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IS---0061
IS---W1 (Rev D)
March 2010
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Suggested Welding Guide
Apparatus Bushings and Bushing Wells
DANGER
All apparatus must be de--energized during installation
or removal of part(s).
All apparatus must be installed and operated in
accordance with individual user, local, and national
work rules. These instructions do not attempt to
provide for every possible contingency.
Do not touch or move energized products.
Excess distortion of the assembled product may result
in its failure.
Inspect parts for damage, rating and compatibility with
mating parts.
FOR MORE INFORMATION ON PARTS, INSTALLATION RATINGS AND COMPATIBILITY, CALL THE NEAREST ELASTIMOLD OFFICE.
This product should be installed only by competent
personnel trained in good safety practices involving
high voltage electrical equipment. These instructions
are not intended as a substitute for adequate training or
experience in such safety practices.
Failure to follow these instructions will result in
damage to the product and serious or fatal injury.
If this product is supplied with a protective shipping
cover(s), remove this shipping cover(s) and replace
with the appropriate HV insulated cap(s) or
connector(s) before submerging or energizing the
circuit.
IMPORTANT
1. Check contents of package to ensure they are complete
and undamaged.
2. Check all components to ensure proper fit with cable
and/or mating products.
WELDING
The following data are suggested recommendations for
welding ELASTIMOLD apparatus bushings and bushing
wells. Because of the many variations in transformer
design, and the various welding techniques used, the
following is intended as a guide only. The most important
factor during welding is that heat must be kept at a
minimum. Excessive heating of the epoxy can affect the
integrity of the bushing.
3. Read entire installation instructions before starting.
4. Have all required tools at hand and maintain cleanliness
throughout the procedure.
WELDING PROCESSES
1. Inert--- gas, tungsten ---arc welding (TIG).
2. Short---arc welding (metal inert--- gas, MIG).
Both of the above processes are fast and, therefore, create
minimum heat.
MATERIALS
No. 308 bare stainless steel wire is used with either process.
IS---0061
IS---W1 (Rev D)
March 2010
Printed In U.S.A.
8155 T&B Boulevard, Memphis, Tennessee 38125
(800) 888--0211 Fax: (800) 888-- 0690
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IS---0061
March 2010
Page 2 of 2
HEAT SINKS
To minimize heat flow to the epoxy, the use of copper heat
sinks is required. The following suggestions are offered:
a. Water Cooled (helical coil---top and bottom). Suggest
setting up three or four work stations in order to allow
enough time to utilize heat sink before removing work
piece.
b. Recommended Configuration.
225_ F. Max.
Bottom heat sink should
be of larger diameter than
top to allow heat to be absorbed by bottom sink rather
than flow into the tank.
c. Non--- water cooled heat sinks must not be left on too
long since heat will flow back into bushing. Air cool
bushing after removal of heat sink.
d. Copper heat sinks are required. Use thermally conductive
paste at face of heat sinks in contact with flange and cover.
e. Venting of heat sinks must be provided.
f. Do not thread heat sink to bushing or bushing well
stud. Expansion due to heat may affect the integrity of
these parts.
Heat line from
welding to be kept
to 1/8” maximum.
RECOMMENDED PROCEDURES
a. Keep heat toa minimum. Visible heat line should not be
greater than 1/8” from weld, 3/16” from O.D. of flange.
b. All surfaces (tank, bushing and bushing well) must be
kept clean. Contamination such as paint, grease, etc.,
will extend welding time, thus raising the temperature
and will affect the integrity of the bushing.
c. Minimize air currents in welding area which will disturb
the gas atmosphere.
INSTALLATION REQUIREMENTS
A. Clearance between epoxy shank and mouting
hole must be 3/16” ± 1/16”.
B. Enclosure cover thickness to be 1/4”
maximum. Consult the factory for enclosures
that exceed 1/4” thick.
C. Clearances from the apparatus connection to
enclosure stiffeners and adjacent ground
planes are critical and must be observed during
installation. For more information regarding
spacing, please consult the manufacturer.
D. Oillevel covering the immersed stud connection
must be greater than 2 inches.
E. Certain equipment surface finishes require a
thermal baking to cure the finish. In such
cases, the bake sequence must not exceed
130_ or 8 hours to prevent damage to critical
sealing aspects of the bushings. In addition,
the bushing metallic contacts should not be
mechanically loaded internally or externally during
this cure process to prevent epoxy distortion.
d. Handling techniques before and after welding must
minimize forces applied to heated stud and flange.
e. No torque is to be applied to epoxy when making any
bus bar connection.
f. Temperatures at points indicated by curved arrows
must not exceed 225_F. This must be determined by
the use of thermocouple detectors during
development of the required heat sink.
1/4”
Remove All Burrs
and Finish with
1/16” Radius.
3/16”
ELASTIMOLD BUSHING ARE NOT DESIGNED FOR USE IN AIR EXCEPT FOR THE 600T1 WITH
BOOTS AND COLLARS.
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