CONTENTS

Sl.No. TITLE Page No.

I. Introduction 4
II. Technical Information 4
III. Design Highlights 6
IV. Erection Instructions 7
V. Marking of Connectors 9
VI. Periodic Maintenance 9
VII. Using this Catalogue of Connectors (Product Coding System) 10
VIII. Purchase Specifications for connectors 11
IX. Index of 132 KV Connector range
I. Busbar Connectors
a. Tee Connectors
i. Conductor to Conductor - Through 12-13
ii. Tube to conductor 12-13
iii. Tube to Twin Conductor (Type-1) 14-15
iv. Tube to Twin Conductor (Type-2) 14-15
b. Parallel connectors 16
i. Conductor to Conductor 16-17
ii. Tube to Twin Conductor 16-17
c. Spacers 18
i. Twin conductor 18-19
ii. Quad Conductor 18-19
d. Post Insulator Clamps 20
i. Rigid Clamp on PI - Conductor 20-21
ii. Rigid Clamp on PI - Twin Conductor 20-21
iii. Rigid Clamp on PI - Tube 22-23
iv. Sliding Clamp on PI - Tube 22-23
v. Rigid Bus Coupler on PI 24-25
vi. Expansion Bus Coupler on PI 24-25
e. Straight Connectors 26
i. Tube to Tube 26-27

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Sl.No. TITLE Page No.

II. Terminal Connectors 28

a. Terminal Connector - Stud 28
i. Stud to Conductor - Horizontal 28-29
ii. Stud to Conductor - Vertical 28-29
iii. Stud to Twin Conductor - Horizontal 30-31
iv. Stud to Twin Conductor - Vertical 30-31
v. Stud to Tube - Horizontal 32-33
vi. Stud to Tube - Expansion 32-33
vii. Stud to Tube - Vertical (Type-1) 34-35
viii. Stud to Tube - Vertical (Type-2) 34-35
b. Terminal Connector - Pad 36
i. Pad to Conductor - Horizontal 36-37
ii. Pad to Conductor - Vertical 36-37
iii. Pad to Tube - Horizontal 38-39
iv. Pad to Tube - Expansion 38-39
X. Index of 245 KV Connector range
I. Busbar Connectors
a. Tee Connectors 40
i. Conductor to Conductor - Through 40-41
ii. Tube to conductor 40-41
iii. Tube to Twin Conductor (Type-1) 42-43
iv. Tube to Twin Conductor (Type-2) 42-43
b. Parallel connectors 44
i. Conductor to Conductor 44-45
ii. Tube to Twin Conductor 44-45
c. Spacers 46
i. Twin conductor 46-47
ii. Quad Conductor 46-47

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Sl.No. TITLE Page No.

d. Post Insulator Clamps 48

i. Rigid Clamp on PI - Conductor 48-49
ii. Rigid Clamp on PI - Twin Conductor 48-49
iii. Rigid Clamp on PI - Tube 50-51
iv. Sliding Clamp on PI - Tube 50-51
v. Rigid Bus Coupler on PI 52-53
vi. Expansion Bus Coupler on PI 52-53
e. Straight Connectors 54
i. Tube to Tube 54-55
II. Terminal Connectors
a. Terminal Connector - Stud 56
i. Stud to Conductor - Horizontal 56-57
ii. Stud to Conductor - Vertical 56-57
iii. Stud to Twin Conductor - Horizontal 58-59
iv. Stud to Twin Conductor - Vertical 58-59
v. Stud to Tube - Horizontal 60-61
vi. Stud to Tube - Expansion 60-61
vii. Stud to Tube - Vertical (Type-1) 62-63
viii. Stud to Tube - Vertical (Type-2) 62-63
b. Terminal Connector - Pad 64
i. Pad to Conductor - Horizontal 64-65
ii. Pad to Conductor - Vertical 64-65
iii. Pad to Tube - Horizontal 66-67
iv. Pad to Tube - Expansion 66-67

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 INTRODUCTION
ADARSH CONNECTORS INDIA PVT LTD is a company involved in Design and Marketing of Clamps and Connectors for MV / HV Electrical
Sub-Stations. Its associate company ADARSH LINE ACCESSORIES (P) LTD. has been in the business of Testing, Manufacture and Export of
EHV Clamps & Connectors, since 1998, to International Markets in Malaysia, Myanmar, Brunei, Italy, Spain, Lithuania, Sweden, Estonia, Saudi
Arabia, etc., ADARSH Clamps have found wide acceptance in these countries.

