BURNDY® HYGROUND™ vs. Exothermic WeldingStandards and CodesNEC® Article 250,Section 250-81

“It shall be permitted to splice the grounding electrode conductor by meansof irreversible compression-type connectors listed for the purpose or by the exothermic welding process.”

The BURNDY HYGROUND compressionsystem also meets or exceeds thegrounding standards set by all of the electrical industry’s overseeing bodies:

System Standards

National Fire Protection Association

• National Electrical Code

• NFPA 780-92 Lightning Protection Code

• NFPA 70E Standard for Electrical SafetyRequirements for Employee Workplaces

Institute of Electrical Electronics Engineers

• IEEE 80-86 Guide for Safety inSubstation Grounding (Worldwide)

• IEEE 142-921 Grounding of Industrialand Commercial Power Systems

• IEEE 1100-92 Powering and GroundingSensitive Electronic Equipment

• T1E1 (U.S., Canada) T1E1-37Grounding and Bonding of NetworkTelecommunications Equipment

Federal Government

• FAA 019B-85 Airport Grounding

• Occupational Safety Hazard Association

Underwriters Laboratories

• UL-96A Installation Requirements for LP Systems

Performance Standards

• IEEE Standard 837-89 Standard forQualifying Permanent Connections Used in Substation Grounding

• UL-467 and CSA C22.2 No. 41Grounding and Bonding Equipment

• UL-96 Standard for Connectors forLightning Protection

Telecommunications

The booming wireless industry is a perfect candidate for the BURNDYHYGROUND system. With expertspredicting that wireless base stationswill dot the landscape at the rate ofone every six miles, HYGROUND

offers the only grounding systemthat installs quickly and

easily, regardless of theweather. “Traditional”phone companies havebeen HYGROUNDusers for many years.

Architectural andConstruction Engineers

Consultant engineering firms — the specifiers — appreciate thebenefits of having a sound, provengrounding system that’s easy toinstall. Including BURNDYHYGROUND on your standards willsave on labor costs and job-siteinjuries and reduces the chance ofwork delays. BURNDY’s availableD.X.F. files are importable intoAutoCad™ 10 or higher for easydrafting, drawing, and specification writing.

Army Corps of Engineers

While the Army Corps of Engineershas not adopted one central standardfor below-grade grounding, BURNDYHYGROUND has been included inseveral major projects of the ArmedForces and is also approved for useby other federal agencies includingthe FAA and OSHA.

Mass Transit

With the modernization and elec-trification of the nation’s railroadsunderway and the unstable cost of oil, BURNDY HYGROUND is proud tobe playing a role in the revitalizationof this industry.

Utilities

Much of the success of BURNDYHYGROUND can be attributed to themany utility companies that haveinstalled the system for a number of applications. While grounding isimportant in any industry, the utilityindustry is especially susceptible to fault currents and may have themost at risk in terms of the services itprovides to the public. BURNDYHYGROUND connectors meet andexceed all industry specifications forsystem standards and performance.

International Firms

Many international firms are havingdifficulty in obtaining export andimport licenses for exothermicmaterial. Current world conditions areforcing some governments to considerexothermic powder an explosive.Care and shipment of this materialare other problems, as is propertraining for overseas installers. Noneof these inherent problems exist withBURNDY HYGROUND materials.

REA Utilities

The Rural Electrification Association(REA) represents more than 1,000rural electric systems that own andmaintain nearly half of the nation’spoles and powerlines, and many are protected by BURNDYHYGROUND. BURNDY has obtainedREA listing for its YGL HYGRID™cross-grid connector to meet therequirements of this market.

Distributors

Unlike exothermic materials, distrib-utors can stock BURNDYHYGROUND connectors without fearof any safety issues or fear of anyinventoried product becoming dampand inoperable. By stocking relativelyfew HYGROUND items, a distributorcan easily service the majority of end-user requirements. And BURNDY’scustomer service and salesdepartments are well regarded withinthe industry.

