• copper welding - klk · copper aluminothermic welding 12 7.1 cable / cable v1. 2013 1 see mould...

• COPPER WELDING

7. Copper alumino-thermic welding _________________________ 4 7.1 Cable / Cable _____________________________________ 12

7.2 Cable / Earth rod __________________________________ 23

7.3 Earth rod / Earth rod _______________________________ 28

7.4 Cable / Steel re-bar ________________________________ 29

7.5 Cable / Steel surface ______________________________ 35 7.6 Cable / Steel pipe _________________________________ 43

7.7 Cable / Bus bar ___________________________________ 44

7.8 Bus bar / Bus bar _________________________________ 54

7.9 LsVIP and ELPA TUBO _____________________64 and 67

- Lid that prevents spattering.

- Lid that reduces the smoke emission.

- Remote ignition device and versatil ignition system.

- Advantages of these NEW procedures.

7. COPPER ALUMINOTHERMIC WELDING

KLK-WELD PROCEDURE

The KLK-WELD process utilizes the high temperature of the reaction between copper oxide and aluminium. The reaction takes place in a graphite mould-crucible, into which the pieces to be welded have been inserted; the melted metal from the aluminothermic reaction fl ows over the pieces, causing them to melt and fuse into a solid homogeneous mass.

The reaction is so quick that the pieces to be welded get a lower temperature, on the zone around the welding point, than that arising when using other process. This is an important fact for protecting insulated cables or the physical characteristics of the pieces to be welded.

The KLK-WELD process may also be used in addition to welding copper to

copper,Eg. connections between copper and other materials.

C

KLK-WELD CONNECTION

The KLK-WELD connection is a perfect molecular weld and not just a mechanical contact. The alloy used has practically the same fusion temperature as that of copper and usually has a section double than that of the conductors to be welded, therefore:

· Connections are not affected by high current surges. Tests have shown that the electrical conductors will melt before the connection when subject to high short-circuit current.

· Connection conductivity is at least equal or greater than the conductors welded.

· There is no possibility of corrosion at the point of the weld, since the conductors become an integral part of the connection.

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KLK-WELD MOULD

KLK-WELD CARTRIDGES AND DISCS

Each plastic container holds the aluminothermic powder at one end (coloured cover)and the starting powder at the other one (black cover). The disc is used to seal the tap hole before depositing the load.

Mould cover

Starting powder

Aluminothermic powder

Metallic disc

Tap hole

Welding cavity

Lower cover, black coloured

Starting powder

Aluminothermic powder

Upper cover, coloured according to cartridge size

Cables

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

COLOUR LIGHT GREY GREY PURPLE WHITE YELLOW ORANGE RED BROWN BLUE GREEN

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


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KLK-WELD EQUIPMENT

The KLK-WELD equipment is light and portable and requires no outside power source, this being useful for fi eld use. It requires very little time or skill to get top quality connections.

MOULDS:

The moulds are manu-factured from a heat-re-sistant material (graphi-te) block that lasts for an average of 70-100 con-nections under normal conditions of use.

The metallic cover pro-tects from the reaction projections.

FLINT IGNITER:

Used to ignite the igni-tion powder. It takes nor-mal lighter fl ints as spare parts.

HANDLE CLAMPS TSC:

CARDCLOTH BRUSH:

MOULD BRUSH:

They are designed to handle the moulds allowing to open and clo-se them safely.

There are three types of handle clamps depen-ding on the Mould size: TSC 50, TSC-80 and TSC-100.

Used for the correct clea-ning of cables to welded.

For cleaning the interior of the mould after each weld.

HANDLE CLAMP MS:

It is designed to fi t Moulds manufactured from a so-lid piece of graphite, spe-cially those used to weld steel pieces.

MOULD SCRAPER:

Its shape is specially de-signed to clean the mould loading hopper.

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TABLES OF CABLES, BUS-BARS AND EARTH RODS

The moulds are cut to fi t the type and size of copper conductors, concrete steel re-bars and earth rods shown on these tables. For any other type and/or size, it is necessary to confi rm the actual overall diameter.

SECTION mm² COMPOSITION Ø EXTERIOR mm.

10 7 x 1,35 4,05

16 7 x 1,70 5,10

25 7 x 2,14 6,42

35 7 x 2,52 7,56

50 19 x 1,83 9,15

70 19 x 2,17 10,85

95 19 x 2,52 12,60

120 19 x 2,85 14,25

150 37 x 2,25 15,75

185 37 x 2,52 17,64

235 37 x 2,85 19,95

300 61 x 2,62 22,68

400 61 x 2,85 25,65

COPPER CONDUCTORS (UNE 21012)

COPPER-STEEL EARHT RODS CONCRETE STEEL RE-BARSEARTH ROD TYPE Ø EXTERIOR mm.

J - ...58 14,3

J - ...34 17,3

...NU 146 14,6

...NU 183 18,3

...ST 143 14,3

Ø NOMINAL Ø EXTERIOR mm.

6 7,2

8 9,6

10 12,0

12 14,4

14 16,8

16 192

20 24,0

25 30,0


PREPARATION OF MATERIAL

PREPARATION OF THE CABLES

To achieve a perfect weld the cable must be clean, dry and well fi tting.

Cables treated with oil or grease must be cleaned with a degreaser (preferably a quick drying and non residual solvent). In extreme cases heat the conductor with a welding torch to remove grease and oil completely.

Rusty cables must be polished with a cardclothbrush.

A moist or muddy conductor will cause a porous weld and molten metal outside the mould. Conductors must be dried with a welding torch and then all mud removed.

Badly-cut or fi tted conductors will prevent the mould from closing properly, causing molten metal to spill.PREPARACIÓN DE LAS PICAS DE PUESTA A TIERRA

PREPARATION OF THE STEEL SURFACES

Steel surface must be rust free and perfectly clean and fl at.

· Rust fi lm, paint, grease or dust must be cleaned off with a grinder.

· Remove moisture with a welding torch.

· Galvanized surfaces may be cleaned without needing to remove the zinc coating.

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PREPARATION OF THE EARTH RODS

Earth rod end on which the weld is to be done must be perfectly clean, dry and without any deformation.

PREPARATION OF THE GRAPHITE MOULD

Moisture in moulds will cause a porous weld. Moulds must be perfectly dry before making a weld.

For making proper coneections, warm the mould before starting the fi rst weld with a welding torch or ignite a cartridge to get the mould over 100º C. When using a cartridge be careful to avoid handle clamp damage due to molten metal leaking.

Generated heat will maintain the mould at the appropiate temperature for the next weld. If delays among welds cause temperature to fall the mould drying process must be started again.

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Remove the insulation-

from the cable on a length of 15 cm. when using in-sulated cable. Using the cardclothbrush brush the cable and the rod end to remove all the dust and oxides.

Before starting the fi rst weld pre-heat the graphi-te mould which the wel-ding torch during at least 5 minutes. This operation is very important because moisture in moulds will cause a porous weld.

Open the mould by se-parating the two arms of the handle clamp. Cable must sit on top of rod.Support mould to keep it from sliding down the rod when welding. Use lock pliers or clamp on rod below mould.

Close securely the mould with the handle clamp to avoid molten metal los-ses.

Place the metallic disc, conical side to bottom, on tap hole.

Open coloured cover of the cartridge size shown on the mould tag and pour.

Open black cover of the cartridge and spread all the starting powder on the welding powder and on the top edge of the mould, under open cover, for easy ignition.

Close the mould cover and placing the fl int igni-tor from aside ignite the starting powder.

It is advisable, once the ignition takes place, to pull away the fl int igniter quickly to avoid its dama-ge.

Wait one minute to open the mould handle clamp.

Open completely, to re-move the welded connec-tion.

Remove slag from the-crucible and tap hole with the mould scraper. Re-move dust from the weld cavity,tap hole, crucible and mould cover with the mouldbrush. If the mould is still warm,you can go on the welding process without pre-heating it again.

KLK-WELD PROCEDURE


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STANDARD CONNECTIONS

CABLE / CABLE

CABLE / EARTH ROD

CABLE / RE - BAR

EARTH ROD /

EARTH ROD

CR-PHCR-TL

CR-TP

CR-TH

CR-PV

CR-XS

CC-L CC-TH

CC-DPH

CC-TV

CC-X CC-XS

PP-V

CP-ARCP-TS

CP-T

CP-V CP-VS

CC-L CC-TH CC-TV

CC-DPH CC-X CC-XS

PP-VCP-VSCP-V

CP-AR

CR-XS CR-TH

CR-PH CR-PV CR-TPCR-TL

CP-T

CP-TS

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STANDARD CONNECTIONS

CABLE /

STEEL SURFACE

CABLE / BUS-BAR CABLE / PIPE

BUS-BAR / BUS-BAR

PL-LVPL-ARI

PL-TVPL-V

PL-TS PL-DPPL-TH

PL-LH

PL-X

CT-TH

CH-TH

CH-PHH

CH-TF

CH-PVHCH-TVDCH-TVI CH-PVVCH-VS

CH-VI

CPL-LCPL-T

CPL-H

CPL-VS

CPL-VI

CH-TF

CH-VICH-TH

CH-TVD

CH-TVICH-PHH CH-PVH CH-VS CH-PVV

CPL-VI

CPL-VS

CPL-H

CPL-T CPL-L

PL-LVPL-ARI PL-V

PL-LH

PL-TV

PL-TH PL-TS PL-X PL-DP

CT-TH

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7.1 CABLE / CABLE

V1.

201

31

See mould price key on tariff.

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 CC-L

DIMENSIONCABLE (mm²)

MAIN TAP CABLEMOULD

(PART. No.)CARTRIDGE CLAMP SCRAPER

PRICEKEY FORMOULDS

25 25 CC-L 25 C-32* TSC-80 R-45

A

3525 CC-L 35/25 C-45* TSC-80 R-45

35 CC-L 35 C-45* TSC-80 R-45

50

25 CCL 50/25 C-45* TSC-80 R-45

35 CC-L 50/35 C-45* TSC-80 R-45

50 CC-L 50 C-45* TSC-80 R-45

70

25 CC-L 70/25 C-45* TSC-80 R-45

35 CC-L 70/35 C-45* TSC-80 R-45

50 CC-L 70/50 C-65 TSC-80 R-45

70 CC-L 70 C-65 TSC-80 R-45

95

25 CC-L 95/25 C-65 TSC-80 R-45

35 CC-L 95/35 C-65 TSC-80 R-45

50 CC-L 95/50 C-90 TSC-80 R-90

70 CC-L 95/70 C-90 TSC-80 R-90

95 CC-L 95 C-90 TSC-80 R-90

120

25 CC-L 120/25 C-65 TSC-80 R-90

35 CC-L 120/35 C-65 TSC-80 R-90

50 CC-L 120/50 C-90 TSC-80 R-90

70 CC-L 120/70 C-90 TSC-80 R-90

95 CC-L 120/95 C-90 TSC-80 R-90

120 CC-L 120 C-115 TSC-80 R-90

150

25 CC-L 150/25 C-90 TSC-80 R-90

35 CC-L 150/35 C-90 TSC-80 R-90

50 CC-L 150/50 C-90 TSC-80 R-90

70 CC-L 150/70 C-90 TSC-80 R-90

95 CC-L 150/95 C-115 TSC-80 R-90

120 CC-L 150/120 C-115 TSC-80 R-90

150 CC-L 150 C-115 TSC-80 R-90

185

25 CC-L 185/25 C-90 TSC-80 R-90

35 CC-L 185/35 C-90 TSC-80 R-90

50 CC-L 185/50 C-90 TSC-80 R-90

70 CC-L 185/70 C-90 TSC-80 R-90

95 CC-L 185/95 C-115 TSC-80 R-90

120 CC-L 185/120 C-150 TSC-80 R-150

150 CC-L 185/150 C-150 TSC-80 R-150

185 CC-L 185 C-150 TSC-80 R-150

240

25 CC-L 240/25 C-90 TSC-80 R-90

35 CC-L 240/35 C-115 TSC-80 R-90

50 CC-L 240/50 C-115 TSC-80 R-90

70 CC-L 240/70 C-115 TSC-80 R-90

95 CC-L 240/95 C-150 TSC-80 R-150

120 CC-L 240/120 C-150 TSC-80 R-150

150 CC-L 240/150 C-200 TSC-80 R-150

185 CC-L 240/185 C-200 TSC-80 R-150

240 CC-L 240 C-200 TSC-80 R-150

OPERATINGINSTRUCTIONS

For 240mm²cables or more,

separate the points inthe centre by (S) 5-6mm. approximately.

S

Possibility of using mini moulds for cartridges C-45 or smaller, with clamp TSC-50 and scrapper R-M.

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7.1 CABLE / CABLE

V1.

