Electropar - Substation & Transmission - Substation-Transmission-Application-Instructions

Substation & Transmission Application Instructions

"Do's" & "Don'ts"

• Always clean aluminium conductors
• Always apply the correct jointing compound
• Always insert conductor/s fully and/or equally into fitting
• Always use the correct compression die - if in doubt, CHECK
• Always compress all the area provided
• Always clean off any excess compound
• Always use peg dies with solid aluminium conductors
• Never use EP Unigrip C compound with bolted connections
• Never use EP Unigrip C compound on copper conductors
• Never bolt aluminium to copper without using EP Jointseal compound and preferably Belleville Washers/Transition Plate
• Never use incorrect fittings
• Never use incorrect compression dies

Product Labelling

All Electropar compression products are either stamped or labelled for easy identification. Labels feature important installation information
and typically include the following details:
• Product Type
• Installation Instructions
• Catalogue Number
• Conductor Size
• Compression Die Size
Should you require special references or part numbers to be featured on the label of any Electropar product, this service is available.

Conductor Preparation

• Before attempting to make any joint in aluminium, aluminium alloy or ACSR conductors, it is of the utmost importance that conductor ends are in good condition, clean and free from all defects and sharp edges.
• If conductors ends are damaged, cut away the damaged section before attempting to make a new connection.
• If necessary, unlay outer strands to give access to inner strands for cleaning.
• Clean and dry the aluminium conductor with a stainless steel wire brush and immediately apply an appropriate EP jointing compound to prevent re-oxidisation. It is good practice to brush the jointing compound onto the conductor.
Tubular Dead End
Assemblies
• Thoroughly clean the bores of the aluminium and steel compression bodies and the ends of the conductors.
• Slide the aluminium body onto the conductor and back it along out of the way.
• With a short length of aluminium wire or clamps, serve the conductor at a distance equal to the length of the steel body bore plus 40mm.
• Cut off the aluminium strands to expose the steel core for a distance equal to the length of the steel body bore plus 12mm. Do not nick the steel core. It is recommended that each aluminium layer be ony partially cut and then broken by bending. It may be necessay to serve the steel core.
• Wipe core grease off both the aluminium strands and the steel core. This is very important.
• Carefully clean the aluminium strands as detailed under Conductor Preparation.
• Loosen serving slightly and thoroughly impregnate steel strands with EP Unigrip C jointing compound.
• Remove servings (if fitted) from the steel core and fully insert it into the steel compression body.
• Ensure that the correct die is in the compression tool and compress the steel compression body, starting at the anchor end and working towards the other end. Make sure that the dies fully close on each compression.
• Remove servings and apply EP Unigrip C to the outside of the compressed steel body and to the aluminium conductors.
• Slide the aluminium body back until it is tight against the shoulder on the steel.
• Ensure that the correct die is in the compression tool and compress the aluminium body onto the steel between the flag and the knurled ring, working from the flag end. Make sure that the dies fully close on each compression.
• Compress the aluminium body between the second knurled ring and the other end of the fitting, working from the knurled ring. The portion between the two knurled rings (i.e. the part of the body covering the steel compression joint) is left uncompressed. Make sure that the dies fully close on each compression.
• Wipe off excess jointing compound from the fitting and the tool.
• When making the bolted joint between the jumper terminal and the flag, first remove the plastic coating from both flag and jumper terminal. A liberal coating of EP Jointseal or EP Uniseal should then be applied to the contact surfaces and these should be bolted together. It is not necessary to scratch brush the contact surfaces as these have been pre-treated.
• Smooth any rough or sharp edges with a file and remove any compression die "flash" from the completed joint.

Tubular Midspan Joint Assemblies

• Thoroughly clean the bores of the aluminium and steel compression bodies and the ends of the conductors.
• Slide the aluminium compression sleeve over one conductor end and back it along out of the way. Rotating the sleeve in the same direction as the lay may help if the sleeve is tight on the shoulder.
• Where the outer aluminium sleeve is supplied with an inner aluminium sleeve, this should be considered as a single unit and installed as outlined above. Note that the inner aluminium sleeve must be installed over the steel sleeve from the opposite side of the steel sleeve to the outer aluminium sleeve.
• With short lengths of aluminium wire or clamps, serve both conductor ends at a distance equal to that of the steel compression sleeve plus 40mm.
• Cut off the aluminium strands to expose the steel core for a distance equal to half the length of the steel compression sleeve plus 12mm. Do not nick the steel core. It is recommended that each aluminium layer be only partially cut and then broken by bending. It may be necessay to serve the steel core.
• Wipe core grease off both the aluminium strands and the steel core
• Loosen serving slightly and thoroughly impregnate steel strands with EP Unigrip C jointing compound.
• Insert the two ends of the steel core into the steel sleeve and check to ensure that they are fully inserted to the centre "stop".
• Ensure that the correct die is in the compression tool and compress the steel sleeve, starting at the centre and working first toward one end of the sleeve and then towards the other. The dies must always overlap previous positions. Make sure that the dies fully close on each compression.
• Liberally coat the steel compression joint with EP Unigrip C.
• Mark the conductor with a pencil or tape at a distance from the centre of the steel sleeve equal to half the length of the aluminium sleeve.
• Remove the servings. Apply EP Unigrip C over the full length of the joint and slip the aluminium sleeve into position so that the centre of the steel joint is exactly in the centre of the aluminium, as indicated by the pencil marks or tape.
• Compress the aluminium sleeve, starling at the knurled ring and working outwards, leaving the centre portion uncompressed. The dies should overlap previous positions by about 12mm. Make sure that the dies fully close on each compression and that the joint is rotated approximately 30° between compressions to overcome the "banana effect".
• Where the outer aluminium sleeve is supplied with an inner aluminium sleeve, this should be considered as a single unit and installed as outlined above. Note that the inner aluminium sleeve must be installed over the steel sleeve from the opposite side of the steel sleeve to the outer aluminium sleeve.
• Smooth any rough or sharp edges with a file and remove any compression die "flash" from the completed joint.

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