures may be used as long as the ampacity
levels are used per the connector rating.
• Use the NEC® to obtain the conductor ampacity ratings.
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• Insulated Temperature Rating
– Never exceed the temperature rating of
an insulated connector. See Packaging
or Product for the marking.
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Conductor Material
– AL 9 Aluminum 90°C
– AL9CU CU9AL Aluminum/Copper 90°C
– AL7 Aluminum 75°C
– AL7CU CU7AL Aluminum/Copper 75°C
AL9CU
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• Grounding
• DB Direct Burial
• The connector is suitable for
direct burial in the soil or
embedded in concrete.
Installation Guide
for Grounding
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DB = Direct Burial
Suitable Conductor
Compression Die Information
Rod size Information
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Look for the product markings for suitability for
attachment to rods, pipe, and concrete encased
reinforcement steel.
Grounding Connections
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Rod size
Conductor size
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Direct burial
Conductor size
Rebar size
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Suggested Ways to
Load or Balance
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X Incorrect application
Improper Way to
Load or Balance
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Straight Cut
Correct
Angled Cut
Incorrect 2. Not fully inserted
3. Straight Cut
on end of wire
5. Correct
insulation
strip length
1.
Fully
inserted
4. Missing wire plugs or
screw plugs
Wire
Plugs
Screw
Plugs
Typical Failure Modes
in Sealed Connectors
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Safety Standards
Wire Connectors
• UL 486A-486B
• CSA C22.2 No. 65
• ANCE NMX-J-543
• ANSI C119.1, C119.4,
C119.5, C119.6
Splicing Wire Connectors
• UL 486C
• CSA C22.2 No. 188
• ANCE NMX-J-548
Grounding and Bonding Equipment
• UL 467
• CSA C22.2 No. 41
• ANCE NMX-J-567