Earth Bonding System

Earth Bonding System
Overview
The Glenair Earth Bonding system is a revolutionary method of creating an
electrical bond between structures and equipment for the secure passage of high
intensity current in case of electrical short circuit.
System Benefits
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Suitable for use with steel, stainless steel and aluminium*
Suitable for plate thickness 1.5 mm and above+
Bond installed from one side
Can be installed into a blind hole
Permanent electrical connection providing low electrical resistance
May be removed and replaced in case of damage
Suitable for use on uneven surfaces
Manufactured from non-corroding materials
Cost effective as repeatable connections require limited tooling
One person operation
Extensive independent testing
Recommended for use by major OEM’s in RMT, Marine and Military Markets
⇒ * Other materials under evaluation
⇒ + Subject to further tests on plates less than 1.5 mm thick
How Does it Work?
The earth bond comprises two components:
1.
2.
A conical dowel having a male thread
A cylindrical flanged bush
A tensile force is applied to the dowel using a hand hydraulic tool with a pre-determined
pulling force. As the dowel is pulled through the bush, the bush remains fixed in the
structure and expands within the hole making electrical contact. The tool completes its
cycle resulting in a permanent electrical connection.
How do you Install it?
1.
2.
3.
4.
5.
Drill a hole in the mounting plate to a pre-determined diameter depending on the plate material,
plate thickness and stud size selected
Screw the bond into the nose of the hydraulic setting tool
Insert the bond into the hole so that the flange is flush with the plate
Pump the handle of the tool until an audible click is heard and release the tool from the stud
Attach termination and tighten to required torque value
Connection is complete
40 Lower Oakham Way, Oakham Business Park, Mansfield, Notts., NG18 5BY
Tel:+44 1623 638 100 ■ Fax: +44 1623 638 111 ■ E-mail: sales@glenair.co.uk
United States ■ United Kingdom ■ Germany ■ France ■ Nordic ■ Italy ■ Spain ■ Benelux
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Earth Bonding System
Typical Performance Values
Principle of the Earth Bond
1) Easy Assembly
2) Tensile Stress
3) Contact Areas
Electrical Performance: Aluminium Plate
Part Number
80958 – M6
Electrical resistance measured at a point between the
terminal lug (copper tin plated) and the aluminium plate
Withstand short circuit test – 3 passes of high intensity
current with no degradation of the connection
Corrosion Test: 500 hours
80959 – M10
80960 – M6
80961-M10
60 micro ohms
T = 2 mm
50 micro ohms
T = 2 mm
60 micro ohms
T = 4 mm
20 micro ohms
T = 4 mm
10 Ka
20 Ka
10 Ka
20 Ka
90 micro ohms
T = 2 mm
50 micro ohms
T = 4 mm
-
T = Plate Thickness
Mechanical Performance: Aluminium Plate
Part Number
80958-M6
Tensile force applied to the dowel or threaded stud
to remove earth bond from the plate
Bending moment (IEC60068-2-21). Force applied
at a point 5 mm from the end of the thread
Pressure Seal: Pressure applied to both sides of bond
for 2 hours with no leak between bush and plate
80959-M10
80960-M6
80961-M10
250 daN
T = 2 mm
34 daN
T = 1.5 mm
200 daN
T = 2 mm
100 daN
T = 2 mm
300 daN
T = 4 mm
200 daN
T = 4 mm
500 daN
T= 4 mm
300 daN
T = 4 mm
6 Bar
6 Bar
6 Bar
6 Bar
T = Plate Thickness
Mechanical Performance: Steel + Stainless Steel Plate
80924-M10
80925-M6
80926-M10
Electrical resistance measured at a point between the
terminal lug (copper tin plated) and the steel plate
Electrical resistance measured at a point between the
terminal lug (copper tin plated) and the stainless steel plate
With stand short circuit test-3 passes of high intensity
current with no degradation of the connection.
