CU-BOND Conductors ASIA TRAINING - Inginn Nwe Trading · 2017-03-23 · Product Training June2015....

Date

ERICO® CU-BOND Composite Cable

ERICO® CU-BOND Round Conductor, Phase 2

Product Training

June 2015

Agenda

• Welcome• Sample Kit Overview• CU-BOND Composite Cable

• History• Features and Benefits• Price Positioning

• CU-BOND Round Conductor, Phase 2• Mechanical Connectors• Straightening Equipment• UL certification to IEC 62561-2 for conductor• New markings on the conductors

Sales / Launch Kits

• CU-BOND Composite Cable

• CU-BOND Round Conductor

• Connection Methods– ERICO® HAMMERLOCK

and CADWELD®

• GEM

• CU-BOND accessories shipped in separate box

ERICO Product Development


June, 2015

Phase I• Galvanized steel / tinned

copper– 3/0 and 4 AWG

• Introduction: December 2008

Phase II• Galvanized steel / tinned

copper– 2/0 and 4/0 AWG

• Testing to validate• Introduction: October 2011

Phase III • Tinned Copper-bonded steel stranding

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• ERICO CU-BOND Composite Cable is a bare concentric stranded

conductor

• Inner copper stranding is tinned for superior corrosive resistance

• Outer strands are made of tinned copper-bonded steel for corrosion resistance and theft deterrence


• Manufacturing Process

– 3/8” 1018 steel plated with 13 mils of copper at EAN

– Drawn down to 0.064” diameter, annealed and tin plated

– Drawn wire stranded with copper wire


– Ideal for exposed electrical distribution and substation grounding leads where theft is possible

– Hard to cut with hand tools

– Magnetic outer stranding to deter thieves from detecting copper with magnetic devices

– Tinned outer strands do not look like copper

•Product Benefits – Theft Deterrence


• Product Benefits – Ease of Use

– Suitable for direct burial applications

– More flexible and easier to work with than copper-clad steel conductors

– Provides increased conductivity over copper-clad steel conductor


CC5A05CB

4 AWGCC5A40CB

4/0 AWGCC5A20CB

2/0 AWG

Available Sizes

16mm295mm250mm2

-nearly 70mm2



Electrical

EquivalencyLength of Reel Weight of Reel

Part Number AWG Metric Imperial Metric Imperial Metric

CC5A05CB 4 AWG 16 mm2 250 ft 76 m 58 lbs 26 kg

CC5A20CB 2/0 AWG 50 mm2 200 ft 61 m 110 lbs 50 kg

CC5A40CB 4/0 AWG 95 mm2 200 ft 61 m 172 lbs 78 kg


Cross-Sectional Area

Conductor Size

CableDiameter

(Inches)

Diameter

(Millimeters)

Cross Sectional

Area (mm2)

4 AWG 0.232 5.9 21.2

25 mm2 0.255 6.5 25.0

35 mm2 0.305 7.8 35.0

CC5A05CB 0.320 8.1 40.0

1 AWG 0.332 8.4 42.4

50 mm2 0.365 9.3 50.0

70 mm2 0.430 10.9 70.0

2/0 AWG 0.470 10.6 67.5

95 mm2 0.505 12.8 95.0

CC5A20CB 0.524 13.3 114.6

4/0 AWG 0.528 13.4 107.2

120 mm2 0.567 14.4 120.0

150 mm2 0.630 16.0 150.0

300 kcmil 0.630 16.0 152.1

CC5A40CB 0.651 16.5 142.9

350 kcmil 0.681 17.3 177.3

• Data Sheets

• PowerPoint

• Sample part numbers – A805A20CBF– A805A05CBF– A805A40CBF

• Test report– Copper equivalency


Additional Items

• ANSI C119.4 Test Program– CC5A40CB– CADWELD and Compression– Scheduled to begin in July

• Reference List of Mechanical Connectors

• Updated Fusing Current Testing– Scheduled in July

• 16mm2, 4 AWG and 25mm2

• 50mm2, 2/0 AWG and 70mm2

• 95mm2, 4/0 AWG and 120mm2


ERICO® CU-BOND Round Conductor

Phase 2

Product Launch


• Phase 1 of introduction in October 2014 covered the below grade applications for the conductor

• Phase 2 introduction of CU-BOND Round Conductor includes above grade applications• New mechanical connectors and existing

mechanical connectors tested to IEC 62561 standard

• Straightening equipment• UL certification to IEC 62561-2 for conductor• New markings for conductor• CADWELD weld metal sizes reduced on several of

the smaller conductor sizes


Product Features

• Copper coating with molecular bond to nickel-sealed high strength steel core

• 254 microns (10 mils) copper plating thickness

• High corrosion resistance and long-lasting design make an optimal grounding conductor

• Copper-bonded coating will not crack or tear when bent

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• Standard covers lightning protection system

components (LPSC)

• Same standard we reference for GEM testing,

just different sections

• Your specific end-use customer may not follow

this standard, but you need to understand the

testing involved to explain why this testing is

challenging to meet

IEC 62561

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IEC 62561 Part 1 sets criteria for:

– Connectors

– Bonding and bridging components

– Expansion pieces

– Test joints

Primary tests:

– Static mechanical pull test (section 6.4)

– Environmental conditioning (section 6.2)

– Electrical impulse test (section 6.3)

