Presentation ILSCO Connector Installation Guide REV 02.03.16
User Manual: ILSCO Connector Installation Guide Technical Resources – ILSCO
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Connector Installation Guide Compression and Mechanical Connectors Typical Cross Section of a Compression Connector Before Installation Before compression, a typical cross section of cable consists of 75% metal and 25% air Typical Cross Section of a Compression Connector After Installation After compression, little air is left. Compression Connector Types 1 - 2 hole lug Single & Dual Narrow Tongue Flared-End C-Taps Mounting holes Splices H-Taps Grid Grounding 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. Marking Information on Connectors: • Manufacturer • Wire Size • Wire material- CU, AL, or AL9CU (indicates Dual Rating and 90° C) • Optional Crimp Indicator Bands • Listing Information 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. Installation Guide for Compression 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. 1st Crimps 2nd Crimps 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. 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. Dieless Tools Select proper installing dieless tool • Crimp as directed by the manufacturer’s instructions. 5. Connector Securement Use a 2-hole connector if there is a concern for twisting the connection. Installation Guide for Mechanical Mechanical Connector Types Double Conductor Lug Double Conductor Lug, NEMA Pad Single Conductor Lug Copper Single Conductor Lug Overhead Transformer Stud Type Transformer Marking Information on Connectors: • • • • • • 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 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. 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 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. Split Bolts • Generally used as taps. • If conductors are different materials, a spacer bar is included. Aluminum conductor should always be positioned on top. • • • • • • 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. • 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. • Insulated Temperature Rating – Never exceed the temperature rating of an insulated connector. See Packaging or Product for the marking. Conductor Material – – – – AL 9 AL9CU CU9AL AL7 AL7CU CU7AL AL9CU Aluminum 90°C Aluminum/Copper 90°C Aluminum 75°C Aluminum/Copper 75°C Installation Guide for Grounding • Grounding • DB Direct Burial • The connector is suitable for direct burial in the soil or embedded in concrete. DB = Direct Burial Suitable Conductor Compression Die Information Rod size Information Grounding Connections Look for the product markings for suitability for attachment to rods, pipe, and concrete encased reinforcement steel. Rod size Conductor size Direct burial Conductor size Rebar size Suggested Ways to Load or Balance Improper Way to Load or Balance X Incorrect application Typical Failure Modes in Sealed Connectors Fully inserted Angled Cut 1. Incorrect Straight Cut Correct 2. Not fully inserted 3. Straight Cut on end of wire Screw Plugs Wire Plugs 4. Missing wire plugs or screw plugs 5. Correct insulation strip length 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
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