Part Number
25 micro ohms
T = 2 mm
120 micro ohms
T = 2 mm
80923-M6
20 micro ohms
T = 2 mm
70 micro ohms
T = 2 mm
25 micro ohms
T = 4 mm
75 micro ohms
T = 4 mm
20 micro ohms
T = 4 mm
60 micro ohms
T = 4 mm
10 Ka
15 Ka
10 Ka
20 Ka
Corrosion test: 500 hours: 2 mm steel plate
30 micro ohms
25 micro ohms
-
-
On 2 mm stainless steel plate
150 micro ohms
90 micro ohms
-
T = Plate Thickness
Mechanical Performance: Steel + Stainless Steel Plate
Part Number
80923-M6
Tensile force applied to the dowel or threaded
stud to remove earth bond from the plate
Bending moment (IEC60068-2-21). Force applied
at a point 5 mm from the end of the thread
Pressure seal: Pressure applied to both sides of bond
for 2 hours with no leak between bond and plate
80924-M10
80925-M6
80926-M10
400 daN
= 2 mm
100 daN
T = 1.5 mm
500 daN
T = 2 mm
190 daN
T = 2 mm
500 daN
T = 4 mm
200 daN
T = 4 mm
800 daN
T = 4 mm
330 daN
T = 4 mm
6 Bar
6 Bar
6 Bar
6 Bar
T = Plate Thickness
40 Lower Oakham Way, Oakham Business Park, Mansfield, Notts., NG18 5BY
Tel:+44 1623 638 100 ■ Fax: +44 1623 638 111 ■ E-mail: sales@glenair.co.uk
United States ■ United Kingdom ■ Germany ■ France ■ Nordic ■ Italy ■ Spain ■ Benelux
www.glenair.com
Earth Bonding Systems
DERA.Tests
Details of Tests Performed by DERA
The earth bonding system has been independently tested by the ‘Defence Evaluation and Research Agency’ (DERA).
The Earth Bonding system has Lloyds Register Type Approval: Certificate number 02/00022 issued 27 March 2002.
Application ENV1, ENV2, ENV5.
Destructive Testing
Test
Specification
Test Level
Comments
Tensile/Compression
IEC60068-2-21
Test to point of failure
Destructive
Torsion
IEC60068-2-21
Test to point of failure
Destructive
Bending Moment
IEC60068-2-21
Test to point of failure
Destructive
M6 –3 x 5 Ka
M10 –3 x 10 Ka
Destructive
Withstand Short Circuit
Sequential Testing
Test
Specification
Test Level
Comments
Electrical Continuity
IEC60512-2b
Measure results
Initial & after test
Pressure Seal
IEC6006802017 Test Qa
20 PSI
Record results
Vibration
IEC60068-2-6
10-500 Hz @ 0.75 mm/4 gn
Sinusoidal
Shock
IEC60068-2-27
300g,3 ms, half sine
Rapid Change of Temperature
IEC60068-14
Temperature range
-25C + 70C
Endurance
IEC60068-2-52
Salt Mist
IEC60068-2-52
16 cycles
10 cycles
500 hours continuous –
Marine environment solution
The Earth Bonding system has been approved for use by the Ministry of Defence, Warship Support Agency and is
NATO codified. The system has been endorsed by the following companies for Railway Mass Transit, Marine,
Military and Industrial applications: Bombardier Transportation Projects, Alston, CAF, Siemens, General Dynamics,
BAE Systems, Network Rail, London Underground Ltd, Stolt Off Shore – Sub Sea Applications.
Peter C Nutkins
pnutkins@glenair.com
Glenair UK Ltd
27 January 2004
26 March 2007 - Up issue
40 Lower Oakham Way, Oakham Business Park, Mansfield, Notts., NG18 5BY
Tel:+44 1623 638 100 ■ Fax: +44 1623 638 111 ■ E-mail: sales@glenair.co.uk
United States ■ United Kingdom ■ Germany ■ France ■ Nordic ■ Italy ■ Spain ■ Benelux
www.glenair.com