1. Introduction
The BURNDY KSA2 Split Bolt Connector is designed for making reliable electrical connections between two conductors. This connector is suitable for a range of aluminum conductors from 8 AWG to 2 AWG. Constructed from high-strength aluminum and tin-plated for enhanced conductivity and corrosion resistance, the KSA2 ensures a secure and durable connection. This manual provides essential information for the safe and correct installation and maintenance of your BURNDY KSA2 Split Bolt Connector.
Image 1.1: The BURNDY KSA2 Split Bolt Connector. This image displays the connector's main body, the split bolt, and the hexagonal nut used for tightening, highlighting its robust construction.
2. Important Safety Information
Always observe the following safety precautions to prevent personal injury or damage to equipment:
- Qualified Personnel Only: Installation and maintenance should only be performed by qualified and trained electrical personnel.
- De-energize Circuits: Ensure all circuits are de-energized and locked out before beginning any work on electrical connections. Verify with a voltage tester.
- Personal Protective Equipment (PPE): Always wear appropriate PPE, including safety glasses, gloves, and arc-rated clothing.
- Proper Tools: Use only insulated and appropriate tools for electrical work.
- Manufacturer's Instructions: Follow all manufacturer's instructions and local electrical codes.
- Material Compatibility: Ensure the connector is compatible with the conductor material (aluminum in this case) and size.
3. Product Components
The BURNDY KSA2 Split Bolt Connector consists of the following primary components:
- Connector Body: The main aluminum, tin-plated housing that encloses the conductors.
- Split Bolt: The threaded bolt that passes through the connector body, designed to apply pressure to the conductors.
- Hexagonal Nut: Used to tighten the split bolt, securing the conductors within the connector body.
Image 3.1: A detailed view of the BURNDY KSA2 Split Bolt Connector. This image provides a closer look at the threads of the bolt and the interior design of the connector, illustrating how it grips the conductors.
4. Technical Specifications
| Specification | Value |
|---|---|
| Model | KSA2 |
| Conductor Range | 8 AWG to 2 AWG (Aluminum) |
| Material | Aluminum, Tin Plated |
| Length | 1.24 inches (31.5 mm) |
| Width | 0.69 inches (17.5 mm) |
| Recommended Torque | 275 in-lb (31.07 Nm) |
| Manufacturer | Hubbell (Burndy Brand) |
5. Setup and Preparation
Before installing the BURNDY KSA2 Split Bolt Connector, ensure the following preparatory steps are completed:
- De-energize Circuit: Confirm that the electrical circuit is completely de-energized and secured against accidental re-energization.
- Gather Tools: Collect all necessary tools, including a torque wrench, wire strippers, and a wire brush.
- Inspect Conductors: Examine the conductors for any damage, nicks, or corrosion. Damaged sections should be removed.
- Strip Insulation: Carefully strip the insulation from the ends of the conductors to the appropriate length, ensuring enough bare conductor is exposed to fully seat within the connector. Avoid nicking the conductor strands.
- Clean Conductors: For aluminum conductors, thoroughly clean the stripped ends with a wire brush to remove any oxidation. Apply an oxide inhibitor compound (not supplied) to the cleaned conductor surfaces immediately to prevent re-oxidation.
6. Installation Instructions
Follow these steps to properly install the BURNDY KSA2 Split Bolt Connector:
- Separate Connector: Loosen the hexagonal nut on the split bolt connector sufficiently to allow the conductors to be inserted into the grooves.
- Insert Conductors: Insert the prepared (stripped, cleaned, and inhibited) conductors into the opposing grooves of the split bolt connector. Ensure each conductor is fully seated and makes good contact with the connector body.
- Initial Tightening: Hand-tighten the hexagonal nut until it is snug and the conductors are held in place.
- Torque Application: Using a torque wrench, tighten the hexagonal nut to the recommended torque value of 275 in-lb (31.07 Nm). Apply torque gradually and evenly. Over-tightening can damage the connector or conductors, while under-tightening can lead to a poor connection and overheating.
- Inspect Connection: After tightening, visually inspect the connection to ensure the conductors are securely held and there are no exposed bare wires beyond the connector body.
- Insulate Connection: Once the connection is complete and verified, properly insulate the entire connector and exposed conductor areas using appropriate electrical tape or heat-shrink tubing, as required by local codes and application.
7. Maintenance
The BURNDY KSA2 Split Bolt Connector is designed for long-term reliability with minimal maintenance. However, periodic inspection is recommended:
- Visual Inspection: Periodically inspect the connection for any signs of overheating (discoloration), corrosion, or physical damage.
- Tightness Check: If accessible and safe to do so (with power off), verify the tightness of the connection. Do not re-torque unless there is evidence of loosening or a specific maintenance procedure requires it.
- Cleaning: If necessary, gently clean the exterior of the insulated connection with a dry, non-abrasive cloth.
8. Troubleshooting
Most issues with split bolt connectors arise from improper installation. Refer to the following for common problems:
| Problem | Possible Cause | Solution |
|---|---|---|
| Connection Overheating | Insufficient torque, improper conductor cleaning, incorrect conductor size. | De-energize circuit. Disassemble, clean conductors, apply oxide inhibitor, re-install with correct torque. Verify conductor size. |
| Loose Connection | Insufficient torque during installation, vibration. | De-energize circuit. Re-tighten to specified torque. Consider vibration dampening if applicable. |
| Corrosion at Connection | Improper cleaning of conductors, lack of oxide inhibitor, environmental exposure. | De-energize circuit. Disassemble, thoroughly clean conductors, apply oxide inhibitor, re-install. Ensure proper insulation. |
9. Warranty Information
For specific warranty details regarding the BURNDY KSA2 Split Bolt Connector, please refer to the official warranty statement provided by Burndy or Hubbell. Warranty terms typically cover defects in materials and workmanship under normal use and service. Keep your purchase receipt as proof of purchase.
10. Customer Support
If you require technical assistance, have questions about installation, or need to report a product issue, please contact Burndy customer support. Contact information can typically be found on the official Burndy or Hubbell website, or through your authorized distributor.
