FrontCon, front face contact system for HV cables with enamelled conductor wires, up to 2500 mm²
FrontCon is a contact technology from the manufacturer for connecting the conductors of high-voltage cables with enamelled wires insulated from each other. The contact runs through the front face of the conductor, so the insulation of the individual wires does not have to be removed. The system is designed for copper conductors up to 2500 mm² and all voltage levels.
- Purpose
- connection of conductors with enamelled wires (segmented, Milliken type)
- Conductor cross-section
- up to 2500 mm² (larger on request)
- Conductor material
- copper (aluminium on request)
- Voltage class
- all voltage levels
Price, availability and lead time on request. We help with analogue selection, customs clearance and delivery.
Description
Conductors made of enamelled wires, often divided into segments of the Milliken type, are used in HV cables more and more often. They reduce the skin effect and the proximity effect, so with the same cross-section the cable carries more power. A conventional connection of such a conductor is labour-intensive. The conductor is unwound, the insulation is stripped from every wire, the wires are cleaned to a shine and then the original shape is roughly restored, trying not to damage any wire. The original structure cannot be restored on site anyway, and at the end of the conductor the advantage of enamelled wires is lost.
FrontCon works differently. The cable is cut square and the outer insulation is removed. The contact system is clamped centrally and with steady pressure onto the bare bundle of wires, contact balls are poured into the connector and the pressure screw is tightened. The balls press against the front faces of the wires, and the current flows through the front surfaces and the balls. Together the balls behave similarly to a liquid, smooth out small irregularities of the front face and give the same contact force over the whole cross-section. A built-in spring mechanism compensates for the shrinkage caused by thermal expansion and contraction of the cable. The contact resistance stays low and the contact force stays stable throughout the whole service life. The conductor structure is preserved, and the assembly is short and compact.
According to the manufacturer, installation takes about two hours, that is, no longer than for a conventional cable with a standard connector. Previously one connection took about 16 hours, so the time is reduced by 80 %. The risk of installation errors and wire damage drops noticeably, and the installer does not have to work with each wire separately.
As standard, FrontCon is made for copper conductors up to 2500 mm²; larger cross-sections and aluminium conductors are made on request. The system is installed vertically or horizontally and can be adapted to any accessory. There are three versions. FrontCon NEX works with CONNEX cable connectors to transformers and GIS, FrontCon MSA with push-on joints of underground cables, FrontCon ESX with outdoor terminations. The technology has passed type tests with specific cables, and the first projects have been in operation for several years.
Technical specifications
| Purpose | connection of conductors with enamelled wires (segmented, Milliken type) |
|---|---|
| Conductor cross-section | up to 2500 mm² (larger on request) |
| Conductor material | copper (aluminium on request) |
| Voltage class | all voltage levels |
| Installation time | about 2 h per connection (previously about 16 h) |
| Versions | FrontCon NEX (CONNEX), FrontCon MSA (joints), FrontCon ESX (terminations) |
| Installation | vertical or horizontal |
Request a price and lead time
FrontCon, front face contact system for HV cables with enamelled conductor wires, up to 2500 mm². We reply within one business day.
Or email sales@usk.ua or call 044 339-50-20.
Customs codes
| UKTZED (Ukraine) | 8535 90 00 00 |
|---|---|
| HS, 6 digits | 8535 90 |
| CN (EU) | 8535 90 00 |
| HTSUS (USA) | 8535 90 80 60 |
| China customs tariff | 8535 90 00 90 |
Codes are for reference: the final code is determined at declaration for the specific model.
Questions and answers
Which conductors is the FrontCon system intended for?
For copper conductors of high-voltage cables with enamelled wires, including segmented Milliken type, with a cross-section up to 2500 mm². Larger cross-sections and aluminium conductors are made on request.
How long does FrontCon installation take?
According to the manufacturer, the connection takes about 2 h instead of about 16 h with conventional technology. The time is reduced by 80 %.
Which accessories is the FrontCon system compatible with?
FrontCon NEX works with CONNEX cable connectors, FrontCon MSA with push-on joints, FrontCon ESX with outdoor terminations. The system can be installed vertically or horizontally.
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