3/9/2015

Electrical Connectors,in their

simplest form, join two or more
conductors in a continuous
electrically conductive path.
New connector surfaces look and feel very
smooth,but the picture changes quickly
when
h
viewed
i
d under
d a microscope.
i
Metallic
lli
surfaces look very rough under high
magnification.
That causes surfaces of mated
connectors to touch only at a few
spots, called asperities.

Tightening connectors applies localized pres sure

to these asperities, which causes them to
deform. Deformations increases the contact
area, but it is still limited to some loadbearing areas, so called a-spots.
They add up,but their overall area is still by
several orders of magnitude smaller than the
apparent contact surface of connectors. 4

3/9/2015

Skin effect is called the property of

alternating current to show higher current
density closer to a conductor surface.
Current flows mainly at the skin of the
conductor between the outer surface and a
level called the skin depth.

A good electrical connection

requires three basic elements:
1 Proper Connector
1.
2. Suitable Cable Preparation
3. Correct Installation Procedure

CREEP
What is creep?
Creep is the permanent elongation of the
cable due to everyday tensions that the cable
experiences over a period of time.
All overhead line will encounter p
periods of
hi h lloads
high
d which
hi h will
ill increase
i
the
h temperature
of the conductor.
At this temperature, copper & aluminum
conductor will move (creep). The Cu more than
Al.
Hence, when making connections the contact
area must be large to minimize the applied
pres sure.
7

3/9/2015

Overhead connectors will

require the full range of
securenes s; from full tension
applications to strain relieve
applications where little
mechanical stres s or
vibrations will occur.
How secure must a
connection be is the key to
MI.

CU

Oxidation

AL

Galvanic

Oxidation can develop on both the

connector and the conductor to be joined

Copper oxide layers will reduce the

number of contacting points in a
connection, thus increasing the contact
resistance
Evidence of copper oxide can be seen as a black
or green surface discoloration. Copper oxide
layers will reduce the number of contacting points
in a connection, thus increasing the contact
resistance. The conductors should be cleaned prior
10
to making a connection.

3/9/2015

Low in
conductivity

11

12

Aluminum oxide, however, is a fast forming, hard,

non-conductive coating that develops on the
surface of aluminum conductors exposed to air.
Unlike copper oxides, aluminum oxide is not
visually obvious and should be as sumed to exist
in all cases of bare aluminum.
Aluminum oxide must be removed from a
conductors surface prior to making a
connection.
13

3/9/2015

Wire brushing and

the immediate
application of an
oxide inhibitor are
recommended to
p
prevent the
reformation of
the nonconductive
coating prior to
connector
installation.
14

An additional problem with aluminum

cable is the oxide layers that develop on
each inner strand of a cable. These
layers can cause high inter-strand
resistance and are not easily removed.

15

Both aluminum and copper conductors are

used in the overhead distribution system.
This use of dis similar metals can lead to
problems of galvanic corrosion if no
preventative action is taken
taken.
Aluminum is the anode in the galvanic cell
that is formed when in contact with
copper, and is therefore the material that
undergoes the corrosion.
16

3/9/2015

Finally, aluminum conductors should be

installed above copper conductors.
Moisture forming on copper conductors
(rain or condensation) will pick up copper
ions.
If this moisture then drops onto aluminum
conductors below, the copper salts will
cause the aluminum conductor to corrode.

17

Service entrance applications require a relatively

small number of connector types. When
connecting insulated conductor, only insulated
splices (insulink) and taps should be used.
Insulated connectors are designed to seal out
contaminants and moisture to minimize the
effects of galvanic corrosion.
The three fundamental connector functions are:
1. Tap
2. Terminal
3. Splice.

18

An electrical connection to a main,

continuous-run conductor for supplying
electrical energy to a branch
application(s) from the main runs
princi p
p
pal load.

19

3/9/2015

A connection used to join two different

forms of conductor, often incorporating
more than one means of connection
methodology

20

A connection that joins two (or more)

similar but non-continuous conductors
into one continuous run; or that joins
together two unconnected continuous
runs.

21

The types of connectors developed

over many years generally fall into
three broad categories:

22

3/9/2015

Mechanical connections employ

hardware or similar mechanical means
to create contact points and to maintain
the connection integrity.

