Burndy B-445 BCC-4 Cable Cross Mold Splice Instruction Manual

1. Introduction

This manual provides instructions for the safe and effective use of the Burndy B-445 BCC-4 Type Horizontal to Horizontal Cable Cross Mold Splice. This product is designed for joining two horizontal cables at right angles, where one cable serves as a through run and the other as a tap.

2. Safety Information

Always follow local electrical codes and safety regulations.

Ensure power is disconnected before installation.

Use appropriate personal protective equipment (PPE) such as gloves and eye protection.

This product is intended for use by qualified personnel only.

The product is UL listed.

3. Product Overview

The Burndy B-445 BCC-4 mold is specifically designed for creating horizontal-to-horizontal cable cross splices. It accommodates a 4/0 AWG cable for the run and a 2/0 AWG cable for the tap.

Key Features:

• BCC-4 type horizontal to horizontal cable cross mold splice.
• Designed for 4/0 AWG cable run.
• Designed for 2/0 AWG cable tap.
• UL listed for safety and performance.

4. Package Contents

Upon opening the package, verify that all components are present and undamaged.

• Burndy B-445 BCC-4 Cable Cross Mold Splice (Tool)

5. Setup and Installation

Required Materials:

• Exothermic welding material (e.g., Burndy Weld powder)
• Igniter
• Cleaning brush
• Cable preparation tools (e.g., wire brush, cable cutter)
• Appropriate cables (4/0 AWG run, 2/0 AWG tap)

Installation Steps:

1. Prepare Cables: Ensure both the 4/0 AWG run cable and the 2/0 AWG tap cable are clean and free of insulation at the splice points as per standard exothermic welding procedures. The run cable will pass through, and the tap cable will be cut and inserted.
2. Clean Mold: Thoroughly clean the inside of the B-445 mold with a wire brush to remove any residue from previous welds or debris.
3. Position Cables: Place the 4/0 AWG run cable into the designated channel in the lower half of the mold. Position the prepared 2/0 AWG tap cable into its channel, ensuring proper alignment for the cross splice.
4. Close Mold: Close the mold halves securely, ensuring the cables are firmly seated and the mold is properly aligned. Use the provided retaining clip to hold the mold closed.
5. Apply Welding Material: Follow the instructions provided with your exothermic welding material (e.g., Burndy Weld powder) for proper loading into the mold's crucible.
6. Ignite: Carefully ignite the welding material according to its specific instructions.
7. Cool and Open: Allow the mold to cool completely after the weld is formed. Once cooled, carefully remove the retaining clip and open the mold.
8. Inspect Weld: Inspect the completed weld for any defects. Clean any slag or residue from the weld and the mold.

6. Operating Instructions

The operation of the B-445 mold is integrated into the installation process described above. Proper cable preparation, mold cleaning, and adherence to the exothermic welding material's instructions are crucial for a successful and safe splice.

7. Maintenance

• Cleaning: After each use, thoroughly clean the mold cavity and crucible with a wire brush to remove all slag and residue. This prevents contamination and ensures proper fit for subsequent welds.
• Storage: Store the mold in a dry, clean environment to prevent corrosion and damage.
• Inspection: Regularly inspect the mold for cracks, wear, or damage. A damaged mold should not be used as it can lead to unsafe or faulty welds.

8. Troubleshooting

Common Issues and Solutions:

• Poor Weld Quality:
  Cause: Insufficient mold cleaning, moisture in the mold or cables, incorrect welding material quantity, or improper cable preparation.
  Solution: Ensure mold is thoroughly cleaned and dry. Verify cables are dry and properly prepared. Use the correct amount of welding material.
• Mold Sticking:
  Cause: Residue buildup, mold not fully cooled before opening.
  Solution: Clean mold thoroughly after each use. Allow sufficient cooling time before attempting to open the mold.
• Incomplete Weld:
  Cause: Insufficient welding material, moisture, or improper ignition.
  Solution: Verify correct welding material charge. Ensure all components are dry. Follow ignition instructions precisely.

9. Specifications

10. Warranty and Support

For warranty information or technical support regarding your Burndy B-445 BCC-4 Cable Cross Mold Splice, please contact Burndy customer service directly.

Visit the official Burndy website for contact details and additional product resources: www.burndy.com