CADWELD® Welded Electrical Connections Facility Electrical Protection
NEW PRODUCTS XBQ/XBZ MOLDS See sec.1, pg 2. (Reference Lit. # X6N) The CADWELD® XB molds are the quickest, most efficient way to make lapped, horizontal X-style connections on solid or concentric stranded cable for a variety of installations. For cable-to-cable X-style connections at power substations and other commercial and industrial sites, there’s never been a faster or easier way to make a reliable CADWELD connection.
WELDED ELECTRICAL CONNECTIONS ERICO, Inc.
INDEX Type Sec Pg Cable to Cable XBQ/XBZ . . . . PC . . . . . . . . . PC . . . . . . . . . PG . . . . . . . . . PG ONE-SHOT PG . . . . . . . . . PH . . . . . . . . . PT . . . . . . . . . . PG . . . . . . . . . SS . . . . . . . . . . TA . . . . . . . . . . XA . . . . . . . . . . XB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 5 - 2 - 3 - 3 - 9 - 10 - 11 - 8 - 8 - 10 - 3 - 6 - 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX ALPHABETICAL LISTING OF MOLDS & GROUNDING ACCESSORIES Type Sec Pg BA . . . . . . . . . . . . . . . . . . . .6 BQ . . . . . . . . . . . . . . . . . . .6 BW . . . . . . . . . . . . . . . . . . .7 B165 & B165R . . . . . . . . .10 B166 & B167 . . . . . . . . . . .10 CC . . . . . . . . . . . . . . . . . . .7 CF . . . . . . . . . . . . . . . . . . . .7 CG . . . . . . . . . . . . . . . . . . .7 CH . . . . . . . . . . . . . . . . . . .7 EP . . . . . . . . . . . . . . . . . . . .6 GB . . . . . . . . . . . .
INTRODUCTION & ORDERING INFORMATION HOW TO ORDER CADWELD PRODUCTS This catalog lists the most popular CADWELD connections using solid or concentric stranded copper conductor, insulated or bare. Look in the index for the connection you need. To save time and money, avoid non-catalog items or specials whenever possible. If you cannot find the connection you need, contact ERICO or your local distributor or agent. We have designed over 45,000 connections, and “specials” are designed every day. 1.
ORDERING INFORMATION & INTRODUCTION Sample Index Page Section Headings by Application Type All connections in this index are coded as follows according to their ease of use: 1 Preferred 2 Easily and commonly used 3 More difficult - use code 1 or 2 if possible by bending cables, prefabricating, using two connections, etc. 4 Difficult / more costly / has limitations. Use another type if possible or contact your CADWELD representative for assistance.
SECTION 1 CABLE TO CABLE CONNECTIONS NAME Horizontal Parallel tyle PG S Availab-SleHOT Now s ONE ection a Con NAME PAGE TYPE EASE * Horizontal Tee 1-4 TA 1 * 1 V Horizontal X 1-6 XA 1 * PG 1 * 1-6 XB 1 V 1-10 SS 1 V 1-3 PC 1 V 1-4 PC 1 * 1-11 PH 1 V 1-4 PG 1 V PAGE TYPE EASE SPLIT 1-8 PG 1 1-8 PT 1-10 n Horizontal Splice Horizontal Tee Parallel Tap Vertical Parallel SPLIT For other connections not listed in this section, see page 1-12 SECTION 2
SECTION 3 CABLE TO STEEL OR CAST IRON NAME PAGE TYPE EASE SPLIT NAME PAGE TYPE EASE SPLIT 3-5 HS 1 V Vertical Steel Surface 3-10 VG 1 V 3-6 HT 1 V 3-4 VN 1 * Vertical Steel Pipes 3-8 VS 1 V 3-7 VS 1 * Vertical Steel Surface 3-9 VB 2 V 3-10 VT 1 * 3-9 VF 1 V 3-11 VV 1 V Horizontal Steel Surface For other connections not listed in this section, see page 3-12 SECTION 4 CABLE TO LUGS AND PREFABRICATED LUG ASSEMBLIES NAME PAGE TYPE EASE SPLIT NAME PAGE
SECTION 7 BUSBAR TO STEEL SURFACE CONNECTIONS NAME Busbar to Steel Surface PAGE TYPE EASE SPLIT NAME 7-2 BW 1 V Busbar to Steel Surface 7-3 CC 1 V 7-2 CF 1 V PAGE TYPE EASE SPLIT 7-3 CG 1 V 7-3 CH 1 V For other connections not listed in this section, see page 7-4 SECTION 8 CABLE TO REBAR CONNECTIONS NAME Cable to Rebar PAGE TYPE EASE SPLIT NAME PAGE TYPE EASE SPLIT 8-8 RC 1 V Cable to Rebar 8-10 RJ 1 V 1 V 1 V 8-4 RR 1 V 8-6 RD For other connect
SECTION 10 GROUND PLATES, AIRCRAFT GROUNDING RECEPTACLES NAME Aircraft Grounding Receptacle Connections to Ground Rods Cast Ground Plates Cast Ground Plate Connections Ph: 1-800-677-9089 www.erico.
THE FOLLOWING INDEX LISTS UNCATALOGED CONNECTIONS AVAILABLE FOR UNUSUAL APPLICATIONS Type Category BB BC BD BF BG BH BJ BK BL BM BN BR BS BT BV BX BY CA CB CD CJ CK CL CM CN CP CQ CR CS DC DD DE DF DJ DM DN DP DQ DR DS DT EA EB EC ED EE EN EQ ER ES ET EV EW FD FE FF FG FH FJ FK FL FM FN FP Pg Busbar . . . . . . . . . . . . . . . . .6-4 Busbar . . . . . . . . . . . . . . . . .6-4 Busbar . . . . . . . . . . . . . . . . .6-4 Busbar . . . . . . . . . . . . . . . . .6-4 Busbar . . . . . . . . . . . . . . . . .