201

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CONNECTION CC-TH (1 OF 2)


MAIN TAP CABLEMOULD


PRICEKEY FORMOULDS

25

25 CC-TH 25/25 C-45* TSC-80 R-45

A

35 CC-TH 25/35 C-45* TSC-80 R-45

50 CC-TH 25/50 C-45* TSC-80 R-45

35

25 CC-TH 35/25 C-45* TSC-80 R-45

35 CC-TH 35/35 C-45* TSC-80 R-45

50 CC-TH 35/50 C-65 TSC-80 R-45

70 CC-TH 35/70 C-65 TSC-80 R-45

50

25 CC-TH 50/25 C-65 TSC-80 R-45

35 CC-TH 50/35 C-65 TSC-80 R-45

50 CC-TH 50/50 C-90 TSC-80 R-90

70 CC-TH 50/70 C-90 TSC-80 R-90

95 CC-TH 50/95 C-90 TSC-80 R-90

70

25 CC-TH 70/25 C-65 TSC-80 R-45

35 CC-TH 70/35 C-65 TSC-80 R-45

50 CC-TH 70/50 C-90 TSC-80 R-90

70 CC-TH 70/70 C-90 TSC-80 R-90

95 CC-TH 70/95 C-90 TSC-80 R-90

120 CC-TH 70/120 C-115 TSC-80 R-90

95

25 CC-TH 95/25 C-90 TSC-80 R-90

35 CC-TH 95/35 C-90 TSC-80 R-90

50 CC-TH 95/50 C-90 TSC-80 R-90

70 CC-TH 95/70 C-90 TSC-80 R-90

95 CC-TH 95/95 C-115 TSC-80 R-90

120 CC-TH 95/120 C-115 TSC-80 R-90

150 CC-TH 95/150 C-115 TSC-80 R-90

120

25 CC-TH 120/25 C-90 TSC-80 R-90

35 CC-TH 120/35 C-90 TSC-80 R-90

50 CC-TH 120/50 C-90 TSC-80 R-90

70 CC-TH 120/70 C-115 TSC-80 R-90

95 CC-TH 120/95 C-115 TSC-80 R-90

120 CC-TH 120/120 C-150 TSC-80 R-150

150 CC-TH 120/150 C-150 TSC-80 R-150

185 CC-TH 120/185 C-200 TSC-80 R-150


For 240 mm² and largerseparate cables (S) 5-6

mm under the centre of the tap hole.

S


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7.1 CABLE / CABLEV

1. 2

013

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CONNECTION CC-TH (MM²) (2 OF 2)

MAIN TAP CABLEMOULD


PRICEKEY FORMOULDS

150

25 CC-TH 150/25 C-90 TSC-80 R-90

A

35 CC-TH 150/35 C-115 TSC-80 R-90

50 CC-TH 150/50 C-115 TSC-80 R-90

70 CC-TH 150/70 C-115 TSC-80 R-90

95 CC-TH 150/95 C-115 TSC-80 R-90

120 CC-TH 150/120 C-150 TSC-80 R-150

150 CC-TH 150/150 C-200 TSC-80 R-150

185 CC-TH 150/185 C-200 TSC-80 R-150

240 CC-TH 150/240 C-200 TSC-80 R-150

185

25 CC-TH 185/25 C-115 TSC-80 R-90

35 CC-TH 185/35 C-115 TSC-80 R-90

50 CC-TH 185/50 C-115 TSC-80 R-90

70 CC-TH 185/70 C-150 TSC-80 R-150

95 CC-TH 185/95 C-150 TSC-80 R-150

120 CC-TH 185/120 C-200 TSC-80 R-150

150 CC-TH 185/150 C-200 TSC-80 R-150

185 CC-TH 185/185 C-200 TSC-80 R-150

240 CC-TH 185/240 C-250 TSC-80 R-150

240

25 CC-TH 240/25 C-115 TSC-80 R-90

35 CC-TH 240/35 C-115 TSC-80 R-90

50 CC-TH 240/50 C-150 TSC-80 R-150

70 CC-TH 240/70 C-150 TSC-80 R-150

95 CC-TH 240/95 C-200 TSC-80 R-150

120 CC-TH 240/120 C-200 TSC-80 R-150

150 CC-TH 240/150 C-200 TSC-80 R-150

185 CC-TH 240/185 C-250 TSC-80 R-150

240 CC-TH 240/240 2 x C-150 TSC-80 R-150


For 240 mm² and larger,separate (S) 5-6 mm.

From the run cable.

S


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7.1 CABLE / CABLE

V1.

201

34



CONNECTION CC-TV (1 OF 2)


MAIN TAP CABLEMOULD


PRICEKEY FORMOULDS

25

25 CC-TV 25 C-45* TSC-80 R-45

A

35 CC-TV 25/35 C-45* TSC-80 R-45

50 CC-TV 25/50 C-45* TSC-80 R-45

35

25 CC-TV 35/25 C-45* TSC-80 R-45

35 CC-TV 35/35 C-45* TSC-80 R-45

50 CC-TV 35/50 C-65 TSC-80 R-45

70 CC-TV 35/70 C-65 TSC-80 R-45

50

25 CC-TV 50/25 C-45* TSC-80 R-45

35 CC-TV 50/35 C-65 TSC-80 R-45

50 CC-TV 50/50 C-90 TSC-80 R-90

70 CC-TV 50/70 C-90 TSC-80 R-90

95 CC-TV 50/95 C-90 TSC-80 R-90

70

25 CC-TV 70/25 C-65 TSC-80 R-45

35 CC-TV 70/35 C-65 TSC-80 R-45

50 CC-TV 70/50 C-90 TSC-80 R-90

70 CC-TV 70/70 C-90 TSC-80 R-90

95 CC-TV 70/95 C-90 TSC-80 R-90

120 CC-TV 70/120 C-115 TSC-80 R-90

95

25 CC-TV 95/25 C-90 TSC-80 R-90

35 CC-TV 95/35 C-90 TSC-80 R-90

50 CC-TV 95/50 C-90 TSC-80 R-90

70 CC-TV 95/70 C-90 TSC-80 R-90

95 CC-TV 95 C-115 TSC-80 R-90

120 CC-TV 95/120 C-115 TSC-80 R-90

150 CC-TV 95/150 C-115 TSC-80 R-90

120

25 CC-TV 120/25 C-90 TSC-80 R-90

35 CC-TV 120/35 C-90 TSC-80 R-90

50 CC-TV 120/50 C-90 TSC-80 R-90

70 CC-TV 120/70 C-115 TSC-80 R-90

95 CC-TV 120/95 C-115 TSC-80 R-90

120 CC-TV 120 C-150 TSC-80 R-150

150 CC-TV 120/150 C-150 TSC-80 R-150

185 CC-TV 120/185 C-150 TSC-80 R-150S


Cut run cable andseparate (S) 5-6 mm

under the centre of thetap hole. But the tap

cable against run cable.

Possibility of using mini moulds for cartridges C-45 or smaller, with clamp TSC-50 and scrapper R-M..

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7.1 CABLE / CABLEV

1. 2

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CONNECTION CC-TV (MM²) (2 OF 2)

MAIN TAP CABLEMOULD


PRICEKEY FORMOULDS

150

25 CC-TV 150/25 C-90 TSC-80 R-90

A

35 CC-TV 150/35 C-115 TSC-80 R-90

50 CC-TV 150/50 C-115 TSC-80 R-90

70 CC-TV 150/70 C-115 TSC-80 R-90

95 CC-TV 150/95 C-115 TSC-80 R-90

120 CC-TV 150/120 C-150 TSC-80 R-150

150 CC-TV 150/150 C-200 TSC-80 R-150

185 CC-TV 150/185 C-200 TSC-80 R-150

240 CC-TV 150/240 C-200 TSC-80 R-150

185

25 CC-TV 185/25 C-115 TSC-80 R-90

35 CC-TV 185/35 C-115 TSC-80 R-90

50 CC-TV 185/50 C-115 TSC-80 R-90

70 CC-TV 185/70 C-150 TSC-80 R-150

95 CC-TV 185/95 C-150 TSC-80 R-150

120 CC-TV 185/120 C-150 TSC-80 R-150

150 CC-TV 185/150 C-200 TSC-80 R-150

185 CC-TV 185/185 C-200 TSC-80 R-150

240 CC-TV 185/240 C-250 TSC-80 R-150

240

25 CC-TV 240/25 C-115 TSC-80 R-90

35 CC-TV 240/35 C-115 TSC-80 R-90

50 CC-TV 240/50 C-150 TSC-80 R-150

70 CC-TV 240/70 C-150 TSC-80 R-150

95 CC-TV 240/95 C-200 TSC-80 R-150

120 CC-TV 240/120 C-200 TSC-80 R-150

150 CC-TV 240/150 C-200 TSC-80 R-150

185 CC-TV 240/185 C-250 TSC-80 R-150

240 CC-TV 240/240 2 x C-150 TSC-80 R-150

S


Cut run cable andseparate (S) 5-6 mm

under the centre of thetap hole. But the tap

cable against run cable.


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7.1 CABLE / CABLE

V1.

201

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CONNECTION CC-DPH (1 OF 2)


MAIN TAP CABLEMOULD


PRICEKEY FORMOULDS

25

25 CC-DPH 25 C-65 TSC-80 R-45

A

35 CC-DPH 25/35 C-65 TSC-80 R-45

50 CC-DPH 25/50 C-90 TSC-80 R-90

70 CC-DPH 25/70 C-90 TSC-80 R-90

95 CC-DPH 25/95 C-90 TSC-80 R-90

120 CC-DPH 25/120 C-115 TSC-80 R-90

35

25 CC-DPH 35/25 C-65 TSC-80 R-45

35 CC-DPH 35 C-90 TSC-80 R-90

50 CC-DPH 35/50 C-90 TSC-80 R-90

70 CC-DPH 35/70 C-90 TSC-80 R-90

95 CC-DPH 35/95 C-115 TSC-80 R-90

120 CC-DPH 35/120 C-115 TSC-80 R-90

150 CC-DPH 35/150 C-115 TSC-80 R-90

50

25 CC-DPH 50/25 C-90 TSC-80 R-90

35 CC-DPH 50/35 C-90 TSC-80 R-90

50 CC-DPH 50/50 C-90 TSC-80 R-90

70 CC-DPH 50/70 C-90 TSC-80 R-90

95 CC-DPH 50/95 C-115 TSC-80 R-90

120 CC-DPH 50/120 C-150 TSC-80 R-150

150 CC-DPH 50/150 C-150 TSC-80 R-150

185 CC-DPH 50/185 C-150 TSC-80 R-150 C

70

25 CC-DPH 70/25 C-90 TSC-80 R-90

A

35 CC-DPH 70/35 C-90 TSC-80 R-90

50 CC-DPH 70/50 C-90 TSC-80 R-90

70 CC-DPH 70/70 C-115 TSC-80 R-90

95 CC-DPH 70/95 C-150 TSC-80 R-150

120 CC-DPH 70/120 C-150 TSC-80 R-150

150 CC-DPH 70/150 C-200 TSC-80 R-150

185 CC-DPH 70/185 C-200 TSC-80 R-150 C

240 CC-DPH 70/240 C-250 TSC-100 R-750 E

95

25 CC-DPH 95/25 C-90 TSC-80 R-90

A

35 CC-DPH 95/35 C-115 TSC-80 R-90

50 CC-DPH 95/50 C-115 TSC-80 R-90

70 CC-DPH 95/70 C-150 TSC-80 R-150

95 CC-DPH 95/95 C-150 TSC-80 R-150

120 CC-DPH 95/120 C-200 TSC-80 R-150

150 CC-DPH 95/150 C-200 TSC-80 R-150

185 CC-DPH 95/185 C-250 TSC-80 R-150 C

240 CC-DPH 95/240 2xC-150 TSC-100 R-750 E


Place cables according to the sketch below.

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7.1 CABLE / CABLEV

1. 2

013

7



CONNECTION CC-DPH (MM²) (2 OF 2)

MAIN TAP CABLEMOULD


PRICEKEY FORMOULDS

120

25 CC-DPH 120/25 C-115 TSC-80 R-90

A

35 CC-DPH 120/35 C-115 TSC-80 R-90

50 CC-DPH 120/50 C-150 TSC-80 R-150

70 CC-DPH 120/70 C-150 TSC-80 R-150

95 CC-DPH 120/95 C-200 TSC-80 R-150

120 CC-DPH 120/120 C-200 TSC-80 R-150

150 CC-DPH 120/150 C-200 TSC-80 R-150

185 CC-DPH 120/185 C-250 TSC-80 R-150 C

240 CC-DPH 120/240 2xC-150 TSC-100 R-750 E

150

35 CC-DPH 150/35 C-115 TSC-80 R-90

A

50 CC-DPH 150/50 C-150 TSC-80 R-150

70 CC-DPH 150/70 C-200 TSC-80 R-150

95 CC-DPH 150/95 C-200 TSC-80 R-150

120 CC-DPH 150/120 C-250 TSC-80 R-150

150 CC-DPH 150/150 C-250 TSC-80 R-150

185 CC-DPH 150/185 2xC-150 TSC-80 R-150

240 CC-DPH 150/240 2xC-200 TSC-100 R-750 E

185

35 CC-DPH 185/35 C-200 TSC-80 R-150

C

50 CC-DPH 185/50 C-250 TSC-80 R-150

70 CC-DPH 185/70 C-200 TSC-80 R-150

95 CC-DPH 185/95 C-250 TSC-80 R-150

120 CC-DPH 185/120 C-250 TSC-80 R-150

150 CC-DPH 185/150 C-250 TSC-80 R-150

185 CC-DPH 185/185 C-250 TSC-80 R-150

240 CC-DPH 185/240 2xC-150 TSC-100 R-750

E240

50 CC-DPH 240/50 C-200 TSC-100 R-750

70 CC-DPH 240/70 C-250 TSC-100 R-750

95 CC-DPH 240/95 2xC-150 TSC-100 R-750

120 CC-DPH 240/120 2xC-150 TSC-100 R-750

150 CC-DPH 240/150 2xC-200 TSC-100 R-750

185 CC-DPH 240/185 2xC-150 TSC-100 R-750

240 CC-DPH 240/240 2xC-250 TSC-100 R-750


Place cables according to the sketch below.

