klk - 1.1 cable / cable 1.2 cable / ground rod …...klk electro materiales, s.l.u camino de la...

1.1 Cable / Cable _____________________________________ 14

1.2 Cable / Ground rod Connection _____________________ 26

1.3 Earth rod / Earth rod _______________________________ 31

1.4 Cable / to Rebar ___________________________________ 32

1.5 Cable / Steel Surface Connection ___________________ 39

1. Copper alumino-thermic welding _________________________ 4

1.6 Cable / Lug Connection / Busbar ____________________ 45

1.7 Busbar / Busbar / Steel Surface _____________________ 50

1.8 Stud / Steel Surface _______________________________ 58

1.9 Cable / Rail _______________________________________ 59

1.10 1 Shot __________________________________________ 60

2 Elpa Tubo __________________________________________ 62

3 LsVIP Process _____________________________________ 66

1. COPPER ALUMINOTHERMIC WELDING

KLK WELD Aluminothermic Welding Process uses the high temperatures generated by the reaction between copper oxide and aluminum to melt and subsequently fuse objects with the welding material. The reaction takes place within a mold or crucible, into which the welding powder and pieces to be welded are introduced in their respective positions.

After the welding mixture is ignited, the molten metal flows into the chambers within the mold forming homogeneous bond with the pieces to be joined. This reaction occurs very quickly and prevents the joined pieces from overheating beyond the points of contact with the welding material. This is an important benefit of the system, as it protects insulated cables and preserves the physical characteristics of the welded pieces.

The KLK WELD process can be used to fuse together a great number of materials:

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About the KLK-WELD exothermic Welding Process

Advantages of the KLK-WELD Process

- Connections are not affected by high current surges. Tests have shown that electrical- conductors will melt before the welding material does.

- Connection conductivity is greater than or equal to the conductors that have been- welded together.

-There is no possibility of corrosion at the welding points. Tests have shown that welded- conductors become an integral part of the welded material.

COPPER

COMMON STEEL

STAINLESS STEEL

STEELS RAILS

COPPER CLAD STEEL

GALVANIZED STEEL

BRASS

BRONZE

NICHROME V

DURIUM

MONEL

ETC.

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KLK-WELD MOLD

Each plastic cartridge contains aluminothermic powder in one end (colored cap) and starting powder in the other (black cap). Mold tap-holes must be covered with the metal disc before pouring aluminothermic powder into the crucible in order to prevent the powder from falling into welding chamber prior combustion.

Lower cover, black color coded

Starting powder

Thermite powder

Upper cover, is color coded according to each cartridge size.

CARTRIDGE C-15 C-25 C-32 C-45 C-65 C-90 C-115 C-150 C-200 C-250

COLOUR LIGHT GREY DARK GREY VIOLET WHITE YELLOW ORANGE RED BROWN BLUE GREEN

UNITS/BOX 20 20 20 20 10 10 10 10 10 10

KLK-WELD CARTRIDGES AND DISCS

From C-15 to C-45 boxes of 20 units. Rest of cartridges boxes of 10 units.

Mould cover

Starting powder

Thermite powder

Metallic disc

Tap hole

Welding cavity

Cables


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KLK-WELD EQUIPMENT

KLK-WELD equipment is designed for heavy duty, yet is portable and easy to use in the field. Operators require no special training, and take little time to achieve professional, top-quality connections.

MOLDS:

FLINT IGNITER:

TSC HANDLE CLAMPS:

CARDCLOTH BRUSH:

MOULD BRUSH:

Designed to handle molds securely allowing them to open and close safely.

There are three types of handle clamps depending on mold size: TSC-50, TSC-80 and TSC-100.

Used for cleaning conduc-tors before welding.

Recommended for easy cleaning of welding cham-ber after every weld.

MASTIC SEALANT:

MOULD SCRAPER:

Shape fits the crucible for safe easy removal of slag.

It is also used to check tap-hole clearance after welding.

Manufactured from heat-reistant graphite blocks that last for an average of at least 50 welds under normal use.

The cover prevents parti-cles from escaping during reaction.

Ceramic paste to seal gaps between steel rebar or cable and molds in certain con-nection types (see operating instructions in selection charts).

Available in 2 pound pac-kages and round strips for easy application.

Used for easy ignition of star-ting powders.Standard lighter flints are used.

Used for easy ignition of starting powders. It includes sufficient cable to allow the charge to be ignited at a certain distance form the mould.

Consumable for the remote ignition procedure used.

FLINT IGNITER

REMOTE IGNITION DEVICE

FUSE

REMOTE IGNITION DEVICE:

FUSE:

CARDCLOTH BRUSH: MOULD SCRAPER:

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Copper Conductors, Reinforcing Bars and Ground RodsTechnical information

Molds are cut to fit the size of copper conductors, steel rebars and ground rods shown in the following tables.

For any other type or size, it is necessary to verify the actual diameter of product to be welded.

CONCENTRIC STRANTED CONDUCTOR

SIZE DIA. IN. DIA. mm.

1,000 MCM 1,152 29,26

800 MCM 1,031 24,49

750 MCM 0,998 25,35

700 MCM 0,964 24,49

600 MCM 0,893 22,49

500 MCM 0,813 20,65

400 MCM 0,728 18,49

350 MCM 0,681 17,30

300 MCM 0,630 16,00

250 MCM 0,575 14,61

4/0 AWG 0,528 13,41

3/0 AWG 0,470 11,94

2/0 AWG 0,419 10,64

1/0 AWG 0,373 9,47

1 AWG 0,332 8,43

2 AWG 0,292 7,42

3 AWG 0,260 6,60

4 AWG 0,232 5,89

6 AWG 0,184 4,67

8 AWG 0,146 3,71

10 AWG 0,116 2,95

BARE SOLID COPPER WIRE


4/0 AWG 0,4600 11,68

3/0 AWG 0,4096 10,40

2/0 AWG 0,3648 9,27

1/0 AWG 0,3249 8,25

1 AWG 0,2893 7,35

2 AWG 0,2576 6,54

3 AWG 0,2294 5,83

4 AWG 0,2043 5,19

6 AWG 0,1620 4,11

8 AWG 0,1258 3,26

10 AWG 0.1019 2,59

REINFORCING BARS


3 (3/8”) 0,413 10,49

4 (1/2”) 0,550 13,97

5 (5/8”) 0,687 17,45

6 (3/4”) 0,825 20,96

7 (7/8”) 0,962 24,43

8 (1”) 1,100 27,94

9 1,240 31,50

10 1,397 35,48

11 1,551 39,40

14 1,862 47,29

18 2,483 63,07

GROUNDS RODS

NOMINAL SIZE MATERIAL TYPE THREAD SIZE OVERALL DIA. IN. OVERALL DIA. mm.

1/2”

Copperciad Sectorial 1/2” 0,500 12,70

Steel Plain - 0,500 12,70

Copperciad Plain - 0,475 12,07

5/8”




3/4”





INSTRUCTIONS FOR SUCCESSFUL CONNECTIONS

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PREPARATION OF THE GROUNDS RODS

Grounds rod ends on which welds are to be performed must be clean, dry and without visible deformations.

PREPARATION OF THE GRAPHITE MOLD

Moisture in molds can cause dangerous splattering and result in porous welds. Molds must be perfectly dry before welding.

For proper connections, pre-heat mold before welding using a welding torch or ignite a test cartridge to pre-heat mold over 212º F. When using test cartridges, be careful to avoid handle clamp damage due to molten metal leaking or splattering.

Heat generated in every weld will maintain molds at the appropriate temperature for the next weld. If excessive delays occur between welds causing mold tempera-tures to fall, pre-heat molds again before resuming welding procedures.

PREPARATION OF CONDUCTORS

Conductors must be clean, dry and well-fitting to obtain proper welds.

Cables with oil or grease must be cleaned with a degreaser (preferably a quick drying and non-residual solvent). In extreme cases, pre-heat conductor with a wel-ding torch to remove grease and oil completely.

Rusty conductors must be cleaned with a brush or sand paper.

Moist or muddy conductors will cause porous welds and splattering of molten me-tal outside the mold. Conductors must be dried with a welding torch and all mud must be removed prior to welding.

Badly cut or ill-fitting conductors will prevent molds from closing properly, causing molten metal to leak. To avoid deformation of cable ends, use appropriate cables cutter.

PREPARATION OF STEEL SURFACES

Steel surfaces must be rust free, clean and flat.

Rust film, paint, grease or dust must be cleaned with a grinder.

Remove moisture by pre-heating molds with a welding torch .

Galvanized surfaces can be cleaned removing the zinc coating.

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Remove insulation of conductor to a length of 6” when using insulated cable. Clean cable and the rod ends to remove all dust and oxides.

Before starting the first weld, pre-heat graphite mold with welding torch for at least 5 minutes. This operation is very im-portant because moisture in molds will cause po-rous welds.

Open molds by separa-ting the two arms of the handle clamps. Cable must sit on top of rod.Support molds to keep them from sliding down rods when welding. Use lock-pliers or clamp the rods below the molds.

Close molds securely with the handle clamps to avoid molten metal los-ses. Place metallic discs, conical side-to-bottom, over tap hole.

Open colored side co-ver of the cartridge size shown on the mold tag and pour the thermic powder into the crucible.

Open black cover side of the cartridge and spread starting powder evenly over the welding powder and on the top edge of the mold, under the co-ver, for easier ignition.

Close mold cover and place flint ignitor close to starting powder to ingni-te. It is advisable to pull away hands quickly to avoid burns and prevent damage to flint gun.

Wait approximately one minute and open mold carefully using the hand-le clamps to remove the welded connection. Care must be used during this operation to avoid brea-king the mold.

KLK-WELD PROCEDURE STANDAR PROCESS

Remove slag from cru-cible and tap hole with the mold scraper. Remo-ve dust from weld cavi-ty, tap hole, crucible and mold cover with the mold brush. If the mold is still warm, you can conti-nue the welding process without pre-heating it again.


KLK-WELD PROCEDURE LsVIP LOW SMOKE VERSATIL IGNITION PROCEDURE

Pour the welding and the ignition pow-der into the crucible, reserving an small amount of ignition powder (around 1/4 of the volume)

Insert the fuse in the clamp (green sides close)

Partially open the upper part of the lid and place the fuse in its seat

move away from the mould as desired and press the red button

put the flint igniter close to the funnel shape opening in the lid and pull the trigger

Pour the reserved ignition powder through the funnel shape opening in the lid

OPTION AFLINT IGNITER

OPTION BREMOTE IGNITION

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STANDARD CONNECTIONS

CABLE TO CABLE

CABLE TO GROUND ROD

CABLE TO REBAR

EARTH ROD / EARTH ROD

` ` Ji ` ` Jqe ` ` Jqs

mmJs

CCL CCTH CCTV

CCDP CCDPV

PPV

CPAR

CRXS

` oJmeCRPH` oJmsCRPV

` oJqmCRTP

` oJqiCRTL

CPTS

CCX CCXS

CPTDPCPTD

CPT

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STANDARD CONNECTIONS

CHTF

CHVI

CHTH

CHPHH

CHPVH CHVS CHPVV

CABLE TO STEEL SURFACE

CABLE TO LUG

CPLL CPLLS

CABLE TO BUSBAR

CPLH CPLPVV PLLV PLARI PLTV

BUSBAR TO STEEL

CPLHCPLH PHPHH

PHVI PHPVV PHPVH

BUSBAR TO BUSBAR

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OTHER CONNECTIONS

YCP-AR YCP-T

YCP-TD YCP-DD

YCP-DPH

CABLE TO RAIL

CRATA CRAPHA

STUD TO STEEL SURFACE

BCHHBCHV

KLK Electro Materiales, s.l.uCamino de la Peñona 38B • 33211 GIJÓN • P.O. BOX 333-33206T. +34 985 321 850 F. +34 985 312 820 • e-mail: [email protected]

CONNECTION CCL

DIMENSION

CABLESIZE

MOLDPART. No.

CARTRIDGEHANDLECLAMP

MOULDSCRAPER

KEY PRICE

8 CCL 8 C-15 TSC-50 R-15

M

8 SOL CCL 8S C-15 TSC-50 R-15

6 CCL6 C-25 TSC-50 R-15


4 CCL 4 C-25 TSC-50 R-15


3 CCL 3 C-32 TSC-50 R-15

2 CCL 2 C-32 TSC-50 R-15


1 CCL 1 C-32 TSC-50 R-15


1/0 CCL 1/0 C-45 TSC-80 R-45

A

1/0 SOL CCL 1/0S C-45 TSC-80 R-45

2/0 CCL 2/0 C-65 TSC-80 R-45

3/0 CCL 3/0 C-90 TSC-80 R-90

4/0 CCL 4/0 C-90 TSC-80 R-90

4/0 SOL CCL 4/0S C-90 TSC-80 R-90

250 CCL 250 C-115 TSC-80 R-90

300 CCL 300 C-115 TSC-80 R-90

350 CCL 350 C-150 TSC-80 R-150

500 CCL 500 C-200 TSC-80 R-150

750 CCL 750 2XC-150 TSC-100 R-750E

1000 CCL 1000 2XC-200 TSC-100 R-750

1.1 CABLE / CABLE

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For cables 500 MCM and larger apply a

gap of 1/4” under the center of tap hole as

shown below.

OPERATINGINSTRUCTIONS

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1.1 CABLE / CABLE


CONNECTION CCTH

CABLE SIZE

Run Tap MOLD

PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

KEY PRICE

4 4 CCTH 4-4 C-32 TSC-80 R-45

A

2 SOL

2 CCTH 2S-2 C-45 TSC-80 R-45

2 SOL CCTH 2S-2S C-45 TSC-80 R-45

4 CCTH 2S-4 C-45 TSC-80 R-45

2

2 CCTH 2-2 C-45 TSC-80 R-45

2 SOL CCTH 2-2S C-45 TSC-80 R-45

4 CCTH 2-4 C-45 TSC-80 R-45

1

1 CCTH 1-1 C-45 TSC-80 R-45

2 CCTH 1-2 C-45 TSC-80 R-45

2 SOL CCTH 1-2S C-45 TSC-80 R-45

4 CCTH 1-4 C-45 TSC-80 R-45

1/0

1/0 CCTH 1/0-1/0 C-90 TSC-80 R-90

1 CCTH 1/0-1 C-45 TSC-80 R-45

2 CCTH 1/0-2 C-45 TSC-80 R-45

2 SOL CCTH 1/0-2S C-45 TSC-80 R-45

4 CCTH 1/0-4 C-45 TSC-80 R-45

2/0

2/0 CCTH 2/0-2/0 C-90 TSC-80 R-90

1/0 CCTH 2/0-1/0 C-90 TSC-80 R-90

1 CCTH 2/0-1 C-45 TSC-80 R-45

2 CCTH 2/0-2 C-45 TSC-80 R-45

2S CCTH 2/0-2S C-45 TSC-80 R-45

4 CCTH 2/0-4 C-45 TSC-80 R-45

3/0

3/0 CCTH 3/0-3/0 C-115 TSC-80 R-90

2/0 CCTH 3/0-2/0 C-90 TSC-80 R-90

1/0 CCTH 3/0-1/0 C-90 TSC-80 R-90

1 CCTH 3/0-1 C-45 TSC-80 R-45

2 CCTH 3/0-2 C-45 TSC-80 R-45

2S CCTH 3/0-2S C-45 TSC-80 R-45

4 CCTH 3/0-4 C-45 TSC-80 R-45

4/0

4/0 CCTH 4/0-4/0 C-150 TSC-80 R-150

3/0 CCTH 4/0-3/0 C-115 TSC-80 R-90

2/0 CCTH 4/0-2/0 C-90 TSC-80 R-90

1/0 CCTH 4/0-1/0 C-90 TSC-80 R-90

1 CCTH 4/0-1 C-90 TSC-80 R-90

2 CCTH 4/0-2 C-90 TSC-80 R-90

2 SOL CCTH 4/0-2S C-90 TSC-80 R-90

4 CCTH 4/0-4 C-90 TSC-80 R-90

For cables 500 MCM and larger apply gap of 1/4”from the run-ning cable as shown

below.