LOW EMISSION CADWELD EXOLON Developed in 1988, CADWELD EXOLON is a significant advance in welded electrical connections. The metallurgy is the same as the standard CADWELD connection approved by over 70% of electric utilities in the USA — but the virtual elimination of visible smoke plus a unique electric starting system makes this improved process easier and more convenient than ever before. Most connections listed in this catalog can be ordered in the CADWELD EXOLON configuration.
OTHER INFORMATION Certain tools may be required for various connections. If required, these tools are listed on the same page as the connection and in Section A. • Some tools listed in Section A can save you a lot of time. • Also refer to A9E, Contractor Tips, to make your job easier, and learn about labor saving ideas. Prices for standard products are shown in Price List G285P For other CADWELD literature, videos and software, See Section C. For all your connection needs — we’re only a phone call away.
GROUNDING CONNECTION SPECIFICATION All grounding connections of copper to copper and copper to steel conductors of #8 and larger sized conductors shall be CADWELD exothermic welded connections. Conductors spliced with a CADWELD exothermic welded connection shall be considered as a continuous conductor, as stated in the notes accompanying NEC 250-50, 250-64, 250-68, 250-70 and IEEE Std 80 – 1986. All grounding connections to equipment shall use bolted lugs.
NOTES... Ph: 1-800-677-9089 www.erico.
CABLE TO CABLE CONNECTIONS SECTION 1 XBQ/XBZ PAGE 5 XB Page 6 PC Page 2 PG Page 8 TA Page 3 PT Page 8 PC Page 3 SS Page 10 PG Page 3 PG Page 10 XA Page 6 PH Page 11 Ph: 1-800-248-WELD www.erico.
PARALLEL TAP CONNECTIONS PC PARALLEL TAP CONNECTIONS • Parallel tap connection of horizontal cables. • Solid conductor may be either copper or Copperweld®. • Concentric strand copper cable unless otherwise noted. • Bold letter in mold part number is the price key.
HORIZONTAL TEE PC/PG/TA HORIZONTAL TEE CONNECTIONS • Tee of horizontal run and tap cables. • PC and PG make parallel style connections which the user can form into a tee. • Concentric stranded copper cable unless otherwise noted. • Solid conductor can be either copper or Copperweld. • Bold letter in mold part number is the price key. Note: For PC, the tap cable is on top.
HORIZONTAL TEE PC/PG/TA CABLE SIZE Run Tap MOLD PART NO.
HORIZONTAL X XBQ/XBZ XBQ/XBZ MOLDS The CADWELD XB molds are the quickest, most efficient way to make lapped, horizontal x-style connections on solid or concentric stranded cable for a variety of installations. For cable-to-cable X-style connections at power substations and other commercial and industrial sites, there’s never been a faster or easier way to make a reliable CADWELD connection.
HORIZONTAL X XA/XB HORIZONTAL X CONNECTIONS • XA – Cross of horizontal cables, tap cable cut – cables in same plane. • XB – Cross of horizontal cables, lapped and not cut. • Concentric stranded copper cable unless otherwise noted. • Solid conductor may be either copper or Copperweld®. • Bold letter in mold part number is the price key.
HORIZONTAL X XA/XB CABLE SIZE Run Tap 3/0 TYPE XA MOLD WELD PART NO. METAL TYPE XB MOLD WELD PART NO.
PARALLEL HORIZONTAL PG/PT PARALLEL HORIZONTAL CONDUCTORS • • • • • PG Parallel through connection of horizontal cables. Run conductor is on the bottom of Type PT molds. Concentric strand copper cable unless otherwise noted. Solid conductor may be either copper or Copperweld®. Bold letter in mold part number is the price key.
PARALLEL HORIZONTAL CABLE SIZE Run Tap 1/0 2/0 MOLD PART NO.
HORIZONTAL SPLICE SS/PG HORIZONTAL SPLICE • • • • • Splice of horizontal cables. Type PG makes a parallel style connection. Concentric stranded copper cable unless otherwise noted. Solid conductor may be either copper or Copperweld®. Also available are splices of different and mixed cable sizes. For Copperweld DSA cables, contact ERICO. • Bold letter in mold part number is the price key.
PARALLEL VERTICAL PH PARALLEL VERTICAL CONDUCTORS • • • • PH Parallel through connection of vertical cables. Solid conductor may be either copper or Copperweld. Concentric stranded copper cable unless otherwise noted. Bold letter in mold part number is the price key.
OTHER CABLE TO CABLE CONNECTIONS The connections shown below are for use only where connections shown in this catalog are not suitable.
CABLE TO GROUND RODS & ROUNDS GR PAGE 2 GT Page 12 GT Page 4 NT Page 12 GY Page 6 NX Page 12 NC Page 8 GN Kit Page 13 ND Page 10 GB Page 14 GR Page 12 Ph: 1-800-677-9089 www.erico.
CABLE TO GROUND ROD GR CABLE TO GROUND ROD • Single cable to top of ground rod. Concentric strand copper cable unless otherwise noted. For copper clad, galvanized, stainless clad or stainless steel ground rods. • Bold letter in mold part number is the price key.
CABLE TO GROUND ROD GROUND ROD SIZE 5/8" 5/8" GR CABLE SIZE MOLD PART NUMBER Copper Clad Steel or Plain Copper Clad (unthreaded) Sectional (threaded) 6 6 SOL 4 4 SOL GRT-161H GRT-161G GRT-161L GRT-161K GRT-311H GRT-311G GRT-311L GRT-311K Copper Clad Sectional (threaded) or Plain Steel 3/4" GRC-161T GRC-161V GRC-161Y GRC-162C GRC-162B GRC-311T GRC-311V GRC-311Y GRC-312C GRC-312B 65 65 65 90 90 2/0 3/0 4/0 250 GRC-162G GRC-162L GRC-162Q GRC-162V GRC-312G GRC-312L GRC-312Q GRC-312V 90 90 90 9
CABLE TO GROUND ROD GT THROUGH CABLE TO GROUND ROD • Through cable to top of ground rod. Connections are for concentric strand copper cable unless otherwise noted. For copper clad, galvanized, stainless clad or stainless steel ground rods. • Bold letter in mold part number is the price key.
