Custom Insulated Jumpers or Macs


Insulated Mechanical Jumper Components and Assemblies

 

Insulated bypass jumper sets consist of three basic components: a pair of clamps, one pair of ferrules, and a length of insulated cable. JM Test Systems can build your custom mechanical jumper configurations to your specifics.

All Salisbury Insulating Jumpers meet ASTM F2321 standards. Confugure your custom jumper assemblies here.

If you need assembled jumper sets, quickly, contact JM Test Systems at jmsales@jmtest.com.


Need custom Jumpers in a Hurry? JM Test Systems can customize to you company's specifics.
INSULATED JUMPER CHECKLIST
1. Specify the style of insulated clamps.

All of the clamps installed wearing rubber insulating gloves, accept either shrouded or unshrouded ferrules, and accept insulated cable up to 4/0, 35kV. Insulated jumper clamps are sold in pairs.
2. Specify the size and length of insulated cable.

Salisbury offers 15kV cable from #2 to 4/0. 25 and 35 kV cable are both available in sizes 1/0 and 2/0. Be sure to specify the length of the cable chosen.
3. Specify if there are any special requirements.

This could include heat shrink tubing, special assembly instructions, markings, packaging etc.

 

1. Insulated Jumper Clamps

Salisbury Sure-Lok® Jumper Clamp

The Salisbury Sure-lok® Jumper clamp is a revolutionary improvement over any other jumper clamp in the world. Featuring a ratchet type locking mechanism, this is the only clamp available guaranteed not to loosen once installed on a line.

 

Model
#

Main Line Range Max Amps
Continous
Rating OAL Length Lbs.
2261 477 MCM (.9”-.162”) 400 36 kV Ø-Ø 11.5 (292 mm) 10
2271 954 MCM (1.25”-.162”) 400 21 kV Ø-GRD 11.5 (292 mm) 11
1786 477 MCM (.9”-.162”) 400 36 kV Ø-Ø 11.5 (292 mm) 8
2116 954 MCM (1.25”-.162”) 400 21 kV Ø-GRD 11.5 (292 mm) 10
Salisbury Sure-Lock Jumper Clamps

 

SALCOR® Insulated Jumper Clamps

SALCOR® Jumper Clamps are available in two main line sizes with a maximum use voltage of 35kV. The SALCOR Jumper Clamp not only provides a superior grip, but also resists ozone cutting and tracking. Being molded of rubber, these handles are inherently impact resistant and extremely durable. The body and jaw are made from a copper base alloy.

 

Model
#

Main Line Range Max Amps
Continous
Rating OAL Length Lbs.
2260 477 MCM (.9”-.162”) 400 36 kV Ø-Ø 11.5 ( 292 mm) 10
2270 954 MCM (1.25”-.162”) 400 21 kV Ø-GRD 11.5 (292 mm) 11
SALCOR Insulated Jumper Clamps

 

Clear Plastic & FRP Insulated Jumper Clamps

Salisbury’s superior stress cracking resistant Clear Jumper Clamps are available in two main line sizes with a maximum use voltage of 35kV. Assemble these clamps with insulated jumper cable and 5/8” - 11 NC threaded ferrules.

Clear Plastic Jumper Clamps - compact lightweight, and virtually unbreakable.

FRP Jumper Clamps - designed for maximum loads, voltages, and cables.

 

 

Model
#

Main Line Range Max Amps
Continous
Rating OAL Length Lbs.
1610 954 MCM (1.25”-.162”) 400 36 kV Ø-Ø 11 (279 mm) 14
1785 477 MCM (.9”-.162”) 400 36 kV Ø-Ø 11.5 (292 mm) 8
2115 954 MCM (1.25”-.162”) 400 21 kV Ø-GRD 11.5 (292 mm) 10
Clear Plastic and FRP Insulated Jumper Clamps in stock at JM Test Systems

 

 

2. Flexible Insulated Jumper Cables


Flexible Insulated Jumper Cables are lightweight and resistant to oil, heat, moisture, ozone and abrasion. The cable is embossed every three feet with conductor size and kV rating. All jumper cables use fine stranded conductor and a new EPR low temperature Unipass orange CV cured jacket. The fine stranded copper conductor is alloy coated and assembled in a unidirectional rope lay for extra flexibility. The conductor has a semiconducting shield surrounding it to relieve voltage stress and improve dielectric strength and service life.

Cable meets requirements of ASTM F2321.

Jumper Cables Meet Requirements of ASTM F2321

Model # Sz and Str. AWG kV Rating Ø to Ø Nominal Ø to Grd Str. Dia In. (mm) O.A Dia. in. (mm) Maz Amps Continous Weight lbs. per 1000 ft. kgs
2754 #2-259W 15 10 .320 (8.1) .75 (19) 200 440 199
2755 1/0-413W 15 10 .403 (10.2) .83 (21) 250 600 272
2756 2/0-427W 15 10 .456 (11.5) .90 (23) 300 710 322
2757 4/0-437W 15 10 .592 (15.0) 1.01 (25.6) 400 1050 476
21300 1/0-413W 25 15 .403 (10.2) 1.06 (27) 250 650 295
21060 2/0-427W 25 15 .456 (11.5) 1.10 (28) 300 750 341
2059 1/0-413W 35 20 .403 (10.2) 1.22 (31) 250 950 431
4370 2/0-427W 35 20 .48 (12.1) 1.31 (33.1) 300 1060 482

 

3. Ferrules - Shrouded / Unshrouded

Ferrules are manufactured in two different styles: unshrouded and shrouded.

Shrouded ferrules are compressed on both the conductor and the insulating jacket of the high voltage EPR cable to reduce bending stress.

Shrouded ferrules are designed to be used on glove-installed high voltage jumpers. Unshrouded ferrules are crimped to the conductor strands only and can be used on either stick- or glove-installed jumpers.

Ferrules are manufactured of 99.5% pure copper with industry standard 5/8”-11 NC threads.

Ferrules are topped with a brass hex jam nut and toothed stainless steel lockwasher.

Jumper Ferrules

 

Model # Cable Sz Strand Die Codes T&B Jacket Die Codes T&B Burndy Die Number Weight
Shrouded
2012 #2-15 kV ERP 66 106 - 1.2 (.5)
2013 1/0-15 kV ERP 66 106 - 1.2 (.5)
2014 2/0-15 kV ERP 66 106 - 1.1 (.5)
2015 4/0-15 kV ERP 66 106 - 0.9 (.4)
           
21353 1/0-25 kV 66 112 - 1.1 (.5)
21354 2/0-25 kV 66 112 - 1.1 (.5)
21356 2/0-35 kV 66 112 - 1.1 (.5)
           
Unshrouded - Tin Plated   Strand Die Codes    
2022 #2 50 - U243 0.5 (.2)
2023 1/0 50 - U243 0.4 (.2)
2024 2/0 60 - U245 0.4 (.2)
2025 4/0 66 - U247 0.6 (.3)
Add suffix "A" to the catalog number when requesting a custom insulated jumper set.

 

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