Petrochemical Plants

At petrochemical plants, safety is aprimary concern. Proper grounding isa large part of safety as managerslook to protect their people, plants,and equipment. Your facility canrealize huge cost savings — andgreat peace of mind — by using theBURNDY HYGROUND compressionsystem that can be safely installed inareas containing hazardous chemicalsor gases.

Application/UsersIf you would like to contact one of the BURNDY® HYGROUND™ users noted in this section, please call our MarketingDepartment at 1-800-346-4175 and we’ll put you in touch.

Less equipment. No more than four to seventools and accessories are required to make anaverage grid installation.

Range-taking. Accommodate a broad range of conductor sizes and configurations thatsignificantly reduce the number of installationcomponents required.

Compatible. Since some competitors’ connec-tors, tools, and die designs are based on theHYGROUND system, compatibilities do exist incertain areas.

Minimal space limitations. The rotatable-headfeature on some BURNDY compression toolmodels further reduces any possible spaceconstraints.

Longer shelf life. Simple storage precautionsmaintain functional performance for prolongedperiods.

Durable. Strip sealing of connectors and the heavy-duty tool construction add furtherprotection to BURNDY’s compression system.

Tool life. BURNDY’s quick-charge batteriesprovide peace of mind in remote areas, and its tools have been life-cycle tested to over100,000 cycles without failure.

Safety. Making a compression connectionusing the BURNDY HYGROUND system is aninherently safe process. There are nopotentially hazardous by-products, and permits use in any location.

Weather or not. HYGROUND connectionsmay be made even in wet and other inclementconditions.

Inspection. HYGROUND compressionconnections can be easily inspecteddimensionally and visually with conclusiveresults.

Installation. Connections can be made even in the most severe site and/or weatherconditions to keep jobs on schedule and man-hours to a minimum.

Costs. User-friendly, all-weather installationcuts labor costs significantly.

More equipment. Multiple tools andaccessories are required to make an averagegrid installation.

Non-range-taking. Each application requires adifferent mold and appropriate accessories foreach conductor combination and configuration.

Severe space restrictions. Makingexothermic connections in confined spaces isseverely limited because of mold size andclamp restrictions.

Shelf life/storage issues. Shelf life of exo-thermic powder and molds is potentially veryshort. Dampness and moisture can adverselyaffect the performance of the powder andmolds by hindering the ignition sequence.

Handle with care. Graphite molds are fragileand require care in handling.

Mold life. The weld reaction process andnormal handling cause the mold openings andmating surfaces to wear and break, renderingthe mold inoperative, normal life expectancy is50 to 75 connections per mold.

Safety. Making an exothermic connectionrequires adherence to strict installationprocedures, including fire safety. This mayrestrict the use of where equipment can beused.

Weather restrictions. Exothermic connectionscan be made under dry conditions only.

Inspection. It is very difficult to properly fieldinspect an exothermic welded connection.

Installation. A typical exothermic installationtakes fives times longer than a comparableBURNDY HYGROUND installation. Poorweather will further delay the job by days —not hours.

Costs. In most cases, high labor costs faroutrun any material savings that may havebeen realized.

BURNDY® HYGROUND™ Quick Reference Guide

An easy call to make —Your base stationconstruction won’t face any delays with BURNDYHYGROUND — the onlygrounding system thatinstalls quickly and easily,regardless of the weather.

47 East Industrial Park Drive, Manchester, NH 03108

In the U.S. call: 1-800-346-4175

International: 1-603-647-5000Ontario, Atlantic & Western Canada:

1-800-361-6975Quebec & Eastern Ontario:

1-800-361-6975

www.fciconnect.com

2006 Hyground Ref. Guide 4/5/06 3:13 PM Page 1

All HYGROUND compression connectorsconform to all applicable sections of theNEC® as well as UL-467.

All HYGROUND compression connectorsmeet IEEE Standard 837 requirements.

Range-taking tool and die designminimize inventory and provide formultiple connector combinations that are consistent and reliable.

Precrimp dies for ground rod connectorsadd mechanical strength to help theconnectors withstand power installationand maintain IEEE and UL performance.