23

Installed with Basic Tools

Tough
Simple to use
Physical Exertion is not exces sive

Reusable Can be dis sembles without

Damage

24

Non tension
Applications

Specific
Torque

Vibration

Difficult to
insulate
25

3/9/2015

Compres sion connections use

engineered tooling to crimp the
connector to the conductor with
high force,creating a permanent
electrical joint.
j

26

Low Cost

27

High
capital
for Tools

Die and
tool
selection

Installers
must be
trained

Physical
exertion

28

3/9/2015

Fusion connections are made primarily

by welding, soldering or brazing.

Welding

Soldering

Exothermic
29

Means of
installation

Tooling
Training
Proper
Application

Safety
30

The basic requirement of any electrical

connection is that it maintains both
structural and electrical integrity
throughout its expected life span.

General practices
that help ensure a
good electrical
connection:
31

10

3/9/2015

32

Conductor coverings and insulations protect

the conductor from corrosion and
mechanical damage, as well as provide
electrical separation conductive layers
and/or from external contact.
When installing a connector, the covering must
be removed completely without damaging the
underlying conductor.
The exposed conductor region must be of
sufficient length to accommodate the entire
contact surface(s) of the connector.
33

The insulation MUST be removed for a length

just greater than the contact length of the
connector to be installed.
In the case of compres sion connections, the
stri p length must include additional length to
compensate for the connectors extrusion
during crimping.
The underlying conductor must not be damaged
by cutting or nicking during the insulation
removal proces s.
Cut or nicked strands reduce the cros s sectional
area of the conductor and may result in an
eventual failure.
34

11

3/9/2015

Whether making mechanical or compres sion

connections,it is generally a recommended
practice to coat contact surfaces with an
oxide inhibiting compound.
These compounds have many attributes that
ensure good contact and enhance the
longevity of the connection. Benefits are:
1. helps produce low initial contact resistance
2. Prevention of oxidation and other corrosion
3. As sistance in increasing pullout strength of
the connection
35

All clamp type connections applications,

depend on the force developed by the
fastening hardware to provide a stable
electrical connection. For hardware to
adequately
this task,, it must:
q
y perform
p
1. Be strong enough to withstand the
torque
2. Develop the correct pres sure
3. Must remain reliable for the entire
expected service life
36

In outdoor installations where mixed metals are

used, aluminum conductors must be installed
above copper conductors whenever pos sible.
Moisture on copper conductor surfaces will
pp ions. If p
positioned above
accumulate copper
aluminum, these copper salts will wash onto the
aluminum and cause galvanic corrosion.

37

12

3/9/2015

In the event the aluminum conductor is located

below the copper, a dri p loop should be
provided on the copper conductor.
The dri p loop redirects the copper conductor
around and below the aluminum conductor for
attachment.
The loop formed allows corrosive moisture to
dri p from the copper conductor safely below
the aluminum.

38

In order to install a compres sion connector

such that its performance is to specification,
the following must be observed;

CABLE INSERTION

39

Premark the
cable

Insertion
i

Completion

Lay the connectors compres sion barrel along

the end of the conductor until the inner-most
crimp line is even with the conductors edge.
Mark the conductor with a pen or tape even
with the open end of the barrel.

As the cable is inserted into the barrel,a

twisting action of the connector / conductor
may
a be
b neces sary
a along
al g with
ith the
th insertion
i
ti
force. Twisting especially helps when the barrel
is lined with an oxide inhibitor.

When the conductor mark (or tape) is flush with

the end of the connectors barrel, the cable is
fully inserted.
40

13

3/9/2015

There is an unsanctioned field practice of adding

or, even worse, removing conductor strands
during the insertion proces s to facilitate
installation.
This practice is NOT recommended and could
result
situation.
lt in
i a dangerous
d
it ti
Changing the original conductor stranding by
adding or removing strands can lead to
improper compres sion which may adversely
affect the integrity of the connection.