CABLE TO GROUND ROD GROUND ROD SIZE 5/8" GT CABLE SIZE MOLD PART NUMBER Copper Clad Steel or Plain Copper Clad (unthreaded) Sectional (threaded) 6 6 SOL 4 4 SOL GTT-161H GTT-161G GTT-161L GTT-161K GTT-311H GTT-311G GTT-311L GTT-311K Copper Clad Sectional (threaded) or Plain 5/8" GTC-311T GTC-311V GTC-311Y GTC-312C GTC-312B GTC-312G GTC-312L 90 90 90 90 115 115 115 4/0 250 300 350 500 GTC-162Q GTC-162V GTC-163A GTC-163D GTC-163Q GTC-312Q GTC-312V GTC-313A GTC-313D GTC-313Q 115 150 200 200 250
CABLE TO GROUND ROD GY CABLE TO GROUND ROD • Through cable to side of ground rod. • Concentric strand copper cable unless otherwise noted. • Ground rods can be copper clad, galvanized, stainless clad or stainless steel. • Bold letter in mold part number is the price key. GY REQUIRED TOOLS Handle Clamps L160 for E Price Key Molds L159 for J Price Key Molds Frames included with E and J Price Key Molds.
CABLE TO GROUND ROD GROUND ROD SIZE CABLE SIZE MOLD PART NUMBER Copper Clad Sectional (threaded) Steel 4 Str or Sol 2 Str or Sol 1 Str or Sol 1/0 NOTE: All "P" priced GY molds require B399ES frame. (Sold separately.
CABLE TO GROUND ROD NC TWO CABLES TO GROUND ROD • Through cable plus tap cable to top of ground rod. • Concentric stranded copper cables. • For copper clad, galvanized, stainless clad, or stainless steel ground rods. • Bold letter in mold part number is the price key.
CABLE TO GROUND ROD GROUND ROD SIZE 5/8" 3/4" 1" Ph: 1-800-677-9089 www.erico.
CABLE TO GROUND ROD ND PARALLEL CABLES TO TOP OF GROUND ROD • Two through cables to top of ground rod. Cables can be bent to form a “T” or “X”. • Concentric strand copper cables listed. • For copper clad, galvanized, stainless clad or stainless steel ground rods. • Bold letter in mold part number is the price key.
ND CABLE TO GROUND ROD GROUND ROD SIZE 5/8" 3/4" 1" Ph: 1-800-677-9089 www.erico.
ONE-SHOT CABLE TO GROUND ROD GR/GT/NT/NX CABLE TO GROUND ROD USING CADWELD ONE-SHOT CONNECTIONS GR For plain or threaded copper clad and galvanized steel or stainless steel rods. The CADWELD ONE-SHOT case is a ceramic disposable body replacing the familiar semi-permanent graphite mold and associated Handle Clamp. Everything required is included except the flint ignitor. R.E.A.
CABLE TO GROUND ROD GN The Unbeatable CADWELD Connection Alternative To “Acorn” Mechanical Connections Whether you’re working in telecommunications, electric distribution or cable television, here’s everything you need to make a permanent and reliable wire-to-ground rod connection at the lowest cost and with maximum convenience.
GROUND ROD SPLICE GB GROUND ROD SPLICE • CADWELD ground rod splices are very strong and use the proven corrosion resistant CADWELD connection. • CADWELD ground rod splices are available for copper clad, galvanized, stainless or stainless clad ground rods. • Bold letter in mold part number is the price key. GB REQUIRED TOOLS Handle Clamps L160 for C Price Key Molds L159 for D and F Price Key Molds.
OTHER CABLE TO GROUND ROD CONNECTIONS The connections shown below are for use only where connections shown in this catalog are not suitable. NAME TYPE EASE SPLIT NAME TYPE EASE SPLIT Parallel Tap GQ 3 V Tee GG 1 * GS 1 V GH 3 V GJ 1 * GK 3 V GM 2 V GN 2 V GX 3 V VW 2 V Parallel Thru DQ GP GW 1 3 1 V V V GD 3 V GE 1 V GF 1 V GV 1 V Splice Ph: 1-800-677-9089 www.erico.
NOTES... Ph: 1-800-677-9089 www.erico.
CABLE TO STEEL OR CAST IRON Ph: 1-800-677-9089 www.erico.
RANGE OF HORIZONTAL STEEL PIPES HA RANGE OF HORIZONTAL STEEL PIPES • Horizontal copper conductor to top of horizontal steel pipe. • CADWELD also has a complete product line for cathodic protection connections. See Bulletin CA1A. • A test weld should be made to check the possibility of burn through on thin sections or thin wall pipe. • When only one pipe size is involved, see Cable to Steel Pipe table on previous page. • Concentric stranded copper cable listed.
HORIZONTAL CAST IRON SURFACE HB HORIZONTAL CAST IRON SURFACE HB • NOT FOR USE ON STEEL PIPE • CADWELD cable connections to horizontal flat cast iron surface; cable to top of horiziontal cast iron pipe. • A test weld should be made on a section of the pipe being used to determine possibility of detrimental metallurgical effects. • Concentric stranded copper cable unless otherwise noted. • Bold letter in mold part number is the price key.
VERTICAL STEEL SURFACE VN VERTICAL STEEL SURFACE • Conductor to vertical flat steel surface or cable to the side of horizontal steel pipe. • Concentric stranded copper cable is listed. • A test weld should be made to check the possibility of burn through on thin sections or thin wall pipe. • Cable to vertical side of horizontal steel pipe. Add right or left hand and nominal pipe size to flat surface mold part number. Example: VNC-2G-LH-4 - weld on left end of conductor, 4" pipe, 2/0 stranded conductor.
