grounding connectors · of ieee 837, providing your substation with a lifetime of worry free...

GROUNDING CONNECTORSABOVE & BELOW GROUND

888-SwaGE-NOwDmCpOwER.COm

2 | dmcpower.com

GroundinG ConneCtor SyStem

The Technically Superior Alternative Has ArrivedWhen it comes to connecting Ground, Cable and Bus runs in the harshest conditions possible, electrical utilities around the world trust the rugged strength and patented technology of the DMC Power Swage system.The robust design and performance of our Swage Tool and Grounding connectors meet and exceed the rigourous testing requirements of IEEE 837, providing your substation with a lifetime of worry free connections and a permanent low-resistance path to ground.

discover the Advantages of dmc power’s Ground connectors■ Ultimate Performance

Made with C11000 copper and the ability to carry the equivalent current (or greater) of the conductor, DMC Power connectors have one of the highest conductivity ratings at 101% IACS with a melting point of 1981° F, ensuring your substation has the highest level of performance and reliability possible.

■ Versatile All weather operation reduces setup time and costly delays. The same tool used for Grounding Connectors can also be used with our Cable Connectors.

■ safeCold compression Swaging requires no special �protective�gear�and�eliminates�heat,�open�flames� and toxic fumes.

■ reliable Produce consistent, repeatable results with our simple one-button operation.

■ conVenientNo molds, extra equipment, mixing shot material or regular maintenance is required.

■ instantly insPectableConfirming�Swage�results�couldn’t�be�easier;�our�“Go/No-Go” Inspection Gauge measures the Swage instantly, leaving you more time to get the job done.

Hand held Ground Tooling is compact, portable and easy to use in all conditions.

Our connectors are available in a variety of�sizes�to�fit�most�jobs�but�when�a�custom�

solution is needed now, turn to DMC Power. Our in-house team can design,

test�and�manufacture�connectors�to�fit�any�specification�or�use,�all�under�one�roof�at� our�ISO�9001:2008�certified�facilities.

Current Cycle Test per ANSI C119.4

360° compaction reduces voids, allowing�the�fitting�to�run�cooler.

Can’t find what you need?

888-SwAGe-now | 3

ELECTROMAGNETIC FORCE & MECHANICAL PULLOUT TESTS: • Tested up to 500 MCM bare copper conductor • 192.4 Peak / 71.3 Sym • Conducted for 3 surges • Current duration: 200ms • Pullout value was 5000 Lbs, 500% more than the IEEE requirementResults: EMF: No mechanical movement of conductor on connector, and no significant change in resistance.SEQUENCIAL TESTING: 8 SAMPLES ARE SUBJECTED TO THE FOLLOWING TESTS, ALL 8 GO THROUGH CURRENT- TEMPERATURE CYCLING AND FREEZE-THAW, FROM THERE 4 GO THROUGH SALT SPRAY AND FAULT CURRENT, WHILE THE OTHER 4 GO THROUGH NITRIC ACID AND FAULT CURRENT.

FAULT-CURRENT TEST:Conducted for 3 surges using a symmetrical rms fault current that is 90% of the fusion current of the control conductor for a duration of at least 10 seconds. The required administered current was calculated based on the remaining cross sectional area of the control samples, and was therefore different for the two sets of samples.Results: No significant damaging effects to the connection. The samples that went through Salt Spray recorded increased resistance within acceptable ranges. Although the samples that went through Nitric Acid did not require a resistance test, values were measured, and no significant increase in resistance was recorded.

SALT SPRAY CORROSION TEST:Conducted for 500 continuous hours.Results: No noticeable corrosive effects, no significant change in resistance.

IEEE AND UL TESTED AND APPROVED

CURRENT-TEMPERATURE CYCLING TEST:Conducted for 25 cycles. Connector temperature cannot exceed that of the control conductor and resistance cannot exceed 1.5 times the original reading.Results: Temperature and resistance were less than the original reading by 1.3%.

FREEZE-THAW TEST:Conducted for 10 cycles for at least two hours each.Results: No significant change in resistance.

ACID CORROSION TEST:Conducted until the cross section of the exposed control conductor was reduced to 80% of its original value.Results: No noticeable corrosive effects.