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1.1 CABLE / CABLE


CONNECTION CCTH

CABLE SIZE

Run Tap MOLD

PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

KEY PRICE

250

250 CCTH 250-250 C-150 TSC-80 R-150

A

4/0 CCTH 250-4/0 C-150 TSC-80 R-150

3/0 CCTH 250-3/0 C-150 TSC-80 R-150

2/0 CCTH 250-2/0 C-90 TSC-80 R-90

1/0 CCTH 250-1/0 C-90 TSC-80 R-90

1 CCTH 250-1 C-90 TSC-80 R-90

2 CCTH 250-2 C-90 TSC-80 R-90

2 SOL CCTH 250-2 S C-90 TSC-80 R-90

4 CCTH 250-4 C-90 TSC-80 R-90

300

300 CCTH 300-300 C-200 TSC-80 R-150

250 CCTH 300-250 C-150 TSC-80 R-150

4/0 CCTH 300-4/0 C-150 TSC-80 R-150

3/0 CCTH 300-3/0 C-150 TSC-80 R-150

2/0 CCTH 300-2/0 C-90 TSC-80 R-90

1/0 CCTH 300-1/0 C-90 TSC-80 R-90

1 CCTH 300-1 C-90 TSC-80 R-90

2 CCTH 300-2 C-90 TSC-80 R-90

2 SOL CCTH 300-2 SOL C-90 TSC-80 R-90

4 CCTH 300-4 C-90 TSC-80 R-90

350

350 CCTH 350-350 C-200 TSC-80 R-150

300 CCTH 350-300 C-200 TSC-80 R-150

250 CCTH 350-250 C-200 TSC-80 R-150

4/0 CCTH 350-4/0 C-150 TSC-80 R-150

3/0 CCTH 350-3/0 C-150 TSC-80 R-150

2/0 CCTH 350-2/0 C-90 TSC-80 R-90

1/0 CCTH 350-1/0 C-90 TSC-80 R-90

1 CCTH 350-1/1 C-90 TSC-80 R-90

2 CCTH 350-2 C-90 TSC-80 R-90

4 CCTH 350-4/4 C-90 TSC-80 R-90

500

500 CCTH 500-500 2xC-150 TSC-80 R-150

350 CCTH 500-350 C-200 TSC-80 R-150

300 CCTH 500-300 C-200 TSC-80 R-150

250 CCTH 500-250 C-200 TSC-80 R-150

4/0 CCTH 500-4/0 C-150 TSC-80 R-150

2/0 CCTH 500-2/0 C-90 TSC-80 R-90

1/0 CCTH 500-1/0 C-90 TSC-80 R-90

1 CCTH 500-1 C-90 TSC-80 R-90

2 CCTH 500-2 C-90 TSC-80 R-90

4 CCTH 500-4 C-90 TSC-80 R-90

For cables 500 MCM and larger apply a

gap of 1/4” under the center of tap hole as

shown below.


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1.1 CABLE / CABLE

For cables 500 MCM and larger apply gap of 1/4”from the run-ning cable as shown

below.



CONNECTION CCTH

CABLE SIZE

Run Tap MOLD

PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

KEY PRICE

750

750 CCTH 750-750 2x C-250 TSC-100 R-750E

500 CCTH 750-500 2x C-200 TSC-100 R-750

350 CCTH 750-350 C-250 TSC-80 R-150

A

300 CCTH 750-300 C-200 TSC-80 R-150

250 CCTH 750-250 C-200 TSC-80 R-150

4/0 CCTH 750-4/0 C-150 TSC-80 R-150

2/0 CCTH 750-2/0 C-150 TSC-80 R-150

1/0 CCTH 750-1/0 C-150 TSC-80 R-150

1000

1000 CCTH 1000-1000 2x C-250 TSC-100 R-750

E750 CCTH 1000-750 2x C-250 TSC-100 R-750

500 CCTH 1000-500 2x C-200 TSC-100 R-750

350 CCTH 1000-350 C-250 TSC-80 R-150

A

300 CCTH 1000-300 C-200 TSC-80 R-150

250 CCTH 1000-250 C-200 TSC-80 R-150

4/0 CCTH 1000-4/0 C-150 TSC-80 R-150

2/0 CCTH 1000-2/0 C-150 TSC-80 R-150

1/0 CCTH 1000-1/0 C-150 TSC-80 R-150

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1.1 CABLE / CABLE

Cut and gap tap cable 1/4” at center

of tap hole as shown below.



