Horizontal Cable Run to Horizontal Cable Tap Tee Joint – CC2

Horizontal Cable Run to Horizontal Cable Tap Tee Joint – CC2

SKU: MDCC2xxx Category: Tag:
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SKU: MDCC2xxx Category: Tag:

Product Information:

Horizontal Cable Run to Horizontal Cable Tap Tee Joint- CC2 is a cable to cable exothermically welded connection that requires an HCD or HCE Handle Clamp.

Features:

A KingsWeld metal consists of copper oxide, aluminium and flux in a granular (powder) form. Comes in standard sizes.

KingsWeld exothermic mould is manufactured from high-quality graphite. This lends itself to easy machining, as well as being able to withstand the high thermal and mechanical shocks produced during the exothermic welding process. The heat obtained in such reactions is in excess of 2000º C.
Our moulds are designed to have an average lifetime of 50 to 60 connections. But, if treated with care, it is possible to obtain a significantly longer life.
Graphite is both brittle and soft, therefore it is important that the operator takes care while handling the product. Worn-out or damaged moulds should not be used.
Each mould has a nameplate, detailing the connection type, part code, and the correct weld metal size to be used.
If you do not see the connection, configuration or size of conductor that you require, please contact our sales office who will be pleased to assist you.

More Information:

To make a KingsWeld connection certain items might be required such as a KingsWeld mould, Handle Clamp, Weld Metal, and/or Flint Gun.

Mould Care Guide:
KingsWeld moulds are manufactured from high quality graphite which, by nature, is soft and needs to be handled with care in order to get the maximum lifetime.

  • Always clean the mould after every weld
  • Only use KingsWeld cleaning equipment (soft brush) to clean the mould
  • Keep the mould dry and away from moisture
  • Do not hit or drop the mould
  • When not in use, keep the mould in its packaging for protection
  • When not in use, keep the mould in its packaging for protection
  • Try not to hit the edges of the mould with the conductors to be connected • Never use a wire brush to clean the mould
  • Always use the correct weld metal size, tools and handle clamps

Mould Inspection:

  • Handle the mould with care.
  • Mould must be dry with fixed lid.
  • Identification plate must be attached.
  • Mould faces must be smooth,so they seal properly.
  • Mould steel disc seat must not show signs of wear, chips or gouges (steel disc must seal the hole properly to prevent weld metal entering the weld cavity prior to welding).
  • Mould steel disc seat must not show signs of wear, chips or gouges (steel disc must seal the hole properly to prevent weld metal entering the weld cavity prior to welding).
  • Tap hole must be well defined.
  • Weld cavity must not show signs of wear, chips or gouges (conductors must have a 3mm gap between them prior to welding, fit snugly and not be loose in the mould).
  • REGULAR CHECKS HELP KEEP MOULDS IN GOOD CONDITION

Mould Sizes:

A (mm)
B (mm)
PRICE KEY
WELD METAL
HANDLE CLAMP
MOULD
16
16
D
#045
HCD
MDCC21616
25
25
D
#045
HCD
MDCC22525
35
25
D
#045
HCD
MDCC23525
35
35
D
#045
HCD
MDCC23535
50
25
D
#065
HCD
MDCC25025
50
35
D
#065
HCD
MDCC25035
50
50
D
#090
HCD
MDCC25050
70
25
D
#065
HCD
MDCC27025
70
35
D
#065
HCD
MDCC27035
70
50
D
#090
HCD
MDCC27050
70
70
D
#090
HCD
MDCC27070
95
35
D
#090
HCD
MDCC29535
95
50
D>D
#090
HCD
MDCC29550
95
70
D
#090
HCD
MDCC29570
95
95
D
#115
HCD
MDCC29595
95
240
D
#150
HCD
MDCC295240
120
50
D
#090
HCD
MDCC212050
120
70
D
#090
HCD
MDCC212070
120
95
D
#150
HCD
MDCC212095
120
120
D
#150
HCD
MDCC2120120
150
70
D
#090
HCD
MDCC215070
150
95
D
#150
HCD
MDCC215095
150
120
D
#150
HCD
MDCC2150120
150
150
D
#200
HCD
MDCC2150150
185
95
D
#150
HCD
MDCC218590
185
120
D
#200
HCD
MDCC2185120
185
150
D
#200
HCD
MDCC2185150
185
185
D
#200
HCD
MDCC2185185
240
120
D
#200
HCD
MDCC2240120
240
150
D
#200
HCD
MDCC2240150
240
185
D
#200
HCD
MDCC2240185
240
240
E
2 x #150
HCE
MECC2240240
300
35
D
#115
HCD
MDCC230035
300
70
D
#200
HCD
MDCC230070
300
120
D
D
#200
HCD
MDCC2300120
300
150
D
#200
HCD
MDCC2300150
300
185
D
#250
HCD
MDCC2300185
300
240
E
2 x #200
HCE
MECC2300240
300
300
E
2 x #200
HCE
MECC2300300
400
240
E
2 x #250
HCE
MECC2400240
400
400
E
2 x #250
HCE
MECC2400400
8 dia
8 dia
D
#065
HCD
MDCC28S8S
10 dia
10 dia
D
#090
HCD
MDCC210S10S