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19

7.1 CABLE / CABLE

V1.

201

38



CONNECTION CC-X (1 OF 2)


MAIN TAP CABLEMOULD


PRICEKEY FORMOULDS

25

25 CC-X 25/25 C-65 TSC-80 R-45

A

35 CC-X 25/35 C-65 TSC-80 R-45

50 CC-X 25/50 C-90 TSC-80 R-90

70 CC-X 25/70 C-90 TSC-80 R-90

95 CC-X 25/95 C-90 TSC-80 R-90

120 CC-X 25/120 C-115 TSC-80 R-90

35

25 CC-X 35/25 C-65 TSC-80 R-45

35 CC-X 35/35 C-90 TSC-80 R-90

50 CC-X 35/50 C-90 TSC-80 R-90

70 CC-X 35/70 C-90 TSC-80 R-90

95 CC-X 35/95 C-115 TSC-80 R-90

120 CC-X 35/120 C-115 TSC-80 R-90

150 CC-X 35/150 C-115 TSC-80 R-90

50

25 CC-X 50/25 C-90 TSC-80 R-90

35 CC-X 50/35 C-90 TSC-80 R-90

50 CC-X 50/50 C-90 TSC-80 R-90

70 CC-X 50/70 C-90 TSC-80 R-90

95 CC-X 50/95 C-115 TSC-80 R-90

120 CC-X 50/120 C-150 TSC-80 R-150

150 CC-X 50/150 C-150 TSC-80 R-150

185 CC-X 50/185 C-150 TSC-80 R-150

70

25 CC-X 70/25 C-90 TSC-80 R-90

35 CC-X 70/35 C-90 TSC-80 R-90

50 CC-X 70/50 C-90 TSC-80 R-90

70 CC-X 70/70 C-115 TSC-80 R-90

95 CC-X 70/95 C-150 TSC-80 R-150

120 CC-X 70/120 C-150 TSC-80 R-150

150 CC-X 70/150 C-200 TSC-80 R-150

185 CC-X 70/185 C-200 TSC-80 R-150

240 CC-X 70/240 C-200 TSC-100 R-750 E

95

25 CC-X 95/25 C-90 TSC-80 R-90

A

35 CC-X 95/35 C-115 TSC-80 R-90

50 CC-X 95/50 C-115 TSC-80 R-90

70 CC-X 95/70 C-150 TSC-80 R-150

95 CC-X 95/95 C-150 TSC-80 R-150

120 CC-X 95/120 C-200 TSC-80 R-150

150 CC-X 95/150 C-200 TSC-80 R-150

185 CC-X 95/185 C-200 TSC-80 R-150

240 CC-X 95/240 C-250 TSC-100 R-750 E


Cut the larger cableand butt the ends

against the smaller one.

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20

7.1 CABLE / CABLEV

1. 2

013

9



CONNECTION CC-X (MM²) (2 OF 2)

MAIN TAP CABLEMOULD


PRICEKEY FORMOULDS

120

25 CC-X 120/25 C-115 TSC-80 R-90

A

35 CC-X 120/35 C-115 TSC-80 R-90

50 CC-X 120/50 C-150 TSC-80 R-150

70 CC-X 120/70 C-150 TSC-80 R-150

95 CC-X 120/95 C-200 TSC-80 R-150

120 CC-X 120/120 C-200 TSC-80 R-150

150 CC-X 120/150 C-200 TSC-80 R-150

185 CC-X 120/185 C-250 TSC-80 R-150

240 CC-X 120/240 2xC-150 TSC-100 R-750 E

150

35 CC-X 150/35 C-115 TSC-80 R-90

A

50 CC-X 150/50 C-150 TSC-80 R-150

70 CC-X 150/70 C-200 TSC-80 R-150

95 CC-X 150/95 C-200 TSC-80 R-150

120 CC-X 150/120 C-200 TSC-80 R-150

150 CC-X 150/150 C-250 TSC-80 R-150

185 CC-X 150/185 2xC-150 TSC-80 R-150

240 CC-X 150/240 2xC-200 TSC-100 R-750 E

185

35 CC-X 185/35 C-200 TSC-80 R-150

A

50 CC-X 185/50 C-150 TSC-80 R-150

70 CC-X 185/70 C-200 TSC-80 R-150

95 CC-X 185/95 C-250 TSC-80 R-150

120 CC-X 185/120 C-250 TSC-80 R-150

150 CC-X 185/150 2xC-150 TSC-80 R-150

185 CC-X 185/185 C-250 TSC-80 R-150

240 CC-X 185/240 2xC-150 TSC-100 R-750

E240

50 CC-X 240/50 C-200 TSC-100 R-750

70 CC-X 240/70 C-200 TSC-100 R-750

95 CC-X 240/95 C-250 TSC-100 R-750

120 CC-X 240/120 2xC-150 TSC-100 R-750

150 CC-X 240/150 2xC-200 TSC-100 R-750

185 CC-X 240/185 2xC-200 TSC-100 R-750

240 CC-X 240/240 2xC-250 TSC-100 R-750


Cut the larger cableand butt the ends

against the smaller one.

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21

7.1 CABLE / CABLE

V1.

201

310



CONNECTION CC-XS (1 OF 2)


MAIN TAP CABLEMOULD


PRICEKEY FORMOULDS

25

25 CC-XS 25/25 C-90 TSC-80 R-90

B

35 CC-XS 25/35 C-115 TSC-80 R-90

50 CC-XS 25/50 C-115 TSC-80 R-90

70 CC-XS 25/70 C-115 TSC-80 R-90

95 CC-XS 25/95 C-150 TSC-80 R-150

120 CC-XS 25/120 C-150 TSC-80 R-150

150 CC-XS 25/150 C-200 TSC-80 R-150

185 CC-XS 25/185 C-200 TSC-80 R-150

240 CC-XS 25/240 C-200 TSC-80 R-150

35

25 CC-XS 35/25 C-115 TSC-80 R-90

35 CC-XS 35 C-115 TSC-80 R-90

50 CC-XS 35/50 C-115 TSC-80 R-90

70 CC-XS 35/70 C-150 TSC-80 R-150

95 CC-XS 35/95 C-150 TSC-80 R-150

120 CC-XS 35/120 C-200 TSC-80 R-150

150 CC-XS 35/150 C-200 TSC-80 R-150

185 CC-XS 35/185 C-200 TSC-80 R-150

240 CC-XS 35/240 C-250 TSC-80 R-150

50

25 CC-XS 50/25 C-115 TSC-80 R-90

35 CC-XS 50/35 C-115 TSC-80 R-90

50 CC-XS 50/50 C-150 TSC-80 R-150

70 CC-XS 50/70 C-150 TSC-80 R-150

95 CC-XS 50/95 C-200 TSC-80 R-150

120 CC-XS 50/120 C-200 TSC-80 R-150

150 CC-XS 50/150 C-200 TSC-80 R-150

185 CC-XS 50/185 C-250 TSC-80 R-150

240 CC-XS 50/240 2xC-150 TSC-80 R-750

70

35 CC-XS 70/35 C-150 TSC-80 R-150

50 CC-XS 70/50 C-150 TSC-80 R-150

70 CC-XS 70/70 C-200 TSC-80 R-150

95 CC-XS 70/95 C-200 TSC-80 R-150

120 CC-XS 70/120 C-250 TSC-80 R-150

150 CC-XS 70/150 C-250 TSC-80 R-150

185 CC-XS 70/185 2xC-150 TSC-100 R-750E

240 CC-XS 70/240 2xC-200 TSC-100 R-750

95

35 CC-XS 95/35 C-150 TSC-80 R-150

B50 CC-XS 95/50 C-200 TSC-80 R-150

70 CC-XS 95/70 C-200 TSC-80 R-150

95 CC-XS 95/95 C-250 TSC-80 R-150

120 CC-XS 95/120 2xC-150 TSC-100 R-750

E150 CC-XS 95/150 2xC-150 TSC-100 R-750

185 CC-XS 95/185 2xC-150 TSC-100 R-750

240 CC-XS 95/240 2xC-200 TSC-100 R-750


Place the largest cableover the smallest.

Demould carefully not todamage the mould.

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22

7.1 CABLE / CABLEV

1. 2

013

11



CONNECTION CC-XS (MM²) (2 OF 2)

MAIN TAP CABLEMOULD


PRICEKEY FORMOULDS

120

50 CC-XS 120/50 C-200 TSC-80 R-150B

70 CC-XS 120/70 C-250 TSC-80 R-150

95 CC-XS 120/95 2xC-150 TSC-100 R-750

E

120 CC-XS 120/120 2xC-150 TSC-100 R-750

150 CC-XS 120/150 2xC-200 TSC-100 R-750

185 CC-XS 120/185 2xC-250 TSC-100 R-750

240 CC-XS 120/240 2xC-250 TSC-100 R-750

150

50 CC-XS 150/50 C-200 TSC-80 R-150B

70 CC-XS 150/70 C-250 TSC-80 R-150

95 CC-XS 150/95 2xC-150 TSC-100 R-750

E

120 CC-XS 150/120 2xC-200 TSC-100 R-750

150 CC-XS 150/150 2xC-200 TSC-100 R-750

185 CC-XS 150/185 2xC-250 TSC-100 R-750

240 CC-XS 150/240 2xC-250 TSC-100 R-750

185

70 CC-XS 185/70 2xC-150 TSC-100 R-750

95 CC-XS 185/95 2xC-150 TSC-100 R-750

120 CC-XS 185/120 2xC-250 TSC-100 R-750

150 CC-XS 185/150 2xC-250 TSC-100 R-750

185 CC-XS 185/185 2xC-250 TSC-100 R-750


Place the largest cableover the smallest.

Demould carefully not todamage the mould.

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ING

23

7.2 CABLE / ROD

V1.

201

312



CONNECTION CP-AR

DIMENSION

RODCABLE(mm²)

MOULD(PART. No.)

CARTRIDGE CLAMP SCRAPERPRICE

KEY FORMOULDS

143

25 CP-AR 143/25 C-65 TSC-80 R-45

A

35 CP-AR 143/35 C-65 TSC-80 R-4550 CP-AR 143/50 C-90 TSC-80 R-9070 CP-AR 143/70 C-90 TSC-80 R-9095 CP-AR 143/95 C-90 TSC-80 R-90120 CP-AR 143/120 C-90 TSC-80 R-90150 CP-AR 143/150 C-115 TSC-80 R-90185 CP-AR 143/185 C-115 TSC-80 R-90240 CP-AR 143/240 C-150 TSC-80 R-150

146

25 CP-AR 146/25 C-65 TSC-80 R-4535 CP-AR 146/35 C-65 TSC-80 R-4550 CP-AR 146/50 C-90 TSC-80 R-9070 CP-AR 146/70 C-90 TSC-80 R-9095 CP-AR 146/95 C-90 TSC-80 R-90120 CP-AR 146/120 C-90 TSC-80 R-90150 CP-AR 146/150 C-115 TSC-80 R-90185 CP-AR 146/185 C-115 TSC-80 R-90240 CP-AR 146/240 C-150 TSC-80 R-150

58

25 CP-AR 58/25 C-65 TSC-80 R-4535 CP-AR 58/35 C-65 TSC-80 R-4550 CP-AR 58/50 C-90 TSC-80 R-9070 CP-AR 58/70 C-90 TSC-80 R-9095 CP-AR 58/95 C-90 TSC-80 R-90

120 CP-AR 58/120 C-90 TSC-80 R-90150 CP-AR 58/150 C-115 TSC-80 R-90185 CP-AR 58/185 C-115 TSC-80 R-90240 CP-AR 58/240 C-150 TSC-80 R-150

183


34



Place end of cable at theaxis of the tap hole androd butted against thecable. Use a clamprod

below mould to support it.

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24

7.2 CABLE / RODV

1. 2

013

13



CONNECTION CP-T

DIMENSION

RODCABLE(mm²)

MOULD(PART. No.)


