BUS CONNECTORS

Standard & EHV to 765 KV

dmcpower.com 888-swage-now
 BUS CONNECTOR SYSTEM

Faster, More Reliable

Bus Installations

If installation speed, quality, safety and total

project cost is important on your job site,
stop welding and start Swaging.

Extensive comparative testing shows the

DMC Power Swaging system outperforms
welded and bolted counterparts in all major
tests. Each Swaged Bus connector results in Typical Test Graph for
a superior mechanical, thermal and electrical Welded Connector Failure

connection for your substation needs.

the proof is in the testing
Qualified to meet or exceed all the nationally Swaged connections carry a greater load
recognized standards, including ANSI C119.4 for a longer amount of time versus welding.
and NEMA CC1, the DMC Power system
raises the quality, safety and productivity
standard on your site, rendering conventional
methods obsolete.

Putting DMC Power to the Test*

Corona/RIV...........Qualified for up to 750kV substations**
Fault Current..........................................................45kA
Current Cycle.............. 500 cycles air, 100 cycles water
Bending................................................ 13,000 lbs. load
Vibration..................2hz to 125hz, over 1 million cycles Typical Test Graph for
Tensile................................................. Over 17,000 lbs. DMC Power Swaged Connector
Salt Fog....................... 1,000 hours per ASTM B117-90

* Typical results for 2 inch bus fittings

** Some parts may require additional shielding

Current Cycle Testing Temperature Rise Testing Bend Testing Vibration Testing

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 Standard product dimensions
The following information and dimensional data is consistent throughout the DMC Power product line
All dimensions are standard sizes and listed in inches (metric available)
Contact DMC Power for information on custom fittings that can be designed to fit your specifications

Standard DMC Power Configuration

These dimensions are consistent throughout this product line and will not be repeated in each table.

DMC Bus C Dia

Size Size (O.D.) D Min. D Max

16 1 2.00 1.50 2.00

24 1-1/2 2.50 1.50 2.00
32 2 3.00 2.00 2.50
40 2-1/2 3.75 2.00 2.50
48 3 4.37 3.00 3.50
56 3-1/2 5.00 3.00 3.50
64 4 5.50 3.00 3.50
80 5 6.50 5.00 5.75
96 6 8.00 6.00 6.75
MARKING
Includes DMC Power part number
and tooling swage die part number

Standard NEMA pad Configurations

Diagrams below are standard dimensions but customization is available for all parts, contact DMC Power for
details. Pad thickness is dependant on Bus size.

Standard Bolt Circle Configurations

Diagrams below are standard dimensions, contact DMC Power for customization options.

Hole Plate
Suffix Hole Size
Diameter Thickness
E1 3" 8: 9/16" x 13/16" 1/2"
E2 5" 8: 11/16" x 1-1/16" 1/2"
E3 7" 8: 13/16" x 1-1/2" 1/2"
16: 9/16" x 13/16"
E12 3" & 5" 3/4"
11/16" x 1-1/16"
16: 11/16" x 1-1/16"
E23 5" & 7" 3/4"
13/16" x 1-1/2"

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 Bus connectors

now available
Split Fittings

For many of our parts, we now offer the split fitting option, where the
main run is separable, making it easy to to tap into existing bus structures.

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Bus connectors

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 Bus connectors

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Bus connectors

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 Bus connectors
PLK2230

Slip / Fixed Bus Supports

Our new Permanent Mold Bus Support is EHV rated up to 500 kV
(for more information on Bolt Circle Patterns, see page 3)
NPS BOLT BOLT
PART NO. SIZE CIRCLE H L W SIZE
PLK2230D16E12 1 3&5 2 9 5 1/2 3/8
PLK2230D24E12 1 1/2 3&5 2 1/2 9 5 1/2 3/8
PLK2230D32E12 2 3&5 2 3/4 10 6 1/2 1/2
PLK2230D40E12 2 1/2 3&5 3 1/8 10 6 1/2 1/2
PLK2230D48E12 3 3&5 3 5/8 10 6 1/2 1/2
PLK2230D56E12 3 1/2 3&5 4 10 6 1/2 5/8
PLK2230D64E12 4 3&5 4 1/2 10 6 1/2 5/8
PLK3230D64E123 (EHV) 4 3, 5 & 7 4 1/2 14 9 3/8 5/8
PLK2230D80E23 5 5&7 5 11 1/2 7 1/2 5/8
PLK3230D80E23 (EHV) 5 6&7 5 14 9 3/8 5/8
PLK2230D96E23 6 7&7 5 1/2 11 1/2 7 1/2 5/8
PLK3230D96E23 (EHV) 7 8&7 5 1/2 14 9 3/8 5/8

PLK3230

BUS SUPPORT/EXPANSION EXAMPLE:

PLK2230 D 24 E12

Slip/Rigid Fit 1 1/2 3 & 5

Bus Support Bus Run Bolt Circle

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Bus connectors

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 Bus connectors

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Bus connectors

your part here

We Make Specials
Need something different?
Dont see the configuration you need?
Let us make it for you.
Most of our standard connectors have come
from customer inquiries and requests.
We offer complete engineering, R&D testing
in NADCAP approved labs and manufacturing
at our ISO 9001:2008 facilities