CONNECTION CCDP

CABLE SIZE

Run Tap MOLD

PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

KEY PRICE

4

4 CCDP 4-4 C-32 TSC-80 R-45

A

6 CCDP 4-6 C-32 TSC-80 R-45

6 SOL CCDP 4-6S C-32 TSC-80 R-45

8 CCDP 4-8 C-32 TSC-80 R-45


2 SOL

2 CCDP 2-2 C-65 TSC-80 R-45


4 CCDP 2-4 C-65 TSC-80 R-45

6 CCDP 2-6 C-45 TSC-80 R-45


8 CCDP 2-8 C-45 TSC-80 R-45


2

2 CCDP 2-2 C-65 TSC-80 R-45

4 CCDP 2-4 C-65 TSC-80 R-45

6 CCDP 2-6 C-45 TSC-80 R-45


8 CCDP 2-8 C-45 TSC-80 R-45


1 SOL

1 CCDP 1S-1 C-65 TSC-80 R-45

2 CCDP 1S-2 C-65 TSC-80 R-45

2 SOL CCDP 1S-2S C-65 TSC-80 R-45

4 CCDP 1S-4 C-65 TSC-80 R-45

6 CCDP 1S-6 C-65 TSC-80 R-45


8 CCDP 1S-8 C-45 TSC-80 R-45


1

1 CCDP 1-1 C-65 TSC-80 R-45


2 CCDP 1-2 C-65 TSC-80 R-45


4 CCDP 1-4 C-65 TSC-80 R-45

6 CCDP 1-6 C-65 TSC-80 R-45


8 CCDP 1-8 C-45 TSC-80 R-45


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1.1 CABLE / CABLE





CONNECTION CCDP

CABLE SIZE

Run Tap MOLD

PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

KEY PRICE

1/0 SOL

1/0 CCDP 1/0S-1/0 C-90 TSC-80 R-90

A

1/0 SOL CCDP 1/0S-1/0S C-90 TSC-80 R-90

1 CCDP 1/0S-1 C-65 TSC-80 R-45

1 SOL CCDP 1/0S-1S C-65 TSC-80 R-45

2 CCDP 1/0S-2 C-65 TSC-80 R-45


4 CCDP 1/0S-4 C-65 TSC-80 R-45

6 CCDP 1/0S-6 C-65 TSC-80 R-45


8 CCDP 1/0S-8 C-65 TSC-80 R-45


1/0

1/0 CCDP 1/0-1/0 C-90 TSC-80 R-90

1/0 SOL CCDP 1/0-1/0S C-90 TSC-80 R-90

1 CCDP 1/0-1 C-65 TSC-80 R-45

1 SOL CCDP 1/0-1S C-65 TSC-80 R-45

2 CCDP 1/0-2 C-65 TSC-80 R-45

2 SOL CCDP 1/0-2S C-65 TSC-80 R-45

4 CCDP 1/0-4 C-65 TSC-80 R-45

6 CCDP 1/0-6 C-65 TSC-80 R-45

6 SOL CCDP 1/0-6S C-65 TSC-80 R-45

8 CCDP 1/0-8 C-65 TSC-80 R-45

8 SOL CCDP 1/0-8S C-65 TSC-80 R-45

2/0

2/0 CCDP 2/0-2/0 C-115 TSC-80 R-90

1/0 CCDP 2/0-1/0 C-115 TSC-80 R-90

1/0 SOL CCDP 2/0-1/0S C-115 TSC-80 R-90

2 CCDP 2/0-2 C-90 TSC-80 R-90

1 CCDP 2/0-1 C-90 TSC-80 R-90

1 SOL CCDP 2/0-1S C-90 TSC-80 R-90

4 CCDP 2/0-4 C-90 TSC-80 R-90

6 CCDP 2/0-6 C-90 TSC-80 R-90

6 SOL CCDP 2/0-6S C-90 TSC-80 R-90

8 CCDP 2/0-8 C-65 TSC-80 R-45

8 SOL CCDP 2/0-8S C-65 TSC-80 R-45

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1.1 CABLE / CABLE


CONNECTION CCDP

CABLE SIZE

Run Tap MOLD

PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

KEY PRICE

3/0

3/0 CCDP 3/0-3/0 C-150 TSC-80 R-150

A

2/0 CCDP 3/0-2/0 C-150 TSC-80 R-150

1/0 CCDP 3/0-1/0 C-115 TSC-80 R-90

1/0 SOL CCDP 3/0-1/0S C-115 TSC-80 R-90

2 CCDP 3/0-2 C-115 TSC-80 R-90

2 SOL CCDP 3/0-2S C-115 TSC-80 R-90

1 CCDP 3/0-1 C-115 TSC-80 R-90

1 SOL CCDP 3/0-1S C-115 TSC-80 R-90

4 CCDP 3/0-4 C-115 TSC-80 R-90

6 CCDP 3/0-6 C-90 TSC-80 R-90

6 SOL CCDP 3/0-6S C-90 TSC-80 R-90

8 CCDP 3/0-8 C-90 TSC-80 R-90

8 SOL CCDP 3/0-8S C-90 TSC-80 R-90

4/0 SOL

4/0 CCDP 4/0S-4/0 C-200 TSC-80 R-150

4/0 SOL CCDP 4/0S-4/0S C-200 TSC-80 R-150

3/0 CCDP 4/0S-3/0 C-200 TSC-80 R-150

2/0 CCDP 4/0S-2/0 C-150 TSC-80 R-150

1/0 CCDP 4/0S-1/0 C-150 TSC-80 R-150

1/0 SOL CCDP 4/0S-1/0S C-150 TSC-80 R-150

1 CCDP 4/0S-1 C-150 TSC-80 R-150

1 SOL CCDP 4/0S-1S C-150 TSC-80 R-150

2 CCDP 4/0S-2 C-150 TSC-80 R-150

2 SOL CCDP 4/0S-2S C-150 TSC-80 R-150

4 CCDP 4/0S-4 C-150 TSC-80 R-150

6 CCDP 4/0S-6 C-90 TSC-80 R-90


8 CCDP 4/0S-8 C-90 TSC-80 R-90


4/0

4/0 CCDP 4/0-4/0 C-200 TSC-80 R-150

4/0 SOL CCDP 4/0-4/0S C-200 TSC-80 R-150

3/0 CCDP 4/0-3/0 C-200 TSC-80 R-150

2/0 CCDP 4/0-2/0 C-150 TSC-80 R-150

1/0 CCDP 4/0-1/0 C-150 TSC-80 R-150

1/0 SOL CCDP 4/0-1/0S C-150 TSC-80 R-150

1 CCDP 4/0-1 C-150 TSC-80 R-150

1 SOL CCDP 4/0-1S C-150 TSC-80 R-150

2 CCDP 4/0-2 C-150 TSC-80 R-150

2 SOL CCDP 4/0-2S C-150 TSC-80 R-150

4 CCDP 4/0-4 C-150 TSC-80 R-150

6 CCDP 4/0-6 C-90 TSC-80 R-90

6 SOL CCDP 4/0-6S C-90 TSC-80 R-90

8 CCDP 4/0-8 C-90 TSC-80 R-90

8 SOL CCDP 4/0-8S C-90 TSC-80 R-90




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21

1.1 CABLE / CABLE


CONNECTION CCDPV

CABLE SIZE

Run Tap MOLD

PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

KEY PRICE

8 SOL 8 SOL CCDPV 8S-8S C-25 TSC-50 R-15M

8 8 CCDPV 8-8 C-25 TSC-50 R-15

6 SOL 6 SOL CCDPV 6S-6S C-25 TSC-80 R-45

B

6 6 CCDPV 6-6 C-25 TSC-80 R-45

4

4 CCDPV 4-4 C-65 TSC-80 R-45

6 CCDPV 4-6 C-90 TSC-80 R-90

6 SOL CCDPV 4-6S C-45 TSC-80 R-45

2 SOL 2 SOL CCDPV 2S-2S C-115 TSC-80 R-90

4 CCDPV 2S-4 C-90 TSC-80 R-90

2

2 CCDPV 2-2 C-115 TSC-80 R-90


4 CCDPV 2-4 C-90 TSC-80 R-90

1

1 CCDPV 1- C-115 TSC-80 R-90

2 CCDPV 1-2 C-90 TSC-80 R-90


4 CCDPV 1-4 C-90 TSC-80 R-90

1/0

1/0 CCDPV 1/0-1/0 C-150 TSC-80 R-150

1 CCDPV 1/0-1 C-115 TSC-80 R-90

2 CCDPV 1/0-2 C-115 TSC-80 R-90

2 SOL CCDPV 1/0-2S C-115 TSC-80 R-90

4 CCDPV 1/0-4 C-115 TSC-80 R-90

2/0

2/0 CCDPV 2/0-2/0 C-150 TSC-80 R-150

1/0 CCDPV 2/0-1/0 C-150 TSC-80 R-150

1 CCDPV 2/0-1 C-150 TSC-80 R-150

2 CCDPV 2/0-2 C-150 TSC-80 R-150

2 SOL CCDPV 2/0-2SOL C-150 TSC-80 R-150

4 CCDPV 2/0-4 C-115 TSC-80 R-90

4/0

4/0 CCDPV 4/0-4/0 2xC-200 TSC-100 R-750 F

2/0 CCDPV 4/0-2/0 C-250 TSC-80 R-150

B

1/0 CCDPV 4/0-1/0 C-250 TSC-80 R-150

1 CCDPV 4/0-1 C-250 TSC-80 R-150

2 CCDPV 4/0-2 C-200 TSC-80 R-150

2 SOL CCDPV 4/0-2S C-200 TSC-80 R-150

300 300 CCDPV 300-300 2xC200 TSC-100 R-750

I350 4/0 CCDPV 350-4/0 2xC200 TSC-100 R-750

500 500 CCDPV 500-500 3xC250 TSC-100 R-750

750 750 CCDPV 750-750 4xC250 TSC-100 R-750 J




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22

1.1 CABLE / CABLE


CONNECTION CCX

CABLE SIZE

Run Tap MOLD

PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

KEY PRICE

6 SOL 6 SOL CCX 6S-6S C-15 TSC-50 R-15M

6 6 CCX 6-6 C-25 TSC-50 R-15

4 4 CCX 4-4 C-45 TSC-80 R-45

A

22 CCX 2-2 C-65 TSC-80 R-45

4 CCX 2-4 C-65 TSC-80 R-45

2 SOL 2 SOL CCX 2S-2S C-65 TSC-80 R-45

1

1 CCX 1-1 C-65 TSC-80 R-45

2 CCX 1-2 C-65 TSC-80 R-45

4 CCX 1-4 C-65 TSC-80 R-45

1/0

1/0 CCX 1/0-1/0 C-90 TSC-80 R-90

1 CCX 1/0-1 C-90 TSC-80 R-90

2 CCX 1/0-2 C-90 TSC-80 R-90

4 CCX 1/0-4 C-90 TSC-80 R-90

2/0

2/0 CCX 2/0-2/0 C-115 TSC-80 R-90

1/0 CCX 2/0-1/0 C-115 TSC-80 R-90

1 CCX 2/0-1 C-115 TSC-80 R-90

2 CCX 2/0-2 C-115 TSC-80 R-90

3/0

3/0 CCX 3/0-3/0 C-150 TSC-80 R-150

2/0 CCX 3/0-2/0 C-150 TSC-80 R-150

1/0 CCX 3/0-1/0 C-115 TSC-80 R-90

1 CCX 3/0-1 C-115 TSC-80 R-90

2 CCX 3/0-2 C-115 TSC-80 R-90

4/0

4/0 CCX 4/0-4/0 C-200 TSC-80 R-150

3/0 CCX 4/0-3/0 C-200 TSC-80 R-150

2/0 CCX 4/0-2/0 C-150 TSC-80 R-150

1/0 CCX 4/0-1/0 C-150 TSC-80 R-150

1 CCX 4/0-1 C-115 TSC-80 R-90

2 CCX 4/0-2 C-115 TSC-80 R-90

250

250 CCX 250-250 C-200 TSC-80 R-150

4/0 CCX 250-4/0 C-200 TSC-80 R-150

3/0 CCX 250-3/0 C-200 TSC-80 R-150

2/0 CCX 250-2/0 C-150 TSC-80 R-150

1/0 CCX 250-1/0 C-150 TSC-80 R-150

1 CCX 250-1 C-115 TSC-80 R-90

2 CCX 250-2 C-115 TSC-80 R-90

Cut the larger cable and place ends aga-inst the smaller one

as shown below.


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23

1.1 CABLE / CABLE


CONNECTION CCX

CABLE SIZE

Run Tap MOLD

PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

KEY PRICE

300

300 CCX 300-300 C-250 TSC-80 R-150

A

250 CCX 300-250 C-250 TSC-80 R-150

4/0 CCX 300-4/0 C-200 TSC-80 R-150

3/0 CCX 300-3/0 C-200 TSC-80 R-150

2/0 CCX 300-2/0 C-150 TSC-80 R-150

1/0 CCX 300-1/0 C-150 TSC-80 R-150

1 CCX 300-1 C-115 TSC-80 R-90

2 CCX 300-2 C-115 TSC-80 R-90

350

350 CCX 350-350 C-250 TSC-80 R-150

300 CCX 350-300 C-250 TSC-80 R-150

250 CCX 350-250 C-250 TSC-80 R-150

4/0 CCX 350-4/0 C-200 TSC-80 R-150

3/0 CCX 350-3/0 C-200 TSC-80 R-150

2/0 CCX 350-2/0 C-200 TSC-80 R-150

1/0 CCX 350-1/0 C-200 TSC-80 R-150

1 CCX 350-1 C-150 TSC-80 R-150

2 CCX 350-2 C-150 TSC-80 R-150

500

500 CCX 500-500 2xC-250 TSC-100 R-750

E

350 CCX 500-350 2xC-200 TSC-100 R-750

300 CCX 500-300 2xC-200 TSC-100 R-750

250 CCX 500-250 2xC-150 TSC-100 R-750

4/0 CCX 500-4/0 2xC-150 TSC-100 R-750

3/0 CCX 500-3/0 2xC-150 TSC-100 R-750

2/0 CCX 500-2/0 C-250 TSC-80 R-150A

1/0 CCX 500-1/0 C-250 TSC-80 R-150

Cut the larger cable and place ends aga-inst the smaller one

as shown below.


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24

1.1 CABLE / CABLE


CONNECTION CCXS

CABLE SIZE

Run Tap MOLD

PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

KEY PRICE

6 SOL 6 SOL CCXS 6S-6S C-32 TSC-50 R-15 A

6 6 CCXS 6-6 C-45 TSC-80 R-45

4 4 CCXS 4-4 C-65 TSC-80 R-45

B

22 CCXS 2-2 C-90 TSC-80 R-90

4 CCXS 2-4 C-65 TSC-80 R-45

2 SOL 2 SOL CCXS 2S-2S C-90 TSC-80 R-90

1

1 CCXS 1-1 C-115 TSC-80 R-90

2 CCXS 1-2 C-90 TSC-80 R-90

4 CCXS 1-4 C-90 TSC-80 R-90

1/0

1/0 CCXS 1/0-1/0 C-150 TSC-80 R-150

1 CCXS 1/0-1 C-150 TSC-80 R-150

2 CCXS 1/0-2 C-115 TSC-80 R-90

4 CCXS 1/0-4 C-115 TSC-80 R-90

2/0

2/0 CCXS 2/0-2/0 C-200 TSC-80 R-150

1/0 CCXS 2/0-1/0 C-200 TSC-80 R-150

1 CCXS 2/0-1 C-150 TSC-80 R-150

2 CCXS 2/0-2 C-150 TSC-80 R-150

3/0

3/0 CCXS 3/0-3/0 C-250 TSC-80 R-150

2/0 CCXS 3/0-2/0 C-200 TSC-80 R-150

1/0 CCXS 3/0-1/0 C-200 TSC-80 R-150

1 CCXS 3/0-1 C-150 TSC-80 R-150

2 CCXS 3/0-2 C-150 TSC-80 R-150

4/0

4/0 CCXS 4/0-4/0 C-250 TSC-80 R-150

3/0 CCXS 4/0-3/0 C-250 TSC-80 R-150

2/0 CCXS 4/0-2/0 C-200 TSC-80 R-150

1/0 CCXS 4/0-1/0 C-200 TSC-80 R-150

1 CCXS 4/0-1 C-150 TSC-80 R-150

2 CCXS 4/0-2 C-150 TSC-80 R-150

250

250 CCXS 250-250 2xC150 TSC-100 R-750

E

4/0 CCXS 250-4/0 2xC150 TSC-100 R-750

3/0 CCXS 250-3/0 2xC150 TSC-100 R-750

2/0 CCXS 250-2/0 C-250 TSC-80 R-150

1/0 CCXS 250-1/0 C-250 TSC-80 R-150

1 CCXS 250-1 C-200 TSC-80 R-150

2 CCXS 250-2 C-150 TSC-80 R-150

Smaller cable must pass over the

larger one in mold as shown below.


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25

1.1 CABLE / CABLE


CONNECTION CCXS

CABLE SIZE

Run Tap MOLD

PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

KEY PRICE

300

300 CCXS 300-300 2xC200 TSC-100 R-750

E

250 CCXS 300-250 2xC200 TSC-100 R-750

4/0 CCXS 300-4/0 2xC150 TSC-100 R-750

3/0 CCXS 300-3/0 2xC150 TSC-100 R-750

2/0 CCXS 300-2/0 C-250 TSC-100 R-750

1/0 CCXS 300-1/0 C-250 TSC-100 R-750

1 CCXS 300-1 C-200 TSC-100 R-750

2 CCXS 300-2 C-150 TSC-100 R-750

350

350 CCXS 350-350 2xC250 TSC-100 R-750

300 CCXS 350-300 2xC250 TSC-100 R-750

250 CCXS 350-250 2xC250 TSC-100 R-750

4/0 CCXS 350-4/0 2xC200 TSC-100 R-750

3/0 CCXS 350-3/0 2xC200 TSC-100 R-750

2/0 CCXS 350-2/0 2xC150 TSC-100 R-750

1/0 CCXS 350-1/0 C-250 TSC-100 R-750

1 CCXS 350-1 C-200 TSC-100 R-750

2 CCXS 350-2 C-200 TSC-100 R-750

500

500 CCXS 500-500 3xC-250 TSC-100 R-750

I

350 CCXS 500-350 3xC-200 TSC-100 R-750

300 CCXS 500-300 3xC-200 TSC-100 R-750

250 CCXS 500-250 2xC250 TSC-100 R-750

4/0 CCXS 500-4/0 2xC250 TSC-100 R-750

3/0 CCXS 500-3/0 2xC250 TSC-100 R-750

2/0 CCXS 500-2/0 2xC200 TSC-100 R-750

1/0 CCXS 500-1/0 2xC150 TSC-100 R-750

Smaller cable must pass over the

larger one in mold as shown below.


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26

1.2 CABLE / ROD


CONNECTION CPAR

DIMENSION

ROD CABLE

MOLD PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

KEY PRICECopper Clad

UnthreadedSteel or Copper Clad

with Threads

1/2”

1 CPAR 12-1 CPAR 12T-1 C-65 TSC-80 R-45

A

1/0 CPAR 12-1/0 CPAR 12T-1/0 C-90 TSC-80 R-90

1/0 SOL CPAR 12-1/0 SOL CPAR 12T-1/0 SOL C-90 TSC-80 R-90

2/0 CPAR 12-2/0 CPAR 12T-2/0 C-90 TSC-80 R-90

3/0 CPAR 12-3/0 CPAR 12T-3/0 C-90 TSC-80 R-90

4/0 CPAR 12-4/0 CPAR 12T-4/0 C-90 TSC-80 R-90

250 CPAR 12-250 CPAR 12T-250 C-90 TSC-80 R-90

300 CPAR 12-300 CPAR 12T-300 C-90 TSC-80 R-90

5/8”

2 CPAR 58-2 CPAR 58T-2 C-65 TSC-80 R-45

2 SOL CPAR 58-2 SOL CPAR 58T-2 SOL C-65 TSC-80 R-45

1 CPAR 58-1 CPAR 58T-1 C-65 TSC-80 R-45

1/0 CPAR 58-1/0 CPAR 58T-1/0 C-90 TSC-80 R-90


2/0 CPAR 58-2/0 CPAR 58T-2/0 C-90 TSC-80 R-90

3/0 CPAR 58-3/0 CPAR 58T-3/0 C-90 TSC-80 R-90

4/0 CPAR 58-4/0 CPAR 58T-4/0 C-90 TSC-80 R-90

250 CPAR 58-250 CPAR 58T-250 C-90 TSC-80 R-90

300 CPAR 58-300 CPAR 58T-300 C-115 TSC-80 R-90

350 CPAR 58-350 CPAR 58T-350 C-115 TSC-80 R-90

500 CPAR 58-500 CPAR 58T-500 C-150 TSC-80 R-150

3/4”

2 CPAR 34-2 CPAR 34T-2 C-90 TSC-80 R-90

2 SOL CPAR 34-2 SOL CPAR 34T-2 SOL C-90 TSC-80 R-90

1 CPAR 34-1 CPAR 34T-1 C-90 TSC-80 R-90

1/0 CPAR 34-1/0 CPAR 34T-1/0 C-90 TSC-80 R-90


2/0 CPAR 34-2/0 CPAR 34T-2/0 C-90 TSC-80 R-90

3/0 CPAR 34-3/0 CPAR 34T-3/0 C-90 TSC-80 R-90

4/0 CPAR 34-4/0 CPAR 34T-4/0 C-90 TSC-80 R-90

250 CPAR 34-250 CPAR 34T-250 C-90 TSC-80 R-90

300 CPAR 34-300 CPAR 34T-300 C-115 TSC-80 R-90

350 CPAR 34-350 CPAR 34T-350 C-115 TSC-80 R-90

500 CPAR 34-500 CPAR 34T-500 C-150 TSC-80 R-150

Place end of cable under center of tap hole and place rod

against the cable as shown below.

Use lock-pliers or clamp on the rod be-low mold to prevent it from sliding down

during welding.


CABLE TO GROUND ROD CONNECTION SINGLE ON TOP OF

GROUND ROD

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27

1.2 CABLE / ROD

Keep rod placed against the cable as

shown below.Use lock-pliers or

clamp on the rod be-low mold to prevent it from sliding down

during welding.