Additional Test: Thermal Shock Test:Used same samples previously subjected to the IEEE 837 test. Consisted of a stringent 10 cycle test. Each cycle included 2.5 hours in an oven, .25 hours in ice water, .5 hours in oven, 20.75 hours at room temperature and electrical current for 100°C above ambient for 72 hours.Results: Only 1% or less change in resistance.

3

1. GC760 Fence Post Connector2. GC740 Cross3. GC733 Split Tee4. GC746 Alternate Cross with thru-hole run5. GC759 Split Cross6. GC736 Alternate Tee with thru-hole run7. GC720 Splice8. GC730 Tee9. GC741 Cross with thru-hole run10. GC732 Parallel11. GC910 Terminal, 1-Hole12. GC920 Terminal, 2- Hole13. GC729 Elbow14. GC731 Tee with thru-hole run15. GC721 Split Parallel16. GC743 Offset Split Tee17. GC739 Split Elbow

1

23

4

5

6

7

8

9

10

11

12

2

13

14

15

16

17

(TESTED TO THE MORE STINGENT IEEE Std 837-2002)

DMC Power Grounding System

IEEE AND UL TESTED AND APPROVED(TESTED TO THE MORE STRINGENT IEEE STD 837-2002)

GroundinG Grid

electromaGnetic force & mecHanical PUlloUt tests:�

•� Tested�up�to�500�MCM�bare�copper�conductor•� 192.4�Peak�/�71.3�Sym•� Conducted�for�3�surges•� Current�duration:�200ms•� Pullout�value�was�5000�Lbs,�500%�more�than�

the IEEE requirementresults:� emf:� no mechanical movement of conductor on connector, and no significant change in resistance.

SEQUENCIAL TESTING: 8 SAMPLES ARE SUBJECTED TO THE FOLLOWING TESTS, ALL 8 GO THROUGH CURRENT-TEMPERATURE CYCLING AND FREEZE-THAW, FROM THERE 4 GO THROUGH SALT SPRAY AND FAULT CURRENT, WHILE THE OTHER 4 GO THROUGH NITRIC ACID AND FAULT CURRENT.

cUrrent-temPeratUre cyclinG test:�Conducted�for�25�cycles.�Connector�temperature�cannot�exceed that of the control conductor and resistance cannot exceed�1.5�times�the�original�reading.results:� temperature and resistance were less than the original reading by 1.3%.

freeZe-tHaW test:�Conducted for 10 cycles for at least two hours each.Results: No significant change in resistance.

salt sPray corrosion test:�Conducted�for�500�continuous�hours.Results: No noticeable corrosive effects, no significant change in resistance.

aciD corrosion test:�Conducted until the cross section of the exposed control conductor was reduced to 80% of its original value.Results: No noticeable corrosive effects.

faUlt-cUrrent test:�Conducted for 3 surges using a symmetrical rms fault current that is 90% of the fusion current of the control conductor for a duration of at least 10 seconds. The required administered current was calculated based on the remaining cross sectional area of the control samples, and was therefore different for the two sets of samples.Results: No significant damaging effects to the connection. The samples that went through Salt Spray recorded increased resistance within acceptable ranges. Although the samples that went through Nitric Acid did not require a resistance test, values were measured, and no significant�increase�in�resistance�was�recorded.

tHermal sHock test:�Used same samples previously subjected to the IEEE 837 test. Consisted of a stringent 10 cycle test. Each cycle included 2.5�hours�in�an�oven,�.25�hours�in�ice�water,�.5�hours�in�oven,�20.75�hours�at�room�temperature�and�electrical�current�for�100°C above ambient for 72 hours.Results: Only 1% or less change in resistance.