16, 25, 35, 50, 70, 95, 120, 150, 185, 240, 300 and 400 = stranded cable (mm²)
8 dia and 10 dia = solid copper/steel

LEGEND:
Conductor Size:
The size of conductors to be joined are denoted by A and B (where applicable). Bar is denoted by its x and y dimensions. Circular conductors are stranded (cable) or solid (ground rod, rebar). Where both stranded and solid circular conductors can be used these are noted in the relevant table footer. Dimensions are given in mm (diameter) unless otherwise stated.

Price Key:
Moulds are priced in bands according to their size and complexity. These are denoted by the price key.

Weld Metal:
Weld metal is sized specifically for each mould. In most cases a single weld metal carton is required. In cases where multiple cartons are required these are denoted by a multiplier (eg 2 x #150).

Clamp:
Each KingsWeld mould type requires a specific clamp. If ordering multiple moulds that utilize the same clamp you only need to purchase a quantity of clamps suitable for the number of operators for your application.

Mould:
Mould part numbers are compiled in a logical manner-prefix ‘MD’ followed by the mould type then followed by size relevant figures (eg CC2 mould to join a 70mm cable to a 50mm cable = MDCC27050).

Sleeve (rail applications):
A copper sleeve that increases the diameter of a small conductor to make it possible to weld the conductor.

Hammer Die:
A hammer die flattens one side of a conductor giving better contact with the rail. Used in rail applications.

The KingsWeld Process:

The KingsWeld exothermic process is a simple, self-contained, efficient way of welding copper-to-copper or copper-to-steel. Click here to see the KingsWeld Exothermic Process.

Each connection uses a KingsWeld weld metal which, when ignited, creates an exothermic reaction between copper oxide and aluminium powder.

The connections are produced inside a graphite mould, specifically designed to suit the size of conductors to be welded as well as the specific joint configuration.
Each connection requires a specific mould designed to suit the joint configuration and conductors being used. Each mould type requires a specific weld metal size.

Once the correct mould and weld metal have been selected, the process is simple and straightforward.

The conductors are positioned in the graphite mould. A steel retaining disc is then inserted into the mould before any weld metal is added. Only after the disc is in place and properly seated can the main weld metal (under the green cap) be poured into the reaction crucible. The ignition temperature of the main weld metal is approximately 1000°C. This is difficult to achieve and so we use a starter powder to start the exothermic reaction, this is contained under the red cap. The starter powder is similar to the main weld metal, but finer, allowing ignition at around 450°C (through using the spark from a flint ignitor).

The resultant exothermic reaction produces high-temperature molten copper (in excess of 2000°C) and aluminium slag.

The molten copper melts the steel retaining disc and flows down the tap hole into the joint cavity. In doing so, the molten copper melts and welds the conductors into a solid homogenous joint.

The whole process takes no more than a few seconds.

The aluminium oxide produced stays on top of the joint and is easily removed.