CABLE TO GROUND ROD CONNECTION

THROUGH CABLE ON TOP OF GROUND ROD


CONNECTION CPT

DIMENSION

ROD CABLE


HANDLE CLAMP

MOULD SCRAPER



with Threads

1/2”

2 CPT 12-2 CPT 12T-2 C-90 TSC-80 R-90

A

2 SOL CPT 12-2S CPT 12T-2S C-90 TSC-80 R-90

1 CPT 12-1 CPT 12T-1 C-90 TSC-80 R-90

1/0 CPT 12-1/0 CPT 12T-1/0 C-90 TSC-80 R-90

1/0 SOL CPT 12-1/0 SOL CPT 12T-1/0 SOL C-90 TSC-80 R-90

2/0 CPT 12-2/0 CPT 12T-2/0 C-90 TSC-80 R-90

3/0 CPT 12-3/0 CPT 12T-3/0 C-115 TSC-80 R-90

4/0 CPT 12-4/0 CPT 12T-4/0 C-115 TSC-80 R-90

250 CPT 12-250 CPT 12T-250 C-150 TSC-80 R-150

300 CPT 12-300 CPT 12T-300 C-200 TSC-80 R-150

5/8”

2 CPT 58-2 CPT 58T-2 C-90 TSC-80 R-90

2 SOL CPT 58-2 SOL CPT 58T-2 SOL C-90 TSC-80 R-90

1 CPT 58-1 CPT 58T-1 C-90 TSC-80 R-90

1/0 CPT 58-1/0 CPT 58T-1/0 C-90 TSC-80 R-90


2/0 CPT 58-2/0 CPT 58T-2/0 C-115 TSC-80 R-90

3/0 CPT 58-3/0 CPT 58T-3/0 C-115 TSC-80 R-90

4/0 CPT 58-4/0 CPT 58T-4/0 C-115 TSC-80 R-90

250 CPT 58-250 CPT 58T-250 C-150 TSC-80 R-150

300 CPT 58-300 CPT 58T-300 C-200 TSC-80 R-150

350 CPT 58-350 CPT 58T-350 C-200 TSC-80 R-150

500 CPT 58-500 CPT 58T-500 C-250 TSC-80 R-150

3/4”

2 CPT 34-2 CPT 34T-2 C-90 TSC-80 R-90

2 SOL CPT 34-2 SOL CPT 34T-2 SOL C-90 TSC-80 R-90

1 CPT 34-1 CPT 34T-1 C-90 TSC-80 R-90

1/0 CPT 34-1/0 CPT 34T-1/0 C-115 TSC-80 R-90


2/0 CPT 34-2/0 CPT 34T-2/0 C-115 TSC-80 R-90

3/0 CPT 34-3/0 CPT 34T-3/0 C-115 TSC-80 R-90

4/0 CPT 34-4/0 CPT 34T-4/0 C-115 TSC-80 R-90

250 CPT 34-250 CPT 34T-250 C-150 TSC-80 R-150

300 CPT 34-300 CPT 34T-300 C-200 TSC-80 R-150

350 CPT 34-350 CPT 34T-350 C-200 TSC-80 R-150

500 CPT 34-500 CPT 34T-500 C-250 TSC-80 R-150

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28

1.2 CABLE / ROD

Place cable and rod into mold as shown

below.Use lock-pliers or

clamp on the rod be-low mold to prevent it from sliding down

during welding.



THROUGH CABLE TO SIDE OF GROUND ROD


CONNECTION CPTS

DIMENSION

ROD CABLE


HANDLE CLAMP

MOULD SCRAPER



with Threads

1/2”

4 or 4 SOL CPTS 12-4 CPTS 12T-4 C-65 TSC-80 R-45

C



1/0 CPTS 12-1/0 CPTS 12T-1/0 C-115 TSC-80 R-90

1/0 SOL CPTS 12-1/0S CPTS 12T-1/0S C-115 TSC-80 R-90

2/0 CPTS 12-2/0 CPTS 12T-2/0 C-115 TSC-80 R-90

3/0 CPTS 12-3/0 CPTS 12T-3/0 C-150 TSC-80 R-150

D4/0 CPTS 12-4/0 CPTS 12T-4/0 C-150 TSC-80 R-150

250 CPTS 12-250 CPTS 12T-250 C-150 TSC-80 R-150

300 CPTS 12-300 CPTS 12T-300 C-200 TSC-80 R-150

5/8”


C



1/0 CPTS 58-1/0 CPTS 58T-1/0 C-115 TSC-80 R-90


2/0 CPTS 58-2/0 CPTS 58T-2/0 C-115 TSC-80 R-90

3/0 CPTS 58-3/0 CPTS 58T-3/0 C-150 TSC-80 R-150

D

4/0 CPTS 58-4/0 CPTS 58T-4/0 C-150 TSC-80 R-150

250 CPTS 58-250 CPTS 58T-250 C-150 TSC-80 R-150

300 CPTS 58-300 CPTS 58T-300 C-200 TSC-80 R-150

350 CPTS 58-350 CPTS 58T-350 C-250 TSC-80 R-150

500 CPTS 58-500 CPTS 58T-500 2xC200 TSC-80 R-150 I

3/4”


C



1/0 CPTS 34-1/0 CPTS 34T-1/0 C-115 TSC-80 R-90


2/0 CPTS 34-2/0 CPTS 34T-2/0 C-115 TSC-80 R-90

3/0 CPTS 34-3/0 CPTS 34T-3/0 C-150 TSC-80 R-150

4/0 CPTS 34-4/0 CPTS 34T-4/0 C-150 TSC-80 R-150

250 CPTS 34-250 CPTS 34T-250 C-200 TSC-80 R-150D

300 CPTS 34-300 CPTS 34T-300 C-250 TSC-80 R-150

350 CPTS 34-350 CPTS 34T-350 2xC2150 TSC-80 R-150I

500 CPTS 34-500 CPTS 34T-500 2xC250 TSC-80 R-150

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29

1.2 CABLE / ROD

Place end of tap cable under center

of tap hole and keep rod placed against

the run cable as shown.

Use lock-pliers or clamp on rod below

mold to prevent it from sliding down

during welding.



THROUGH CABLE PLUS TOP CABLE TO TOP OF

GROUND ROD


CONNECTION CPTD

DIMENSION

ROD CABLE


HANDLE CLAMP

MOULD SCRAPER



with Threads

1/2”

4 CPTD 12-4 CPTD 12T-4 C-90 TSC-80 R-90

B

2 CPTD 12-2 CPTD 12T-2 C-90 TSC-80 R-90

1 CPTD 12-1 CPTD 12T-1 C-90 TSC-80 R-90

1/0 CPTD 12-1/0 CPTD 12T-1/0 C-115 TSC-80 R-90

2/0 CPTD 12-2/0 CPTD 12T-2/0 C-150 TSC-80 R-150

3/0 CPTD 12-3/0 CPTD 12T-3/0 C-200 TSC-80 R-150

4/0 CPTD 12-4/0 CPTD 12T-4/0 C-200 TSC-80 R-150

5/8”

4 CPTD 58-4 CPTD 58T-4 C-90 TSC-80 R-90

2 CPTD 58-2 CPTD 58T-2 C-115 TSC-80 R-90

1 CPTD 58-1 CPTD 58T-1 C-115 TSC-80 R-90

1/0 CPTD 58-1/0 CPTD 58T-1/0 C-150 TSC-80 R-150

2/0 CPTD 58-2/0 CPTD 58T-2/0 C-200 TSC-80 R-150

3/0 CPTD 58-3/0 CPTD 58T-3/0 C-250 TSC-80 R-150

4/0 CPTD 58-4/0 CPTD 58T-4/0 C-250 TSC-80 R-150

250 CPTD 58-250 CPTD 58T-250 2xC-150 TSC-100 R-750 H

3/4”

4 CPTD 34-4 CPTD 34T-4 C-90 TSC-80 R-90

B

2 CPTD 34-2 CPTD 34T-2 C-115 TSC-80 R-90

1 CPTD 34-1 CPTD 34T-1 C-115 TSC-80 R-90

1/0 CPTD 34-1/0 CPTD 34T-1/0 C-150 TSC-80 R-150

2/0 CPTD 34-2/0 CPTD 34T-2/0 C-200 TSC-80 R-150

3/0 CPTD 34-3/0 CPTD 34T-3/0 C-250 TSC-80 R-150

4/0 CPTD 34-4/0 CPTD 34T-4/0 C-250 TSC-80 R-150

250 CPTD 34-250 CPTD 34T-250 2xC-150 TSC-100 R-750

H300 CPTD 34-300 CPTD 34T-300 2xC-200 TSC-100 R-750



1”

4 CPTD 1-4 CPTD 1T-4 C-115 TSC-80 R-90

B

2 CPTD 1-2 CPTD 1T-2 C-150 TSC-80 R-150

1 CPTD 1-1 CPTD 1T-1 C-150 TSC-80 R-150

1/0 CPTD 1-1/0 CPTD 1T-1/0 C-200 TSC-80 R-150

2/0 CPTD 1-2/0 CPTD 1T-2/0 C-250 TSC-80 R-150

3/0 CPTD 1-3/0 CPTD 1T-3/0 2xC-150 TSC-100 R-750

H

4/0 CPTD 1-4/0 CPTD 1T-4/0 2xC-150 TSC-100 R-750





CO

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MIN

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30

For cables larger than 4/0 AWG use

1/4” gap under the center of tap hole

and keep rpd placed against the bottom

cable as shown.Use lock-pliers or

clamp on rod below mold to prevent it from sliding down

during welding.



PARALELL THROUGH TO TOP OF GROUND ROD


1.2 CABLE / ROD

CONNECTION CPTDP

DIMENSION

ROD CABLE


HANDLE CLAMP

MOULD SCRAPER



with Threads

1/2”

4 CPTDP 12-4 CPTDP 12T-4 C-115 TSC-80 R-90

B



1/0 CPTDP 12-1/0 CPTDP 12T-1/0 C-150 TSC-80 R-90




5/8”






3/0 CPTDP 58-3/0 CPTDP 58T-3/0 2xC-150 TSC-100 R-750

H


250 CPTDP 58-250 CPTDP 58T-250 2xC-200 TSC-100 R-750




3/4”


B






H






1”


B2 CPTDP 1-2 CPTDP 1T-2 C-200 TSC-80 R-150




H






CO

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31

1.3 EARTH ROD / EARTH ROD

Upper pointed rod is placed against lower

one and blunt rods must be gapped 3/8”

at axis of the gap hole as shown.

Use lock-pliers or clamp on rod below

mold to prevent it from sliding down

during welding.


GROUND TO ROD SPLICE


CONNECTION PPV

DIMENSION

Rod SizeMOLD PART. No.

CARTRIDGEHANDLE CLAMP

MOULD SCRAPER



with Threads

1/2” PPV 12 PPV 12 T C-250 TSC-80 R-150

B5/8” PPV 58 PPV 58 T 2xC-150 TSC-100 R-750

3/4” PPV 34 PPV 34 T 2xC-200 TSC-100 R-750

CO

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ING

32

1.4 CABLE / REBAR

Wrap mastic around steel rebar below the weld cavity as

shown.Place cable and rebar

into the mold.Use lock-pliers or


during welding.


CABLE TO REBAR HORIZONTAL THROUGH

CABLE TO VERTICAL REBAR


CONNECTION CRPH

DIMENSION

Rebar Size Cable Size MOLD

PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

KEY PRICE

3

6 CRPH 3-6 C-90 TSC-80 R-90

C

4 CRPH 3-4 C-90 TSC-80 R-90

2 SOL CRPH 3-2 S C-90 TSC-80 R-90

2 CRPH 3-2 C-90 TSC-80 R-90

1 CRPH 3-1 C-115 TSC-80 R-90

1/0 CRPH 3-1/0 C-115 TSC-80 R-90

2/0 CRPH 3-2/0 C-115 TSC-80 R-90

3/0 CRPH 3-3/0 C-150 TSC-80 R-150D

4/0 CRPH 3-4/0 C-150 TSC-80 R-150

4

6 CRPH 4-6 C-90 TSC-80 R-90

C

4 CRPH 4-4 C-90 TSC-80 R-90

2 SOL CRPH 4-2 S C-90 TSC-80 R-90

2 CRPH 4-2 C-90 TSC-80 R-90

1 CRPH 4-1 C-115 TSC-80 R-90

1/0 CRPH 4-1/0 C-115 TSC-80 R-90

2/0 CRPH 4-2/0 C-115 TSC-80 R-90

3/0 CRPH 4-3/0 C-150 TSC-80 R-150D

4/0 CRPH 4-4/0 C-150 TSC-80 R-150

5

6 CRPH 5-6 C-90 TSC-80 R-90

C

4 CRPH 5-4 C-90 TSC-80 R-90

2 SOL CRPH 5-2 S C-90 TSC-80 R-90

2 CRPH 5-2 C-90 TSC-80 R-90

1 CRPH 5-1 C-115 TSC-80 R-90

1/0 CRPH 5-1/0 C-115 TSC-80 R-90

2/0 CRPH 5-2/0 C-115 TSC-80 R-90

3/0 CRPH 5-3/0 C-150 TSC-80 R-150D

4/0 CRPH 5-4/0 C-150 TSC-80 R-150

6

6 CRPH 6-6 C-90 TSC-80 R-90

C

4 CRPH 6-4 C-90 TSC-80 R-90

2 SOL CRPH 6-2 S C-90 TSC-80 R-90

2 CRPH 6-2 C-90 TSC-80 R-90

1 CRPH 6-1 C-115 TSC-80 R-90

1/0 CRPH 6-1/0 C-115 TSC-80 R-90

2/0 CRPH 6-2/0 C-115 TSC-80 R-90

3/0 CRPH 6-3/0 C-150 TSC-80 R-150D

4/0 CRPH 6-4/0 C-150 TSC-80 R-150

CO

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ELD

ING

33

1.4 CABLE / REBAR


shown.Place cable and rebar

into the mold.Use lock-pliers or


during welding.


CABLE TO REBAR HORIZONTAL THROUGH



7

4 CRPH 7-4 C-90 TSC-80 R-90

C

2 SOL CRPH 7-2 S C-90 TSC-80 R-90

2 CRPH 7-2 C-90 TSC-80 R-90

1 CRPH 7-1 C-115 TSC-80 R-90

1/0 CRPH 7-1/0 C-115 TSC-80 R-90

2/0 CRPH 7-2/0 C-115 TSC-80 R-90

3/0 CRPH 7-3/0 C-150 TSC-80 R-150D

4/0 CRPH 7-4/0 C-150 TSC-80 R-150

8

2 SOL CRPH 8-2 S C-90 TSC-80 R-90

C

2 CRPH 8-2 C-90 TSC-80 R-90

1 CRPH 8-1 C-115 TSC-80 R-90

1/0 CRPH 8-1/0 C-115 TSC-80 R-90

2/0 CRPH 8-2/0 C-115 TSC-80 R-90

3/0 CRPH 8-3/0 C-150 TSC-80 R-150D

4/0 CRPH 8-4/0 C-150 TSC-80 R-150

9

2 SOL CRPH 9-2 S C-90 TSC-80 R-90

C

2 CRPH 9-2 C-90 TSC-80 R-90

1 CRPH 9-1 C-115 TSC-80 R-90

1/0 CRPH 9-1/0 C-115 TSC-80 R-90

2/0 CRPH 9-2/0 C-115 TSC-80 R-90

3/0 CRPH 9-3/0 C-150 TSC-80 R-150D

4/0 CRPH 9-4/0 C-150 TSC-80 R-150

CONNECTION CRPH

DIMENSION


PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

KEY PRICE

CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

34

1.4 CABLE / REBAR

Wrap mastic around steel rebar on both

sides of the weld cavity as shown

below.Place cable end

under center of tap hole of the mold.


