Burndy BD12 Flexible Copper Braid Instruction Manual

1. Product Overview

The Burndy BD12 is a flexible copper braid jumper designed for electrical connections. It is engineered to accommodate linear expansion and contraction, compensate for misalignment, and absorb vibratory movement in electrical equipment and devices. This component is constructed from flat, extra-flexible, tinned, pure copper braid, featuring unplated, seamless, pure copper ferrules formed into a rectangular shape at each end for secure termination.

Key Features:

• Flexible copper braid construction.
• Designed to manage linear expansion and contraction.
• Compensates for misalignment in electrical systems.
• Absorbs vibratory movement from electrical equipment.
• Made from flat, extra-flexible, tinned, pure copper braid.

Figure 1: Burndy BD12 Flexible Copper Braid. This image shows the tinned copper braid with rectangular copper ferrules at each end, ready for connection.

2. Safety Information

Always adhere to local and national electrical codes and safety regulations when installing or working with electrical components. Failure to do so may result in serious injury, property damage, or death.

• Disconnect Power: Ensure all power sources are disconnected and locked out before beginning any installation or maintenance.
• Qualified Personnel: Installation and maintenance should only be performed by qualified and trained electrical personnel.
• Proper Tools: Use appropriate insulated tools for electrical work.
• Inspect Components: Before installation, inspect the braid for any signs of damage, corrosion, or defects. Do not install damaged components.
• Environmental Suitability: Ensure the product's specifications (e.g., ampere rating, material) are suitable for the intended indoor or outdoor application and environmental conditions.

3. Package Contents

The standard package for the Burndy BD12 Flexible Copper Braid typically includes:

• 1 x Burndy BD12 Flexible Copper Braid
• Note: Any necessary installation tools (e.g., crimping tools, wrenches) are sold separately.

4. Setup and Installation

The Burndy BD12 Flexible Copper Braid is designed for secure electrical connections in applications requiring flexibility and vibration absorption. Follow these general steps for installation:

1. Preparation: Ensure the contact surfaces on the equipment to which the braid will be connected are clean, dry, and free from oxidation or contaminants.
2. Positioning: Position the flexible copper braid between the two connection points, ensuring it has sufficient slack to accommodate expected movement without excessive tension or compression.
3. Connection: Secure the rectangular copper ferrules to the connection points using appropriate fasteners (e.g., bolts, nuts, washers, not included). Ensure proper alignment of the holes.
4. Torque: Tighten fasteners to the manufacturer's recommended torque specifications for the specific connection hardware used. Over-tightening or under-tightening can lead to poor electrical contact or damage.
5. Verification: After installation, visually inspect all connections to ensure they are secure and properly seated.

Figure 2: Technical drawing of the Burndy BD12 Flexible Copper Braid, illustrating key dimensions such as 0.94" width, 12" length, 0.13" height, and 1.25" hole spacing, along with copper ferrule details.

5. Operation

Once properly installed, the Burndy BD12 Flexible Copper Braid functions as a reliable electrical conductor while providing mechanical flexibility. It maintains electrical continuity across connections that may experience movement, vibration, or thermal expansion/contraction, thereby preventing stress on rigid conductors and ensuring consistent performance of the electrical system.

6. Maintenance

Regular inspection of the Burndy BD12 Flexible Copper Braid is recommended to ensure continued safe and efficient operation.

• Visual Inspection: Periodically check the braid and its connections for any signs of wear, fraying, discoloration (indicating overheating), corrosion, or loose fasteners.
• Cleaning: If necessary, gently clean the braid and connections using a non-abrasive cleaner suitable for electrical components. Ensure power is disconnected before cleaning.
• Tightness Check: Verify the tightness of all connection fasteners during routine maintenance, especially in environments with significant vibration.
• Replacement: Replace any braid that shows signs of damage, excessive wear, or degradation to prevent potential electrical failures.

7. Troubleshooting

If issues arise with the electrical connection where the BD12 braid is installed, consider the following:

• Overheating: If the braid or connections are unusually hot, this may indicate a poor connection, insufficient ampere rating for the load, or damage to the braid. Disconnect power and inspect thoroughly.
• Intermittent Connection: Check for loose fasteners or corroded contact surfaces. Re-tighten connections to specified torque and clean surfaces if necessary.
• Physical Damage: Inspect for any cuts, kinks, or severe fraying in the braid. Damaged braids should be replaced immediately.
• Excessive Movement: If the braid is experiencing more movement than anticipated, ensure it was installed with adequate slack and that the equipment it connects is properly secured.

8. Specifications

9. Certifications

The Burndy BD12 Flexible Copper Braid meets recognized safety and quality standards:

• UL Listed: Underwriters Laboratories Listed.
• CSA Certified: Canadian Standards Association Certified.

10. Warranty and Support

For information regarding product warranty, technical support, or service, please contact Burndy directly through their official website or customer service channels. Keep your purchase receipt for warranty claims.