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FULL TENSIONCONNECTORS Bullet 1 6000 series aluminum alloy2 BulletFits cablesizes 1/0 - 3500 kcmil Single and Two-Stage applications Bullet 3Meets pull out requirement of over 95% strength of cableBullet 4Pre-drilledinspection hole for proper cable insertionCustom dimensions and configurations availableTHINKING OUTSIDE THE FENCEEvery day a continuously increasing demandis placed on our nation’s transmissionconductors, often causing them to operateat temperatures exceeding 130 C. Keepingthese transmission lines safely in the airis the single most critical requirement ofany connector and traditional installationmethods simply cannot survive long underthis kind of burden. That’s why DMC Powerdesigned the next generation of Full Tensionconnectors for AAC, ACSR, ACSS and StaticWire applications.Only 4 Swages required on AAC Single Pad DeadendsDMC Power has spent several years testingto all industry standards including ANSIC119.4 Class "AA" current cycling on ourSingle Stage system, establishing us asthe only "High Temperature" Single Stagesystem option.Additional Thermal/Mechanical testing ofour Single Stage "One Die" ACSR fittings atan elevated temperature of 150 C and 25%tension showed that all of our test samplesran an average of 25% cooler than thecontrol conductor temperature, provingDMC Power's superior performance over allother compression systems.DMC Power’s strict manufacturingprocesses and ISO 9001:2008 qualitysystem ensures that each and everyconnector you receive meets and exceedsall utility and industry standards. Trust thesuperior quality and proven reliability ofthe DMC Power Swage System on yournext Transmission project.40360 compression with just the push of a buttonFULL 360º COMPRESSIONUnlike other connection systems that usedangerous explosives, inferior connector materialor fixed dies that produce inefficient compression,our Swage System provides 360 compressionaround the outside of the high strength 6000series aluminum alloy fitting to produce:20%40%50%AREA OFREDUCTIONHIGHER IACSRATINGHIGHER THERMALCONDUCTIVITYRATING888-SWAGE-NOW
THE MOST NOVEL FULL TENSIONTRANSMISSION APPLICATION IN 30 YEARS Internal step downfor stress relief Flared out sectionprovides a "choking" effect 360 flex die appliessymmetrical forces forgreater holding strength Flexible gripping coreto prevent scrapingout holding grit Yields a 20% area ofreduction for superiorelectrical performanceMANUFACTURING Machined to exact sizes (Tolerance: .005) Cores are machined for maximum accuracy Exact surface finish allows maximum contact Optimum strength through precise heat treatment Special galvanizing and superior corrosion protection TIG welding for best connection and conductivity Gun Drill Machining produces 5x tighter tolerance vs. extrusionAPPLICATIONNOTESPERFORMANCE FEATURES Higher conductivity alloy Superior mechanical strength Step down stress relief Fewer compressions for fast installation Lighter tool for improved ergonomics No need to rotate the tool, no bowing Lower total ownership costPULL DMC OVER THE ROLLERSTransmission line construction specialists recognize the time and costsassociated with temporary joints used to pull cables through the rollers. Theneed for access roads or helicopters to install permanent splices can add 1,000,000 to your projectfor every 100 splices! DMCPower's Swage design allowsfor splices to run OVER theroller during installationwithout impacting spliceperformance -- just Swageyour reels together and startstringing!www.dmcpower.com41
COMPLETE LINE OF FULL TENSIONDMC Power offers a complete line of Full Tension connectorconfigurations for any Transmission application. Identifyingthe proper base part number is easy - simply replace the "x"in the listed part number with the corresponding letter of theconductor type being used. See page 53 for complete partordering information.CONDUCTOR CODESFULL TENSION CONNECTORSDB AACDC ACSRDJ ACSSDL ACSS TW Equal AreaDN Static WireDQ ACSS TW Equal DiameterEXAMPLEAAC (DB) Single Pad Deadend (Dx99) DB99Dx99SINGLE PAD DEADENDUp toPads765kV2"/3"/4"ANGLESEHV Kit includes Bolt Package and Jumper Terminal 2-Stage Connector Dx79Dx98DEADENDUp to765kVEHV Includes Deadend only For use with Tees (Dx93) or Taps (Dx92) 2-Stage Connector Dx78Dx97DUAL PAD DEADENDUp toPads765kV2"/3"/4"ANGLESEHV Kit includes two Bolt Packages andtwo Jumper Terminals 2-Stage Connector Dx77Dx96SPLICE CONNECTORUp to765kVEHV Superior sheave performance Save installation time and money by going over the roller 2-Stage Connector Dx7642888-SWAGE-NOW