CABLE TO REBAR HORI-ZONTAL CABLE TOP TO

HORIZONTAL REBAR


CONNECTION CRTP

DIMENSION


PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

KEY PRICE

3

6 CRTP 3-6 C-25 TSC-50 R-15

A

4 CRTP 3-4 C-32 TSC-50 R-15

2 SOL CRTP 3-2S C-45 TSC-80 R-45

2 CRTP 3-2 C-45 TSC-80 R-45

1 CRTP 3-1 C-65 TSC-80 R-45

1/0 CRTP 3-1/0 C-90 TSC-80 R-90

2/0 CRTP 3-2/0 C-90 TSC-80 R-90

3/0 CRTP 3-3/0 C-115 TSC-80 R-90

4/0 CRTP 3-4/0 C-115 TSC-80 R-90

4

6 CRTP 4-6 C-25 TSC-80 R-45

4 CRTP 4-4 C-32 TSC-80 R-45


2 CRTP 4-2 C-45 TSC-80 R-45

1 CRTP 4-1 C-65 TSC-80 R-45

1/0 CRTP 4-1/0 C-90 TSC-80 R-90

2/0 CRTP 4-2/0 C-90 TSC-80 R-90

3/0 CRTP 4-3/0 C-115 TSC-80 R-90

4/0 CRTP 4-4/0 C-115 TSC-80 R-90

5

6 CRTP 5-6 C-25 TSC-80 R-45

4 CRTP 5-4 C-32 TSC-80 R-45


2 CRTP 5-2 C-45 TSC-80 R-45

1 CRTP 5-1 C-65 TSC-80 R-45

1/0 CRTP 5-1/0 C-90 TSC-80 R-90

2/0 CRTP 5-2/0 C-90 TSC-80 R-90

3/0 CRTP 5-3/0 C-115 TSC-80 R-90

4/0 CRTP 5-4/0 C-115 TSC-80 R-90

6

6 CRTP 6-6 C-25 TSC-80 R-45

4 CRTP 6-4 C-32 TSC-80 R-45


2 CRTP 6-2 C-45 TSC-80 R-45

1 CRTP 6-1 C-65 TSC-80 R-45

1/0 CRTP 6-1/0 C-90 TSC-80 R-90

2/0 CRTP 6-2/0 C-90 TSC-80 R-90

3/0 CRTP 6-3/0 C-115 TSC-80 R-90

4/0 CRTP 6-4/0 C-115 TSC-80 R-90

CO

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MIN

OT

HE

RM

IC W

ELD

ING

35

1.4 CABLE / REBAR


sides of the weld cavity as shown.Place cable end

under center of tap hole of the mold.


CABLE TO REBAR HORI-ZONTAL CABLE TOP TO

HORIZONTAL REBAR


7

4 CRTP 7-4 C-32 TSC-80 R-45

A


2 CRTP 7-2 C-45 TSC-80 R-45

1 CRTP 7-1 C-65 TSC-80 R-45

1/0 CRTP 7-1/0 C-90 TSC-80 R-90

2/0 CRTP 7-2/0 C-90 TSC-80 R-90

3/0 CRTP 7-3/0 C-115 TSC-80 R-90

4/0 CRTP 7-4/0 C-115 TSC-80 R-90

8


2 CRTP 8-2 C-45 TSC-80 R-45

1 CRTP 8-1 C-65 TSC-80 R-45

1/0 CRTP 8-1/0 C-90 TSC-80 R-90

2/0 CRTP 8-2/0 C-90 TSC-80 R-90

3/0 CRTP 8-3/0 C-115 TSC-80 R-90

4/0 CRTP 8-4/0 C-115 TSC-80 R-90

9


2 CRTP 9-2 C-45 TSC-80 R-45

1 CRTP 9-1 C-65 TSC-80 R-45

1/0 CRTP 9-1/0 C-90 TSC-80 R-90

2/0 CRTP 9-2/0 C-90 TSC-80 R-90

3/0 CRTP 9-3/0 C-115 TSC-80 R-90

4/0 CRTP 9-4/0 C-115 TSC-80 R-90

CONNECTION CRTP

DIMENSION


PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

KEY PRICE

CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

36

1.4 CABLE / REBAR


shown.Place tap cable

against rebar.Use lock-pliers or


during welding.


CABLE TO REBAR CONNECTION TEE CON-NECTION HORIZONTAL


CONNECTION CRTL

DIMENSION


PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

KEY PRICE

3

6 CRTL 3-6 C-45 TSC-80 R-45

D

4 CRTL 3-4 C-65 TSC-80 R-45

2 SOL CRTL 3-2S C-65 TSC-80 R-45

2 CRTL 3-2 C-65 TSC-80 R-45

1 CRTL 3-1 C-90 TSC-80 R-90

1/0 CRTL 3-1/0 C-115 TSC-80 R-90

2/0 CRTL 3-2/0 C-115 TSC-80 R-90

3/0 CRTL 3-3/0 C-150 TSC-80 R-150

4/0 CRTL 3-4/0 C-150 TSC-80 R-150

4

6 CRTL 4-6 C-45 TSC-80 R-45

4 CRTL 4-4 C-65 TSC-80 R-45


2 CRTL 4-2 C-65 TSC-80 R-45

1 CRTL 4-1 C-90 TSC-80 R-90

1/0 CRTL 4-1/0 C-115 TSC-80 R-90

2/0 CRTL 4-2/0 C-115 TSC-80 R-90

3/0 CRTL 4-3/0 C-150 TSC-80 R-150

4/0 CRTL 4-4/0 C-150 TSC-80 R-150

5

6 CRTL 5-6 C-45 TSC-80 R-45

4 CRTL 5-4 C-65 TSC-80 R-45


2 CRTL 4-2 C-65 TSC-80 R-45

1 CRTL 4-1 C-90 TSC-80 R-90

1/0 CRTL 4-1/0 C-115 TSC-80 R-90

2/0 CRTL 4-2/0 C-115 TSC-80 R-90

3/0 CRTL 4-3/0 C-150 TSC-80 R-150

4/0 CRTL 4-4/0 C-150 TSC-80 R-150

6

6 CRTL 6-6 C-45 TSC-80 R-45

4 CRTL 6-4 C-65 TSC-80 R-45


2 CRTL 6-2 C-65 TSC-80 R-45

1 CRTL 6-1 C-90 TSC-80 R-90

1/0 CRTL 6-1/0 C-115 TSC-80 R-90

2/0 CRTL 6-2/0 C-115 TSC-80 R-90

3/0 CRTL 6-3/0 C-150 TSC-80 R-150

4/0 CRTL 6-4/0 C-150 TSC-80 R-150

CO

PP

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MIN

OT

HE

RM

IC W

ELD

ING

37

1.4 CABLE / REBAR


shown.Place tap cable

against rebar.Use lock-pliers or


during welding.


CABLE TO REBAR CONNECTION TEE CON-NECTION HORIZONTAL



CONNECTION CRTL

DIMENSION


PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

KEY PRICE

7

4 CRTL 7-4 C-65 TSC-80 R-45

D


2 CRTL 7-2 C-65 TSC-80 R-45

1 CRTL 7-1 C-90 TSC-80 R-90

1/0 CRTL 7-1/0 C-115 TSC-80 R-90

2/0 CRTL 7-2/0 C-115 TSC-80 R-90

3/0 CRTL 7-3/0 C-150 TSC-80 R-150

4/0 CRTL 8-4/0 C-150 TSC-80 R-150

8


2 CRTL 8-2 C-65 TSC-80 R-45

1 CRTL 8-1 C-90 TSC-80 R-90

1/0 CRTL 8-1/0 C-115 TSC-80 R-90

2/0 CRTL 8-2/0 C-115 TSC-80 R-90

3/0 CRTL 8-3/0 C-150 TSC-80 R-150

4/0 CRTL 8-4/0 C-150 TSC-80 R-150

9


2 CRTL 9-2 C-65 TSC-80 R-45

1 CRTL 9-1 C-90 TSC-80 R-90

1/0 CRTL 9-1/0 C-115 TSC-80 R-90

2/0 CRTL 9-2/0 C-115 TSC-80 R-90

3/0 CRTL 9-3/0 C-150 TSC-80 R-150

4/0 CRTL 9-4/0 C-150 TSC-80 R-150

CO

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IC W

ELD

ING

38

1.4 CABLE / REBAR


sides of the weld cavity as shown.Place cable over

the rebar.


CABLE TO REBAR CONNECTION ‘X’ CON-NECTION HORIZONTAL CABLE TO HORIZONTAL

REBAR


CONNECTION CRXS

DIMENSION


PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

KEY PRICE

3

6 CRXS 3-6 C-65 TSC-80 R-45

B

4 CRXS 3-4 C-65 TSC-80 R-45

2 SOL CRXS 3-2S C-90 TSC-80 R-90

2 CRXS 3-2 C-90 TSC-80 R-90

1 CRXS 3-1 C-90 TSC-80 R-90

1/0 CRXS 3-1/0 C-115 TSC-80 R-90

2/0 CRXS 3-2/0 C-115 TSC-80 R-90

3/0 CRXS 3-3/0 C-150 TSC-80 R-150E

4/0 CRXS 3-4/0 C-150 TSC-80 R-150

4

6 CRXS 4-6 C-65 TSC-80 R-45

B

4 CRXS 4-4 C-65 TSC-80 R-45


2 CRXS 4-2 C-90 TSC-80 R-90

1 CRXS 4-1 C-90 TSC-80 R-90

1/0 CRXS 4-1/0 C-115 TSC-80 R-90

2/0 CRXS 4-2/0 C-115 TSC-80 R-90

3/0 CRXS 4-3/0 C-150 TSC-80 R-150E

4/0 CRXS 4-4/0 C-150 TSC-80 R-150

5

6 CRXS 5-6 C-65 TSC-80 R-45

B

4 CRXS 5-4 C-65 TSC-80 R-45


2 CRXS 5-2 C-90 TSC-80 R-90

1 CRXS 5-1 C-90 TSC-80 R-90

1/0 CRXS 5-1/0 C-115 TSC-80 R-90

2/0 CRXS 5-2/0 C-115 TSC-80 R-90

3/0 CRXS 5-3/0 C-150 TSC-80 R-150E

4/0 CRXS 5-4/0 C-150 TSC-80 R-150

6

6 CRXS 6-6 C-65 TSC-80 R-45

B

4 CRXS 6-4 C-65 TSC-80 R-45


2 CRXS 6-2 C-90 TSC-80 R-90

1 CRXS 6-1 C-90 TSC-80 R-90

1/0 CRXS 6-1/0 C-115 TSC-80 R-90

2/0 CRXS 6-2/0 C-115 TSC-80 R-90

3/0 CRXS 6-3/0 C-150 TSC-80 R-150E

4/0 CRXS 6-4/0 C-150 TSC-80 R-150

CO

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HE

RM

IC W

ELD

ING

39

1.5 CABLE / STEEL SURFACE

Place cable end under center of

tap hole as shown below.

Hold down mold co-ver to prevent mold

from tipping over.


CABLE TO STEEL SURFACE CONNECTION CABLE TO HORIZONTAL CONCENTRIC COPPER

CONDUCTOR TO OFF SURFACE

Welding to thin sections or thin-walled pipes may causeburn-through.Test-weld before welding final parts.

For welding Cable to Steel Pipe, add the following suffix to Mold Part No.


CONNECTION CHTH

DIMENSION

CABLE SIZEMOLD

PART. No.CARTRIDGE

HANDLECLAMP

MOULDSCRAPER

KEY PRICE

6 CHTH 6 C-45 TSC-50 R-15

M

4 CHTH 4 C-45 TSC-50 R-15

2 CHTH 2 C-45 TSC-50 R-15

2SOL CHTH 2S C-45 TSC-50 R-15

1 CHTH 1 C-65 TSC-50 R-15

1/0 CHTH 1/0 C-90 TSC-80 R-90

A

2/0 CHTH 2/0 C-90 TSC-80 R-90

3/0 CHTH 3/0 C-115 TSC-80 R-90

4/0 CHTH 4/0 C-115 TSC-80 R-90

250 CHTH 250 C-115 TSC-80 R-90

300 CHTH 300 C-150 TSC-80 R-150

350 CHTH 350 C-200 TSC-80 R-150

500 CHTH 500 C-200 TSC-80 R-150

CABLE SIZE PIPE SIZE SUFFIX

# 1 and smaller12” and smaller Nominal Pipe Size

14” and larger None

# 1/0 thru 25028” and smaller Nominal Pipe Size


CO

PP

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MIN

OT

HE

RM

IC W

ELD

ING

40


Cable end must be placed against the

steel surface as shown below.

Secure mold to steelsurface with a clamp if possible to prevent

mold from tipping over.


CABLE TO STEEL SURFACE CONNECTION

CABLE TO VERTICAL STEEL SURFACE OR

TO HORIZONTAL STEEL PIPE

Welding to thin sections or thin-walled pipes may cause burn-through.Test-weld before welding final parts.

For welding Cable to vertical Steel Pipe, add V and the following suffix to Mold Part No.For welding Cable to horizontal Steel Pipe, add H and the following suffix to Mold Part No.





CONNECTION CHTF

DIMENSION

CABLE SIZEMOLD

PART. No.CARTRIDGE

HANDLECLAMP

MOULDSCRAPER

KEY PRICE

6 CHTF 6 C-45 TSC-50 R-15

M

4 CHTF 4 C-45 TSC-50 R-15

2 CHTF 2 C-45 TSC-50 R-15

2SOL CHTF 2S C-45 TSC-50 R-15

1 CHTF 1 C-65 TSC-50 R-15

1/0 CHTF 1/0 C-90 TSC-80 R-90

A

2/0 CHTF 2/0 C-90 TSC-80 R-90

3/0 CHTF 3/0 C-115 TSC-80 R-90

4/0 CHTF 4/0 C-115 TSC-80 R-90

250 CHTF 250 C-115 TSC-80 R-90

300 CHTF 300 C-150 TSC-80 R-150

350 CHTF 350 C-200 TSC-80 R-150

500 CHTF 500 C-200 TSC-80 R-150

CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

41


Cut cable and gap 1/8”under center of


Hold down mold co-ver to prevent mold

from tippingover.


CABLE TO STEEL SURFACE CONNECTION CABLE TO HORIZONTAL

FLAT STEEL SURFACE OR TO HORIZONTAL PIPE

Welding to thin sections or thin-walled pipes may causeburn-through.Test-weld before welding final parts.

For welding Cable to Steel Pipe, add the following suffix to Mold Part No.