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 Bus ehv connectors
All parts tested Corona free for use at and above 500 kV
Corrosion-resistant material machined to a high quality surface finish, designed-in shielding rings, and
generous mass & radii for high ampacity and voltage
Manfactured to the highest standards to preserve quality and connector performance
Swaging reduces installation time, maintenance and cost

PLK3039 PLK3160 PLK3200

Offset Splice Ground Stud Bus Support (slip)

PLK3162 Double Grounding Stud

PLK3166 Split Main Run

PLK3210 PLK3361 PLK3401

Bus Support (fixed/slip) End Cap (ball) Large Radius Elbow

PLK3360 End Cap (ring)

PLK3400 PLK3600 PLK3698

Elbow Expansion (bus to pad) Expansion Terminal - Partial Corona Ring

PLK3700 PLK3810 PLK8000

Expansion (with support) Expansion (bus to bus) Bolt Shield Pad

PLK8000D6
6 hole pad

PLK8000D4
4 hole pad
PLK3701 Reduced Expansion
PLK3702 2 Corona Ring Expansion

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 BUS VOLTAGE RATINGS
Voltage ratings are dependent upon connector configuration and application
Bolt shields are required for all terminal EHV pads
Voltage based on testing completed in lab setting, non-tested connectors rated by similarity

Voltage Rating (kV) by Bus Size

Part Number Description
3" 3.5" 4" 5" 6"
PLK1000 Splice 500 500 500 765 765
PLK1001 Long Splice 500 500 500 765 765
COUPLERS
PLK1010 Reducer 500 500 500 500 500
PLK1099 Reducer, From 8" (Weld) 500 500 500 500 500
PLK1400 Elbow 230 230 230 230 230
ELBOWS PLK3400 EHV Elbow - Corona Ring 500 500 500 500 500
PLK3401 EHV Elbow - Large Radius 500 500 500 765 765
PLK1160 Grounding Stud 230 230 230 230 230
PLK3160 EHV Grounding Stud 500 500 500 500 500
GROUNDING PLK1161 Grounding Stirrup 230 230 230 230 230
PLK3162 EHV Double Grounding Stud 500 500 500 500 500
PLK3166 EHV Grounding Stud (Split Run) 500 500 500 500 500
PLK1350 End Cap 230 230 230 230 230
PLK1360 Rounded End Cap 230 230 230 230 230
END CAPS
PLK3360 EHV End Cap - Ring 500 500 500 500 500
PLK3361 EHV End Cap - Ball 500 500 500 500 500
PLK1100 Tee, 4 Hole Pad Tap 500 500 500 500 500
PLK5100 Tee, 4 Hole Pad Tap, Split 500 500 500 500 500
PLK1106 Tee, 6 Hole Pad Tap 500 500 500 500 500
PLK1120 Tee, Two 4 Hole Pad Taps 500 500 500 500 500
PLK1150 Tee, Transverse 4 Hole Pad Tap 500 500 500 500 500
PLK1170 Tee, Two Transverse 4 Hole Pad Taps 500 500 500 500 500
PLK3039 EHV Offset Splice 500 500 500 500 500
TEE/VEE
PLK1500 Tee - Bus to Bus 500 500 500 765 765
PLK5500 Tee - Bus to Bus, Split 500 500 500 500 500
PLK1600 A-Frame - Bus to Bus 500 500 500 765 765
PLK1650 A-Frame (Wide Body) - Bus to Bus 500 500 500 765 765
PLK1700 Cross - Bus to Bus 500 500 500 765 765
PLK1701 Cross - Reducer - Bus to Bus 500 500 500 500 500
PLK1702 Cross - Mixed Sizes - Bus to Bus 500 500 500 500 500
PLK1850 Centerline NEMA Terminal 345 500 500 500 500
PLK1856 Centerline NEMA Terminal, 6 Hole 345 500 500 500 500
PLK1860 NEMA Terminal, 4 Hole Pad, 45 345 500 500 500 500
PLK1861 NEMA Terminal, 6 Hole Pad, 45 345 500 500 500 500
PLK1863 NEMA Terminal, 4 Hole Pad, 30 345 500 500 500 500
TERMINALS PLK1866 NEMA Terminal, 4 Hole Pad, 60 345 500 500 500 500
PLK1870 NEMA Terminal, 4 Hole Pad, 90 230 345 345 345 345
PLK1873 Triangular NEMA Terminal Assembly, 4 Hole Pad 345 500 500 500 500
PLK1880 NEMA Terminal, Offset 4 Hole Pad 345 500 500 500 500
PLK1883 Double NEMA Terminal, 4 Hole Pad 345 500 500 500 500
PLK1886 NEMA Terminal, Offset 6 Hole Pad 345 500 500 500 500
PLK2200 Bus Support - Slip 345 345 345 345 345
PLK3200 EHV Bus Support - Slip 500 500 500 500 500
PLK2210 Bus Support - Rigid or Slip 345 345 345 345 345
PLK3210 EHV Bus Support - Rigid or Slip 500 500 500 500 500
SUPPORT
PLK3212 EHV Bus Support - Rigid 500 500 500 500 500
PLK2230 Bus Support - Clamp 230 230 230 230 230
PLK2260 Vertical Bus Support 345 345 345 345 345
PLK3501 EHV Bus Support Tee 500 500 500 500 500
PLK2600 Expansion Terminal - Bus to Pad 230 230 230 230 230
PLK3600 EHV Expansion Terminal - Bus to Pad 500 500 500 500 500
PLK2602 Expansion Terminal - Bus to Pad Reduced 230 230 230 230 230
PLK2610 Expansion Terminal - Bus to Offset Pad 230 230 230 230 230
PLK2631 Expansion Terminal - Bus to Pad (Cable) 345 345 345 345 345
PLK3698 EHV Expansion Terminal - Partial Corona Ring 500 500 500 500 500
PLK3699 EHV Expansion Terminal - Special 500 500 500 500 500
EXPANSION PLK2700 Expansion Support - Bus to Bus 230 230 230 230 230
PLK3700 EHV Expansion Bus Support - Bus to Bus 500 500 500 500 500
PLK2701 Expansion Support - Bus to Bus Reduced 230 230 230 230 230
PLK3701 EHV Expansion Bus Support - Bus to Bus 500 500 500 500 500
PLK3702 EHV Expansion Bus Support - Bus to Bus - 2 Corona Rings 500 500 500 500 500
PLK2810 Expansion Connector - Bus to Bus 230 230 230 230 230
PLK3810 EHV Expansion Connector - Bus to Bus - 2 Corona Rings 500 500 500 500 500
PLK3910 EHV Clamp On Corona Rings, Dual 500 500 500 500 500
PLK8000D4 Corona Bolt Shield, 4 Hole Pad 500 500 500 500 500
BOLT SHIELDS
PLK8000D6 Corona Bolt Shield, 6 Hole Pad 500 500 500 500 500

