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QWI-DMCP-7.3-003 Rev “B“ of 13 Ground Connector Fitting Installation Procedure

DATE REV. DESCRIPTION OF CHANGE

8/15/2011 NC (-) New Procedure - Replaces SOP611-003

1/25/2012 A

A1: Added Section 8.0 - DMC Power Ground Connector Instructions .......Manual Quick Reference Guide A2: Updated Figure 1 with New Rendering. A3: Deleted "*1" from Table 1. Changed "*2" to "*". Added .....aDLT06MAPE2200 to Optional Electric Battery Pump. A4: Updated Figure 6 with New Rendering. A5: Deleted Figure from Section 4.6 and Updated "Caution" Note.

3/7/2013 B B1: Replaced all pictures with clearer photos B2: Modified format for Table of Contents B3: Improved clarity of Figure 4 of SOP and Figure 2 of Addendum


TABLE OF CONTENTS

1.0 INTRODUCTION…………………………………………………………. 4

2.0 TRAINING………………………………………………………………… 4

3.0 DMC POWER SWAGE TOOLING SYSTEM…………………………. 5

4.0 INSTALLATION PROCEDURE………………………………………... 7 4.1 CUT AND CLEAN THE END OF THE

COPPER CONDUCTOR……………………………………… 7 4.2 ASSEMBLING THE DMC POWER GROUND

CONNECTOR FITTING………………………………………. 7 4.3 ASSEMBLING THE DMC POWER SWAGE TOOL………… 7 4.4 SWAGING THE DMC POWER GROUND

CONNECTOR FITTING………………………………………. 8 4.5 INSPECT THE SWAGED CONNECTOR FITTING………….. 10 4.6 DMC POWER FENCE POST CONNECTOR………………… 10

5.0 TOOLING MAINTENANCE…………………………………………….. 12

6.0 REFERENCE…………………………………………………………….. 13

7.0 WARRANTY INFORMATION…………………………………………...13

8.0 DMC POWER GROUND CONNECTOR INSTRUCTIONS MANUAL QUICK REFERENCE GUIDE………... 14


1.0 INTRODUCTION DMC Power Ground Connector fittings are used to join permanent electrical connections on copper conductors used in substation grounding for the electric utilities and the like. The connection is achieved by means of mechanically compressing a DMC Power Ground Connector fitting over the copper conductor using DMC Power Swaging Tools. The DMC Power Swaging Tools consist of a power unit, head assembly, and a hydraulic pump. The DMC Power Swaging Tool is activated by 10,000 Psi which is provided by the hydraulic pump. The power unit has a piston inside the power unit which is connected to the die block (shown in figure 1). The die block holds one swage die while the head holds another swage die. The Swage Tool is placed over the fitting after the DMC Power Ground Connector fitting is placed over the bare copper conductor. When the pump is activated, the piston inside the power unit will extend with the die block which swages the Ground Connector fitting onto the bare copper conductor. The swage is then checked using an inspection gauge.

The purpose of this manual is to provide instructions for the proper installation of the DMC Power Ground Connector fittings using DMC Power Swage Tools.

2.0 TRAINING DMC Power provides optional training at no additional cost to the customer. Training courses are designed to teach personnel how to properly install DMC Power Ground Connectors and operate DMC Power Swage Tools. The training will be conducted by a certified instructor or by an authorized DMC Power representative.


3.0 DMC POWER SWAGE TOOLING SYSTEM The DMC Power Tooling System consists of the DLT Power Swage Tool, DMC Power Ground Connector fitting, and a hydraulic pump. The DMC Power Swage Tool which is used to swage bare copper conductors sizes 1/2, 1, 1-1/4, 1-1/2, 1-7/8, 2, 2-1/4, and 2-3/4 inches is shown in figure 1 (table 1 shows the conductor size). There are 2 types of hydraulic pumps that can be used with DMC Power Swage Tools (refer to table 1).

CAUTION: THE EQUIPMENT USED IN SWAGING IS SUBJECTED TO HIGH PRESSURE. IMPROPER USE MAY RESULT IN TOOL FAILURE AND/OR SERIOUS PERSONAL INJURY.

IT IS NOT SAFE TO APPLY HYDRAULIC PRESSURE WHEN THE HEAD ASSEMBLY IS NOT ENGAGED WITH THE POWER UNIT.


Figure 1: DMC Power Swage Tool nomenclature.

SAFETY LANYARD

HEAD ASSEMBLY

SWAGE DIES

HEAD (YOKE)

DIE BLOCK ASSEMBLY

PISTON

POWER UNIT

HANDLE

SWIVEL ASSEMBLY

FEMALE PIONEER COUPLER


Ground Conductor

OD [in]

Power Unit Head Assembly Inspection Gauge Hydraulic Pump

1/2

DLT45MAPW0000

DLT45CLHA00004 GCIG200-02G

DLT12MAPE1000*

1 DLT45CLHA02500 DLT45CLIG02500

1 1/4 DLT45CLHA03975 GCIG200-03975

1 1/2 DLT45CLHA05565 GCIG200-05565

1 7/8 DLT45CLHA08745 GCIG200-08745

2 DLT45CLHA11130 GCIG200-11130

2 1/4 DLT45CLHA15900 GCIG200-15900

2 3/4 DLT58MAPW0000 DLT58CLHA25000 DLT58CLIG25000

*: Optional electric battery operated pump (P/N DLT06MAPE2001 or DLT06MAPE2200) available upon request.

