This technical information has been contributed by
Tyco Electronics

High-Current Connectors for Wind Power Applications

HARRISBURG, Pa.--ShearBolt splice connectors, manufactured by Tyco Electronics for wind power applications, are said to allow power cables to be connected "quickly and reliably." The high-amperage, aluminum ShearBolt connectors minimize connection resistance through the use of shear-head bolts that ensure proper torque and optimal contact force. Engineered to shear at a predetermined torque, the bolts reportedly provide a consistent and controlled compression force on the conductor. Installation is performed using a standard ratchet wrench or battery-powered impact wrench.

According to the manufacturer, the ShearBolt is a robust connector that's designed to avoid the thermal runaway associated with compression connectors, which contributes to the failure of insulation systems. Also, fatigue and strain are no longer issues for the installer because the connector eliminates the need for a compression tool.

ShearBolt connectors are available in six standard sizes to handle a wide range of aluminum and copper conductors from 2 AWG to 1000 kcmil. Additional sizes are available upon request. The connectors are compatible with Tyco Electronics' Raychem cable accessories and insulation products.

According to Tyco, the connector bodies are made of a high-tensile, tin-plated aluminum alloy, with grooved internal serrations to enhance electrical contact. Inserts have length-wise serrations and a positioning guide. The patented hex-head bolts are made of a special aluminum alloy, treated with a special lubricating wax that reportedly helps reduce friction between the bolt threads and connector body. The lubricating agent is said to convert the installed tightening torque into contact force for maximum effect. Connectors are chamfered at the edges to reduce the step-down to the conductor insulation.