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 BUS TO CABLE CONNECTORS

ORDERING INFORMATION - BUS CONNECTORs

Refer to the Standard Product Dimensions on page 3 for our Bus Size and Bolt Circle Configurations

PLKXXX D XX XXXXX

4 (OPTIONAL) SECOND BUS OR CABLE RUN

3 BUS RUN SIZE

2 MATERIAL CODE (D=Aluminum) ORDERING EXAMPLE:

1 BASIC PART NUMBER

PLK1000 D 16

Bus-to-Bus Splice 1 Bus Run

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 BUS TOOLING SELECTION CHART

ONE TOOL IS ALL YOU NEED TO

START SWAGING

Our compact and portable tools (as little as 30 pounds) are hydraulically actuated using
a 10,000 psi pump and are capable of producing up to 115 tons of Swaging power!
DMC Power will train and certify your entire crew in less than 30 minutes, helping you
spend more time installing Bus, Cable and Grounding and less time waiting.

HEAD ASSEMBLY SIZE

DMC Bus Model 57/58* Model 65 Model 85 Model 115 Inspection
Swage Dies Pump Type
Size Size Power Unit Power Unit Power Unit Power Unit Gauge
16 1" DLT57PLHA0016 DLT65PLHA0016 DLT56PLDI0016 PLKIG2000-16
24 1-1/2" DLT57PLHA0024 DLT65PLHA0024 DLT56PLDI0024 PLKIG2000-24
DLT06MAPE2001
32 2" DLT57PLHA0032 DLT65PLHA0032 DLT56PLDI0032 PLKIG2000-32 (Battery)
40 2-1/2" DLT57PLHA0040 DLT65PLHA0040 DLT56PLDI0040 PLKIG2000-40
or
48 3" DLT57PLHA0048 DLT65PLHA0048 DLT56PLDI0048 PLKIG2000-48
56 3-1/2" DLT65PLHA0056 DLT65PLDI0056 PLKIG2000-56 DLT12MAPE1000
(Electric)
64 4" DLT65PLHA0064 DLT65PLDI0064 PLKIG2000-64
80 5" DLT86PLHA0080 DLT85PLDI0080 PLKIG2000-80

96 6" PLT115PLTA0000 PLT115PLDI0096 PLKIG2000-96 PLT115MAPE1000

*Model 58 Power Unit can also Swage Cable Connectors from 2000 to 2500 MCM

All tooling is available for PURCHASE, RENTAL and LEASE

Call 888-SWAGE-NOW or contact your local Territory Manager for more information

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SAFER
FASTER
ALL-WEATHER
HIGHER QUALITY
LOWER TOTAL PROJECT COST

Sales Offices Located Nationwide

to Better Serve You

14502 South Figueroa Street

Gardena, CA 90248 USA
www.dmcpower.com
888-SWAGE-NOW
12-2010

888-792-4366