Burndy YS32 Hylink Splice Long Barrel Instruction Manual

Introduction

This manual provides detailed instructions for the safe and effective installation and application of the Burndy YS32 Hylink Splice Long Barrel. This copper compression splice is designed for joining 400 kcmil AWG conductors in various electrical applications, ensuring reliable and durable connections.

Safety Information

Adherence to safety precautions is paramount when working with electrical components. Please read and understand all safety warnings before proceeding with installation.

• Always disconnect power from the circuit before installing or servicing electrical components to prevent electrical shock.
• Wear appropriate personal protective equipment (PPE), including safety glasses and insulated gloves, to protect against potential hazards.
• Ensure all connections are made in accordance with local electrical codes, national standards, and industry best practices.
• Improper installation can lead to severe consequences, including electrical shock, fire, or permanent equipment damage.
• If you are unsure about any installation steps or procedures, consult a qualified and certified electrician.

Product Overview

The Burndy YS32 Hylink Splice is a long barrel, copper compression splice engineered for robust electrical connections. It features a center wire stop to ensure proper conductor insertion and provides high pull-out force for enhanced mechanical and electrical integrity.

Key Features:

• Long barrel length designed for optimal contact and strength in heavy-duty applications.
• Suitable for 600-volt heavy-duty applications, and certified for use at higher voltages up to 35KV.
• Incorporates four (4) center conductor stops to facilitate precise and consistent conductor positioning.
• UL listed and CSA certified, ensuring compliance with recognized safety and performance standards.

Image: Burndy YS32 Hylink Splice Long Barrel. This image displays the general form factor of the copper compression splice, designed for joining electrical conductors.

Setup and Installation

Follow these steps for proper installation of the Burndy YS32 Hylink Splice to ensure a secure and reliable electrical connection:

1. Prepare Conductors: Ensure the conductors are clean, free of insulation, and stripped to the recommended length of 2-3/16 inches (approximately 55.5 mm). Use a wire stripper appropriate for the conductor size.
2. Insert First Conductor: Insert one prepared conductor into one end of the splice until it firmly meets the internal center wire stop. The center stop is crucial for ensuring equal insertion depth for both conductors.
3. Crimp First End: Using the appropriate crimping tool and dies (refer to Burndy tooling specifications for the YS32 model), perform the required number of crimps on the first end of the splice. Ensure crimps are evenly spaced, fully formed, and meet manufacturer specifications.
4. Insert Second Conductor: Insert the second prepared conductor into the opposite end of the splice until it also meets the center wire stop.
5. Crimp Second End: Perform the required number of crimps on the second end of the splice, mirroring the crimping process for the first end. Verify that all crimps are consistent and secure.
6. Inspect Connection: Visually inspect all crimps and the entire splice to ensure they are properly formed, free of damage, and securely attached to both conductors. A properly crimped splice should exhibit no gaps or loose strands.

Application Guidelines

The Burndy YS32 Hylink Splice is designed for specific operational parameters to ensure optimal performance and safety:

• Temperature Rating: Rated for a maximum operating temperature of 90 degrees C (194 degrees F). Do not exceed this temperature rating.
• Voltage Rating: Suitable for applications ranging from 600 Volts up to 35 kV. Always ensure the splice is used within the voltage rating of the overall electrical system and insulation.
• Conductor Size: Specifically designed and tested for use with 400 kcmil AWG conductors. Using incorrect conductor sizes may compromise the integrity of the connection.

Maintenance

Once properly installed, the Burndy YS32 Hylink Splice requires minimal maintenance. However, periodic inspection of electrical connections is recommended as part of a routine maintenance schedule. Look for any signs of corrosion, loosening, physical damage, or discoloration which could indicate overheating. If any issues are observed, immediately disconnect power from the circuit and consult a qualified professional for assessment and necessary repair or replacement.

Troubleshooting

If issues arise during or after the installation of the Burndy YS32 Hylink Splice, consider the following common problems and potential solutions:

• Loose Connection: If the connection feels loose or exhibits excessive movement, it may indicate improper crimping or insufficient conductor insertion. Ensure conductors are fully inserted against the center stop and all crimps are properly formed according to manufacturer specifications. Re-crimp if necessary, or replace the splice if damage to the barrel is evident.
• Overheating: Signs of overheating, such as discoloration or melting insulation near the splice, can indicate a poor electrical connection or an undersized conductor/splice for the current load. Verify the conductor size matches the splice rating, check crimp integrity, and assess the system's current load against the splice's capacity.
• Damaged Splice: If the splice appears physically damaged (e.g., bent, cracked, or corroded) before or during installation, do not use it. A damaged splice will not provide a reliable connection and poses a safety risk. Replace it with a new, undamaged unit.

Specifications

Detailed technical specifications for the Burndy YS32 Hylink Splice Long Barrel:

Warranty Information

For specific warranty details regarding the Burndy YS32 Hylink Splice, please refer to the official Burndy website or contact Burndy customer service directly. Warranty terms typically cover manufacturing defects under normal use conditions and are subject to the manufacturer's policies. Keep your purchase receipt as proof of purchase.

Support and Contact Information

If you require further assistance, technical support, or have questions about the Burndy YS32 Hylink Splice that are not covered in this manual, please visit the official Burndy website. You can typically find contact information for their customer support department, including phone numbers and email addresses, on their website or product packaging.