# 1/0 thru 25028” and smaller Nominal Pipe Size



CONNECTION CHPHH

DIMENSION

CABLE SIZEMOLD

PART. No.CARTRIDGE

HANDLECLAMP

MOULDSCRAPER

KEY PRICE

6 CHPHH 6 C-45 TSC-50 R-15

M

4 CHPHH 4 C-45 TSC-50 R-15

2 CHPHH 2 C-45 TSC-50 R-15

2SOL CHPHH 2S C-45 TSC-50 R-15

1 CHPHH 1 C-65 TSC-50 R-15

1/0 CHPHH 1/0 C-90 TSC-80 R-90

A

2/0 CHPHH 2/0 C-115 TSC-80 R-90

3/0 CHPHH 3/0 C-115 TSC-80 R-90

4/0 CHPHH 4/0 C-150 TSC-80 R-150

250 CHPHH 250 C-150 TSC-80 R-150

300 CHPHH 300 C-200 TSC-80 R-150

350 CHPHH 350 C-250 TSC-80 R-150

CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

42


Fill the gap between cable and steel with

mastic on both sides of the weld cavity as

shown below.Secure mold to the steel surface with a clamp if possible to

prevent moldfrom tipping over.



CABLE TO VERTICAL STEEL SURFACE OR TO VERTICAL STEEL PIPE

Welding to thin sections or thin-walled pipes may causeburn-through. Test-weld before welding final parts.


CONNECTION CHPVH

CABLE SIZE

CABLE SIZEMOLD

PART. No.CARTRIDGE

HANDLECLAMP

MOULDSCRAPER

KEY PRICE

6 CHPVH 6 C-45 TSC-80 R-45

A

4 CHPVH 4 C-45 TSC-80 R-45

2 CHPVH 2 C-45 TSC-80 R-45

2SOL CHPVH 2S C-45 TSC-80 R-45

1 CHPVH 1 C-65 TSC-80 R-45

1/0 CHPVH 1/0 C-115 TSC-80 R-90

2/0 CHPVH 2/0 C-115 TSC-80 R-90

3/0 CHPVH 3/0 C-150 TSC-80 R-150

4/0 CHPVH 4/0 C-150 TSC-80 R-150

250 CHPVH 250 C-150 TSC-80 R-150

CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

43


Cable end must be placed as shown

below.Secure mold to steel surface with a clamp if possible to prevent

mold


CABLE TO STEEL SURFACE CONNECTION CABLE UP TO VERTICAL

STEEL SURFACE



CONNECTION CHVS

DIMENSON

CABLE SIZEMOLD

PART. No.CARTRIDGE

HANDLECLAMP

MOULDSCRAPER

KEY PRICE

6 CHPVV 6 C-90 TSC-80 R-90

C

4 CHPVV 4 C-90 TSC-80 R-90

2 CHPVV 2 C-115 TSC-80 R-90

2SOL CHPVV 2S C-115 TSC-80 R-90

1 CHPVV 1 C-115 TSC-80 R-90

1/0 CHPVV 1/0 C-200 TSC-80 R-150

2/0 CHPVV 2/0 C-200 TSC-80 R-150

3/0 CHPVV 3/0 C-250 TSC-80 R-150

4/0 CHPVV 4/0 C-250 TSC-80 R-150

250 CHPVV 250 C-250 TSC-80 R-150

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44


Cable end must be placed as shown

below.Secure mold to steelsurface with a clamp if possible to prevent


Fill the gap between cable and steel with

mastic below the weld cavity asshown below.



CABLE DOWN TO VERTICAL STEEL

SURFACE



CONNECTION CHVI

DIMENSION

CABLE SIZEMOLD

PART. No.CARTRIDGE

HANDLECLAMP

MOULDSCRAPER

KEY PRICE

6 CHVI 6 C-65 TSC-80 R-45

A

4 CHVI 4 C-65 TSC-80 R-45

2 CHVI 2 C-65 TSC-80 R-45

2SOL CHVI 2S C-65 TSC-80 R-45

1 CHVI 1 C-90 TSC-80 R-90

1/0 CHVI 1/0 C-115 TSC-80 R-90

2/0 CHVI 2/0 C-115 TSC-80 R-90

3/0 CHVI 3/0 C-150 TSC-80 R-150

4/0 CHVI 4/0 C-150 TSC-80 R-150

250 CHVI 250 C-200 TSC-80 R-150

300 CHVI 300 C-200 TSC-80 R-150

350 CHVI 350 C-250 TSC-80 R-150

500 CHVI 500 2xC-200 TSC-80 R-150

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ING

45

1.6 CABLE / LUG CONNECTION

Place ends of busbar and cable under

center of tap hole as shown below.


CABLE TO LUG CONNECTION CABLE TO LUG HORIZONTAL

CONNECTION


CONNECTION CPLL

DIMENSION

Cable Size Bus Size MOLD

PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

KEY PRICE

4 1/8 x 1 CPLL 4-1/8x1 C-45 TSC-80 R-45

A

2 1/8 x 1 CPLL 2-1/8x1 C-45 TSC-80 R-45

2 SOL 1/8 x 1 CPLL 2S-1/8x1 C-45 TSC-80 R-45

1 1/8 x 1 CPLL 1-1/8x1 C-45 TSC-80 R-45

1/0

1/8 x 1 CPLL 1/0-1/8x1 C-45 TSC-80 R-45

3/16 x 1 CPLL 1/0-3/16x1 C-65 TSC-80 R-45

1/4 x 1 CPLL 1/0-1/4x1 C-65 TSC-80 R-45

2/0

1/8 x 1 CPLL 2/0-1/8x1 C-65 TSC-80 R-45

3/16 x 1 CPLL 2/0-3/16x1 C-65 TSC-80 R-45

1/4 x 1 CPLL 2/0-1/4x1 C-65 TSC-80 R-45

3/0

1/8 x 1 CPLL 3/0-1/8x1 C-65 TSC-80 R-45

3/16 x 1 CPLL 3/0-3/16x1 C-90 TSC-80 R-90

1/4 x 1 CPLL 3/0-1/4x1 C-90 TSC-80 R-90

4/0

3/16 x 1 CPLL 4/0-3/16x1 C-90 TSC-80 R-90

1/4 x 1 CPLL 4/0-1/4x1 C-90 TSC-80 R-90

1/4 x 1 1/2 CPLL 4/0-1/4x1 1/2 C-90 TSC-80 R-90

1/4 x 2 CPLL 4/0-1/4x2 C-90 TSC-80 R-90

1/4 x 3 CPLL 4/0-1/4x3 C-90 TSC-80 R-90

250

3/16 x 1 CPLL 250-3/16x1 C-90 TSC-80 R-90

1/4 x 1 CPLL 250-1/4x1 C-90 TSC-80 R-90

1/4 x 1 1/2 CPLL 250-1/4x1 1/2 C-90 TSC-80 R-90

1/4 x 2 CPLL 250-1/4x2 C-90 TSC-80 R-90

1/4 x 3 CPLL 250-1/4x3 C-90 TSC-80 R-90

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46






CONNECTION


CONNECTION CPLL

DIMENSION


PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

KEY PRICE

300

1/4 x 1 CPLL 300-1/4x1 C-90 TSC-80 R-90

A

1/4 x 1 1/2 CPLL 300-1/4x1 1/2 C-90 TSC-80 R-90

1/4 x 2 CPLL 300-1/4x2 C-90 TSC-80 R-90

1/4 x 3 CPLL 300-1/4x3 C-90 TSC-80 R-90

350

1/4 x 1 CPLL 350-1/4x1 C-115 TSC-80 R-90

1/4 x 1 1/2 CPLL 350-1/4x1 1/2 C-115 TSC-80 R-90

1/4 x 2 CPLL 350-1/4x2 C-115 TSC-80 R-90

1/4 x 3 CPLL 350-1/4x3 C-115 TSC-80 R-90

500

1/4 x 1 1/2 CPLL 500-1/4x1 1/2 C-200 TSC-80 R-150

1/4 x 2 CPLL 500-1/4x2 C-200 TSC-80 R-150

1/4 x 3 CPLL 500-1/4x3 C-200 TSC-80 R-150

3/8 x 1 1/2 CPLL 500-3/8x1 1/2 C-200 TSC-80 R-150

750

1/4 x 2 CPLL 750-1/4x2 2 x C-150 TSC-100 R-750

C

1/4 x 3 CPLL 750-1/4x3 2 x C-150 TSC-100 R-750

3/8 x 1 1/2 CPLL 750-3/8x1 1/2 2 x C-150 TSC-100 R-750

3/8 x 2 CPLL 750-3/8x2 2 x C-150 TSC-100 R-750

3/8 x 3 CPLL 750-3/8x3 2 x C-150 TSC-100 R-750

1000

1/4 x 3 CPLL 1000-1/4x3 2 x C-200 TSC-100 R-750

3/8 x 2 CPLL 1000-3/8x2 2 x C-200 TSC-100 R-750

3/8 x 3 CPLL 1000-3/8x3 2 x C-200 TSC-100 R-750

1/2 x 2 CPLL 1000-1/2x2 2 x C-250 TSC-100 R-750

1/2 x 3 CPLL 1000-1/2x3 2 x C-250 TSC-100 R-750

SO

LDA

DU

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OT

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MIC

A D

EL

CO

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E47






CONNECTION


CONNECTION CPLLS

DIMENSION

Cable Size Lug Size MOLD

PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

KEY PRICE

4

1/8” x 1

CPLLS 4-1/8x1 C-32 TSC-80 R-45

B

2 CPLLS 2-1/8x1 C-32 TSC-80 R-45

2 SOL CPLLS 2S-1/8x1 C-32 TSC-80 R-45

1 CPLLS 1-1/8x1 C-32 TSC-80 R-45

1/0 CPLLS 1/0-1/8x1 C-45 TSC-80 R-45

2/0 CPLLS 2/0-1/8x1 C-45 TSC-80 R-45

3/0 CPLLS 3/0-1/8x1 C-65 TSC-80 R-45

4/03/16” x 1

CPLLS 4/0-3/16x1 C-65 TSC-80 R-45

250 CPLLS 250-3/16x1 C-65 TSC-80 R-45

3001/4” x 1

CPLLS 300-1/4x1 C-90 TSC-80 R-90

350 CPLLS 350-1/4x1 C-90 TSC-80 R-90

500 1/4” x 1 1/2 CPLLS 500-1/4x1 1/2 C-150 TSC-80 R-150

CO

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ING

48

1.6 CABLE / BUSBAR

Place tap cable against upper edge

of running busbar as shown below.


CABLE TO BUSBAR CONNECTION TOP OF

HORIZONTAL CABLE TO EDGE OF HORIZONTAL

FLAT BUSBAR


CONNECTION CPLH

DIMENSION


PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

KEY PRICE

2

1/4” x 1 1/2” & Wider

CPLH 2-1/4x1 1/2 C-65 TSC-80 R-45

A

2 SOL CPLH 2S-1/4x1 1/2 C-65 TSC-80 R-45

1/0 CPLH 1/0-1/4x1 1/2 C-90 TSC-80 R-90

2/0 CPLH 2/0-1/4x1 1/2 C-90 TSC-80 R-90

3/0 CPLH 3/0-1/4x1 1/2 C-90 TSC-80 R-90

4/0 CPLH 4/0-1/4x1 1/2 C-90 TSC-80 R-90

250 CPLH 250-1/4x1 1/2 C-115 TSC-80 R-90

300 CPLH 300-1/4x1 1/2 C-115 TSC-80 R-90

350 CPLH 350-1/4x1 1/2 C-150 TSC-80 R-150

500 CPLH 500-1/4x1 1/2 C-200 TSC-80 R-150

2

3/8” x 1 1/2” & Wider

CPLH 2-3/8x1 1/2 C-65 TSC-80 R-45

2 SOL CPLH 2S-3/8x1 1/2 C-65 TSC-80 R-45

1/0 CPLH 1/0-3/8x1 1/2 C-90 TSC-80 R-90

2/0 CPLH 2/0-3/8x1 1/2 C-90 TSC-80 R-90

3/0 CPLH 3/0-3/8x1 1/2 C-115 TSC-80 R-90

4/0 CPLH 4/0-3/8x1 1/2 C-115 TSC-80 R-90

250 CPLH 250-3/8x1 1/2 C-150 TSC-80 R-150

300 CPLH 300-3/8x1 1/2 C-150 TSC-80 R-150

350 CPLH 350-3/8x1 1/2 C-200 TSC-80 R-150

500 CPLH 500-3/8x1 1/2 C-250 TSC-80 R-150

750 CPLH 750-3/8x1 1/2 2 x C-150 TSC-100 R-750E

1000 CPLH 100-3/8x1 1/2 2 x C-200 TSC-100 R-750

2

1/2” x 1 1/2” & Wider

CPLH 2-1/2x1 1/2 C-90 TSC-80 R-90

A

2 SOL CPLH 2S-1/2x1 1/2 C-90 TSC-80 R-90

1/0 CPLH 1/0-1/2x1 1/2 C-115 TSC-80 R-90

2/0 CPLH 2/0-1/2x1 1/2 C-115 TSC-80 R-90

3/0 CPLH 3/0-1/2x1 1/2 C-150 TSC-80 R-150

4/0 CPLH 4/0-1/2x1 1/2 C-150 TSC-80 R-150

250 CPLH 250-1/2x1 1/2 C-200 TSC-80 R-150

300 CPLH 300-1/2x1 1/2 C-200 TSC-80 R-150

350 CPLH 350-1/2x1 1/2 C-250 TSC-80 R-150

500 CPLH 500-1/2x1 1/2 2 x C-150 TSC-100 R-750

E750 CPLH 750-1/2x1 1/2 2 x C-200 TSC-100 R-750

1000 CPLH 1000-1/2x1 1/2 2 x C-250 TSC-100 R-750

CO

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ING

49

1.6 CABLE / BUSBAR

Fill the gap between cable and mold with

mastic below weld cavity as shown

below.