Both the companies are located in the southern state of Tamilnadu in India. Adarsh Line Accessories (P) Ltd. has two plants one in Chennai for the
Testing & Assembly of EHV Power Connectors and the second at Coimbatore for the Manufacture of Aluminium Castings (which form part of the
inputs for the manufacture of Power Connectors) for Adarsh Connectors India Pvt Ltd.

TECHNICAL INFORMATION
01. Reference Standards
ADARSH Connectors are designed to the following standards
- B.S. 159
- I.S. 5561
- ANSI / NEMA CC1
Design & supply can be made as per customer requirements / Specification.

02. Rating of Connectors

(a) System Voltage
(b) Continuous Current
(c) Short Time Rating
- Upto 132 KV
- Upto 245 KV
- 400 A to 4000 A
- Higher Ratings can be supplied.
- Upto 50 KA for 3 Secs

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03. Range of Connectors
- Tee Connectors
- Parallel Groove Connectors
- Bus Supports
- Bus Couplers
- Rigid and Expansion Type Connectors for Busbar and Equipment
- Spacer Clamps
- Any other Special Type to suit customer requirement can be designed and supplied
- Earthing Connectors

04. Type Tests

ADARSH Design has been validated by carrying out Type Tests at:

- Central Power Research Institute (CPRI), Bhopal, India (a STL Laboratory)

- Global Power Research Laboratory, Vadalur, India (a ISO / IEC 17025 NABL Approved HV Laboratory)

The following Type Tests have been carried out

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 DESIGN HIGHLIGHTS
01. Electrical Performance gradient to a minimum. The connector parts are designed with large
surface area to reduce voltage stress and the Bolts in the Connector
ADARSH POWER CONNECTORS are designed to provide trouble
Body are shrouded.
free service under normal and abnormal load and weather conditions.
Our Design provides for the joint to run cooler than the associated 04. Corrosion Resistance
busbar under normal and fault conditions and the temperature to be
ADARSH Connectors are suitable for use in outdoor substations in
within the specified limits.
coastal areas and in the vicinity of Chemical industries. For this
02. Mechanical Strength purpose proper materials are selected as inputs in all our connectors.
Adarsh also supplies the Anti Corrosive Compound for Electrical
ADARSH Connectors are designed to be mechanically strong
joints that inhibits oxidation, seals out moisture from joints and
enough to withstand the Loads imposed during installation, Normal
prevents localised heating for Aluminium and Copper Connectors.
Service and Fault conditions. For this purpose, adequate cross-
section is provided on all our Clamps. The design also ensures proper 05. Connector Materials
distribution of contact pressure from the Bolts.
For our Aluminium range for the Connector Body, we use Aluminium
03. Corona and RIV Controlled Connectors Alloy Grade ENAB 44100 as per BSEN 1676 1997 (Equivalent to

ADARSH Connectors are SELF-SHIELDED Corona Free Type. LM6 Alloy). Fasteners are either HDG Clause 4.6 S.S. to BS EN

They are designed to keep the voltage gradient at the Connector 100008-3-2005 (Equivalent to A2-70) as per customer requirement.

surface at a level that will not cause Corona and resultant Radio Wherever Aluminium to Copper joints are required, Al-Cu Bi-

Interference (RIV) under dry and wet conditions. This is achieved by metallic Sleeves are used to avoid Galvanic Corrosion.