41

The Y35 HYPRESS Tool incorporates a Cshaped,rotatable head for overhead line
work and compres sion grounding
applications.
The hook style head with extensive ram
travel provides for easy tapping and
splicing of overhead lines.
The Y35 HYPRESS head, body and handles
are covered with 3/16"rubber for tool
impact protection.
42

Installs full range of

connectors (taps,splices,
terminals): #14 through 4/0.
Full Tension and Non-Tension.
The MD6-8 installs almost all of the line, pole and
house connections. The tool has two (2)
permanent die grooves,O and D3 for
distribution tap connectors. The D3 groove also
serves as a seat for die inserts to install additional
splices, taps and terminal connectors.
43

14

3/9/2015

Installs service entrance splice connectors. Conductor

range: #10 through 1/0. The OH25 incorporates a full
cycle ratchet and cam mechanism allowing an easy,
one-hand crimping operation.
The ratchet mechanism provides for properly completed
crimps every time before the tool can be removed from
the connection.
The OH25 is designed to install 5/8" INSULINK service
entrance connectors with only (1) crimp per connector
end, speeding installation time.
The single crimp covers the complete
contact area, eliminating pos sible
overlapping or failure to make the
proper number of crimps.
44

The G06-300 Pfisterer

compres sion tool is used to
apply compres sion connectors
to all overhead line conductors.
The dies come in two thicknes s,
5mm for copper connectors and
7mm for aluminium connectors.
The operating size of the die will be the
same,if both bear the same identification
e.g. KP 22. The two halves of the die are
held together by means of a flexible steel
45
spring.

Installing the compres sion connector requires

the correct number of crimps to be applied by
the tool and die.
Making too few crimps can seriously impair
the long-term performance of a connection.
Crimp information is in the catalog,
catalog on the
specification sheet, and directly on the
connector itself.
Clearly marked knurls or color bands indicate
both the position and the number of crimps to
be applied.
46

15

3/9/2015

Normal practice is to start the crimping

from the middle, or innermost, crimp spaces.
Crimping is performed on alternating sides,
moving out towards the ends of the
connector.
9

10

47

Similar to splice connectors,crimping of

terminal connectors should start from
the point closest to the tongue.
Succes sive crimps are made moving
towards the end of the barrel.

4
48

Depending on the size of the

compres sion tap connector,beginning
the crimp in the middle of the connector
is usually good practice.
Place
crimps
here

49

16

3/9/2015

This is a Mechanical
Tap Connector whose
range of use is
between 4/0 and
336.4 MCM. There
are also the KVSU37
KVSU37
and KVSU 28 for
conductors larger
than 336.4 MCM and
below 4/0
respectively.
50

These uses are

limited to Tap
applications and are
of different sized.
Some of these are;
KSU22, KSU 23, KSU
26, KSU 28.

51

All insulated
connector for
making connection
of service
conductors unto
bundle secondary
mains. This is a
mechanical
connector.
52

17

3/9/2015

A wide range of
compres sion connectors
are used within GPL. They
are used in a variety of
applications; Tap or NonTension (Squeeze-on &
Parallel Tap), Terminal
(Compres sion Tube &
Lugs) and Splice or
Tension Connector (Tube /
Barrel / Mid-Span Joint)
53

This is an all insulated

connector to be used for
service connections to the
consumer building. They
come in a variety of sized
from 4mm2 to 4/0 AWG.
These connectors can
also be used to splice
service conductors,both
live and neutral.