CABLE TO BUSBAR CONNECTION VERTICAL

THROUGH CABLE TO TOP OF HORIZONTAL

FLAT BUSBAR

CONNECTION CPLPVV

DIMENSION


PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

KEY PRICE

2

1/4” x 1 1/2” & Wider

CPLPVV 2-1/4x1 1/2 C-250 TSC-80 R-150D

2 SOL CPLPVV 2S-1/4x1 1/2 C-250 TSC-80 R-150

1 CPLPVV 1-1/4x1 1/2 2xC-150 TSC-100 R-750

I

1/0 CPLPVV 1/0-1/4x1 1/2 2xC-200 TSC-100 R-750

2/0 CPLPVV 2/0-1/4x1 1/2 2xC-200 TSC-100 R-750

4/0 CPLPVV 4/0-1/4x1 1/2 2xC-250 TSC-100 R-750

250 CPLPVV 250-1/4x1 1/2 2xC-250 TSC-100 R-750

500 CPLPVV 500-1/4x1 1/2 2xC-250 TSC-100 R-750

750 CPLPVV 750-1/4x1 1/2 3xC-200 TSC-100 R-750

2

3/8” x 1 1/2” & Wider

CPLPVV 2-3/8x1 1/2 C-250 TSC-80 R-150D

2 SOL CPLPVV 2S-3/8x1 1/2 C-250 TSC-80 R-150

1 CPLPVV 1-3/8x1 1/2 2xC-150 TSC-100 R-750

I

1/0 CPLPVV 1/0-3/8x1 1/2 2xC-200 TSC-100 R-750

2/0 CPLPVV 2/0-3/8x1 1/2 2xC-200 TSC-100 R-750

4/0 CPLPVV 4/0-3/8x1 1/2 2xC-250 TSC-100 R-750

250 CPLPVV 250-3/8x1 1/2 2xC-250 TSC-100 R-750

500 CPLPVV 500-3/8x1 1/2 2xC-250 TSC-100 R-750

750 CPLPVV 750-3/8x1 1/2 3xC-200 TSC-100 R-750

2

1/2” x 1 1/2” & Wider

CPLPVV 2-1/2x1 1/2 2xC-150 TSC-100 R-750

2 SOL CPLPVV2S-1/2x1 1/2 2xC-150 TSC-100 R-750

1 CPLPVV 1-1/2x1 1/2 2xC-200 TSC-100 R-750

1/0 CPLPVV 1/0-1/2x1 1/2 2xC-250 TSC-100 R-750

2/0 CPLPVV 2/0-1/2x1 1/2 2xC-250 TSC-100 R-750

4/0 CPLPVV 4/0-1/2x1 1/2 3xC-200 TSC-100 R-750

250 CPLPVV 250-1/2x1 1/2 3xC-200 TSC-100 R-750

500 CPLPVV 500-1/2x1 1/2 3xC-200 TSC-100 R-750

750 CPLPVV 750-1/2x1 1/2 3xC-250 TSC-100 R-750

CO

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ELD

ING

50

1.7 BUSBAR/ BUSBAR

Busbars 1/8” thick must be cut under center of tap hole

and gapped 1/4” as shown below.

For busbars 3/16” orthicker gap to ½”


BUSBAR TO BUSBAR HORIZONTAL ON

EDGE BUSBAR


CONNECTION PLLV

BUSBAR SIZE

Width Thick MOLD

PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

KEY PRICE

1”

1/8”

PLLV 1x1/8 C-45 TSC-80 R-45

A1 1/2” PLLV 1 1/2x1/8 C-65 TSC-80 R-45

2” PLLV 2x1/8 C-90 TSC-80 R-90

3” PLLV 3x1/8 C-200 TSC-80 R-150

4” PLLV 4x1/8 C-250 TSC-100 R-750 E1”

3/16”PLLV 1x3/16 C-65 TSC-80 R-45

A

2” PLLV 2x3/16 C-115 TSC-80 R-90

1”

1/4”

PLLV 1x1/4 C-90 TSC-80 R-90

1 1/4” PLLV 1 1/4x1/4 C-115 TSC-80 R-90

1 1/2” PLLV 1 1/2x1/4 C-150 TSC-80 R-150

2” PLLV 2x1/4 C-200 TSC-80 R-150

2 1/2” PLLV 2 1/2x1/4 C-250 TSC-80 R-150

3” PLLV 3x1/4 2xC-200 TSC-100 R-750E

4” PLLV 4x1/4 2xC-250 TSC-100 R-750

1”

3/8”

PLLV 1x3/8 C-150 TSC-80 R-150A

1 1/2” PLLV 1 1/2x3/8 C-250 TSC-80 R-150

2” PLLV 2x3/8 2xC-150 TSC-100 R-750

E3” PLLV 3x3/8 2xC-250 TSC-100 R-750

4” PLLV 4x3/8 3xC-200 TSC-100 R-750

1”1/2”

PLLV 1x1/2 C-200 TSC-80 R-150 A

2” PLLV 2x1/2 2xC-200 TSC-100 R-750 E

CO

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ING

51

1.7 BUSBAR / BUSBAR

Busbars 1/8” thick must be cut under center of tap hole

and gapped 1/4” asshown below.

For busbars 3/16” orthicker gap to ½”


BUSBAR TO BUSBARHORIZONTAL L

TAP DOWN


CONNECTION PLARI

BUSBAR SIZE

Width Thick MOLD

PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

KEY PRICE

1”

1/8”

PLARI 1x1/8 C-45 TSC-80 R-45

A1 1/2” PLARI 1 1/2x1/8 C-65 TSC-80 R-45

2” PLARI 2x1/8 C-90 TSC-80 R-90

3” PLARI 3x1/8 C-200 TSC-80 R-150

4” PLARI 4x1/8 C-250 TSC-100 R-750 E

1”3/16”

PLARI 1x3/16 C-65 TSC-80 R-45

A

2” PLARI 2x3/16 C-115 TSC-80 R-90

1”

1/4”

PLARI 1x1/4 C-90 TSC-80 R-90

1 1/4” PLARI 1 1/4x1/4 C-115 TSC-80 R-90

1 1/2” PLARI 1 1/2x1/4 C-150 TSC-80 R-150

2” PLARI 2x1/4 C-200 TSC-80 R-150

2 1/2” PLARI 2 1/2x1/4 C-250 TSC-80 R-150

3” PLARI 3x1/4 2xC-200 TSC-100 R-750E

4” PLARI 4x1/4 2xC-250 TSC-100 R-750

1”

3/8”

PLARI 1x3/8 C-150 TSC-80 R-150A

1 1/2” PLARI 1 1/2x3/8 C-250 TSC-80 R-150

2” PLARI 2x3/8 2xC-150 TSC-100 R-750

E3” PLARI 3x3/8 2xC-250 TSC-100 R-750

4” PLARI 4x3/8 3xC-200 TSC-100 R-750

1”1/2”

PLARI 1x1/2 C-200 TSC-80 R-150 A2” PLARI 2x1/2 2xC-200 TSC-100 R-750 E

CO

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ELD

ING

52

1.7 BUSBAR / BUSBAR

Place end of tapping busbar evenly

with upper edge of running bus bar

as shown below.


BUSBAR TO BUSBAR

CONNECTIONTEE TAP DOWN

HORIZONTAL ON EDGE


BUSBARSIZE RUN

BUSBARSIZE TAP

Width ThickMOLD

PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

KEY PRICE

1”1/8”

1”x 1/8” PLTV 1x1/8-1x1/8 C-90 TSC-80 R-90

A

2”& Wider 2” x 1/8” PLTV 2x1/8-2x1/8 C-200 TSC-80 R-150

1”3/16”

1” x 3/16” PLTV 1x3/16-1x3/16 C-115 TSC-80 R-90

2” & Wider 2” x 3/16” PLTV 2x3/16-2x3/16 C-200 TSC-80 R-150

1”

1/4”

1” x 1/4” PLTV 1x1/4-1x1/4 C-150 TSC-80 R-150

1 1/4” 1 1/4” x 1/4” PLTV 1 1/4x1/4-1 1/4x1/4 C-200 TSC-80 R-150

1 1/2” 1 1/2” x 1/4” PLTV 1 1/2x1/4-1 1/2x1/4 C-250 TSC-80 R-150

2”& Wider 2” x 1/4” PLTV 2x1/4-2x1/4 2xC-200 TSC-100 R-750 E3”& Wider 3” x 1/4” PLTV 3x1/4-3x1/4 2xC-200 TSC-100 R-750 F4”& Wider 4” x 1/4” PLTV 4x1/4-4x1/4 3xC-250 TSC-100 R-750 J

1”

3/8”

1” x 3/8” PLTV 1x3/8-1x3/8 C-250 TSC-80 R-150 A1 1/2” 1 1/2” x 3/8” PLTV 1 1/2x3/8- 1 1/2x3/8 2xC-200 TSC-100 R-750

E2”& Wider 2” x 3/8” PLTV 2x3/8-2x3/8 2xC-250 TSC-100 R-750

3”& Wider 3” x 3/8” PLTV 3x3/8-3x3/8 3xC-250 TSC-100 R-750 H4”& Wider 4” x 3/8” PLTV 4x3/8-4x3/8 4xC-250 TSC-100 R-750 J

1 “1/2”

1” x 1/2” PLTV 1x1/2-1x1/2 2xC-250 TSC-100 R-750E

2”& Wider 2” x 1/2” PLTV 2x1/2-2x1/2 3xC-250 TSC-100 R-750

CONNECTION PLTV

CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

53

1.7 BUSBAR / STEEL SURFACE

Place busbar end under center of


Hold down mold cover to prevent

mold from tipping.


BUSBAR TO STEEL SURFACE CONNECTION

HORIZONTAL BUS TAP TO HORIZONTAL STEEL

SURFACE


CONNECTION PHTH

BUSBAR SIZE

Width Thick MOLD

PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

KEY PRICE

1”

1/8”

PHTH 1x1/8 C-115 TSC-80 R-90

A

1 1/2” PHTH 1 1/2x1/8 C-150 TSC-80 R-150

2” PHTH 2x1/8 C-200 TSC-80 R-150

1”

3/16”

PHTH 1x3/16 C-150 TSC-80 R-150

1 1/2” PHTH 1 1/2x3/16 C-200 TSC-80 R-150

2” PHTH 2x3/16 C-250 TSC-80 R-150

1”

1/4”

PHTH 1x1/4 C-150 TSC-80 R-150

1 1/4” PHTH 1 1/4x1/4 C-200 TSC-80 R-150

1 1/2” PHTH 1 1/2x1/4 C-250 TSC-80 R-150

2” PHTH 2x1/4 2xC-150 TSC-100 R-750 E1”

3/8”

PHTH 1x3/8 C-200 TSC-80 R-150A

1 1/2” PHTH 1 1/2x3/8 C-250 TSC-80 R-150

2” PHTH 2x3/8 2xC-200 TSC-100 R-750 E1”

1/2”

PHTH 1x1/2 C-250 TSC-80 R-150 A1 1/2” PHTH 1 1/2x1/2 2xC-200 TSC-100 R-750

E2” PHTH 2x1/2 2xC-250 TSC-100 R-750

CO

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ING

54


Busbar end must beplaced as shown

below.Secure mold to steelsurface with a clamp if possible to prevent




TAP DOWN OF BUS BAR TO VERTICAL

STEEL SURFACE


CONNECTION PHVI

BUSBAR SIZE

Width Thick MOLD

PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

KEY PRICE

1”

1/8”

PHVI 1x1/8 C-115 TSC-80 R-90

A

1 1/2” PHVI 1 1/2x1/8 C-150 TSC-80 R-150

2” PHVI 2x1/8 C-200 TSC-80 R-150

1”

3/16”

PHVI 1x3/16 C-150 TSC-80 R-150

1 1/2” PHVI 1 1/2x3/16 C-200 TSC-80 R-150

2” PHVI 2x3/16 C-250 TSC-80 R-150

1”

1/4”

PHVI 1x1/4 C-150 TSC-80 R-150

1 1/4” PHVI 1 1/4x1/4 C-200 TSC-80 R-150

1 1/2” PHVI 1 1/2x1/4 C-250 TSC-80 R-150

2” PHVI 2x1/4 2xC-150 TSC-100 R-750 E1”

3/8”

PHVI 1x3/8 C-200 TSC-80 R-150A

1 1/2” PHVI 1 1/2x3/8 C-250 TSC-80 R-150

2” PHVI 2x3/8 2xC-200 TSC-100 R-750 E1”

1/2”

PHVI 1x1/2 C-250 TSC-80 R-150 A

1 1/2” PHVI 1 1/2x1/2 2xC-200 TSC-100 R-750E

2” PHVI 2x1/2 2xC-250 TSC-100 R-750

CO

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ING

55


Busbar edge and flatsurface must be in contact with mold

as shown below to prevent leakage.Hold down mold cover to prevent

mold from tipping.


BUSBAR TO STEEL SURFACE CONNECTIONHORIZONTAL BUS RUN

TO HORIZONTALSTEEL SURFACE


CONNECTION PHPHH

BUSBAR SIZE

Width Thick MOLD

PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

KEY PRICE

1”1/8”

PHPHH 1x1/8 C-115 TSC-80 R-90

A

1 1/2” & Wider PHPHH 1 1/2x1/8 C-150 TSC-80 R-150

1”3/16”

PHPHH 1x3/16 C-150 TSC-80 R-150


1”

1/4”

PHPHH 1x1/4 C-150 TSC-80 R-150

1 1/4” PHPHH 1 1/4x1/4 C-200 TSC-80 R-150


1”3/8”

PHPHH 1x3/8 C-200 TSC-80 R-150


1”1/2”

PHPHH 1x1/2 C-250 TSC-80 R-150

1 1/2” & Wider PHPHH 1 1/2x1/2 2xC200 TSC-100 R-750 E

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Bus bar edge and flatsurface must be in

contact with mold to prevent leakage.


mold.



VERTICAL BUSBAR TO VERTICAL

STEEL SURFACE


CONNECTION PHPVV

BUSBAR SIZE

Width Thick MOLD

PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

KEY PRICE

1”

1/8”

PHPVV 1x1/8 C-115 TSC-80 R-90

A

1 1/2” PHPVV 1 1/2x1/8 C-150 TSC-80 R-150

2”& Wider PHPVV 2x1/8 C-200 TSC-80 R-150

1”

3/16”

PHPVV 1x3/16 C-150 TSC-80 R-150

1 1/2” PHPVV 1 1/2x3/16 C-200 TSC-80 R-150

2”& Wider PHPVV 2x3/16 C-250 TSC-80 R-150

1”

1/4”

PHPVV 1x1/4 C-150 TSC-80 R-150

1 1/4” PHPVV 1 1/4x1/4 C-200 TSC-80 R-150

1 1/2” PHPVV 1 1/2x1/4 C-250 TSC-80 R-150

2”& Wider PHPVV 2x1/4 2xC-150 TSC-100 R-750 E1”

3/8”

PHPVV 1x3/8 C-200 TSC-80 R-150A

1 1/2” PHPVV 1 1/2x3/8 C-250 TSC-80 R-150

2”& Wider PHPVV 2x3/8 2xC-200 TSC-100 R-750 E1”

1/2”

PHPVV 1x1/2 C-250 TSC-80 R-150 A1 1/2” PHPVV 1 1/2x1/2 2xC-200 TSC-100 R-750

E2”& Wider PHPVV 2x1/2 2xC-250 TSC-100 R-750

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Bus bar edge and flatsurface must be in

contact with mold to prevent leakage.


mold.