HORIZONTAL STEEL SURFACE HA/HS HORIZONTAL STEEL SURFACE HA • Horizontal concentric copper conductor to flat steel surface or top of horizontal pipe • CADWELD also has a complete product line for cathodic protection connections. See Bulletin CA1A. • A test weld should be made to check the possibility of burn through on thin sections or thin wall pipe. • Concentric stranded copper cable listed. • Bold letter in mold part number is the price key.
HORIZONTAL STEEL SURFACE HC/HT HORIZONTAL STEEL SURFACE HC Cable on surface • Cable to horizontal flat steel surface or cable to top of horizontal steel pipe. • CADWELD also has a complete product line for cathodic protection connections. See Bulletin CA1A. • Concentric stranded copper cable listed. • A test weld should be made to check the possibility of burn through on thin sections or thin wall pipe. • Bold letter in mold part number is the price key.
VERTICAL STEEL SURFACE VS VERTICAL STEEL SURFACE • Cable down at 45° to vertical steel surface including pipe. • Cable to vertical flat steel surface; cable to side of vertical or horizontal steel pipe. • CADWELD also has a complete product line for cathodic protection connections. See Bulletin CA1A. • Concentric stranded copper cable listed. • A test weld should be made to check the possibility of burn through on thin sections or thin wall pipe. • Bold letter in mold part number is the price key.
RANGE OF VERTICAL PIPES VS RANGE OF VERTICAL PIPES • Cable down at 45° to range of vertical steel pipes. • CADWELD also has a complete product line for cathodic protection connections. See Bulletin CA1A. • A test weld should be made to check the possibility of burn through on thin sections or thin wall pipe. • When only one pipe size rather than a range of sizes is involved, see Cable to Steel Pipe Table on previous page. • Concentric stranded copper cable is listed.
VERTICAL STEEL SURFACE VB/VF VERTICAL STEEL SURFACE • Connection of vertical cable to vertical flat steel surface or to side of vertical or horizontal steel pipe. • A test weld should be made to check the possibility of burn through on thin sections or thin wall pipe. • Concentric stranded copper cable listed. • Cable to steel pipe. Add pipe orientation and nominal pipe size to flat surface mold part number. Examples: VFC-2G-V6, 2/0 conductor to vertical 6" pipe.
VERTICAL STEEL SURFACE VG/VT VERTICAL STEEL SURFACE • CADWELD through connections to vertical flat steel surface; cable to vertical side of horizontal pipe (Type VG only); cable to vertical steel pipe (Type VT only). • A test weld should be made to check the possibility of burn through on thin sections or thin wall pipe. • Concentric stranded copper cable is listed. • Cable to steel pipe. Add nominal pipe size to flat surface mold part number.
VERTICAL STEEL SURFACE VV VERTICAL STEEL SURFACE VV • Through connections to vertical flat surface or to side of vertical or horizontal steel pipe. • A test weld should be made to check the possibility of burn through on thin sections or thin wall pipe. • Concentric stranded copper cable is listed. • Cable to steel pipe. Add pipe orientation and nominal pipe size to flat surface mold part number.
OTHER CABLE TO STEEL OR CAST IRON The connections shown below are for use only where connections shown in this catalog are not suitable. NAME TYPE EASE SPLIT NAME TYPE Tap Cast Iron VH 1 V Tap Steel VJ 1 V VK 1 V VL VR Tap Steel 1 1 EASE SPLIT VA 1 V VC 1 V VE 2 V Thru Cast Iron HE 1 * Thru Steel HH 2 * HJ 2 * HK 1 V VX 2 V V V HF 1 * HG 2 * 3-12 Ph: 1-800-677-9089 www.erico.
CABLE TO LUGS AND PREFABRICATED LUG ASSEMBLIES Prefabricated Lug Bonds Page 5 NEMA LUGS Page 2 LA Page 3 Telecom Lugs Page 6 GL Page 4 Ph: 1-800-677-9089 www.erico.
NEMA LUGS LA LUGS FOR TYPE LA LUG CONNECTIONS NEMA lugs for Type LA connections are made from electrolytic grade copper bar stock to provide an efficient bolting surface for grounding and power applications. All listed lugs are tin plated. Telephone type lugs also available. Contact ERICO. For sizes not listed or for 45° or 90° lugs, contact ERICO. LA LA Offset Lug Straight Lug Lug Size No.
COPPER LUGS LA COPPER LUGS • Cable to lug or busbar connections. Can be either field fabricated from copper busbar or factory-made lugs. Ideal for power applications. Connection must be made with cable and lug horizontal. • Concentric stranded copper cable is listed. • Bold letter in mold part number is the price key.
COPPER LUGS GL COPPER LUGS • Lugs and connections for equipment and structures. Ideal for power applications. • Concentric stranded copper cable is listed. • Bold letter in mold part number is the price key.
PREFABRICATED LUG BONDS LUG BOND PREFABRICATED LUG BONDS Prefabricated lug bonds are custom made to your specifications. Common usage includes cable tray bonding and grounding, structure bonds, surge arrester leads and power jumpers. Specifications: Prefabricated Lug Bonds (lug stub bonds) shall be made using bare annealed copper cable conforming to ASTM B8, Class A with a tinned pure copper lug conforming to ASTM B-187 on both ends (or one end only), welded to the cable with CADWELD Type GL connections.
TELECOM LUGS ORDERING INFORMATION CADWELD Telecom Mold Part No. is GLPCC001TC and includes B399B Mini EZ change handle clamp and T320 flint ignitor. CADWELD weld metal size #25 works for all 7 lug sizes. One Hole Lug F ONE HOLE UPTURN LUG Part Number Thickness A Width B B921CC14 B921CC38 .125 .125 .63 .63 Length Centers C D .875 .875 N/A N/A E Bolt Size F .375 .375 1/4" 3/8" E B Note: All CADWELD lugs are electrotin plated copper alloy.
CABLE TO BUSBAR OR LUG SECTION 5 LJ Page 3 LQ Page 2 Ph: 1-800-677-9089 www.erico.
CABLE TO BUSBAR LQ CABLE TO BUSBAR • Through vertical conductor to top of horizontal busbar with face in vertical plane. • Concentric stranded copper cable is listed. • Bold letter in mold part number is the price key.