All compression elements made of purewrought copper — the same material asthe conductor.

Heavy-duty connector design carries the equivalent or greater current-carryingcapacity of the conductor.

All compression elements are strip sealedto keep all contact surfaces clean.

Most compression elements are pre-filled with our exclusive PENETROX™compound to inhibit moisture andcontaminants.

Requires no special training or compli-cated tooling for easy installation.

Each connection can be made in lessthan three minutes.

Compression connections can be installed in all kinds of weather for betterjob scheduling.

INo drilling, tapping, or welding requiredfor connections to most structural steel forsafer installation and lower labor costs.

Each connector is clearly marked for easyand accurate identification.

Inspection ports are provided in terminaland splice connectors to ensure properinsertion of the conductor for increasedquality assurance.

Crimping embosses the die index numberon the connector, confirming consistentconnections and providing for easyinspectability.

Features and Benefits

A B C D E F G H I J K L M N O

Components

Benefit Key

Safety

Performance

Cost savings

Time savings

Inspectability

Embossed number shows that the output force used to make thecompression connection was correct.

Leave your hammer at home.

The inspectability of completed grounding connections is of great concern within the electrical community. A growing number of industries are demanding a higher degree of traceability to confirm the quality of an installation. This is another solid example of why the BURNDY HYGROUNDcompression grounding system is the clear choice.

When a BURNDY HYGROUND tool and die combination makes a compression connection, it alsoembosses an identification code into the installed connector. This mark allows you and the electrical inspector to visually — and quickly — confirm that the proper connector, tool, and installa-tion die were used and that the connector has been correctly placed. And since BURNDYHYGROUND compression tools are designed to complete the crimp before releasing, you can be fur-ther assured of the installation quality.

The permanent embossment of BURNDY HYGROUND’s range-taking connectors allows for properinspection days or even weeks after the installation was completed. This method of inspection is farmore reliable and less subjective than checking an exothermic connection with the tap of a hammer.

Photo tocome

Hygrid™ CrossConnector (YGL-C)

• Designed for crossconnections as well as“ells” and “tees.”

• Rotating elementsfacilitate positioning prior to crimp.

• Conductor range #6 through 500 kcmil.

Gridlok™ Ground Rodto Grid Connector

(YGLR-C)

• Provides high torqueconnection to ground rod.

• Rotating elementsfacilitate installation.

• Conductor range #2through 500 kcmil.

• Ground rod sizes 1/2",5/8", 3/4", and 1".

Figure “6” Hytap™Connector (YGHP-C)

• Can be used as tapconnector or a lap splice connector.

• Conductor range #8through 500 kcmil.

• Ground rod 1/2", 5/8", and 3/4".

Figure “C” Hytap Connector (YGHC-C)

• Can be used for tap orcross connections.

• “C”-shaped openingpermits placing twoparallel cables intoconductor groove.

• Conductor range #6 through 500 kcmil.

Hytail™ Ground RodTap Connector

(YGHR-C)

• Provides tap or pigtail-type connection fromground rods to groundingcounterpoise or grid.

• Conductor range #2through 500 kcmil.

• Ground rod sizes 1/2",5/8", and 3/4".

Hytap GroundElectrode Tap

Connector (YGHP-C)

• A ground rod connectorwith open groove for both continuous run and tapping applications(second groove for tap only).

• “Third hand” constrainsconductors while installercompletes crimp.

Double H-TapConnector (YSHG)

• Can be used on anysecondary splice or tapapplication.

• Conductor range #14through 500 kcmil.

• Ground rod sizes 3/4" and 1".

• Rebar sizes #6, #8, and #9.

Hylug™ Heavy-DutyTerminals (YGHA)

• Designed to carry short-circuit load and withstandhigh mechanical stress.

• Inspection hole ensuresproper cable insertion.

• Conductor range #2through 500 kcmil.

Hylug™ Terminals(YGA)

• Designed for groundapplications.

• Inspection hole ensuresproper cable insertion.

• Standard NEMA holespacing.