54

SIDE A (GPL)
CATALOG #

SIDE B (CUSTOMER)
AL & CU

COLOUR
CODE

# 10

4 MM 2

BROWN

#8

10 MM 2

GREEN

ORANGE

#6

16 MM 2

BLUE

25 MM 2

ORANGE

#4

25 MM 2

ORANGE

#2

35 MM 2

RED

# 10

4 MM 2

BROWN

#2

35 MM 2

RED

#8

10 MM 2

GREEN

ES 2R6R

#2

35 MM 2

RED

#6

16 MM 2

BLUE

ES 2R2W

#2

35 MM 2

RED

#4

25 MM 2

ORANGE

ASCR

AL & CU

COLOUR
CODE

ASCR

ES 2W8W

#4

25 MM 2

ORANGE

ES 24R8R

#4

25 MM 2

ORANGE

ES 4R6R

#4

25 MM 2

ES 4R4R

#4

ES 2R8W
ES 2R8R

ES 2R2R

#2

35 MM 2

RED

#2

35 MM 2

RED

ES 25R6W

1/0

50 MM 2

YELLOW

#8

10 MM 2

GREEN

ES 25R4W

1/0

50 MM 2

YELLOW

#6

16 MM 2

BLUE

ES 25A4R

1/0

50 MM 2

YELLOW

#4

25 MM 2

ORANGE

ES 25A2R

1/0

50 MM 2

YELLOW

#2

35 MM 2

RED

ES 25A25A

1/0

50 MM 2

YELLOW

1/0

50 MM 2

YELLOW

YSU2R4W (Neutral)

#2

35 MM 2

RED

#6

16 MM 2

BLUE

DIE SET
#

OH 25
OR
THE 840
WITH
X-NBG
DIE

55

18

3/9/2015

ENDOF CONNECTOR THEORY

LESSON
ANY QUESTIONS / SUGGESTIONS?
NEXT CONDUCTOR THEORY

56

GPL Network utilizes various types of

conductors for supplying power
throughout the country.

57

The point where lowvoltage lines, or

services connect the
services,
secondary main
conductors to the
customers building
is called the service
entrance.
58

19

3/9/2015

Secondary Mains can either

be Bundle conductor or
Bare conductor. This is in
the form of Duplex, Tri plex
and Quadruplex. They
g from # 6 AWG to 4/0
range
AWG.
Bare conductor may
range from 50mm2 to
477 MCM depending
on the load.
59

Type

Code Name

Size / Unit

Strands
Aluminum

BARE CONDUCTORS
477 MCM
26

Steel
7

Amphere (A)

Applications Within
GPL

640

T & I Lines
Pri & Sec Mains
Pri & Sec Mains

ASCR

Hawk

AAC

Cosmos

477 MCM

19

Nil

640

AAC

Tulip

336.4 MCM

19

Nil

513

ASCR

Partridge

266.8 MCM

26

455

AAC

Oxlip

4/0 AWG

Nil

383

AAC

Wasp

4/0 AWG

Nil

383

AAC

Poppy

AAC

Ant

1/0 AWG

Nil

247

1/0 AWG

Nil

247

Trans, Pri & Sec Mains

Pri & Sec Mains
Pri & Sec Mains
Pri & Sec Mains
Pri & Sec Mains

QUADRAPLEX & TRIPLEX

AAC

Shetland

1/0 AWG

19

Nil

140

AAC
ASCR
ASCR
AAC
AAC
AAC
AAC

Costena
Voluta
Periwinkle
Barnacles
Shrimp
Solaster
Gammarus

1/0 AWG
6 AWG
4 AWG
4 AWG
2 AWG
2 AWG
1/0 AWG

19
7
7
7
7
7
7

Nil
1
1
Nil
Nil
Nil
Nil

140
70
90
90
120
120
160

AAC

Lepas

4/0 AWG

19

Nil

245

ASCR

Zuzara

4/0 AWG

19

245

7
7
7

Nil
Nil
1

70
70
70

Service Mains
Service Mains
Service Mains
Service Mains
Service Mains
Service Mains
Service Mains
Service Mains
Sec & Service Mains
Sec & Service Mains

DUPLEX
AAC
AAC
ASCR

Vizsla
Collie
Shepherd

6 AWG
6 AWG
6 AWG

AAC

Whippet

4 AWG

Nil

90

AAC

Schnauzer

2 AWG

Nil

120

Service Mains
Service Mains
Service Mains
Service Mains
60
Service Mains

Always ensure that the correct connector is

selected for the conductor to be joined.
Do not use a Tap connector to splice conductors
under tension.
Always make sure the compres sion connector is
filled with oxide inhibitor.
Always make the correct number of crimps.
Use the correct die and tool to make
connections.
Always clean the conductor thoroughly before
making connections.
Do not remove or add any conductor strands into
the connector before making a connection. 61

20

3/9/2015

62

63

64

21

3/9/2015

END OF CONDUCTOR THEORY

LESSON
ANY QUESTIONS / SUGGESTIONS?
NEXT PRACTICAL APPLICATIONS

65

22