CABLE TO BUSBAR LJ CABLE TO BUSBAR • Tap of horizontal cable to edge of horizontal, flat busbar. • Concentric stranded copper cable is listed. • The minimum distance between centers of adjacent welds is indicated as “C” dimension. • Bold letter in mold part number is the price key.
OTHER CABLE TO BUSBAR OR LUG The connections shown below are for use only where connections shown in this catalog are not suitable.
BUSBAR CONNECTIONS SECTION 6 BA Page 3 BQ Page 2 EP Page 3 Ph: 1-800-677-9089 www.erico.
BUSBAR BQ BUSBAR • Tee tap down - horizontal, on edge, busbars • Bold letter in mold part number is the price key. BQ REQUIRED TOOLS Handle Clamps L160 for C Price Key Molds L159 for D and F Price Key Molds Handles are included with K price key molds Flint Ignitor T320 (Included with handle clamp or frame but also available separately) SUGGESTED TOOLS Slag Removal Spade Mold Cleaning Brush Torch Head B136B T394 T111 ACCESSORIES See Section A Run BUSBAR SIZE Tap MOLD PART NO.
BUSBAR BA/EP BUSBAR • Type BA - Horizontal, on edge, busbars • Type EP - Ell, tap down - Horizontal, on edge, busbars • Bold letter in mold part number is the price key. BA REQUIRED TOOLS Handle Clamps L160 L159 Flint Ignitor T320 for C Price Key Molds for D Price Key Molds (Included with handle clamp but also available separately).
OTHER BUSBAR CONNECTIONS The connections shown below are for use only where connections shown in this catalog are not suitable.
BUSBAR TO STEEL SURFACE SECTION 7 BW Page 2 CC Page 3 CF Page 2 CG Page 3 CH Page 3 Ph: 1-800-677-9089 www.erico.
BUSBAR TO STEEL SURFACE BW/CF BUSBAR TO STEEL SURFACE • A test weld should be made to check the possibility of burn through when intended for use on thin sections or thin wall pipe. • Bold letter in mold part number is the price key. REQUIRED TOOLS Handle Clamps L160 for C Price Key Molds L159 for D Price Key Molds Flint Ignitor T320 (Included with handle clamp but also available separately).
BUSBAR TO STEEL SURFACE CC/CG/CH BUSBAR TO STEEL SURFACE CC • A test weld should be made to check the possibility of burn through when intended for use on thin sections or thin wall pipe. • Bold letter in mold part number is the price key.
OTHER BUSBAR TO STEEL SURFACE CONNECTIONS The connections shown below are for use only where connections shown in this catalog are not suitable. NAME TYPE EASE SPLIT NAME TYPE EASE Tap BX 3 V Tap DF 2 V BY 3 V HL 1 V CA 3 V HM 1 V CB 2 V HN 1 * CJ 2 V CD 3 V DC 3 * CK 2 V DD 3 V Thru 7-4 SPLIT Ph: 1-800-677-9089 www.erico.
CABLE TO REBAR CONNECTIONS Ph: 1-800-677-9089 www.erico.
NOTES... 8-2 Ph: 1-800-677-9089 www.erico.
CADWELD CONNECTIONS CADWELD® Connections Used for Grounding Reinforcing Bars CADWELD provides efficient and permanent connections for both grounding and attaching lightning protection conductors to rebar. When making CADWELD connections to rebar, the normal materials required are: mold, handle and weld metal. In addition, packing material is also required. These materials act as a seal between the mold and rebar to prevent leaks. One unit of packing material must be ordered for each weld.
CABLE TO REBAR RR CABLE TO REBAR • Horizontal cable tap to horizontal rebar. • Rebar material characteristics and location of weld must be considered when selecting connections to rebar. • Concentric stranded copper cable is listed. • Bold letter in mold part number is the price key.
CABLE TO REBAR RR REBAR CABLE SIZE SIZE MOLD PART NO. WELD METAL PACKING PART NO. 4 2 2 SOL 1 1/0 RRA-551L RRA-551V RRA-551T RRA-551Y RRH-552C 32 45 45 65 90 B-143B B-143B B-143B B-143B B-144C RRH-552G RRH-552L RRH-552Q 90 115 115 B-144C B-144A B-144A RRA-561T RRA-561V RRA-561Y RRH-562C 45 45 65 90 B-143B B-143B B-143B B-144C RRH-562G RRH-562L RRH-562Q 90 115 115 B-144C B-144A B-144A 7 2/0 3/0 4/0 8 2 SOL 2 1 1/0 2/0 3/0 4/0 REBAR CABLE SIZE SIZE MOLD PART NO.
CABLE TO REBAR RD CABLE TO REBAR • X connection horizontal cable to horizontal rebar. • Rebar material characteristics and location of weld must be considered when selecting connections to rebar. • Concentric stranded copper cable is listed. • Bold letter in mold part number is the price key.
CABLE TO REBAR REBAR CABLE SIZE SIZE 7 4 2 SOL 2 1 1/0 2/0 3/0 4/0 8 9 RD MOLD PART NO. WELD METAL PACKING PART NO.
CABLE TO REBAR RC CABLE TO REBAR • Through connection horizontal cable to vertical rebar. • Rebar material characteristics and location of weld must be considered when selecting connections to rebar. • Concentric stranded copper cable is listed. • Bold letter in mold part number is the price key.
CABLE TO REBAR REBAR CABLE SIZE SIZE 7 4 2 SOL 2 1 1/0 2/0 3/0 4/0 8 9 MOLD PART NO. RCE-551L RCE-551T RCE-551V RCE-551Y RCE-552C RCE-552G RCE-552L RCE-552Q WELD METAL 90 90 90 115 115 115 150 150 RC PACKING PART NO. B-144B B-144B B-144B B-144B B-144B REBAR SIZE CABLE SIZE MOLD PART NO. WELD METAL PACKING PART NO.