Dx89Dx88SINGLE PADADJUSTABLE DEADENDUp toPads765kV2"/3"/4"ADJUSTABLEDEADENDUp toANGLES765kVEHVEHV Kit includes Bolt Package and Jumper Terminal 2-Stage Connector Dx69 Includes Deadend only For use with Tees (Dx93) or Taps (Dx92) 2-Stage Connector Dx68Dx87DN79DUAL PAD ADJUSTABLEDEADENDUp toPads765kV2"/3"/4"SINGLE PAD STATICWIRE DEADENDUp toANGLES765kVEHVANGLESEHVDx92Dx93TAPSUp toPads765kV2"/3"/4"TEESUp toSPLITANGLESEHV765kVSPLITANGLESEHV Split fitting design slides easily over existing cable Custom pad sizes and configurations available Split fitting design slides easily over existing cable Any size cable and configuration availableDx94Dx95 Connects to Deadend NEMApads to keep the current flowing Standard and custom angles available Jumper Terminal included with Deadendorders or available separately Provides a lifelong Swage connection forweak points in cable runs Split fitting design slides easily overexisting cablePLK8000DPFT8014 Bolts directly onto existingNEMA Pad to smooth out the electric fieldprofile created by sharp edges Can be used at high altitude, coastal orindustrial areas for added protection Included with all EHV Deadend orders Kit contains 4 Bolts, Washers and Nuts One standard kit included per Deadendand Jumper Terminal orderJUMPER TERMINALSEHV BOLT SHIELDSwww.dmcpower.comFULL TENSION CONNECTORS Kit includes two Bolt Packages and twoJumper Terminals 2-Stage Connector Dx67 Kit includes Bolt Package and Jumper Terminal Static Wire Splice (DN76), Deadend (DN78) and DualPad Deadend (DN77) also availableREPAIR SLEEVESMOUNTINGHARDWARE43
AAC CABLE SELECTOR CHART Step 1:Select your base connector styleDEADENDAAC1 PADNO PAD2 PADADJUSTABLE1 PADADJUSTABLENO PADADJUSTABLE2 AIRLOOPREDUCERDB96DB95DB91DB90 Steps 2 & 3:44JUMPER TERMINALFind the AAC Conductor you're using and select the correspondingouter aluminum BARREL DIE # and CABLE CODE #AACSIZE(kcmil)STRCABLE ODBARRELDIE #CABLECODE AGE-NOW
AAC CABLE SELECTOR CHARTAAC SIZE(kcmil)STRCABLE ODBARRELDIE #CABLECODE uebonnet35001272.15832585HANG TRANSMISSION CABLE IN SECONDS WITH JUST 4 STEPS:2. SWAGE1. INSERT3. INSPECTwww.dmcpower.com4. CONNECT45
ACSRAAC CABLECABLESELECTORSELECTORCHARTCHART Step 1:Select your base connector styleDEADENDJUMPER TERMINAL1 PADNO PAD2 PADADJUSTABLE1 PADACSR Single StageDC99DC98DC97DC89DC88DC87ACSR Two ESSTANDARD REPAIRACSR Single StageDC96ACSR Two StageDC76 Step 2 & 3:DC95LOOPDC91REDUCERDC90DC70ADJUSTABLE ADJUSTABLE SINGLEDOUBLENO PAD2 PADTERMINAL TERMINALDC94DC84Find the ACSR Conductor you're using and select the correspondingouter aluminum BARREL DIE # and Single or Two Stage CABLE CODE #(NOTE: Internal Die # required for 2-Stage installation but not used to build the part number)1 & 2-STAGE46CABLE CODE #ACSRSIZE(kcmil)STR(Al/St)CABLEODBARRELDIE /10.9401753030Swift63636/10.93017532322-STAGE ONLYINTERNALCORE DIE #N/A063075088075088075888-SWAGE-NOW
ACSRAAC CABLECABLESELECTORSELECTORCHARTCHART1 & 2-STAGECABLE CODE #ACSRSIZE(kcmil)STR(Al/St)CABLEODBARRELDIE 484www.dmcpower.com2-STAGE ONLYINTERNALCORE DIE #088100088100088100100113N/A12547
ACSSAAC CABLECABLESELECTORSELECTORCHARTCHART Step 1: Select your base connector styleDEADENDACSSJUMPER TERMINAL1 PADNO PAD2 PADADJUSTABLE1 PADDJ79DJ78DJ77DJ69ADJUSTABLENO PADADJUSTABLE2 J76DJ95DJ91DJ70 Step 2 & 3: Find the ACSS Conductor you’re using and select the correspondingouter aluminumBARREL DIE #andCABLE CODE #(NOTE: Internal Die # required for 2-Stage installation but not used to build the part number)ACSSSIZE(kcmil)STR(Al/St)CABLE ODBARREL DIE #CABLECODE NTERNALCORE DIE #063075088088100088100THERMAL MECHANICAL ACSS TESTINGOur ACSS line of high temperature Deadends andSplices have been independently tested to the rigorousinternational standards of CIGRE TB 426. Accordingly,samples were subjected to 500 current cycles at 250 Cwith 25% RBS constant tension including 5 separatesustained holds at 70% RBS for 24 hours. All DMC Powerconnectors passed easily with the post-aging tensionedconductor breaking at a remarkable 103% RBS.48888-SWAGE-NOW
ACSSAAC )STR(Al/St)CABLE ODBARREL DIE #CABLECODE 3527584INTERNALCORE DIE #100113125RUN COOLER, LONGERDuring ANSI C119.4 type testing, DMC Power ACSSDeadends and Splices showed superior resistancestability on all samples through 500 thermal cyclesat 250 C-285 C above room temperature. Additionalextreme temperature cycling to 325 C was performedfor 280 more cycles with all samples averaging 50%cooler than the control and the post-aging tensile loadyielding 104% RBS.www.dmcpower.com49
AACACSSCABLETWSELECTORCABLE CHARTCHART ACSS/TW Equal Area size chart is listed belowACSS/TW Equal Diameter and Static Wire are on the following page Step 1: Select your base connector styleDEADENDJUMPER TERMINAL1 PADNO PAD2 PADADJUSTABLE1 PADADJUSTABLENO PADADJUSTABLE2 PADSINGLETERMINALDOUBLETERMINALACSS TW - EADL79DL78DL77DL69DL68DL67DL94
to all industry standards including ANSI C119.4 Class "AA" current cycling on our Single Stage system, establishing us as the only "High Temperature" Single Stage system option. Additional Thermal/Mechanical testing of our Single Stage "One Die" ACSR fittings at an elevated temperature of 150 C and 25% tension showed that all of our test samples