KEY FORMOULDS

143

25 CP-T 143/25 C-90 TSC-80 R-90

A

35 CP-T 143/35 C-90 TSC-80 R-9050 CP-T 143/50 C-90 TSC-80 R-9070 CP-T 143/70 C-115 TSC-80 R-9095 CP-T 143/95 C-115 TSC-80 R-90120 CP-T 143/120 C-150 TSC-80 R-150150 CP-T 143/150 C-200 TSC-80 R-150185 CP-T 143/185 C-200 TSC-80 R-150240 CP-T 143/240 C-250 TSC-80 R-150

146

25 CP-T 146/25 C-90 TSC-80 R-9035 CP-T 146/35 C-90 TSC-80 R-9050 CP-T 146/50 C-90 TSC-80 R-9070 CP-T 146/70 C-115 TSC-80 R-9095 CP-T 146/95 C-115 TSC-80 R-90

120 CP-T 146/120 C-150 TSC-80 R-150150 CP-T 146/150 C-200 TSC-80 R-150185 CP-T 146/185 C-200 TSC-80 R-150240 CP-T 146/240 C-250 TSC-80 R-150

58

25 CP-T 58/25 C-90 TSC-80 R-9035 CP-T 58/35 C-90 TSC-80 R-9050 CP-T 58/50 C-90 TSC-80 R-9070 CP-T 58/70 C-115 TSC-80 R-9095 CP-T 58/95 C-115 TSC-80 R-90120 CP-T 58/120 C-150 TSC-80 R-150150 CP-T 58/150 C-200 TSC-80 R-150185 CP-T 58/185 C-200 TSC-80 R-150240 CP-T 58/240 C-250 TSC-80 R-150

183


34



For 120 mm² and largercut run cable and space

(S) 5-6 mm. under centreof tap hole. Use a clamp

on rod below mould.

S

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25

7.2 CABLE / ROD

V1.

201

314



CONNECTION CP-TS

DIMENSION

RODCABLE(mm²)

MOULD(PART. No.)


KEY FORMOULDS

143

25 CP-TS 143/25 C-90 TSC-80 R-90

D

35 CP-TS 143/35 C-90 TSC-80 R-9050 CP-TS 143/50 C-115 TSC-80 R-9070 CP-TS 143/70 C-115 TSC-80 R-9095 CP-TS 143/95 C-115 TSC-80 R-90120 CP-TS 143/120 C-150 TSC-80 R-150150 CP-TS 143/150 C-150 TSC-80 R-150185 CP-TS 143/185 C-250 TSC-80 R-150

240 CP-TS 143/240 2xC-200 TSC-80 R-150 H

146

25 CP-TS 146/25 C-90 TSC-80 R-90

D


240 CP-TS 146/240 2xC-200 TSC-80 R-150 H

58

25 CP-TS 58/25 C-90 TSC-80 R-90

D


240 CP-TS 58/240 2xC-200 TSC-80 R-150 H

183

25 CP-TS 183/25 C-90 TSC-80 R-90

D

35 CP-TS 183/35 C-90 TSC-80 R-9050 CP-TS 183/50 C-115 TSC-80 R-9070 CP-TS 183/70 C-150 TSC-80 R-15095 CP-TS 183/95 C-150 TSC-80 R-150120 CP-TS 183/120 C-200 TSC-80 R-150150 CP-TS 183/150 C-250 TSC-80 R-150185 CP-TS 183/185 2xC-150 TSC-80 R-150

H240 CP-TS 183/240 2xC-250 TSC-80 R-150

34

25 CP-TS 34/25 C-90 TSC-80 R-90

D

35 CP-TS 34/35 C-90 TSC-80 R-9050 CP-TS 34/50 C-115 TSC-80 R-9070 CP-TS 34/70 C-150 TSC-80 R-15095 CP-TS 34/95 C-150 TSC-80 R-150120 CP-TS 34/120 C-200 TSC-80 R-150150 CP-TS 34/150 C-250 TSC-80 R-150185 CP-TS 34/185 2xC-150 TSC-80 R-150

H240 CP-TS 34/240 2xC-250 TSC-80 R-150


Insert cable into themould and secure it torod with backing plate

attachment. Use anotherclamp on rod below

mould.

CO

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ING

26

7.2 CABLE / RODV

1. 2

013

15



CONNECTION CP-V

DIMENSION

RODCABLE(mm²)

MOULD(PART. No.)


KEY FORMOULDS

143

25 CP-V 143/25 C-65 TSC-80 R-45A

35 CP-V 143/35 C-65 TSC-80 R-4550 CP-V 143/50 C-90 TSC-80 R-90

D

70 CP-V 143/70 C-90 TSC-80 R-9095 CP-V 143/95 C-90 TSC-80 R-90120 CP-V 143/120 C-90 TSC-80 R-90150 CP-V 143/150 C-115 TSC-80 R-90185 CP-V 143/185 C-115 TSC-80 R-90240 CP-V 143/240 C-150 TSC-80 R-150

146

25 CP-V 146/25 C-65 TSC-80 R-45A


D


58

25 CP-V 58/25 C-65 TSC-80 R-45A


D


183

25 CP-V 183/25 C-90 TSC-80 R-9035 CP-V 183/35 C-90 TSC-80 R-9050 CP-V 183/50 C-90 TSC-80 R-9070 CP-V 183/70 C-90 TSC-80 R-9095 CP-V 183/95 C-90 TSC-80 R-90120 CP-V 183/120 C-90 TSC-80 R-90150 CP-V 183/150 C-115 TSC-80 R-90185 CP-V 183/185 C-115 TSC-80 R-90240 CP-V 183/240 C-150 TSC-80 R-150

34

25 CP-V 34/25 C-90 TSC-80 R-9035 CP-V 34/35 C-90 TSC-80 R-9050 CP-V 34/50 C-90 TSC-80 R-9070 CP-V 34/70 C-90 TSC-80 R-9095 CP-V 34/95 C-90 TSC-80 R-90120 CP-V 34/120 C-90 TSC-80 R-90150 CP-V 34/150 C-115 TSC-80 R-90185 CP-V 34/185 C-115 TSC-80 R-90240 CP-V 34/240 C-150 TSC-80 R-150

S


Separate rod and cable(S) 5- 6 mm. At the axis ofthe tap hole. Use a clamp

on rod below mould.

CP-V 143/35

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ING

27

7.2 CABLE / ROD

V1.

201

316



CONNECTION CP-VS

DIMENSION

RODCABLE(mm²)

MOULD(PART. No.)


KEY FORMOULDS

143

25 CP-VS 143/25 C-90 TSC-80 R-90

D

35 CP-VS 143/35 C-90 TSC-80 R-9050 CP-VS 143/50 C-115 TSC-80 R-9070 CP-VS 143/70 C-150 TSC-80 R-15095 CP-VS 143/95 C-150 TSC-80 R-150120 CP-VS 143/120 C-200 TSC-80 R-150150 CP-VS 143/150 C-250 TSC-80 R-150

I185 CP-VS 143/185 2xC-150 TSC-80 R-150240 CP-VS 143/240 2xC-250 TSC-80 R-150

146

25 CP-VS 146/25 C-90 TSC-80 R-90

D



58

25 CP-VS 58/25 C-90 TSC-80 R-90

D



183

25 CP-VS 183/25 C-90 TSC-80 R-90

D



34

25 CP-VS 34/25 C-90 TSC-80 R-90

D




Insert cable until theaxis of the tap hole. Use a

clamp on rod below mould.

CO

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ELD

ING

28

7.3 ROD / RODV

1. 2

013

17



CONNECTION PP-V

DIMENSION

RODMOULD


PRICEKEY FORMOULDS

143 PP-V 143 C-200 TSC-80 R-150

D

146 PP-V 146 C-200 TSC-80 R-150

58 PP-V 58 C-200 TSC-80 R-150

183 PP-V 183 2xC-150 TSC-80 R-150

34 PP-V 34 2xC-150 TSC-80 R-150

S


Place tip point of therods in the centre of the

tap rod. If they do nothave a point, separate

them (S) 10 mm. Use aclamp on lower rod

below mould.

CO

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ELD

ING

29

7.4 CABLE / RE-BAR

V1.

201

318



CONNECTION CR-XS

DIMENSION

RE-BAR(mm)

CABLE(mm²)

MOULD(PART. No.)


KEY FORMOULDS

10

25 CR-XS 10/25 C-90 TSC-80 R-90

B

35 CR-XS 10/35 C-90 TSC-80 R-90

50 CR-XS 10/50 C-115 TSC-80 R-90

70 CR-XS 10/70 C-150 TSC-80 R-150

95 CR-XS 10/95 C-150 TSC-80 R-150

16

25 CR-XS 16/25 C-115 TSC-100 R-90

E

35 CR-XS 16/35 C-115 TSC-100 R-90

50 CR-XS 16/50 C-150 TSC-100 R-150

70 CR-XS 16/70 C-150 TSC-100 R-150

95 CR-XS 16/95 C-200 TSC-100 R-150

120 CR-XS 16/120 C-200 TSC-100 R-150

150 CR-XS 16/150 C-200 TSC-100 R-150

20

25 CR-XS 20/25 C-115 TSC-100 R-90

35 CR-XS 20/35 C-115 TSC-100 R-90

50 CR-XS 20/50 C-150 TSC-100 R-150

70 CR-XS 20/70 C-150 TSC-100 R-150

95 CR-XS 20/95 C-200 TSC-100 R-150

120 CR-XS 20/120 C-200 TSC-100 R-150

150 CR-XS 20/150 C-250 TSC-100 R-150

185 CR-XS 20/185 C-250 TSC-100 R-150

240 CR-XS 20/240 2xC-150 TSC-100 R-750


Seal the re-bar withpaste on both sides ofthe weld cavity. Place

cable over the top of rebar.

CO

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MIN

OT

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RM

IC W

ELD

ING

30

7.4 CABLE / RE-BARV

1. 2

013

19



CONNECTION CR-TH

DIMENSION

RE-BAR(mm)

CABLE(mm²)

MOULD(PART. No.)


KEY FORMOULDS

10

25 CR-TH 10/25 C-90 TSC-80 R-90

A

35 CR-TH 10/35 C-90 TSC-80 R-90

50 CR-TH 10/50 C-115 TSC-80 R-90

70 CR-TH 10/70 C-115 TSC-80 R-90

95 CR-TH 10/95 C-150 TSC-80 R-150

16

25 CR-TH 16/25 C-150 TSC-80 R-150

35 CR-TH 16/35 C-150 TSC-80 R-150

50 CR-TH 16/50 C-150 TSC-80 R-150

70 CR-TH 16/70 C-150 TSC-80 R-150

95 CR-TH 16/95 C-200 TSC-80 R-150

120 CR-TH 16/120 C-200 TSC-80 R-150

150 CR-TH 16/150 C-250 TSC-80 R-150

20

25 CR-TH 20/25 C-150 TSC-80 R-150

35 CR-TH 20/35 C-150 TSC-80 R-150

50 CR-TH 20/50 C-200 TSC-80 R-150

70 CR-TH 20/70 C-200 TSC-80 R-150

95 CR-TH 20/95 C-200 TSC-80 R-150

120 CR-TH 20/120 C-250 TSC-80 R-150

150 CR-TH 20/150 C-250 TSC-80 R-150

185 CR-TH 20/185 2xC-150 TSC-80 R-150

240 CR-TH 20/240 2xC-200 TSC-100 R-750 E


Seal the re-bar withpast on both sides of the

weld cavity, on the out-side.

Butt tap cable against there-bar.

CO

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ER

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MIN

OT

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RM

IC W

ELD

ING

31

7.4 CABLE / RE-BAR

V1.

201

320



CONNECTION CR-TL

DIMENSION

RE-BAR(mm)

CABLE(mm²)

MOULD(PART. No.)


KEY FORMOULDS

10

25 CR-TL 10/25 C-90 TSC-80 R-90

D

35 CR-TL 10/35 C-90 TSC-80 R-90

50 CR-TL 10/50 C-115 TSC-80 R-90

70 CR-TL 10/70 C-115 TSC-80 R-90

95 CR-TL 10/95 C-150 TSC-80 R-150

120 CR-TL 10/120 C-150 TSC-80 R-150

150 CR-TL 10/150 C-200 TSC-80 R-150

16

25 CR-TL 16/25 C-150 TSC-80 R-150

35 CR-TL 16/35 C-150 TSC-80 R-150

50 CR-TL 16/50 C-150 TSC-80 R-150

70 CR-TL 16/70 C-150 TSC-80 R-150

95 CR-TL 16/95 C-200 TSC-80 R-150

120 CR-TL 16/120 C-200 TSC-80 R-150

150 CR-TL 16/150 C-250 TSC-80 R-150

20

25 CR-TL 20/25 C-150 TSC-80 R-150

35 CR-TL 20/35 C-150 TSC-80 R-150

50 CR-TL 20/50 C-200 TSC-80 R-150

70 CR-TL 20/70 C-200 TSC-80 R-150

95 CR-TL 20/95 C-200 TSC-80 R-150

120 CR-TL 20/120 C-250 TSC-80 R-150

150 CR-TL 20/150 C-250 TSC-80 R-150

185 CR-TL 20/185 2xC-150 TSC-80 R-150

240 CR-TL 20/240 2xC-200 TSC-80 R-150


Seal the re-barwith paste below theweld cavity. Butt thetap cable against the

re-bar. Use a clamp onre-bar below mould.

CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

32

7.4 CABLE / RE-BARV

1. 2

013

21



CONNECTION CR-PV

DIMENSION

RE-BAR(mm)

CABLE(mm²)

MOULD(PART. No.)


KEY FORMOULDS

10

25 CR-PV 10/25 C-90 TSC-80 R-90

D

35 CR-PV 10/35 C-90 TSC-80 R-90

50 CR-PV 10/50 C-115 TSC-80 R-90

70 CR-PV 10/70 C-150 TSC-80 R-150

95 CR-PV 10/95 C-150 TSC-80 R-150

16

25 CR-PV 16/25 C-115 TSC-80 R-90

35 CR-PV 16/35 C-115 TSC-80 R-90

50 CR-PV 16/50 C-150 TSC-80 R-150

70 CR-PV 16/70 C-150 TSC-80 R-150

95 CR-PV 16/95 C-200 TSC-80 R-150

120 CR-PV 16/120 C-200 TSC-80 R-150

150 CR-PV 16/150 C-200 TSC-80 R-150

20

25 CR-PV 20/25 C-115 TSC-80 R-90

35 CR-PV 20/35 C-115 TSC-80 R-90

50 CR-PV 20/50 C-150 TSC-80 R-150

70 CR-PV 20/70 C-150 TSC-80 R-150

95 CR-PV 20/95 C-200 TSC-80 R-150

120 CR-PV 20/120 C-200 TSC-80 R-150

150 CR-PV 20/150 C-250 TSC-80 R-150

185 CR-PV 20/185 C-250 TSC-80 R-150

240 CR-PV 20/240 2xC-150 TSC-80 R-150OPERATING

INSTRUCTIONS

Seal the re-bar withpaste on both sides ofthe weld cavity, on the

outside. Insert the cablein the mould and secure

it to the re-bar.Place the backing partand secure it to re-bar.Use a clamp on cable

below mould.

CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

33

7.4 CABLE / RE-BAR

V1.

201

322



CONNECTION CR-PH

DIMENSION

RE-BAR(mm)

CABLE(mm²)

MOULD(PART. No.)


KEY FORMOULDS

10

25 CR-PH 10/25 C-90 TSC-80 R-90

D35 CR-PH 10/35 C-90 TSC-80 R-90

50 CR-PH 10/50 C-115 TSC-80 R-90

70 CR-PH 10/70 C-115 TSC-80 R-90

95 CR-PH 10/95 C-150 TSC-80 R-150 H

16

25 CR-PH 16/25 C-90 TSC-80 R-90

D35 CR-PH 16/35 C-90 TSC-80 R-90

50 CR-PH 16/50 C-115 TSC-80 R-90

70 CR-PH 16/70 C-115 TSC-80 R-90

95 CR-PH 16/95 C-150 TSC-80 R-150

H120 CR-PH 16/120 C-150 TSC-80 R-150

150 CR-PH 16/150 C-200 TSC-80 R-150

20

25 CR-PH 20/25 C-90 TSC-80 R-90

D35 CR-PH 20/35 C-90 TSC-80 R-90

50 CR-PH 20/50 C-115 TSC-80 R-90

70 CR-PH 20/70 C-115 TSC-80 R-90

95 CR-PH 20/95 C-150 TSC-80 R-150

H

120 CR-PH 20/120 C-150 TSC-80 R-150

150 CR-PH 20/150 C-200 TSC-80 R-150

185 CR-PH 20/185 C-250 TSC-80 R-150

240 CR-PH 20/240 2xC-200 TSC-100 R-750OPERATINGINSTRUCTIONS

Seal the re-bar with pastebelow the weld cavity.

Insert the cable into themould and secure it to the

re-bar.Place the backplate

attachment. Use a clamp onre-bar below mould.

CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

34

7.4 CABLE / RE-BARV

1. 2

013

23



CONNECTION CR-TP

DIMENSION

RE-BAR(mm)

CABLE(mm²)

MOULD(PART. No.)


KEY FORMOULDS

10

25 CR-TP 10/25 C-90 TSC-80 R-90

A

35 CR-TP 10/35 C-90 TSC-80 R-90

50 CR-TP 10/50 C-115 TSC-80 R-90

70 CR-TP 10/70 C-115 TSC-80 R-90

95 CR-TP 10/95 C-150 TSC-80 R-150

16

25 CR-TP 16/25 C-90 TSC-80 R-90

35 CR-TP 16/35 C-90 TSC-80 R-90

50 CR-TP 16/50 C-115 TSC-80 R-90

70 CR-TP 16/70 C-115 TSC-80 R-90

95 CR-TP 16/95 C-150 TSC-80 R-150

120 CR-TP 16/120 C-150 TSC-80 R-150

150 CR-TP 16/150 C-200 TSC-80 R-150

20

25 CR-TP 20/25 C-90 TSC-80 R-90

35 CR-TP 20/35 C-90 TSC-80 R-90

50 CR-TP 20/50 C-115 TSC-80 R-90

70 CR-TP 20/70 C-115 TSC-80 R-90

95 CR-TP 20/95 C-150 TSC-80 R-150

120 CR-TP 20/120 C-150 TSC-80 R-150

150 CR-TP 20/150 C-200 TSC-80 R-150

185 CR-TP 20/185 C-250 TSC-80 R-150

240 CR-TP 20/240 C-250 TSC-80 R-150


Seal the re-bar withpaste on both sides ofthe weld cavity, on the

outside. Insert thecable up to the centre

of the tap hole.

CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

35

7.5 CABLE / METAL PLATE

V1.

201

324



CONNECTION CH-TH

DIMENSION

CABLE (mm²)MOULD


PRICEKEY FORMOULDS

25 CH-TH 25 C-45* TSC-80 R-45

A

35 CH-TH 35 C-65 TSC-80 R-45

50 CH-TH 50 C-90 TSC-80 R-90

70 CH-TH 70 C-90 TSC-80 R-90

95 CH-TH 95 C-115 TSC-80 R-90

120 CH-TH 120 C-115 TSC-80 R-90

150 CH-TH 150 C-150 TSC-80 R-150

185 CH-TH 185 C-200 TSC-80 R-150

240 CH-TH 240 C-200 TSC-80 R-150


Insert the cable at thecentre of the tap hole.Press on mould cover

to prevent metal leaks.


CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

36

7.5 CABLE / METAL PLATEV

1. 2

013

25



CONNECTION CH-TF

DIMENSION

CABLE (mm²)MOULD


PRICEKEY FORMOULDS

25 CH-TF 25 C-45* TSC-80 R-45

A

35 CH-TF 35 C-45* TSC-80 R-45

50 CH-TF 50 C-90 TSC-80 R-90

70 CH-TF 70 C-90 TSC-80 R-90

95 CH-TF 95 C-115 TSC-80 R-90

120 CH-TF 120 C-115 TSC-80 R-90

150 CH-TF 150 C-150 TSC-80 R-150

185 CH-TF 185 C-200 TSC-80 R-150

240 CH-TF 240 C-200 TSC-80 R-150


Insert the cable untilreaching the metalplate. Secure withclamp, if possible.


CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

37


V1.

201

326



CONNECTION CH-VI

DIMENSION

CABLE (mm²)MOULD


PRICEKEY FORMOULDS

25 CH-VI 25 C-45* TSC-80 R-45

A

35 CH-VI 35 C-65 TSC-80 R-45

50 CH-VI 50 C-90 TSC-80 R-90

70 CH-VI 70 C-90 TSC-80 R-90

95 CH-VI 95 C-115 TSC-80 R-90

120 CH-VI 120 C-115 TSC-80 R-90

150 CH-VI 150 C-150 TSC-80 R-150

185 CH-VI 185 C-150 TSC-80 R-150

240 CH-VI 240 C-200 TSC-80 R-150


Insert the cable until the centre of the tap hole. Seal the space

between the cable and the plate with mastic

below the weld cavity.Secure mould to the plate with a clamp, if

possible.

Possibility of using mini moulds for cartridges C-45 or smaller, with clamp TSC-50 and scrapper R-M. See

CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

38


1. 2

013

27



CONNECTION CH-TVD/CH-TVI

DIMENSION

CABLE (mm²)MOULD


PRICEKEY FORMOULDS

25 CH-TVD/ CH-TVI 25 C-45* TSC-80 R-45

A

35 CH-TVD/ CH-TVI 35 C-65 TSC-80 R-45









Insert the cable up to thecentre of the tap hole.

Seal the space betweenthe cable and the plate

outside the weld cavity.Secure the mould to the

plate with a clamp, ifpossible.


CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

39


V1.

201

328



CONNECTION CH-PHH

DIMENSION

CABLE (mm²)MOULD


PRICEKEY FORMOULDS

25 CH-PHH 25 C-65 TSC-80 R-45

A

35 CH-PHH 35 C-90 TSC-80 R-90

50 CH-PHH 50 C-90 TSC-80 R-90

70 CH-PHH 70 C-115 TSC-80 R-90

95 CH-PHH 95 C-115 TSC-80 R-90

120 CH-PHH 120 C-150 TSC-80 R-150

150 CH-PHH 150 C-200 TSC-80 R-150

185 CH-PHH 185 C-250 TSC-80 R-150

240 CH-PHH 240 2xC-150 TSC-80 R-150


Cut and separate thecable 3 to 4 mm.

Under centre of taphole. Press on the

cover of the mould toprevent metal leaks.

S

CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

40


1. 2

013

29



CONNECTION CH-PVH

DIMENSION

CABLE (mm²)MOULD


PRICEKEY FORMOULDS

25 CH-PVH 25 C-65 TSC-80 R-45

A

35 CH-PVH 35 C-90 TSC-80 R-90

50 CH-PVH 50 C-115 TSC-80 R-90

70 CH-PVH 70 C-115 TSC-80 R-90

95 CH-PVH 95 C-150 TSC-80 R-150

120 CH-PVH 120 C-150 TSC-80 R-150

150 CH-PVH 150 C-200 TSC-80 R-150

185 CH-PVH 185 C-250 TSC-80 R-150

240 CH-PVH 240 2xC-150 TSC-80 R-150


Seal the spacebetween the cable andthe plate on both sides

of the weld cavity.Secure the mould to the

plate with a clamp, if possible.

CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

41


V1.

201

330



CONNECTION CH-VS

DIMENSION

CABLE (mm²)MOULD


PRICEKEY FORMOULDS

25 CH-VS 25 C-65 TSC-80 R-45

A35 CH-VS 35 C-90 TSC-80 R-90

50 CH-VS 50 C-115 TSC-80 R-90

70 CH-VS 70 C-150 TSC-80 R-150

C95 CH-VS 95 C-200 TSC-80 R-150

120 CH-VS 120 C-200 TSC-80 R-150

150 CH-VS 150 C-250 TSC-80 R-150

185 CH-VS 185 2xC-150 TSC- 80 R-150F

240 CH-VS 240 2xC-150 TSC-80 R-150


Insert the cable up tothe centre of the tap

hole. Secure the mouldto the plate with aclamp, if possible.

CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

42


1. 2

013

31



CONNECTION CH-PVV

DIMENSION

CABLE (mm²)MOULD


PRICEKEY FORMOULDS

25 CH-PVV 25 C-90 TSC-80 R-90A

35 CH-PVV 35 C-115 TSC-80 R-90

50 CH-PVV 50 C-150 TSC-80 R-150

C70 CH-PVV 70 C-200 TSC-80 R-150

95 CH-PVV 95 C-250 TSC-80 R-150

120 CH-PVV 120 C-250 TSC-80 R-150

150 CH-PVV 150 2xC-150 TSC-100 R-750

F185 CH-PVV 185 2xC-150 TSC-100 R-750

240 CH-PVV 240 2xC-200 TSC-100 R-750


Cut and separate thecable 5 to 6 mm in thecentre of the tap hole.Seal the gap between

the cable and theplate with mastic

below the weld cavity.Secure the mould with

a clamp, if possible.

CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

43

7.6 CABLE / PIPE

V1.

201

332



CONNECTION CT-TH

DIMENSION

CABLE (mm²)MOULD


PRICEKEY FORMOULDS

10 CT-TH 10 C-15 MS R-45

A

16 CT-TH 16 C-15 MS R-45

25 CT-TH 25 C-25 MS R-45

35 CT-TH 35 C-32 MS R-45

50 CT-TH 50 C-45 MS R-45

70 CT-TH 70 C-65 MS R-45


Insert the cable untilthe centre of the tap

hole. Seal the gapbetween the cableand the plate withmastic outside theweld cavity. Press

on the mould toprevent metal leaks.

CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

44

7.7 CABLE / BUS-BARV

1. 2

013

33



CONNECTION CPL-VI (1 OF 2)

DIMENSION

CABLE(mm²)

BUS-BAR PART. No. CARTRIDGE CLAMP SCRAPERPRICE

KEY FORMOULDS

25

20x2 CPL-VI 25/20x2 C-65 TSC-80 R-45

A

20x3 CPL-VI 25/20x3 C-90 TSC-80 R-90

20x5 CPL-VI 25/20x5 C-90 TSC-80 R-90

25x3 CPL-VI 25/25x3 C-90 TSC-80 R-90

25x5 CPL-VI 25/25x5 C-115 TSC-80 R-90

30x3 CPL-VI 25/30x3 C-115 TSC-80 R-90

35

20x3 CPL-VI 35/20x3 C-115 TSC-80 R-90

20x5 CPL-VI 35/20x5 C-115 TSC-80 R-90

25x3 CPL-VI 35/25x3 C-115 TSC-80 R-90

25x5 CPL-VI 35/25x5 C-115 TSC-80 R-90

30x3 CPL-VI 35/30x3 C-115 TSC-80 R-90

40x3 CPL-VI 35/40x3 C-115 TSC-80 R-90

40x5 CPL-VI 35/40x5 C-115 TSC-80 R-90

50

20x3 CPL-VI 50/20x3 C-115 TSC-80 R-90

20x5 CPL-VI 50/20x5 C-115 TSC-80 R-90

25x3 CPL-VI 50/25x3 C-115 TSC-80 R-90

25x5 CPL-VI 50/25x5 C-115 TSC-80 R-90

30x3 CPL-VI 50/30x3 C-115 TSC-80 R-90

30x5 CPL-VI 50/30x5 C-115 TSC-80 R-90

40x3 CPL-VI 50/40x3 C-115 TSC-80 R-90

40x5 CPL-VI 50/40x5 C-115 TSC-80 R-90

50x5 CPL-VI 50/50x5 C-150 TSC-80 R-150

70

20x3 CPL-VI 70/20x3 C-115 TSC-80 R-90

20x5 CPL-VI 70/20x5 C-150 TSC-80 R-150

25x3 CPL-VI 70/25x3 C-150 TSC-80 R-150

25x5 CPL-VI 70/25x5 C-150 TSC-80 R-150

30x3 CPL-VI 70/30x3 C-150 TSC-80 R-150

30x5 CPL-VI 70/30x5 C-150 TSC-80 R-150

40x3 CPL-VI 70/40x3 C-150 TSC-80 R-150

40x5 CPL-VI 70/40x5 C-150 TSC-80 R-150

50x5 CPL-VI 70/50x5 C-200 TSC-80 R-150


Insert end of tap cableeven with upper edge

of run bus-bar, seal thegap between the cable

and the mould withmastic below the weld

cavity.

SO

LDA

DU

RA

ALU

MIN

OT

ÉR

MIC

A D

EL

CO

BR

E45

7.7 CABLE / BUS-BAR

V1.

201

334



CONNECTION CPL-VI (2 OF 2)CABLE(mm²)


KEY FORMOULDS

95

20x3 CPL-VI 95/20x3 C-150 TSC-80 R-150

A

20x5 CPL-VI 95/20x5 C-150 TSC-80 R-150

25x3 CPL-VI 95/25x3 C-150 TSC-80 R-150

25x5 CPL-VI 95/25x5 C-150 TSC-80 R-150

30x3 CPL-VI 95/30x3 C-200 TSC-80 R-150

30x5 CPL-VI 95/30x5 C-200 TSC-80 R-150

40x3 CPL-VI 95/40x3 C-200 TSC-80 R-150

40x5 CPL-VI 95/40x5 C-200 TSC-80 R-150

50x5 CPL-VI 95/50x5 C-250 TSC-80 R-150

60x5 CPL-VI 95/60x5 2xC-150 TSC-100 R-750 D

120

20x5 CPL-VI 120/20x5 C-200 TSC-80 R-150

A

25x3 CPL-VI 120/25x3 C-200 TSC-80 R-150

25x5 CPL-VI 120/25x5 C-200 TSC-80 R-150

30x3 CPL-VI 120/30x3 C-200 TSC-80 R-150

30x5 CPL-VI 120/30x5 C-200 TSC-80 R-150

40x3 CPL-VI 120/40x3 C-250 TSC-80 R-150

40x5 CPL-VI 120/40x5 C-250 TSC-80 R-150

50x5 CPL-VI 120/50x5 2xC-150 TSC-100 R-750D

60x5 CPL-VI 120/60x5 2xC-150 TSC-100 R-750

150

25x5 CPL-VI 150/25x5 C-200 TSC-80 R-150

A

30x3 CPL-VI 150/30x3 C-200 TSC-80 R-150

30x5 CPL-VI 150/30x5 C-200 TSC-80 R-150

40x3 CPL-VI 150/40x3 C-250 TSC-80 R-150

40x5 CPL-VI 150/40x5 C-250 TSC-80 R-150

50x5 CPL-VI 150/50x5 2xC-150 TSC-100 R-750D

60x5 CPL-VI 150/60x5 2xC-150 TSC-100 R-750

185

25x5 CPL-VI 185/25x5 C-250 TSC-80 R-150

A30x3 CPL-VI 185/30x3 C-250 TSC-80 R-150

30x5 CPL-VI 185/30x5 C-250 TSC-80 R-150

40x3 CPL-VI 185/40x3 2xC-150 TSC-100 R-750

D

40x5 CPL-VI 185/40x5 2xC-150 TSC-100 R-750

50x5 CPL-VI 185/50x5 2xC-150 TSC-100 R-750

60x5 CPL-VI 185/60x5 2xC-200 TSC-100 R-750

240

25x6 CPL-VI 240/25x6 C-250 TSC-100 R-750

30x7 CPL-VI 240/30x7 C-250 TSC-100 R-750

30x9 CPL-VI 240/30x9 C-250 TSC-100 R-750

40x7 CPL-VI 240/40x7 2xC-150 TSC-100 R-750

40x9 CPL-VI 240/40x9 2xC-150 TSC-100 R-750

50x6 CPL-VI 240/50x6 2xC-150 TSC-100 R-750

60x6 CPL-VI 240/60x6 2xC-200 TSC-100 R-750


Insert end of tap cableeven with upper edge

of run bus-bar, seal thegap between the cable

and the mould withmastic below the weld

cavity.

CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

46


1. 2

013

35



CONNECTION CPL-VS (1 OF 2)

DIMENSION

CABLE(mm²)


KEY FORMOULDS

25

20x2 CPL-VS 25/20x2 C-45 TSC-80 R-45

D

20x3 CPL-VS 25/20x3 C-65 TSC-80 R-45

20x5 CPL-VS 25/20x5 C-65 TSC-80 R-45

25x3 CPL-VS 25/25x3 C-90 TSC-80 R-90

25x5 CPL-VS 25/25x5 C-90 TSC-80 R-90

35

20x2 CPL-VS 35/20x2 C-65 TSC-80 R-45

20x3 CPL-VS 35/20x3 C-90 TSC-80 R-90

20x5 CPL-VS 35/20x5 C-90 TSC-80 R-90

25x3 CPL-VS 35/25x3 C-90 TSC-80 R-90

25x5 CPL-VS 35/25x5 C-115 TSC-80 R-90

30x3 CPL-VS 35/30x3 C-115 TSC-80 R-90

50

20x3 CPL-VS 50/20x3 C-115 TSC-80 R-90

20x5 CPL-VS 50/20x5 C-115 TSC-80 R-90

25x3 CPL-VS 50/25x3 C-115 TSC-80 R-90

25x5 CPL-VS 50/25x5 C-115 TSC-80 R-90

30x3 CPL-VS 50/30x3 C-115 TSC-80 R-90

30x5 CPL-VS 50/30x5 C-115 TSC-80 R-90

40x3 CPL-VS 50/40x3 C-115 TSC-80 R-90

40x5 CPL-VS 50/40x5 C-115 TSC-80 R-90

70

20x3 CPL-VS 70/20x3 C-115 TSC-80 R-90

20x5 CPL-VS 70/20x5 C-115 TSC-80 R-90

25x3 CPL-VS 70/25x3 C-115 TSC-80 R-90

25x5 CPL-VS 70/25x5 C-115 TSC-80 R-90

30x3 CPL-VS 70/30x3 C-115 TSC-80 R-90

30x5 CPL-VS 70/30x5 C-115 TSC-80 R-90

40x3 CPL-VS 70/40x3 C-115 TSC-80 R-90

40x5 CPL-VS 70/40x5 C-115 TSC-80 R-90

50x5 CPL-VS 70/50x5 C-150 TSC-80 R-150


Run bus-bar is insertedto seat in mould. Butt

tap cable against upperedge of run bus-bar.

CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

47

7.7 CABLE / BUS-BAR

V1.

201

336



CONNECTION CPL-VS (2 OF 2)CABLE(mm²)


KEY FORMOULDS

95

20x3 CPL-VS 95/20x3 C-115 TSC-80 R-90

D

20x5 CPL-VS 95/20x5 C-150 TSC-80 R-150

25x3 CPL-VS 95/25x3 C-150 TSC-80 R-150

25x5 CPL-VS 95/25x5 C-150 TSC-80 R-150

30x3 CPL-VS 95/30x3 C-150 TSC-80 R-150

30x5 CPL-VS 95/30x5 C-150 TSC-80 R-150

40x3 CPL-VS 95/40x3 C-150 TSC-80 R-150

40x5 CPL-VS 95/40x5 C-150 TSC-80 R-150

50x5 CPL-VS 95/50x5 C-200 TSC-80 R-150

120

20x3 CPL-VS 120/20x3 C-150 TSC-80 R-150

20x5 CPL-VS 120/20x5 C-150 TSC-80 R-150

25x3 CPL-VS 120/25x3 C-150 TSC-80 R-150

25x5 CPL-VS 120/25x5 C-150 TSC-80 R-150

30x3 CPL-VS 120/30x3 C-200 TSC-80 R-150

30x5 CPL-VS 120/30x5 C-200 TSC-80 R-150

40x3 CPL-VS 120/40x3 C-200 TSC-80 R-150

40x5 CPL-VS 120/40x5 C-200 TSC-80 R-150

50x5 CPL-VS 120/50x5 C-250 TSC-80 R-150

60x5 CPL-VS 120/60x5 2xC-150 TSC-80 R-150

150

20x5 CPL-VS 150/20x5 C-200 TSC-80 R-150

25x3 CPL-VS 150/25x3 C-200 TSC-80 R-150

25x5 CPL-VS 150/25x5 C-200 TSC-80 R-150

30x3 CPL-VS 150/30x3 C-200 TSC-80 R-150

30x5 CPL-VS 150/30x5 C-200 TSC-80 R-150

40x3 CPL-VS 150/40x3 C-250 TSC-80 R-150

40x5 CPL-VS 150/40x5 C-250 TSC-80 R-150

50x5 CPL-VS 150/50x5 2xC-150 TSC-80 R-150

60x5 CPL-VS 150/60x5 2xC-150 TSC-80 R-150

185

25x5 CPL-VS 185/25x5 C-200 TSC-80 R-150

30x3 CPL-VS 185/30x3 C-200 TSC-80 R-150

30x5 CPL-VS 185/30x5 C-200 TSC-80 R-150

40x3 CPL-VS 185/40x3 C-250 TSC-80 R-150

40x5 CPL-VS 185/40x5 C-250 TSC-80 R-150

50x5 CPL-VS 185/50x5 2xC-150 TSC-80 R-150

60x5 CPL-VS 185/60x5 2xC-150 TSC-80 R-150

240

25x5 CPL-VS 240/25x5 C-250 TSC-80 R-150

30x3 CPL-VS 240/30x3 C-250 TSC-80 R-150

30x5 CPL-VS 240/30x5 C-250 TSC-80 R-150

40x3 CPL-VS 240/40x3 2xC-150 TSC-80 R-150

40x5 CPL-VS 240/40x5 2xC-150 TSC-80 R-150

50x5 CPL-VS 240/50x5 2xC-150 TSC-80 R-150

60x5 CPL-VS 240/60x5 2xC-200 TSC-80 R-750




CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

48


1. 2

013

37



CONNECTION CPL-H (1 OF 2)

DIMENSION

CABLE(mm²)


KEY FORMOULDS

2520x2 CPL-H 25/20x2 C-45* TSC-80 R-45

A

20x3 CPL-H 25/20x3 C-65 TSC-80 R-45

35

20x2 CPL-H 35/20x2 C-45* TSC-80 R-45

20x3 CPL-H 35/20x3 C-45* TSC-80 R-45

20x5 CPL-H 35/20x5 C-45* TSC-80 R-45

25x3 CPL-H 35/25x3 C-45* TSC-80 R-45

50

20x2 CPL-H 50/20x2 C-45* TSC-80 R-45

20x3 CPL-H 50/20x3 C-45* TSC-80 R-45

20x5 CPL-H 50/20x5 C-65 TSC-80 R-45

25x3 CPL-H 50/25x3 C-65 TSC-80 R-45

70

20x2 CPL-H 70/20x2 C-45* TSC-80 R-45

20x3 CPL-H 70/20x3 C-65 TSC-80 R-45

20x5 CPL-H 70/20x5 C-65 TSC-80 R-45

25x3 CPL-H 70/25x3 C-90 TSC-80 R-90

25x5 CPL-H 70/25x5 C-90 TSC-80 R-90

95

20x2 CPL-H 95/20x2 C-65 TSC-80 R-45

20x3 CPL-H 95/20x3 C-90 TSC-80 R-90

20x5 CPL-H 95/20x5 C-90 TSC-80 R-90

25x3 CPL-H 95/25x3 C-90 TSC-80 R-90

25x5 CPL-H 95/25x5 C-115 TSC-80 R-90

30x3 CPL-H 95/30x3 C-115 TSC-80 R-90

120

20x3 CPL-H 120/20x3 C-115 TSC-80 R-90

20x5 CPL-H 120/20x5 C-115 TSC-80 R-90

25x3 CPL-H 120/25x3 C-115 TSC-80 R-90

25x5 CPL-H 120/25x5 C-115 TSC-80 R-90

30x3 CPL-H 120/30x3 C-115 TSC-80 R-90

30x5 CPL-H 120/30x5 C-115 TSC-80 R-90

40x3 CPL-H 120/40x3 C-115 TSC-80 R-90

40x5 CPL-H 120/40x5 C-115 TSC-80 R-90





CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

49

7.7 CABLE / BUS-BAR

V1.