CABLE TO REBAR RJ CABLE TO REBAR • Tee connection horizontal cable tap to vertical rebar. • Rebar material characteristics and location of weld must be considered when selecting connections to rebar. • Concentric stranded copper cable is listed. • Bold letter in mold part number is the price key.
CABLE TO REBAR REBAR SIZE CABLE SIZE MOLD PART NO. 7 4 2 SOL 2 1 1/0 RJE-551L RJE-551T RJE-551V RJE-551Y RJE-552C 8 9 RJ WELD METAL PACKING PART NO. 65 65 65 90 115 B-144A B-144A B-144A B-144A B-144B 2/0 3/0 4/0 RJE-552G RJE-552L RJE-552Q 115 150 150 B-144B B-144B B-144B 2 SOL 2 1 1/0 RJE-561T RJE-561V RJE-561Y RJE-562C 65 65 90 115 B-144A B-144A B-144A B-144B 2/0 3/0 4/0 RJE-562G RJE-562L RJE-562Q 115 150 150 B-144B B-144B B-144B REBAR SIZE CABLE SIZE MOLD PART NO.
OTHER CABLE TO REBAR CONNECTIONS The connections shown below are for use only where connections shown in this catalog are not suitable. NAME Ell Parallel tap Parallel thru Splice TYPE EASE SPLIT NAME TYPE EASE SPLIT DT 2 V Tee RH 1 * DR 2 V RK 1 * RV 2 V RL 2 V RT 2 V RM 2 V RW 2 V RN 2 V RE 2 V RP 2 V RF 2 V RQ 2 V RG 1 V XJ 1 * SF 2 V SR 1 V X 8-12 Ph: 1-800-677-9089 www.erico.
CABLE TO RAIL OR STRUCTURES W Page 3 ST Page 2 TP Page 2 Ph: 1-800-677-9089 www.erico.
CABLE TO RAIL ST/TP CABLE TO RAIL • Connections for grounding cable to the rail web of 85 lb. to 140 lb. standard rails • Concentric stranded copper cable is listed. • Contact ERICO for crane or girder rail applications. • Note: Rail materials characteristics, use and locations of weld should be considered when selecting connections to a rail. • For cable sizes not listed, multiple connections using smaller cables are suggested. • Bold letter in mold part number is the price key.
CABLE TO RAIL AND STRUCTURES W CABLE TO RAIL AND STRUCTURES • Type W Bonds are for bonding and grounding of standard rails. These bonds are welded to the web of rail sections 85 lb. to 140 lb. • Mold frame includes adjusting screw to position bond at neutral axis of rail where stresses are minimal. • Contact ERICO for crane and girder rails. • Concentric stranded copper cable is listed.
NOTES... Ph: 1-800-677-9089 www.erico.
CAST GROUND PLATES, AIRCRAFT GROUNDING RECEPTACLES SECTION 10 HV Page 2 B165/ B165R Page 4 GB Page 6 HV/VF Page 2 B166/ B167 Page 4 RA Page 7 HV/VE Page 2 Cast Ground Plate Assemblies Page 5 RB Page 7 Cast Ground Plate Page 3 GB/GR Page 6 HX Page 8 Cast Ground Plate Page 3 GB/GT Page 6 HV Page 8 Ph: 1-800-677-9089 www.erico.
CAST GROUND PLATE CONNECTIONS B161/162/164 CAST GROUND PLATE CONNECTIONS TO STRUCTURES • CADWELD cast ground plates used in concrete structures offer convenient ground system connection points. These ground points are used for equipment, machinery and structure grounding after completion of the concrete work. • For structural reasons, cast ground plates should always be encased in concrete. • For B-161-2Q, B-162-2Q or B-164-2Q Cast Ground Plates Only. • Concentric stranded copper cable is listed.
CADWELD CAST GROUND PLATES CADWELD CAST GROUND PLATES CADWELD ground plates used in concrete structures offer convenient ground system connection points. These ground points are used for equipment, machinery and structure grounding after completion of the concrete work. 2-1/2” The castings are made from a copper alloy. CADWELD ground plate connections result in current carrying capacity equal to that of the conductor or stud and cannot loosen or corrode.
AIRCRAFT GROUNDING RECEPTACLES B165 and B165R The B165 and B165R Grounding Receptacles are copper alloy castings intended for use in static grounding systems of aircraft refueling areas. They are easily connected to the grounding system conductor and/or ground rods with CADWELD connections. Designed for simple installation flush with the paved surface. The attachment point (3/4" ball) is an integral part of the casting on the B165 and is removable on the B165R. BALL, 3/4” DIA. (B165R) BALL, 5/8” DIA.
CAST GROUND PLATE ASSEMBLIES ORDERING INFORMATION TA L L L L L L RA SS RB 1/2” pipe can be used to support and position cast ground plate GROUND PLATE STYLE RA STYLE RB STYLE SS STYLE TA B1612Q B1613Q B1622Q B1642Q B1643Q B530A"XL" B530B"XL" B530C"XL" B530D"XL" B530E"XL" B531A"XL" B531B"XL" B531C"XL" B531D"XL" B531E"XL" B532A"XL" B532B"XL" B532C"XL" B532D"XL" B532E"XL" B533A"XL" B533B"XL" B533C"XL" B533D"XL" B533E"XL" NOTE: Add appropriate suffix: For "XL": X = Conductor Code L = Length in
AIRCRAFT GROUNDING RECEPTACLES GROUNDING RECEPTACLES GB GB/GR GB/GT Connection of grounding receptacle on ground rod. Connection of grounding receptacle, installed rod and cable tap. Connection of grounding receptacle, installed rod and through cable. • CADWELD splices for Grounding Receptacles B165 and B165R to the top of ground rods with or without cable connection for most sizes and types of ground rods, including copperclad and stainless, stainless clad or galvanized steel.
AIRCRAFT GROUNDING RECEPTACLES RA AND RB TYPES FOR AIRCRAFT GROUNDING • CADWELD connection is made with the receptacle in the inverted position. The resulting riser fits inside a 1/2" pipe for proper elevation locating – see page 10-5. • Concentric stranded copper cable is listed. • Bold letter in mold part number is the price key.