1. GC760 Fence Post Connector

2. GC740 Cross3. GC733 Split Tee4. GC746 Alternate Cross

with thru-hole run5.� GC759�Split�Cross6. GC736 Alternate Tee

with thru-hole run7. GC720 Splice8. GC730 Tee9. GC741 Cross

with thru-hole run10. GC732 Parallel11. GC910 Terminal, 1-Hole12. GC920 Terminal, 2- Hole13. GC729 Elbow14. GC731 Tee

with thru-hole run15.�GC721�Split�Parallel16. GC743 Offset Split Tee17. GC739 Split Elbow

4 | dmcpower.com

GroundinG ConneCtorS

EX:

EX:

EX:

EX:

EX:

EX: GC721B025-025250 mcm wire to 250 mcm wire

EX:

EX:

EX:

888-SwAGe-now��|��5

GroundinG ConneCtorS

GC910Terminal

1-Hole

GC920Terminal

2-Hole

▪ All terminals have NEMA standard mounting holes▪ Add "T" tail code for tin plating option on terminals

Pad dimension 3.500 Bolt holes .562

EX: GC909B040T400 mcm wire

Pad dimension 1.750 Bolt hole .562


GC909 90° Terminal

2-Hole

Pad dimension 3.500Bolt hole .562


GC746 Alternate Cross

Cable to CableCable to Rod

EX: GC739B025-562250 mcm wire to 5/8 copperclad rod

Identifier #1624324048566480

Pipe Sizes1"

1-1/2"2"

2-1/2"3"

3-1/2"4"5"

GC760/761/762 Pipe Sizes

Identifier #04G06G08G

Cable Size#4#6#8

GC761 Cable Sizes

GC759Offset Split Cross



RUN/TAP

RUN/TAP

GC760 Fence Post Connector

Cable/Rod to PostEX: GC760B32-002-000T

Left Side 2/0 AWG to 2" Pipe

GC762Fence Post Connector

Cable/Rod to Post to GateEX: GC762B32-000-002T

Right Side 2/0 AWG to 2" Pipe

▪ Available with left, right & dual barrels▪ Tin Plating option available

GC740Cross


GC741Thru-Hole Cross


GC742Offset Split Cross





GC743Offset Split Tee



RUN2

RUN1

RUN

TAP

6 | dmcpower.com

GROUNDING CONNECTORS

orderinG information ■ Follow these steps to complete the part number nomenclature shown below■ Refer to the Grounding Connetor Size Selection Chart on Page 7 for Copper Cable and Ground Rod Size

GCXXX B T–XXX XXX

1 basic Part nUmber

2 material coDe (B = Copper)

3 rUn / rUn1 / taP1 (Cable or Ground Rod Identifier Number)

4 taP / taP2 / rUn2 (Cable or Ground Rod Identifier Number)

5 (Optional) tin PlateD finisH

GCXXX B – –XX XXX XXX

1 basic Part nUmber

2 material coDe (B = Copper)

3 PiPe siZe iDentifier nUmber (See chart on page 5)

4 left barrel iDentifier nUmber (Cable or Ground Rod; Use ”000” for none)

5 riGHt barrel iDentifier nUmber (Cable or Ground Rod; Use ”000” for none)

sinGle barrel orDerinG eXamPle:�

No right barrel connector;�tin Plating

7/#9 Copperweld Stranding for left barrel

Cable/Rod to Fence Post

2” Pipe

GC760 B – –32 002 000T

DUal barrel orDerinG eXamPle:�

300 MCM Barestrand cable for right barrel;�no finish

250�MCM�cable�for left barrel

Cable/Rod to Fence Post

4” Pipe

GC760 B – –64 025 030

FENCE POST CONNECTORS

orDerinG eXamPle:�

GC731 B –025 682T

3/4" Copperclad rod for tap; tin Plating

Thru Hole Tee

250�MCM�cable�for the run

888-SwAGe-now | 7

Size SeleCtion Chart

Copper Cable (Ref. ASTM B8)bare stranded copper size aWG/kcmil

Dead soft annealed copperweld

stranding/aWG

bare stranded copper size (mm2) SI/Metric

connector Identifier number

connector O.D.

(±.015)#6 AWG 1/#6 10.8 & 12.6 06G

1.25

1.00 for parallel#4 AWG 1/#4 & 3/#10 14.1, 16, 17.8 & 19.6 04G

#2 AWG 1/#2, 3/#8 & 3/#9 22,�25,�27.6,�29.2,�34.4�&�35 02G

2.00 for parallel

1/0 AWG 3/#5,�3/#6�&�3/#7 48.3�&�50 0022/0 AWG 7/#8, 7/#9 & 7/#10 70 & 74.93/0 AWG 7/#7 & 7/#6 83.6,�93.3�&�95 0034/0 AWG 7/#5 96.8, 116 & 120 (Compacted Wires) 004250�MCM 19/#9 120 & 134 025#4 AWG 1/#4 & 3/#10 14.1, 16, 17.8 & 19.6 04G