Table 1: DMC Power Swage Tooling Systems.

4.0 INSTALLATION PROCEDURE

4.1 CUT AND CLEAN THE END OF THE BARE COPPER CONDUCTOR Cut the bare copper conductor so that the strand ends are even. Clean an area of 2-1/2 inches from the end of the conductor using a wire brush.

4.2 ASSEMBLING THE DMC POWER GROUND CONNECTOR FITTING Insert the bare copper conductor until it bottoms out making sure that the conductor is visible through the inspection hole as shown in figure 2.

Figure 2: Fully inserted conductor in the DMC Power Ground Connector fitting.

4.3 ASSEMBLING THE DMC POWER SWAGE TOOL Mount the Die Block onto the Power Unit and make sure it is locked in place with the pushpin. Slide the Power Unit and Head together. Properly align the Head and the Power Unit such that the face is flush as shown in figure 3.


Figure 3: Flushed Head and Power Unit.

4.4 SWAGING THE DMC POWER GROUND CONNECTOR FITTING Position the Swage Tool as shown in figure 4 ensuring that the Swage Dies’ teeth are aligned between then fitting end and the swage line. Start the Hydraulic Pump to actuate the tool. Swaging is complete when the Die Block makes contact with the Head and the pressure reaches 10,000 psi. Disengage the Head from the Power Unit once the Die Block fully retracts.


Figure 4: Proper alignment of the Swage Tool, Conductor, and Ground Connector fitting.

POWER UNIT

DMC POWER GROUND CONNECTOR FITTING

HEAD ASSEMBLY

COPPER CONDUCTOR

ALIGN SWAGE DIE TEETH WITH FITTING END AND SWAGE LINE ON GROUND CONNECTOR FITTING


4.5 INSPECT THE SWAGED CONNECTOR FITTING Use the Inspection Gauge to verify the swage by positioning the Gauge on the swaged portion of the fitting as shown in Figure 5.

Figure 5: Inspection Gauge.

REPEAT STEPS 4.1 THROUGH 4.5 FOR EACH CABLE CONNECTOR FITTING END.

4.6 DMC POWER FENCE POST CONNECTOR ASSEMBLY The specified torque must be met when clamping bolts are employed on DMC Power Fence Post Connectors as shown in table 2. DMC Fence Post Connectors are shown in figure 6.

Figure 6: DMC Fence Post Connectors.


Bolt Nominal Pipe Size

[in]

Bolt Size [in]

Tightening Torque [lb-ft]

Fence Post 1 - 3 3/8 20

Fence Post 3-1/2 – 5 1/2 39

Slotted Fence Post 1 - 5 1/2 15 Table 2: Torque Requirements for DMC Fence Post Connectors.

CAUTION: ALWAYS POSITION YOURSELF AWAY FROM THE SIDES OF THE YOKE (HEAD ASSEMBLY) DURING SWAGING.


5.0 TOOL MAINTENANCE This section covers regular inspection and cleaning of the DMC Swage Tools. The quick disconnects and hoses are all rated for 10,000 psi and are not to be substituted. In handling the tools, do not hold tools by the quick disconnect or the hose.

Refer to table 3 for Preventive Maintenance.

PROCEDURE FREQUENCY

Ensure the swivel is secured tightly. Before each use

Ensure the quick disconnect is tight and works properly. Before each use

Ensure the piston is retracted to its lowest position. Before each use

Ensure the head sliding areas are free of dirt and damage. Before each use

Ensure the pushpin in the die block is operating properly and ensure the die block engages properly with the piston.

Before each use

With the Head Assembly attached to the Power Unit, actuate the Swage Tool a few times.

Before each use

Check swage dies for foreign material between slots and for any cracks. Clean the dies using a wire brush to remove metal chips accumulated between the slots of the dies. Clean the head and die block.

Before each use

Apply DMC Power Swage Lube on head and lower die block. Frequently, after dies and head are cleaned.

Perform die penetrate inspection on the cylinder and head At lease once a year Table 3: Preventive Maintenance.

CAUTION: DLT TOOLS ARE NOT TO BE REPAIRED BY THE CUSTOMER, UNLESS

AUTHORIZED BY DMC POWER TO DO SO. ANY UNAUTHORIZED REPAIRS DONE BY THE CUSTOMER WILL VOID THE WARRANTY. THIS ALSO MAY CAUSE THE EQUIPMENT TO PERFORM IN AN UNSATISFACTORY MANNER. A DMC POWER REPRESENTATIVE HAS TO BE CONTACTED REGARDING RETURN OF TOOLS FOR EVALUATION AND REPAIRS.