providing generous radi on all outside surfaces to keep the voltage

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 ERECTION INSTRUCTIONS FOR
EHV SUB STATION CONNECTORS (BOLTED TYPE)
I. General :- 5) Special care has to be taken on the expansion connectors :
1) Suitability of connector to the associated size of Bus Bar / a) Tube gap should be set as shown in general :
equipment terminal to be checked.
2) It is recommended to handle connectors with care because even Arrangement drawing which
slight damage of the outer surface can produce Corona Discharge. will permit the tube to linear
expansion as show in Fig(iii)
3. Avoid placing connectors on sand / soil which will penetrate to the
thread of the Bolts & Nuts - galling of the bolts may occur b) Even slight damage on
4) Whereever Aluminium to Copper connector connections are flexible conductors of the
required, Aluminium - Copper Bi-Matallic Sheet / Sleeve to be expansion connectors can
used. cause breakage, excessive
heating & corona
a) Aluminium Copper Bi-Metallic Sheet :
Aluminium connector portion 6) Cleaning the Busbars & Connectors :
should have contact with
Aluminium portion of a) Take the Bolt from the connectors and put them in a clean place
Aluminium Copper Bi-Metallic in order to avoid impurities settling on the thread.
Sheet & Copper portion of
equipment terminal should have b) Remove the oxide film from the contact surface of the
contact with Copper portion of connector and the busbar with a steel wire brush for a length of
Aluminium Copper Bi-Metallic 25mm greater than the contact length of the connector.
Sheet as shown in Fig (i)
c) If the equipment is coated with silver / tin, it has to be smoothly
b) Aluminium Copper Bi-Metallic Sleeve : polished without removing the coating.
Aluminium Copper Bi-
Metallic Sleeve Split (GAP) d) After cleaning the contact surface, to avoid oxide reforming,
should match with gap of the immediately thereafter (within a few minutes) apply Anti
connectors as shown in Corrosive Compound to 1mm thickness(aprox) and cover the
Fig(ii) entire contact area of the connector / conductor / tube / equipment
terminal.

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 e) Put the Conductor on the connector groove mount, (gap as shown in Fig iv) with the relevant hardware
and begin to tighten the bolt by hand.

7. Tightening the bolts :

By using the torque wrench, tighten the bolts as per sequence shown below :
a) Torque wrench will be prepared at 50% of the recommended torque
b) By applying rated torque, tighten the bolts sequentially as shown in Fig (v)

Ensure that the distance between clamping and body remains equal on all the sides of connector.
Cover with anti corrosive compound at the outer edge of the connector in order to obtain a good seal of the
connector.

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 IDENTIFICATION MARKING OF CONNECTORS

The following information is punched on ADARSH Connectors for identification:


Company Emblem


Size of Conductor / Tube/ Terminal size to be used


Recommended Tightening Torque for Bolted Type


Drawing Number & Purchase Order Item No. (Sticker)

PERIODIC MAINTENANCE OF CONNECTORS


Connectors do not require any special maintenance.

It is useful to check the tightness of the bolts once in three years.

The possibility of loosening of bolts is more in the case of connectors associated with the stranded conductors and in expansion
connectors.

If a connector has to be dismantled from the circuit, when it is reinstalled, it is essential that contact grease be removed from the contact
surface and it has to be reinstalled thereafter as per erection instruction.

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PRODUCT CODING SYSTEM

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 PURCHASE SPECIFICATIONS FOR CONNECTORS
THE FOLLOWING INFORMATION IS REQUIRED FOR DESIGNING THE CONNECTORS AND TO GIVE BEST PRICE AT ENQUIRY /
ORDER STAGE.

ENQUIRY STAGE :

SPECIFICATION / STANDARD :

SYSTEM VOLTAGE IN KV :

SHORT TIME CURRENT RATING IN KV :

DURATION IN SECONDS :

CONTINUOUS CURRENT RATING OF
BUSBAR / CONNECTORS: IN AMPS :
AMBIENT IN ºC :
RISE IN ºC :

CORONA EXTINCTION LEVEL IN KV (RMS) :

R.I.V. LEVEL :

SIZE AND MATERIAL OF THE BUSBAR :

TERMINAL DETAILS :
STUD / PAD :
PAD DRILLING DETAILS :
MATERIAL (AL. / CU.) :
APPROACH (VER / HOR) :

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 Designed & Marketed by :
Designed & Marketed by :
ADARSH CONNECTORS INDIA PVT LTD
#1, M.T.H. Road, (Opp. Stedford Hospital),
Ambattur, Chennai-600 053. INDIA
Email : info@adarshconnectors.com

Manufactured at ;
ADARSH LINE ACCESSORIES PVT LTD
321, SIDCO Industrial Estate, North Phase,
Ambattur, Chennai 600 098. INDIA
Ph.: 91-44-42060007, Fax : 91-44-42060008
Email. conector@airtelmail.in
www.adarshconnectors.in

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