Connection Components: IEC 62561-1

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• Three specimens arranged per instruction sheet

• 900N [202 lbf] tensile force for one minute

– Pass: <1mm slip

IEC 62561-1: Static Mechanical Test (6.4)

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Three new specimens subjected to three environmental tests in succession:

1. Salt mist treatment (IEC 60068-2-52:1996)

2. Humid sulfurous atmosphere (ISO 6988:1985)

3. Ammonia atmosphere (ISO 6957:1988)

• ONLY for connectors containing <80% copper

IEC 62561-1: Environmental Aging (6.2)

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• All environmental aging specimens are tested

• Three 100kA 10/350 μs

impulses each

• Pass:

– <17mm of slip

– Resistance <2.5 mΩ

– Loosen torque > 25% install torque

IEC 62561-1: Electrical Impulse Test (6.3)

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IEC 62561 Part 4 sets criteria for fasteners used with :

– Air termination systems

– Down conductors

Primary tests:

– Environmental Conditioning (6.3)

– Mechanical Loading Tests (6.4)

Positioning Components: IEC 62561-4

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Metallic fasteners

Six specimens subjected to three environmental

tests in succession:

1. Salt mist treatment (IEC 60068-2-52:1996)

2. Humid sulfurous atmosphere (ISO 6988:1994)

3. Ammonia atmosphere treatment (ISO 6957:1988)

1. ONLY for fasteners containing <80% copper


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Non-metallic fasteners

Nine new specimens subjected to ultraviolet light

conditioning (ISO 4892-2 or ISO 4892-4)

Composite fasteners

Nine new specimens subjected to environmental

test for both metallic and nonmetallic fasteners


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Lateral Load Test:

•Three specimens from

Environmental Aging

•200N [~45 lbf] load for:

– 5 min. (metallic)

– 60 min. (nonmetallic/composite)

IEC 62561-4: Mechanical Tests (6.4)

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•


28

•


ERICO® CU-BOND Round ConductorConnectors and Splices

ERICO® CU-BOND Round ConductorPositioning Devices

ERICO® CU-BOND Round ConductorBonding Lugs

ERICO® CU-BOND Round ConductorFence and Gate Clamps

ERICO® CU-BOND Round ConductorInternal Cross-Reference for Connectors

• Other connectors were evaluated but we did not

pursue formal testing due to performance and / or cost reasons

• Internal cross-reference document details not only IEC certified connectors but also other connectors that should work for CU-BOND Round applications

• We can consider testing additional items if the potential sales volume would justify the cost

ERICO® CU-BOND Round ConductorManual Straightening Tool

42


Electric Straightener and Uncoiler

• Develop a new machine, able to straighten the 8 mm and 10 mm CBSC diameter , equipped with an electric motor controller. ( Bigger diameter are underevaluation)

• The Voltage rating used for this machine is 220V AC (50/60hz) by default and 110V AC (50/60hz) withspecific additional transformer.

• Maximum speed of 15 to 20 meters / minute

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Solid

Rubber

Wheels

Solid Feet

Input of the

CBSC

Electrical

cabinet +

Urgency stop

Output of the

CBSC4 Drive

wheels

Mobile

handles to

move the

machine

Protective

enclosure

Adjustment of

the wheels

44



Safety switch to run

only with closed

enclosure

Same wheel

for CBSC8 and

CBSC10, just

need to

rotate them

Electrical

Motor + gear

box

45

3 Windows

* The rear of the enclosure is

hiden on this picture

Storage of the

wheels

Safety switch

if the crank is

usedCrank (if needed)



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Rotative Rigid

frame

* The rear of the enclosure is hide

on this picture

Steel bar to

fix the

uncoiler to

the

straightenerSolid

Rubber

Wheels

Solid feet

Mobile

handle to

move the

machine or

carry the coil

Stop to

straighten

manually the

end of the rod



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• First prototype expected to be available in Q3• Production quantities of the straightener to be available

in Q4• Aiming to have the ability to sell one machine that would

also be scalable to run the larger diameters of CU-BOND Round Conductor

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CADWELD

• For many connections with CBSC8 and CBSC10, amount of weld metal has been reduced

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IEC 62561-2 Certification for Conductor

• Not only are we pursuing IEC certification for the connectors, but we are also pursuing certification for the conductor itself

• ERICO already has a test report that tested CBSC10 to meet IEC 62561-2

• We are in the process of having all sizes of the conductor tested through UL

• UL will witness testing and – assuming successful test results – these conductors will be UL certified to IEC 62561-2

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IEC 62561-2 Certification for Conductor

Certification means that we will be able to have the UL certified logo on our product

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Conductor Markings

Stampings �

Inkjet Printing �

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Sample Part Numbers

CBSC8SAMPCBSC10SAMPCBSC13SAMPCBSC14SAMPCBSC16SAMPCBSC18SAMP

All sample part numbers are one foot in length

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PRODUCT APPLICATIONS - MOBITEL

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PRODUCT APPLICATION - MOBITEL

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PRODUCT APPLICATION - INDONESIASMARTFREN

INDONESIA

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TOWER BERSAMA

INDONESIA

Thank You

CU-BOND Conductors ASIA TRAINING - Inginn Nwe Trading · 2017-03-23 · Product Training June2015....

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Transcript of CU-BOND Conductors ASIA TRAINING - Inginn Nwe Trading · 2017-03-23 · Product Training June2015....