1.50

2.00 for parallel#2 AWG 1/#2, 3/#8 & 3/#9 22,�25,�27.6,�29.2,�34.4�&�35 02G

1/0 AWG 3/#5,�3/#6�&�3/#7 38.2,�48.3�&�50 002

2.25�to�2.75�for�parallel

2/0 AWG 7/#8, 7/#9 & 7/#10 70 & 74.93/0 AWG 7/#7 & 7/#6 83.6,�93.3�&�95 0034/0 AWG 7/#5 96.8, 116 & 120 (Compacted Wires) 004250�MCM 19/#9 120 & 134 025

300 MCM 19/#8 145.8,�146,�150�&�185� (Compacted Wires) 030

350�MCM - 181.6,�182�&�185 035400 MCM 19/#7 194 & 240 (Compacted Wires) 040450�MCM - - 045500�MCM 19/#6 240 050

500ROPELAY 19/#5 300 0531000 MCM - 500 100 1.875

Ground rod

size material typeconnector Identifier number

connector O.D.

(±.015)3/8” #3 Steel rebar 003

1.25 2.00 for parallel

1/2" Copperclad-plain & sectional with 1/2” thread 0251/2" Steel & copperclad sectional with 9/16” thread & #4 Steel rebar 5005/8" Copperclad-plain�&�sectional�with�5/8"�thread 5625/8" Steel�plain�&�#5�Steel�rebar 6253/4" Copperclad-plain & sectional with 3/4" thread 6823/8” #3 Steel rebar 003

1.50 2.25�for�parallel

1/2" Copperclad-plain & sectional with 1/2" thread 0251/2" Steel & copperclad sectional with 9/16” thread & #4 Steel rebar 5005/8" Copperclad-plain�&�sectional�with�5/8"�thread 0305/8" Steel�plain�&�#5�Steel�rebar 0353/4" Copperclad-plain & sectional with 3/4" thread 0403/4" Steel plain 7501" Copperclad-plain & sectional with 1" thread 9141" Steel plain 950

■ Any combination of wire and/or rod connector is available■ The largest designator determines the part OD■ Consult�DMC�Power�for�N.B.-Metric�Rods�and�Rebar�identifier�code

GroundinG tool SeleCtion Chart

connector type Connector Identifier # connector

O.D.swage tool

Head assembly inspection Gauge swage tool Power Unit

Tee Splice Cross Elbow

Terminal Fence

Connector

02G 04G 06G

1.25 DLT45CLHA03975GCIG200-03975

or GCIG202-397-556

DLT45MAPW0000

*Swage Tool Power Units are run by a 10,000

psi pump

002 003 004025 500 562625 68202G 04G 002

1.50 DLT45CLHA05565GCIG200-05565

orGCIG202-397-556

003 004 025030 035 040045 050 053500 750 914

Parallel

04G 06G 1.00 DLT45CLHA02500 DLT45CLIG02500

02G1.50 DLT45CLHA05565 GCIG200-055651.875 DLT45CLHA08745 GCIG200-08745�

002 003

2.00 DLT45CLHA11130 GCIG200-11130004 025500 562/030600 625/035040 045 050

2.25 DLT45CLHA15900 GCIC200-15900750 914 950

To find the correct tooling:

12-2

010

Select required connector

1 Use the chart on page 7 to determine the Connector�Identifier�Number�and�Connector�O.D.Use the larger O.D. for two different sized runs (ex: 06G/1.25 O.D. & 500/1.50 O.D.)

2 Select the proper Head Assembly & Inspection Gauge based on the Connector O.D.

3

CRimp

exOtheRmiC

why take a ChanCe with CritiCal utility infraStruCture?

Wire strands become cold-welded to the connector creating a superior connection without the heat!

sWaGeD

14502�South�Figueroa�StreetGardena, CA 90248 USAwww.dmcpower.com

888-SwAGe-now888-792-4366

Sales Offices located nationwideto better serve you

Exceptions exist for some cable size combinations; refer to individual model drawing to confirm tooling

grounding connectors · of ieee 837, providing your substation with a lifetime of worry free...

Documents