COPPER AND STEEL STUDS HX/HV COPPER AND STEEL STUDS • Connections of copper or steel studs to steel surfaces. Copper studs on grounded structures provide a convenient point for attachment of temporary protective ground clamps. • Bold letter in mold part number is the price key.
HEAVY DUTY ELECTRICAL CONNECTIONS ABOUT HEAVY DUTY ELECTRICAL CONNECTIONS for stranded concentric copper conductors. Heavy Duty connections were developed to be used on reclaimed cable. Heavy Duty connections use a larger size connection cavity in the mold and a larger size weld metal than the equivalent standard connections. The larger size weld metal supplies extra BTU's (but not a higher temperature) to melt the heavy oxide coating on the conductor and to overcome severe field conditions.
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OTHER CONNECTIONS COPPER TUBE TO GROUND RODS The connections shown below are for use only where connections shown in this catalog are not suitable. NAME TYPE EASE SPLIT Ell FT 1 V NAME TYPE EASE SPLIT Tee FV 1 V COPPER TUBE TO COPPER TUBE The connections shown below are for use only where connections shown in this catalog are not suitable.
CABLE TO COPPER TUBE The connections shown below are for use only where connections shown in this catalog are not suitable.
MATERIALS, TOOLS & ACCESSORIES SECTION A PAGE A - SAFETY FIRST Safety Glasses and Gloves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 CADWELD WELD METAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 CADWELD MOLDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 ADAPTING MOLDS TO FIT CONDUCTORS Wrap Sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Adapter Sleeves . . . . . . . . . . . . . . .
MATERIALS, TOOLS & ACCESSORIES SAFETY FIRST ERICO recommends SAFETY FIRST when making CADWELD Connections as you should consider with all tasks. We offer the following safety equipment. We recommend gloves and glasses as shown. SECTION A T393 Gloves Heavy canvas gloves with leather palms. Safety Glasses These glasses may be worn separately or over prescription glasses. T378L CADWELD WELD METAL CADWELD Weld Metal is a mixture of copper oxide and aluminum, packaged by size in plastic tubes.
MATERIALS, TOOLS & ACCESSORIES SECTION A ADAPTING MOLDS TO FIT CONDUCTORS Cables smaller than indicated on mold tag can be welded by using either Wrap Sleeve or Adapter Sleeves. CADWELD Wrap Sleeve B140A B140A CADWELD Wrap Sleeve is wrapped around the cable until the diameter is about the same as the cable opening in the mold. CADWELD Adapter Sleeves CADWELD Adapter Sleeves are used to adapt a limited range of smaller size cables to a larger size CADWELD Mold.
MATERIALS, TOOLS & ACCESSORIES SECTION A CABLE AND WORK SURFACE PREPARATION Cable Cleaning Brushes Two types of brushes are available to aid in removing oxides from copper surfaces. T313 Card Cloth Brush with short stiff bristles is generally preferred for cleaning concentric conductors and busbars, which are not heavily oxidized. T313 T314 T314 Cable Cleaning Brush cleans any conductor and is especially useful for coarse or very dirty conductors.
MATERIALS, TOOLS & ACCESSORIES SECTION A Surefire™ Torch Head T111 Self igniting propane torch head. Squeeze the control knob for an instant flame. Release and it’s out. No flame adjusting. The burn tip remains cool during normal use. Operates on its side or upside down. Can withstand 60MPH winds without flareout. Fits all standard 14 and 16 oz. propane cylinders.
MATERIALS, TOOLS & ACCESSORIES SECTION A MOLD CARE AND USE Mold Cleaning Brush Mold cleaning brush T394 is very useful for removing slag from molds – especially vertical split molds. T394 Slag Removal Spades Slag Removal Spades are useful for removing the slag after making a CADWELD Connection – especially useful with horizontally split molds. Slag Spade Part No.
MATERIALS, TOOLS & ACCESSORIES SECTION A Wear Plates Wear Plates reduce mechanical abrasion of molds at cable entry points and help prevent leakage of molten metal (particularly on larger 7 strand conductor). These features prolong mold life. Most CADWELD Molds are available with factory mounted Wear Plates for the following sizes: Copper Cable: 1/0 AWG thru 500 Kcmil DSA Copperweld®: 7/#10 thru 19/#6 Ground Rods: 1/2" thru 1" To order WEAR PLATES, specify: Mold Part No. followed by the suffix "-W" i.e.
MATERIALS, TOOLS & ACCESSORIES SECTION A MOLD FASTENING AND MOUNTING CADWELD Handle Clamps Handle Clamps such as the one shown are required for most molds. Specialized frames with handles are used on some molds. Flint ignitors are included with all Handle Clamps. The following Handle Clamps are most widely used. 1. L160 for all molds having a "C", "E", "Q", or "R" mold price listing. (3" wide molds) 2.
MATERIALS, TOOLS & ACCESSORIES SECTION A Magnetic Handle Clamps The CADWELD mold can be securely held to a large flat or slightly curved vertical surface using the Handle Clamp with Magnetic Support. Used on vertically split molds. Clamp Part No. Fits Mold Price Key Minimum Width Required* B396 B159M B399AM B399BM C & R Price Key D & F Price Key T Price Key P & N Price Key 8” 10-1/2” 6” 7” *Width will vary slightly depending upon the type of connection being made.
MATERIALS, TOOLS & ACCESSORIES SECTION A GROUND ROD SPECIALTY TOOLS ERITECH® Ground Rod Drivers Product # Description EGRD58 5' Driver body with insert for up to 5/8" ground rods EGRD58I* Replacement insert for 5/8" ground rods EGRD34 5' Driver body with insert for up to 3/4" ground rods EGRD34I* Replacement insert for 3/4" ground rods *Both 5/8" and 3/4" inserts fit standard body of EGRD58 or EGRD34.