• Conductor range #8through 500 kcmil.

Hylink™ Heavy-DutySplice (YGHS)

• Designed to carry short-circuit load and withstandhigh mechanical stress.

• Inspection hole and centerstop ensure proper cableinsertion.

• Conductor range #2through 500 kcmil.

Hylink® Splice (YGS)

• Designed to carry short-circuit load and withstandhigh mechanical stress.

• Inspection hole and centerstop ensure proper cableinsertion.

• Conductor range #2through 500 kcmil.

Grounding Plate (YGF)

• Withstands the rigors ofconcrete construction.

• Pretapped two- or four-hole NEMA spacing.

• Tapped hole on undersidefor ease of repositioning.

• Holes plugged to keep dirt out.

• Conductor range #2through 500 kcmil.

GroundLink™Connector (YGIB)

• Patented design allows for ground attachment tostructural steel.

• Available for straight orangled steel.

• Includes thread protectionstuds to prevent holedeformation.

Static GroundingReceptacle (YGT

and YTTAG)

• Connects to ground gridand finished flush.

• YTTAG for aircraftapplications.

Versitail™ StructuralSteel Connector

(GSTUD-HY)

• Welds to steel surfacesquickly with regularequipment.

• Eliminates costly diskgrinding.

• Knurled area copperplated for excellentgripping and electricalintegrity.

Sample BURNDY® HYGROUND™ Compression Connector Grid

Safe and easy to install

• BURNDY HYGROUND is the safest, most cost-effective, time-efficient, and easily inspected grounding system available today. A BURNDY HYGROUND compression connection can be made in three minutes, or about one-half the time of a similar exothermicconnection.

• The efficiency and consistency of installing a BURNDYHYGROUND compression grid translates to tremendous labor savings. And unlike exothermic connections, compression connec-tions can be easily removed and replaced for even greater time-saving opportunities.

• With BURNDY HYGROUND you can keep your entire job-site workon schedule as compression connections can be made in even themost inclement weather conditions — rain, wind, or snow.

Inspectability

A

B

CD

E

H

I

JK

LM

O

BURNDY Compression Tools

• HYPRESS™ Hydraulic Tool (Y750BH)• HYPRESS™ Remote-Operated Hydraulic Tool (Y46)

• BURNDY® PATRIOT® (PAT750XT)• Y-DC Series Battery-Powered Hydraulic Pump (Y700DC-1B)

• EPP Series Electric/Hydraulic Pump (EPP10)

“As a distributor

of industrial

chemicals,

safety is

our greatest

concern and

that’s why we

use BURNDY

HYGROUND.”

John ReedChemCentral/

ChicagoBedford Park, IL

G

“The time savings

in installing

BURNDY

HYGROUND was

a big factor in

our changing

from exothermic,

as well as the

safety concerns.

BURNDY’s

reusable tools and

dies also proved

more economical

than the ongoing

expense of the

molds.”

Skip LaCosteArc ElectricalContractors

Pensacola, FL

The connector identificationletters, including conductorranges and requiredinstallation die.

After a compression connection has been made, the embossed and factory-stamped die numbers should matchexactly as noted here. This confirmsthat the correct die was used to makethe grounding connection.

BURNDY HYGROUND is looking for contractors and engineers who want to make themselves and their companies more competitive and attractive to customers through increased work efficiencies, better attention to safety, and greater cost awareness.

It’s these individuals who are primed to become users of the BURNDY HYGROUND compression grounding system. Our unique system of cross-grid, tap, splice, cable to ground rod, ground plate, and termination connections is the safest, most cost-effective, and most time-efficient grounding method available today. Add in its corrosion-resistant properties and inspectability and you have a grounding system that isunmatched in its performance, durability, and ease of use.

Meets Code Requirements! Standards and Codes

NEC® Article 250, Section 250-81

“It shall be permitted to splice the grounding electrode conductor by means of irreversible compression-type connectors listed for the purpose or by the exothermic welding process.”

2006 Hyground Ref. Guide 4/5/06 3:14 PM Page 2