BUSBAR TO STEEL SURFACE CONNECTIONHORIZONTAL BUS BAR TO HORIZONTAL STEEL

SURFACE


CONNECTION PHPVH

BUSBAR SIZE

Width Thick MOLD

PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

KEY PRICE

1”

1/8”

PHPVH 1x1/8 C-115 TSC-80 R-90

A

1 1/2” PHPVH 1 1/2x1/8 C-150 TSC-80 R-150

2”& Wider PHPVH 2x1/8 C-200 TSC-80 R-150

1”

3/16”

PHPVH 1x3/16 C-150 TSC-80 R-150

1 1/2” PHPVH 1 1/2x3/16 C-200 TSC-80 R-150

2”& Wider PHPVH 2x3/16 C-250 TSC-80 R-150

1”

1/4”

PHPVH 1x1/4 C-150 TSC-80 R-150

1 1/4” PHPVH 1 1/4x1/4 C-200 TSC-80 R-150

1 1/2” PHPVH 1 1/2x1/4 C-250 TSC-80 R-150

2”& Wider PHPVH 2x1/4 2xC-150 TSC-100 R-750 E1”

3/8”

PHPVH 1x3/8 C-200 TSC-80 R-150A

1 1/2” PHPVH 1 1/2x3/8 C-250 TSC-80 R-150

2”& Wider PHPVH 2x3/8 2xC-200 TSC-100 R-750 E1”

1/2”

PHPVH 1x1/2 C-250 TSC-80 R-150 A1 1/2” PHPVH 1 1/2x1/2 2xC-200 TSC-100 R-750

E2”& Wider PHPVH 2x1/2 2xC-250 TSC-100 R-750

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1.8 STUD / STEEL SURFACE

Cut stud end at 25º angle and place it against the steel surface as shown. Secure mold to steel surface with a clamp if possible to prevent mold from tipping over.


VERTICAL STUD TO HORIZONTAL STEEL SURFACE

CONNECTION BCHH

DIMENSION

STUDMATERIAL

Stud Size MOLD

PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

STEELSTUDSONLY

1/4” BCHH 1/4 C-25 TSC-80 R-45

5/16” BCHH 5/16 C-25 TSC-80 R-45

3/8” BCHH 3/8 C-45 TSC-80 R-45

1/2” BCHH 1/2 C-65 TSC-80 R-45

3/4” BCHH 3/4 C-150 TSC-80 R-150

1” BCHH 1 2xC-150 TSC-80 R-150

Cut stud end at 25º angle and place it against the steel surface as shown. Secure mold to steel surface with a clamp if possible to prevent mold from tipping over.


HORIZONTAL STUD TO VERTICAL STEEL SURFACE

CONNECTION BCHV

DIMENSION

STUDMATERIAL

Stud Size MOLD

PART. No.CARTRIDGE

HANDLE CLAMP

MOULD SCRAPER

STEELSTUDSONLY

1/4” BCHH 1/4 C-25 TSC-80 R-45

5/16” BCHH 5/16 C-25 TSC-80 R-45

3/8” BCHH 3/8 C-45 TSC-80 R-45

1/2” BCHH 1/2 C-65 TSC-80 R-45

3/4” BCHH 3/4 C-150 TSC-80 R-150

1” BCHH 1 C-250 TSC-80 R-150

COPPER& COPPER

ALLOYSSTUDSONLY

1/2” BCHH 1/2 CU C-115 TSC-80 R-90

5/8” BCHH 5/8 CU C-150 TSC-80 R-150

3/4” BCHH 3/4 CU C-250 TSC-80 R-150

7/8” BCHH 7/8 CU 2xC-150 TSC-100 R-750

1” BCHH 1 CU 2xC-200 TSC-100 R-750

Welding to thin sections or thin-walled pipes may cause burn-through. Test-weld before to welding final parts.


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1.9 CABLE / RAIL

Place cable end under center of tap hole and fill gap between cable and rail with mastic sealant as shown left. Secure mold to rail surface with a clamp if possible to prevent mold from tipping over.


CABLE TERMINAL TO RAIL OR STRUCTURES

Fill gap between cable and rail with mastic on both sides of the weld cavity as shown above. Secure mold to the rail surface with a clamp if possible to prevent mold from tipping over.


CABLE PARALLEL TO RAIL OR STRUCTURES


For more references, please, ask for our specific catalogue.

CONNECTION CRATA

DIMENSION

CABLE SIZEMOLD

PART. No.CARTRIDGE

HANDLECLAMP

MOULDSCRAPER

4 CRATA 4 C-65R TRA-A R-45



1/0 CRATA 1/0 C-90R TRA-A R-60

2/0 CRATA 2/0 C-90R TRA-A R-90

4/0 CRATA 4/0 C-115R TRA-A R-60

CONNECTION CRAPHA

DIMENSION

CABLE SIZEMOLD

PART. No.CARTRIDGE

HANDLECLAMP

MOULDSCRAPER

4 CRAPHA 4 C-90R TRA-A R-90



1/0 CRAPHA 1/0 C-115R TRA-A R-60

2/0 CRAPHA 2/0 C-115R TRA-A R-60

4/0 CRAPHA 4/0 C-150R TRA-A R-150

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1.10 1 SHOT


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1.10 1 SHOT

RODSIZE

CABLE SIZE MOLD PART. NO.SETS PER

STD.PACKAGE

SOLID STRANDED TYPE AR TYPE T TYPE TD TYPE DD

1/2”

6 & 8 8 YCP-AR 12/A YCP-T 12/A YCP-TD 12/A YCP-DD 12/A

12

3 & 4 4 & 6 YCP-AR 12/B YCP-T 12/B YCP-TD 12/B YCP-DD 12/B

1 & 2 2 & 3 YCP-AR 12/C YCP-T 12/C YCP-TD 12/C YCP-DD 12/C

5/8”


3 & 4 4 & 6 YCP-AR 58/B YCP-T 58/B YCP-TD 58/A YCP-DD 58/A


2/0 & 1/0 1/0 & 1 YCP-AR 58/D YCP-T 58/D

2/0 YCP-AR 58/E YCP-T 58/E

4/0 YCP-AR 58/F

3/4”


3 & 4 4 & 6 YCP-AR 34/B YCP-T 34/B YCP-TD 34/B YCP-DD 34/B


2/0 & 1/0 1/0 & 1 YCP-AR 34/D YCP-T 34/D

2/0 YCP-AR 34/E YCP-T 34/E

4/0 YCP-AR 34/FCABLE TO GROUND ROD CONNECTIONS

Above molds are suitable for both plain or threaded Steel or Copper Clad steel rods.

CABLE SIZE

MOLD PART. NO.SETS PER

STD.PACKAGE

SOLID STRANDED

3 & 4 4 & 6 YCC-DPH 20 12

CABLE TO CABLE PARALELLEL TAP CONNECTION

Every KLK WELD set includes all the consumables needed for making one connection:Mold w/cable entrance sleeves, Weld cartridge and Metallic disc, except the Flint ignitor.

YCP-AR

YCP-T

YCP-TD

YCP-DD

YCP-DPH


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2. ELPA TUBO

The ELPA-TUBO KLK-weld procedure is the best solution for making the electrical con-nections of copper cable to steel pipe in order to give cathodic protection to the pipe, as the resulting weld has a low electrical resistivity and a high mechanical strength in the con-nection. This procedure does not change the structure of the steel pipe as the temperature never exceeds 450 ºC.

WELDING PROCEDUREELPA TUBOWelding of electric copper cable to steel pipe


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2. ELPA TUBO

a

The ELPA-Pipe KLK-weld procedure combines aluminothermic welding and braze- welding processes in which the latter partially uses the heat produced by the former. A ferritic steel plate is placed between the copper conductor and the pipe absorbing the thermal shock of the aluminothermic molten metal. As a result of this, the plate will be welded to the cable’s end. A tin-silver alloy on the pipe side of this plate makes the pipe/plate joint possible through the combination of the heat that melts this alloy and the strength of the device that pushes the plate to the pipe during the solidification process. The result is a fault free braze-weld

The procedure has two versions:• The first version uses one-shot moulds and reusable fixing tools.• The second version consists of one-shot moulds mounted onnon-reusable fixing tools.

For both options, there is no need to completely unearth the pipes because the fixing devices do not encompass them. To make the welds, it is sufficient to uncover the top of the pipe.

Also, the same kit may be used with any size of pipe (greater than a minimum). It is also possible to supply kits that can be used with different sections of cable. The most common ones go from 10 mm2 to 70mm2.

As an option, the LsVIP (Low smoke Versatile Ignition Procedure)may be used. This allows safe distance to be kept during welding.

WELDING PROCEDURE ELPA-TUBE

THE ELPA-TUBE KLK-WELD KIT INCLUDES THE FOLLOWING PARTS:

Ceramic mould with a steel plate, sleeve for cable

entrance, metal disc to seal the crucible draining

hole, sealing joints, lid with fuse for the remote

starting and, depending on the above mentioned

version, a fixing device.

Cartridge containing the welding and

the ignition powder.

Flux portion.

Flare to ignite the powder.

Additional sleeves to be used with other cable

sections (as an option).

User’s guide.


b

c

d

e

f

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2. ELPA TUBO

WELDING PROCEDURE ELPA-TUBE


EASY AND CONVENIENT USE:

Remove protective insulation, grind and apply the flux to the

area.

1

Finished weld.

Pour the welding and ignition powder into the mould and

ignite.

4

Place the mould and activate the fixing device.

2

Insert the cable to the shop in the mould’s sleeve.

3

Break the mould and clean the weld.

7

As an option, the LsVIP (Low smoke Versatile Ignition

Procedure) may be used to ignite the powder.

5

Either the flint ignitor or the flare may be used to ignite the

powder.

6

8

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2. ELPA TUBO

ADVANTAGES OF THE ELPA-TUBO KIT

Advantages of the new welding procedure at low-temperature to make electrical connections of copper cable to steel pipe, in order to provide cathodic protection to the pipe.

The advantages of this low-temperature welding procedure which has the trade name of Elpa-Tubo, are listed below:

1. The connections achieved have excellent electric conductivity.

2. The connections achieved have high mechanical resistance.

3. The internal steel structure of the pipe is not altered.

4. Easy and fast to use.

5. Absolute reliability.

6. To weld it is not necessary to completely unbury the pipe, uncovering part of it is sufficient.

7. Good price.

8. The same kit can be used on pipes of different diameters (please enquire).

9. Possibility of supplying kits that can be used with cables of different sections.

10. Possibility of remote ignition.

11. Possibility of using on active pipes without the need to cancel the supply or transport.


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3. LSVIP PROCESS

The LsVIP KLK-weld Ignition Procedure is the best solution to ignite the aluminothermic welding charges from the point of view of safety and cleanliness, as it prevents spattering from the crucible-mould during the aluminothermic reaction, minimizes smoke emis-sions and, furthermore, it enables the charge to be ignited at a certain distance from the mould, using the KLK-weld Remote Ignition Device.

IGNITION PROCEDURELsVIP

Ignition procedure for aluminothermic welding charges for electrical connections


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3. LSVIP PROCESS

The special lid used in the Ignition Procedure can be used either with the standard flint igniter or with the KLK-weld Remote Ig-nition Device. The same applies to the cartridges, ignition pow-der, and the other welding accessories, thus there is a complete versatility to use either of the two ignition options.

The connections achieved using the KLK-weld wel-ding procedures, and in particular those achieved af-ter using the LsVIP Ignition Procedure, are connections with a very high electrical conductivity, equal or grea-ter to that of the welded conductor.

The KLK-weld Remote Ignition Device includes sufficient cable to allow the charge to be ignited at a certain distance from the mould where the reaction takes place. It only requires two standard batteries and it includes warning lights that indicate when the batteries are dead or if the fuse is properly inserted into the clamp.For each ignition using the KLK-weld Remote Ignition Device it is also necessary to use a fuse, one end of which is inserted into the device clamp, the other end into the lid seat made for this purpose. The fuses are the only additional consumables for the remote ignition procedure.

The LsVIP KLK-weld Ignition Procedure uses a special lid that completely closes the mould crucible, so that it prevents spat-tering from the aluminothermic reaction. But at the same time it allows the release of overpressures within the crucible. Fur-thermore, the smoke emissions are much lower than in other ignition procedures.

Apart from the supplying of moulds with the special lid used in the procedure (the LsVIP moulds) a quick fastening special lid can also be supplied, this can be easily fitted onto a mould that uses the usual lid.

In this case, to use the special lid, it is sufficient to leave the usual lid open.


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3. LSVIP PROCESS

IGNITION PROCEDURE LsVIP

Insert the fuse into the clamp of the device.

1

Pour the reserved ignition powder through the funnel shape opening in the lid.

4

Pour the welding and the ignition powder into the

crucible, reserving a small amount of the ignition powder.

2

Partially open the upper part of the lid and place the fuse in

its seat.

3

If the option chosen is remote ignition, move away from the

mould as desired and press the button.

5If the option chosen is the

flintigniter, put it close to the funnel shape opening in the lid

and pull the trigger.

6


EASY AND QUICK TO USE:

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3. LSVIP PROCESS

ADVANTAGES OF THE LsVIP PROCEDURE

1.- KLK’s Remote ignition (LsVIP) is performed with the same cartridges and it is not necessary to have another reference of special cartridges. Our cartridges keep both powders separated yet together in the same container, which prevents the user from forgetting the ignition powder.

2.- It is possible to use the same moulds used for all the other welding works, only the lid changes, as our moulds have interchangeable lids. Distance welding is possible, safe welding without splattering and traditional welding. If requesting mould with Ref. LsVIP the mould already includes the lid.

3.- Our ignition system allows igniting with remote control and with igniter.

4.- Our remote ignition system uses an interchangeable lid for moulds which signifi-cantly reduces the smoke arising from the work and prevents spattering from the aluminothermic reaction.

5.- It is the best solution to comply with the most demanding safety requirements in the field of aliminothermic welding.

6.- Due to versatility of LsVIP the users and clients do not need any more tools or new utensils and do not need to change the traditional ignition system and extend and modify their possible stock of material, and will never forget the ignition powder, allowing them to weld at all times.


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NOTES


Camino de la Peñona, 38-B33211 Gijón (Asturias) · Spain

Tel. +34 985 321 850Fax. +34 985 312 820

[email protected]

RAILTECH BOUTET, Inc.

25 interstate DriveP.O. Box 69

Napoleon, OH 43545Phone. (419) 592-5050

Fax. (419) [email protected]

KLK Electro Materiales, S.L.UC/ Rosario Pino, Nº18, 4º - 7ª

28020 Madrid · SpainTel. +34 915 709 692 Fax. +34 915 713 540

[email protected]

EKE Electra-KLK Europe, S.à.r.l.Z.A. de L’Europe, 6 rue de l’Orge

68920 Wintzenheim Logelbach · FranceTel. +33 (0) 389 201 730 Fax. +33 (0) 389 201 731

[email protected]

klk - 1.1 cable / cable 1.2 cable / ground rod …...klk electro materiales, s.l.u camino de la...

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