MATERIALS, TOOLS & ACCESSORIES SECTION A Ceramic Blanket The woven Ceramic Blanket (Part T306) can be used to hold a hot mold or keep the work surface free of slag when cleaning the mold. T306 Screwdriver T305 File Pliers T329 T304 Welding Tray The Welding Tray (Part XLB974-B2) can contain a spill of molten weld metal. It is for personnel safety. Recommended when working overhead or over expensive equipment.
MATERIALS, TOOLS & ACCESSORIES SECTION A Ground System Testers EST Series Product # EST 101 EST 201 EST 301 EST Reel Kit 500 EST101 Description 2 pole resistance, 3 pole ground to earth resistance measurement @128Hz 2 pole AC resistance, 3 pole ground to earth resistance measurement, 4 pole soil resistivity measurement 2 pole AC resistance, 2 & 3 pole ground to earth resistance measurement, 4 pole soil resistivity, and clamp-on stakeless and selective adapters ESTREELKIT500 EST Reel Kit 500 feet long (
TECHNICAL INFORMATION SECTION B GROUNDING SYSTEM – CONDUCTORS AND CONNECTORS IEEE Std. 80-2000, Guide for Safety in Substation Grounding, the accepted industry standard, uses a fusing formula as the basis for selecting minimum conductor size to avoid fusing (melting) under fault conditions. The grounding conductor size is based on the maximum magnitude and duration of available fault current, and on the type of connections being used in the grounding system.
TECHNICAL INFORMATION SECTION B BARE CLASS A, B, AND C CONCENTRIC STRANDED CONDUCTOR Based on A.S.T.M. Standard Specifications. Size in Circular mils Size A.W.G. Conductor Dia. In. 1,000,000 800,000 750,000 700,000 1.152 1.031 .998 .964 600,000 500,000 400,000 .893 .813 .728 350,000 300,000 250,000 .681 .630 .575 7 19 NUMBER OF WIRES 37 61 91 CADWELD Cable code .1644* .1470* .1424* .1375* .1280 .1145 .1109 .1071 .1048 .0938 .0908 .0877 4Y 4Q 4L 4G .1273 .1162 .1040 .0992 .0905 .0810 .
TECHNICAL INFORMATION BARE SOLID COPPER WIRE SECTION B DSA COPPERWELD CONDUCTOR Based on A.S.T.M. Standard Specifications Size A.W.G. Cross Sectional Area Wire CADWELD Circular Mils Dia. In. Cable code 4/0 3/0 2/0 1/0 211,600 167,800 133,100 105,500 .4600 .4096 .3648 .3249 2P 2K 2F 2B 1 2 3 4 83,690 66,370 52,630 41,740 .2893 .2576 .2294 .2043 1X 1T 1P 1K 6 8 10 12 14 26,250 16,510 10,380 6,530 4,110 .1620 .1285 .1019 .0808 .0064 1G 1D 1A Cable Stranding Nominal Diameter kcmil .306 .
TECHNICAL INFORMATION SECTION B RECTANGULAR COPPER BUSBAR Thickness Inches Width Inches 1/8 1 1-1/2 2 159,200 238,700 318,300 .484 .726 .969 CE CG CH 1 2 238,700 477,500 .727 1.45 DE DH 1/4 1 1-1/2 2 3 4 318,300 477,500 636,600 954,900 1,273,000 .969 1.45 1.94 2.91 3.88 EE EG EH EK EM 3/8 1 1-1/2 2 3 4 477,500 716,200 954,900 1,432,000 1,910,000 1.45 2.18 2.91 4.36 5.81 GE GG GH GK GM 1/2 2 3 4 1,273,000 1,910,000 2,546,000 3.88 5.81 7.
TECHNICAL INFORMATION SECTION B CAST IRON PIPE – CLASS A THRU D STANDARD STEEL WIRE GAGE (WASHBURN MOEN GAGE) SOLID AWWA Specification 1908, ASA A21.2 Class 100-250. Gage No. Dia. Inches Gage No. Dia. Inches 7/0 6/0 5/0 .490 .4615 .4305 6 7 8 .1920 .1770 .1620 4/0 3/0 2/0 .3938 .3625 .3310 9 10 11 .1483 .1350 .1205 1/0 1 2 .3065 .2830 .2625 12 13 14 .1055 .0915 .0800 3 4 5 .2437 .2253 .2070 15 16 17 .0720 .0625 .
LITERATURE SECTION C OTHER SPECIALIZED APPLICATION CATALOGS, APPLICATIONS, BULLETINS AND TECHNICAL INFORMATION A1L STATIC GROUNDING CONNECTIONS A4G SUBSTATION GROUNDING Numerous applications and guidelines for grounding electrical supply station (substations). A4P COMPUTER ROOM GROUNDING Widely accepted system of grounding and signal reference grids to protect vital computer data and reduce downtime.
LITERATURE SECTION C TRAINING VIDEOS CWTAPEA How To Make a CADWELD Connection CWTAPEB Basic Grounding, Includes Testing CWTAPEC Basic Grounding CWTAPED CADWELD ONE-SHOT CWTAPEE EXOLON CWTAPEF How to Make a Heavy Duty Ground Rod Splice CWTAPEG Reducing Transient Threats with SRGs CWTAPEH Signal Reference Grid Installation CWTAPEJ CADWELD in the Rain CWTAPEK GRIDMAKER vs.
ERICO SURGE AND LIGHTNING PROTECTION ELECTRICAL GROUNDING and BONDING LIGHTNING PROTECTION Lightning Protection Products Molds & Weld Metal EXOLON – Low Emission ONE-SHOT – Disposable Molds Lugs, Tools & Accessories Ground Rods & Accessories Chemical Ground Rods Ground Clamps Ground Plate Electrodes Ground Rod Couplings Ground Rod Drivers Ground Rods – Copperbonded, Galvanized, Stainless Steel Bonding Products Aircraft Ground Receptacles Bonding Jumpers Equipment Ground Plates Equipotential Mesh Fence &
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