6.0 REFERENCE

For a shorter, two page laminated version of this instruction manual refer to QWI-DMCP-7.3-003 Rev “-” Addendum.

7.0 WARRANTY INFORMATION DMC Power agrees to repair or replace, free of charge, any DLT tolling manufactured by DMC Power which proves to be defective due to faulty workmanship or materials within 1 year of shipment from the factory. This will be done provided written notice is received by the company immediately following the discovery of such defect. All parts returned for warranty service must be shipped, prepaid, to the factory by the customer. DMC Power shall have no liability for damages or delays resulting from the use of defective materials or workmanship in its parts, or from any repairs or alterations to the parts made by the customer, or from the use of substitute service parts, unless such use was authorized in writing by DMC Power. DMC Power’s liability is confined to the replacement of defective parts, subject to conditions expressed in this warranty. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EITHER EXPRESSED OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

DMC Power Ground Connector Assembly Instructions

Step 1: CUT AND CLEAN THE END OF THE COPPER CONDUCTOR Confirm that the DMC Power Ground Connector fitting matches the cable or rod size. Also, confirm that the Swage Tool matches the Ground Connector fitting size. Cut the copper conductor so that the strand ends are even. Clean an area of 2 inches from the end of the conductor using a wire brush.

Step 2: ASSEMBLE THE DMC POWER GROUND CONNECTOR FITTING WITH THE COPPER CONDUCTOR Insert the copper conductor into the Ground Connector fitting making sure that the conductor is visible through the inspection hole as shown in figure 1.

Step 3: ASSEMBLE THE DMC POWER SWAGE TOOL Mount the Die Block onto the Power Unit and make sure it is locked in place with the

pushpin/setscrew. Slide the Power Unit and Head together.

Step 4: CONNECT THE HYDRAULIC PUMP TO THE POWER UNIT Connect the DMC Power Swage Tool to the hydraulic pump via the quick disconnect (threaded or push-pull) fitting to the hydraulic hose line. Properly align the Head and the Power Unit such that the face is flush as shown in picture 2.

Step 5: PERFORMING A SWAGE

Position the Swage Tool over the DMC Power Ground Connector fitting. Ensure that the Swage Dies’ teeth are

aligned between the end of the fitting and the Swage Line mark as shown in figure 1. Start the Hydraulic Pump to

actuate the tool. Swaging is complete when the Die Block makes contact with the Head and the pressure reaches

10,000 psi. Disengage the Head from the Power Unit once the Die Block fully retracts.

Step 6: INSPECT THE SWAGED CONNECTOR FITTING Use the Inspection Gauge (figure 2) to verify that the swage is good by positioning the Inspection Gauge

on the swaged portion of the fitting as shown in picture 3. If there are no Inspection Gauges available, refer to table 1 for “Depth of Swage” dimension for the swage inspection.

REPEAT STEPS 1 THROUGH 6 FOR EACH GROUND CONNECTOR FITTING END.

14502 S. Figueroa St., CA 90248 Customer Service: (888) SWAGE NOW

www.dmcpower.com QWI-DMCP-7.3-003 Rev A (Addendum)

Remove the Swage Dies when dirty and clean the slots with a wire brush to remove the excess build-up. Once cleaned, re-lubricate with DMC Power Swage Lube.

Refer to DMC Power Ground Connector Standard Operating Procedure QWI-DMCP-7.3-003 Rev “-“ for more detailed information.

DO NOT USE ON ANY OTHER PRODUCT OTHER THAN DMC POWER FITTINGS.

DO NOT OPERATE THE DMC POWER SWAGE TOOL WITHOUT ATTACHING THE HEAD ASSEMBLY ON THE POWER UNIT. IMPROPER USE MAY RESULT IN TOOL FAILURE AND/OR SERIOUS INJURY.

http://www.dmcpower.com/

Cut the cable/rod such that the ends are even. Insert the cable/rod into the DMC Power Ground Connector making sure that the cable/rod is visible through the

Inspection Hole.

Position the DMC Power Swage Tool making sure that the Swage Die Teeth are aligned s

between the Swage Line and the end of thed Ground Connector ,,,,,,,,,,,,,

Verify the Swage using the Inspection Gauge

14502 S. Figueroa St., Gardena, CA 90248 Customer Service: (888) SWAGE NOWll

www.dmcpower.com.

QWI-DMCP-7.3-003 Rev A (Addendum) ....

Pic. 1

Pic. 2

Pic. 3

Fig. 1

Pic. 3

Fig. 2

INSPECTION GAUGE

PLACE THE SWAGED PORTION OF THE DMC CABLE CONNECTOR HERE

GCIG200-XXXXX

DEPTH OF SWAGE

INSPECTION GAUGE PART

NUMBER

COPPER CONNECTOR

OD (in) DEPTH OF

SWAGE (in)

GCIG200-02G 0.545 0.493

GCIG200-03975 1.250 1.103

GCIG200-05565 1.500 1.323

GCIG200-08745 1.875 1.642

GCIG200-11130 2.000 1.884

GCIG200-15900 2.250 2.037

Table 1

http://www.dmcpower.com/

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