201

338



CONNECTION CPL-H (2 OF 2)CABLE(mm²)


KEY FORMOULDS

150

20x3 CPL-H 150/20x3 C-115 TSC-80 R-90

A

20x5 CPL-H 150/20x5 C-115 TSC-80 R-90

25x3 CPL-H 150/25x3 C-115 TSC-80 R-90

25x5 CPL-H 150/25x5 C-115 TSC-80 R-90

30x3 CPL-H 150/30x3 C-115 TSC-80 R-90

30x5 CPL-H 150/30x5 C-115 TSC-80 R-90

40x3 CPL-H 150/40x3 C-115 TSC-80 R-90

40x5 CPL-H 150/40x5 C-115 TSC-80 R-90

50x5 CPL-H 150/50x5 C-150 TSC-80 R-150

185

20x3 CPL-H 185/20x3 C-115 TSC-80 R-90

20x5 CPL-H 185/20x5 C-150 TSC-80 R-150

25x3 CPL-H 185/25x3 C-150 TSC-80 R-150

25x5 CPL-H 185/25x5 C-150 TSC-80 R-150

30x3 CPL-H 185/30x3 C-150 TSC-80 R-150

30x5 CPL-H 185/30x5 C-150 TSC-80 R-150

40x3 CPL-H 185/40x3 C-150 TSC-80 R-150

40x5 CPL-H 185/40x5 C-150 TSC-80 R-150

50x5 CPL-H 185/50x5 C-200 TSC-80 R-150

240

20x3 CPL-H 240/20x3 C-150 TSC-80 R-150

20x5 CPL-H 240/20x5 C-150 TSC-80 R-150

25x3 CPL-H 240/25x3 C-150 TSC-80 R-150

25x5 CPL-H 240/25x5 C-150 TSC-80 R-150

30x3 CPL-H 240/30x3 C-200 TSC-80 R-150

30x5 CPL-H 240/30x5 C-200 TSC-80 R-150

40x3 CPL-H 240/40x3 C-200 TSC-80 R-150

40x5 CPL-H 240/40x5 C-200 TSC-80 R-150

50x5 CPL-H 240/50x5 C-250 TSC-80 R-150

60x5 CPL-H 240/60x5 2xC-150 TSC-80 R-150




CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

50


1. 2

013

39



CONNECTION CPL-T (1 OF 2)

DIMENSION

CABLE(mm²)


KEY FORMOULDS

25

20x2 CPL-T 25/20x2 C-45* TSC-80 R-45

A

20x3 CPL-T 25/20x3 C-45* TSC-80 R-45

20x5 CPL-T 25/20x5 C-45* TSC-80 R-45

25x3 CPL-T 25/25x3 C-45* TSC-80 R-45

35

20x2 CPL-T 35/20x2 C-45* TSC-80 R-45

20x3 CPL-T 35/20x3 C-45* TSC-80 R-45

20x5 CPL-T 35/20x5 C-65 TSC-80 R-45

25x3 CPL-T 35/25x3 C-65 TSC-80 R-45

50

20x2 CPL-T 50/20x2 C-45 TSC-80 R-45

20x3 CPL-T 50/20x3 C-65 TSC-80 R-45

20x5 CPL-T 50/20x5 C-65 TSC-80 R-45

25x3 CPL-T 50/25x3 C-90 TSC-80 R-90

25x5 CPL-T 50/25x5 C-90 TSC-80 R-90

70

20x2 CPL-T 70/20x2 C-65 TSC-80 R-45

20x3 CPL-T 70/20x3 C-90 TSC-80 R-90

20x5 CPL-T 70/20x5 C-90 TSC-80 R-90

25x3 CPL-T 70/25x3 C-90 TSC-80 R-90

25x5 CPL-T 70/25x5 C-115 TSC-80 R-90

30x3 CPL-T 70/30x3 C-115 TSC-80 R-90

95

20x3 CPL-T 95/20x3 C-115 TSC-80 R-90

20x5 CPL-T 95/20x5 C-150 TSC-80 R-150

25x3 CPL-T 95/25x3 C-150 TSC-80 R-150

25x5 CPL-T 95/25x5 C-150 TSC-80 R-150

30x3 CPL-T 95/30x3 C-150 TSC-80 R-150

30x5 CPL-T 95/30x5 C-150 TSC-80 R-150

40x3 CPL-T 95/40x3 C-150 TSC-80 R-150

40x5 CPL-T 95/40x5 C-150 TSC-80 R-150

50x5 CPL-T 95/50x5 C-200 TSC-80 R-150


Butt tap bus-bar againstside of run cable.


CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

51

7.7 CABLE / BUS-BAR

V1.

201

340



CONNECTION CPL-T (2 OF 2)CABLE(mm²)


KEY FORMOULDS

120

20x3 CPL-T 120/20x3 C-150 TSC-80 R-150

A

20x5 CPL-T 120/20x5 C-150 TSC-80 R-150

25x3 CPL-T 120/25x3 C-150 TSC-80 R-150

25x5 CPL-T 120/25x5 C-150 TSC-80 R-150

30x3 CPL-T 120/30x3 C-200 TSC-80 R-150

30x5 CPL-T 120/30x5 C-200 TSC-80 R-150

40x3 CPL-T 120/40x3 C-200 TSC-80 R-150

40x5 CPL-T120/40x5 C-200 TSC-80 R-150

50x5 CPL-T 120/50x5 C-250 TSC-80 R-150

60x5 CPL-T 120/60x5 2xC-150 TSC-100 R-750 F

150

20x5 CPL-T 150/20x5 C-200 TSC-80 R-150

A

25x3 CPL-T 150/25x3 C-200 TSC-80 R-150

25x5 CPL-T 150/25x5 C-200 TSC-80 R-150

30x3 CPL-T 150/30x3 C-200 TSC-80 R-150

30x5 CPL-T 150/30x5 C-200 TSC-80 R-150

40x3 CPL-T 150/40x3 C-250 TSC-80 R-150

40x5 CPL-T150/40x5 C-250 TSC-80 R-150

50x5 CPL-T 150/50x5 2xC-150 TSC-80 R-150

60x5 CPL-T 150/60x5 2xC-150 TSC-100 R-750 F

185

25x5 CPL-T 185/25x5 C-200 TSC-80 R-150

A

30x3 CPL-T 185/30x3 C-200 TSC-80 R-150

30x5 CPL-T 185/30x5 C-200 TSC-80 R-150

40x3 CPL-T 185/40x3 C-250 TSC-80 R-150

40x5 CPL-T185/40x5 C-250 TSC-80 R-150

50x5 CPL-T 185/50x5 2xC-150 TSC-80 R-150

60x5 CPL-T 185/60x5 2xC-150 TSC-100 R-750 F

240

25x5 CPL-T 240/25x5 C-250 TSC-80 R-150

A

30x3 CPL-T 240/30x3 C-250 TSC-80 R-150

30x5 CPL-T 240/30x5 C-250 TSC-80 R-150

40x3 CPL-T 240/40x3 2xC-150 TSC-80 R-150

40x5 CPL-T 240/40x5 2xC-150 TSC-80 R-150

50x5 CPL-T 240/50x5 2xC-150 TSC-80 R-150

60x5 CPL-T 240/60x5 2xC-200 TSC-100 R-750 F


Butt tap bus-bar againstside of run cable.

CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

52


1. 2

013

41



CONNECTION CPL-L (1 OF 2)

DIMENSION

CABLE(mm²)


KEY FORMOULDS

2520x2 CPL-L 25/20x2 C-32* TSC-80 R-45

B

20x3 CPL-L 25/20x3 C-45* TSC-80 R-45

35

20x2 CPL-L 35/20x2 C-45* TSC-80 R-45

20x3 CPL-L 35/20x3 C-45* TSC-80 R-45

20x5 CPL-L 35/20x5 C-45* TSC-80 R-45

25x3 CPL-L 35/25x3 C-45* TSC-80 R-45

50

20x2 CPL-L 50/20x2 C-45* TSC-80 R-45

20x3 CPL-L 50/20x3 C-45* TSC-80 R-45

20x5 CPL-L 50/20x5 C-65 TSC-80 R-45

25x3 CPL-L 50/25x3 C-65 TSC-80 R-45

70

20x2 CPL-L 70/20x2 C-45* TSC-80 R-45

20x3 CPL-L 70/20x3 C-65 TSC-80 R-45

20x5 CPL-L 70/20x5 C-65 TSC-80 R-45

25x3 CPL-L 70/25x3 C-90 TSC-80 R-90

25x5 CPL-L 70/25x5 C-90 TSC-80 R-90

95

20x2 CPL-L 95/20x2 C-65 TSC-80 R-45

20x3 CPL-L 95/20x3 C-90 TSC-80 R-90

20x5 CPL-L 95/20x5 C-90 TSC-80 R-90

25x3 CPL-L 95/25x3 C-90 TSC-80 R-90

25x5 CPL-L 95/25x5 C-115 TSC-80 R-90

30x3 CPL-L 95/30x3 C-115 TSC-80 R-90

120

20x3 CPL-L 120/20x3 C-115 TSC-80 R-90

20x5 CPL-L 120/20x5 C-115 TSC-80 R-90

25x3 CPL-L 120/25x3 C-115 TSC-80 R-90

25x5 CPL-L 120/25x5 C-115 TSC-80 R-90

30x3 CPL-L 120/30x3 C-115 TSC-80 R-90

30x5 CPL-L 120/30x5 C-115 TSC-80 R-90

40x3 CPL-L 120/40x3 C-115 TSC-80 R-90

40x5 CPL-L 120/40x5 C-115 TSC-80 R-90


Butt ends ofcable and bus-bar

under centre of taphole.


CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

53

7.7 CABLE / BUS-BAR

V1.

201

342



CONNECTION CPL-L (2 OF 2)CABLE(mm²)


KEY FORMOULDS

150

20x3 CPL-L 150/20x3 C-115 TSC-80 R-90

B

20x5 CPL-L 150/20x5 C-115 TSC-80 R-90

25x3 CPL-L 150/25x3 C-115 TSC-80 R-90

25x5 CPL-L 150/25x5 C-115 TSC-80 R-90

30x3 CPL-L 150/30x3 C-115 TSC-80 R-90

30x5 CPL-L 150/30x5 C-115 TSC-80 R-90

40x3 CPL-L 150/40x3 C-115 TSC-80 R-90

40x5 CPL-L 150/40x5 C-115 TSC-80 R-90

50x5 CPL-L 150/50x5 C-150 TSC-80 R-150

185

20x3 CPL-L 185/20x3 C-115 TSC-80 R-90

20x5 CPL-L 185/20x5 C-150 TSC-80 R-150

25x3 CPL-L 185/25x3 C-150 TSC-80 R-150

25x5 CPL-L 185/25x5 C-150 TSC-80 R-150

30x3 CPL-L 185/30x3 C-150 TSC-80 R-150

30x5 CPL-L 185/30x5 C-150 TSC-80 R-150

40x3 CPL-L 185/40x3 C-150 TSC-80 R-150

40x5 CPL-L 185/40x5 C-150 TSC-80 R-150

50x5 CPL-L 185/50x5 C-200 TSC-80 R-150

240

20x3 CPL-L 240/20x3 C-150 TSC-80 R-150

20x5 CPL-L 240/20x5 C-150 TSC-80 R-150

25x3 CPL-L 240/25x3 C-150 TSC-80 R-150

25x5 CPL-L 240/25x5 C-150 TSC-80 R-150

30x3 CPL-L 240/30x3 C-200 TSC-80 R-150

30x5 CPL-L 240/30x5 C-200 TSC-80 R-150

40x3 CPL-L 240/40x3 C-200 TSC-80 R-150

40x5 CPL-L 240/40x5 C-200 TSC-80 R-150

50x5 CPL-L 240/50x5 C-250 TSC-80 R-150

60x5 CPL-L 240/60x5 2xC-150 TSC-100 R-750 F


Butt ends ofcable and bus-bar

under centre of taphole.

CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

54

7.8 BUS-BAR / BUS-BARV

1. 2

013

43




End of bus-bar less than30 mm wide must be

cut in “V” undercentre tap holes (S) 5

to 6 mm. Bus-barwider than 30 mm(S)

10 to 12 mm.

CONNECTION PL-LV

DIMENSION

BUS-BARMOULD


PRICEKEY FORMOULDS

20x2 PL-LV 20x2 C-45* TSC-80 R-45

A

20x3 PL-LV 20x3 C-45* TSC-80 R-45

20x5 PL-LV 20x5 C-65 TSC-80 R-45

25x3 PL-LV 25x3 C-65 TSC-80 R-45

25x5 PL-LV 25x5 C-90 TSC-80 R-90

30x3 PL-LV 30x3 C-90 TSC-80 R-90

30x5 PL-LV 30x5 C-115 TSC-80 R-90

40x3 PL-LV 40x3 C-115 TSC-80 R-90

40x5 PL-LV 40x5 C-150 TSC-80 R-150B

50x5 PL-LV 50x5 C-200 TSC-80 R-150

60x5 PL-LV 60x5 2xC-150 TSC-100 R-750 E

S


CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

55

7.8 BUS-BAR / BUS-BAR

V1.

201

344




End of bus-bar less than30 mm wide must be cut

in “V” under centre tapholes (S) 5 to 6 mm.

Busbarwider than 30 mm(S)

10 to 12 mm.

CONNECTION PL-ARI

DIMENSION

BUS-BARMOULD


PRICEKEY FORMOULDS

20x2 PL-ARI 20x2 C-45* TSC-80 R-45

A

20x3 PL-ARI 20x3 C-45* TSC-80 R-45

20x5 PL-ARI 20x5 C-65 TSC-80 R-45

25x3 PL-ARI 25x3 C-65 TSC-80 R-45

25x5 PL-ARI 25x5 C-90 TSC-80 R-90

30x3 PL-ARI 30x3 C-90 TSC-80 R-90

30x5 PL-ARI 30x5 C-115 TSC-80 R-90

40x3 PL-ARI 40x3 C-115 TSC-80 R-90

40x5 PL-ARI 40x5 C-150 TSC-80 R-150B

50x5 PL-ARI 50x5 C-200 TSC-80 R-150

60x5 PL-ARI 60x5 2xC-150 TSC-100 R-750 E

S


CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

56


1. 2

013

45




Insert the end of tapbus-bar even with upper

edge of run bus-bar.

CONNECTION PL-TV

DIMENSION

BUS-BARMOULD


PRICEKEY FORMOULDS

20x2 PL-TV 20x2 C-45* TSC-80 R-45

A

20x3 PL-TV 20x3 C-65 TSC-80 R-45

20x5 PL-TV 20x5 C-65 TSC-80 R-45

25x3 PL-TV 25x3 C-90 TSC-80 R-90

25x5 PL-TV 25x5 C-90 TSC-80 R-90

30x3 PL-TV 30x3 C-90 TSC-80 R-90

30x5 PL-TV 30x5 C-115 TSC-80 R-90

40x3 PL-TV 40x3 C-115 TSC-80 R-90

40x5 PL-TV 40x5 C-150 TSC-80 R-150B

50x5 PL-TV 50x5 C-200 TSC-80 R-150

60x5 PL-TV 60x5 2xC-150 TSC-100 R-750 E


CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

57


V1.

201

346




The ends of bus-bars ofup to 6 mm thick must

be separated (S) 5-6mm. in the centre of thetap hole. Bus-bar thicker

than 6 mm (S)10-12mm.

CONNECTION PL-V

DIMENSION

BUS-BARMOULD


PRICEKEY FORMOULDS

20x2 PL-V 20x2 C-65 TSC-80 R-45B

20x3 PL-V 20x3 C-65 TSC-80 R-45

20x5 PL-V 20x5 C-90 TSC-80 R-90

D25x3 PL-V 25x3 C-90 TSC-80 R-90

25x5 PL-V 25x5 C-115 TSC-80 R-90

30x3 PL-V 30x3 C-115 TSC-80 R-90

30x5 PL-V 30x5 C-150 TSC-80 R-150

H40x3 PL-V 40x3 C-150 TSC-80 R-150

40x5 PL-V 40x5 C-200 TSC-80 R-150

50x5 PL-V 50x5 C-250 TSC-80 R-150

60x5 PL-V 60x5 2xC-150 TSC-100 R-750 J

S

CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

58


1. 2

013

47



CONNECTION PL-TS

DIMENSION

BUS-BARMOULD


PRICEKEY FORMOULDS

20x2 PL-TS 20x2 C-115 TSC-80 R-90

D

20x3 PL-TS 20x3 C-115 TSC-80 R-90

20x5 PL-TS 20x5 C-150 TSC-80 R-150

25x3 PL-TS 25x3 C-150 TSC-80 R-150

25x5 PL-TS 25x5 C-200 TSC-80 R-150

30x3 PL-TS 30x3 C-200 TSC-80 R-150

30x5 PL-TS 30x5 C-250 TSC-80 R-150

40x3 PL-TS 40x3 C-250 TSC-80 R-150

40x5 PL-TS 40x5 2xC-150 TSC-100 R-750

I50x5 PL-TS 50x5 2xC-200 TSC-100 R-750

60x5 PL-TS 60x5 2xC-250 TSC-100 R-750

S


Leave a gap of(S) 5-6 mm between

the tap bus-bar and therun bus-bar. Secure

them with backing plateattachment.

CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

59


V1.

201

348




Insert end of tap bus-barup to the centre of the taphole. Tab bus-bar must beat least 70 mm parallel to

the run bus-bar.

CONNECTION PL-DP

DIMENSION

BUS-BARMOULD


PRICEKEY FORMOULDS

20x2 PL-DP 20x2 C-90 TSC-80 R-90B

20x3 PL-DP 20x3 C-90 TSC-80 R-90

20x5 PL-DP 20x5 C-90 TSC-80 R-90

C

25x3 PL-DP 25x3 C-90 TSC-80 R-90

25x5 PL-DP 25x5 C-90 TSC-80 R-90

30x3 PL-DP 30x3 C-115 TSC-80 R-90

30x5 PL-DP 30x5 C-115 TSC-80 R-90

40x3 PL-DP 40x3 C-115 TSC-80 R-90

40x5 PL-DP 40x5 C-200 TSC-80 R-150

50x5 PL-DP 50x5 C-200 TSC-80 R-150

60x5 PL-DP 60x5 2xC-200 TSC-100 R-750 I

70

CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

60


1. 2

013

49




Bus-bar up to 3 mmthick must be separated

(S) 3 mm in the centre ofthe tap hole. Bus-bars

thicker than 3 mm mustbe separated (S) 5-6

mm.

CONNECTION PL-LH

DIMENSION

BUS-BARMOULD


PRICEKEY FORMOULDS

20x2 PL-LH 20x2 C-45* TSC-80 R-45

B

20x3 PL-LH 20x3 C-45* TSC-80 R-45

20x5 PL-LH 20x5 C-65 TSC-80 R-45

25x3 PL-LH 25x3 C-65 TSC-80 R-45

25x5 PL-LH 25x5 C-90 TSC-80 R-90

30x3 PL-LH 30x3 C-90 TSC-80 R-90

30x5 PL-LH 30x5 C-115 TSC-80 R-90

40x3 PL-LH 40x3 C-150 TSC-80 R-150

40x5 PL-LH 40x5 C-150 TSC-80 R-150

50x5 PL-LH 50x5 C-200 TSC-80 R-150

60x5 PL-LH 60x5 2xC-150 TSC-100 R-750 F

S


CO

PP

ER

ALU

MIN

OT

HE

RM

IC W

ELD

ING

61


V1.

201

350




Tap bus-bars of up to 6mm thick must be

separated (S) 5-6 mmfrom the run bus bar.

Busbarthicker than 6 mm

must be separated (S)10mm.

CONNECTION PL-TH

DIMENSION

BUS-BARMOULD


PRICEKEY FORMOULDS

20x2 PL-TH 20x2 C-45* TSC-80 R-45

B

20x3 PL-TH 20x3 C-45* TSC-80 R-45

20x5 PL-TH 20x5 C-65 TSC-80 R-45

25x3 PL-TH 25x3 C-65 TSC-80 R-45

25x5 PL-TH 25x5 C-90 TSC-80 R-90

30x3 PL-TH 30x3 C-90 TSC-80 R-90

30x5 PL-TH 30x5 C-115 TSC-80 R-90

40x3 PL-TH 40x3 C-150 TSC-80 R-150

40x5 PL-TH 40x5 C-150 TSC-80 R-150

50x5 PL-TH 50x5 C-200 TSC-80 R-150

60x5 PL-TH 60x5 2xC-150 TSC-100 R-750 F

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Place bus-bar in themould slots.

CONNECTION PL-X

DIMENSION

BUS-BARMOULD


PRICEKEY FORMOULDS

20x2 PL-X 20x2 C-45* TSC-80 R-45

B

20x3 PL-X 20x3 C-65 TSC-80 R-45

20x5 PL-X 20x5 C-65 TSC-80 R-45

25x3 PL-X 25x3 C-65 TSC-80 R-45

25x5 PL-X 25x5 C-90 TSC-80 R-90

30x3 PL-X 30x3 C-90 TSC-80 R-90

30x5 PL-X 30x5 C-115 TSC-80 R-90

40x3 PL-X 40x3 C-115 TSC-80 R-90

40x5 PL-X 40x5 C-150 TSC-80 R-150

50x5 PL-X 50x5 C-200 TSC-80 R-150

60x5 PL-X 60x5 C-250 TSC-80 R-150


©

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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 emissions and, furthermore, it enables the charge to be ignited at a certain distance from the mould, using the KLK-weld Remote Ignition Device.

IGNITION PROCEDURE LsVIP

Ignition procedure for aluminothermic welding charges for electrical connections

Camino de la Peñona, 38-B33211 Gijón (Asturias) · Spain

Tel. +34 985 321 850Fax. +34 985 312 820

[email protected]

KLK-USA Co.(dba Dwight & Wilson Co.)

30 Interstate driveP.O. Box 363 Napoleon, OH · 43545 USA

Phone. +1 419 591 3778Fax. +1 419 599 [email protected]

KLK Electro Materiales, S.A.C/ 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]

www.klk.es

•••

®

The special lid used in the Ignition Procedure can be used either with the standard flint igniter or with the KLK-weld Remote Ignition Device. The same applies to the cartridges, ignition powder, and the other welding accessories, thus there is a complete versatility to use either of the two ignition options.

IGNITION PROCEDURE LsVIP••• EASY AND QUICK TO USE:

The connections achieved using the KLK-weld welding procedures, and in particular those achieved after using the LsVIP Ignition Procedure, are connections with a very high electrical conductivity, equal or greater 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 spattering from the aluminothermic reaction. But at the same time it allows the release of overpressures within the crucible. Furthermore, 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.

LsVIP: Low Smoke Versatile Ignition Procedure

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 desiredand press the button.

5If the option chosen is the flint igniter, put it close to the funnel

shape opening in the lid and pull the trigger.

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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 fi eld 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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The ELPA-Pipe KLK-weld procedure is the best solution for making the electrical connections 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 connection. This procedure does not change the structure of the steel pipe as the temperature never exceeds 450 ºC.

WELDING PROCEDURE ELPA-PIPE

Welding of electric copper cable to steel pipe


Tel. +34 985 321 850Fax. +34 985 312 820

[email protected]






[email protected]



[email protected]

www.klk.es

®

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 on non-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-PIPE

THE ELPA-PIPE KLK-WELD KIT INCLUDES THE FOLLOWING PARTS:

EASY AND CONVENIENT USE

a 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.

b Cartridge containing the welding and the ignition powder.

c Flux portion.

d Flare to ignite the powder.

e Additional sleeves to be used with other cable sections (as an option).

f User’s guide.

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 stop 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

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ADVANTAGES OF THE ELPA-PIPE 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-Pipe, 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 suffi cient.

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.

El procedimiento de soldadura ELPA-Tubo KLK-weld es el mejor procedimiento para realizar conexión eléctrica de cable de cobre a tubería de acero, con el fin de realizar protección catódica de esa tubería, pues se consigue una baja resistividad eléctrica y una alta resistencia mecánica en la conexión, todo ello sin afectar al acero de la tubería, pues la temperatura en la misma no supera los 450ºC.

PROCEDIMIENTO DE SOLDADURA ELPA-TUBO

Procedimiento de soldadura de conexiones eléctricas de cable de cobre a tubería de acero


Tel. +34 985 321 850Fax. +34 985 312 820

[email protected]






[email protected]



[email protected]

www.klk.es©

®

RAILTECH BOUTET, Inc.

25 Interstate Drive P.O. Box 69

Napoleon, OH 43545 Phone. (419) 592-5050

Fax. (419) [email protected]

KLK Electro Materiales, S.L.UC/ Rosario Pino, Nº18, 4º - 7ª


[email protected]



[email protected]

• copper welding - klk · copper aluminothermic welding 12 7.1 cable / cable v1. 2013 1 see mould...

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