Rayphen Hot Line Clamp

Looking for a reliable, and trusted manufacturer for hot line clamp products? Leading industries worldwide, Rayphen is the best solution! We have 14 years of service in manufacturing hot line clamp.

Rayphen hot line clamp is constructed especially for line tap distribution connections. The common material utilized by Rayphen hot line clamp is a high-strength bronze alloy, aluminum alloy, or copper. Rayphen hot line clamp has features of corrosion resistance, high strength, and conductor compatibility.

The material of the hot wire clamp: the body is aluminum alloy, the eye bolt is tinned bronze, the hexagon nut, the spring, and the washer is stainless steel. According to the surface, we have a tin-plated hot line tap clamp and a natural finish hot line tap clamp.

Forged eyestem of hot line tap clamp provide corrosion-free strength and uniformed expansion under loading.  lock washer assures permanent connection. And Rayphen hot line clamp is with standard inhibitor. We specialized in innovating the extreme design of hot line clamp.

Rayphen combines deep research, design, and machining services such as thread forming, finishing, tapping, slotting, rolling, turning, surface hardening, and much more. No matter what the type is, Rayphen hot line clamps guarantee 100% durable, functional, and reliable performance. What’s more? The service life of our hot line clamp is long-lasting.

We have state-of-the-art fabricating machinery utensils with an automatic and manual way to bring your complete range of fabrication requirements and specifications. Make your hot line clamp beautiful and smooth. No matter what, we can make your hot line clamp according to your request. the most dependable team you can count on when you`re looking for efficiently organized hot line clamp products.

Allow Rayphen to be part of your growing business! Personalized customer service and friendly staff await you! As a professional hot line clamp manufacturer with rich experience in distribution connectors, we have enough confidence to satisfy your special requirement on any hot line clamp needs.

Hot Line Clamp: Ultimate FAQ Guide

This FAQ guide covers everything you need to know about hot line clamps. It also contains hot line clamp installation processes, use, features, and components.

Q1 What Is a Hot Line Clamp?

                                                         Figure 1: Hot Line Clamp

A hot line clamp is a metallic tool for making line tap connections. Hot line clamps are especially common for making connections between hot lines and transformers.

Because hotlines carry electricity with very high voltage, the clamps have to be made with stringent quality under provided standards. Therefore, strong metal alloys are employed, the most prominent of which are bronze and aluminum alloy. These alloys can endure varying weather conditions for years.

Since there is significant risk involved, only professional electricians make use of hot line clamps. They use it in making connections, as attachments for fixing lines on hotlines.

The line taps are connections made in parallel to transmission or a distribution line. Any wire that comes off the main line in an electricity distribution system is a hot line. On the other hand, a hot line is a wire carrying high voltage electricity but low current.

With the hotline, electricity is converted within a transformer to a more useful form, with a higher current and a low voltage. Hotline clamps are designed to ensure that the high flow of current from the hotline to the transformer moves in a contained and continuous fashion.

Q2 What Are Some Features of Hot Line Clamps?

                                                        Figure 2: Hot Line Clamps Features

To perform the precise function of connecting hotlines to their main lines, hot line clamps must meet specific requirements.

As to be expected, hotline clamps have to be able to conduct electricity with great efficiency. Hotline clamps can also provide incredibly potent insulation – While still controlling the flow of electricity to prevent shocking hazards.

Due to the nature of live lines and the sensitivity involved in working on them, instruments attached to them have to be effectively durable.

Also, hot line clamps are very resilient. They can withstand adverse environmental forces like wind, dust, rainwater, etc. In addition to similarly significant resistance to mechanical forces. Hotline clamps are strong and hard. They lack elasticity and are impervious to deformation from external forces.

Manufacturers use bronze, copper, and aluminum to make most hot line clamps because of these specific needs. Bronze is especially recommended because of its reaction to exposure to air. When exposed, bronze oxidizes, but only the outer layer forms a layer that prevents the apparatus from further corrosion.

Q3 What Is a Hot Line Clamp Made of?

Hot line clamps are made of metals primarily. But the parts in a hot line clamp require it to be made from specific types of metals. It is not uncommon in the fact that most materials used on sensitive electric systems are from alloys. Consequently, most hot line clamps are made mostly of aluminum, bronze, and steel.

The main body of hotline clamps is made of bronze of significantly high strength. An example of such is the C955/C956 class. Bronze is used because it offers the best of qualities needed for the role hot line clamps serve.

Bronze alloy can withstand deformity and has lasting durability. They are also corrosion-resistant. An outer coat is formed on the metal from oxidation, which protects the metal from corrosion. Bronze also offers incredible conductor compatibility – for both copper and aluminum taps.

But aluminum can be used in place of bronze in making the body and the keeper. It is a cheaper alternative with very similar properties to bronze. Aluminum is also the go-to choice for making the keeper.

Then you have the more delicate parts, like the eyebolts made from stainless steel or copper. Tin-plated bronze can sometimes be used in place of stainless steel. The eyelets can be made from bronze alloy, forged steel, aluminum, as well as stainless steel.

For added protection, the body made of bronze alloy can be plated with tin.

Q4 What Are Hot Line Clamps Used for?

                                                 Figure 3: Hot line clamp on the transformer

Hotline clamps are used in electrical distribution systems to make tap line connections. These connections are made parallel to the overhead distribution line carrying electricity at extremely high voltage but low current.

Manufacturers make tap lines in connection to transformers. The transformers being responsible for converting high voltage, low current electricity to a more useful low voltage, high current form. At the most critical angle, where electric lines are channeled from the mainline to tap lines, hot line clamps become the important tool for connections and attachments.

The need for transformers occurs in the first place because electricity usually has to be transported over very long distances. You can make this connection from the spot where it is generated (isolated plants like dams and nuclear power plants) to homes, offices, schools, factories, and other places where you use electricity.

Transmitting electricity at high voltage and with little current is very efficient. The electric current suffers little resistance in the conductors it flows through. Therefore, you can use thinner and lighter cables over long distances. After which you can increase the currents and voltage reduced in a transformer.

Though transformers are the major connections tap lines are made to, they are often made to cutouts and arresters.

You should also know that transformers, by definition, can convert electricity from either a high current form to a low current form or from a low current state to a higher current form. The voltage, in either case, is indirectly proportional to its currents. Whenever there is a high electric current in a conductor, it usually accompanies a low voltage and vice versa.

Q5 Can Hot Line Clamps Be Replaced?

Yes, you can replace hotline clamps when the need arises. They are very durable tools and do not often require replacement once installed. That being said, they are not indestructible. Several factors can lead to the damage of hot line clamps.

Sometimes hot line clamps can grow to become ineffective, causing blinking lights. It can also get really hot when it starts to burn. Therefore, electricians usually have to remove faulty clamps and replace them, usually with newer models such as those with washers or more durable materials.

You can install replacement hotline clamps through different techniques depending on the electrician and the available resources. Often, it is more economical and safe to use a hot stick to complete this task.

The hot stick, also known as a shotgun stick, provides insulation and effective distance between the electrician and the wirings. Because of the range distribution lines serve, it is often uneconomical, perhaps downright dangerous, to cut off electricity in them just to work on a single tap line. Therefore, electricians have to work with live lines when installing or replacing devices like hot line clamps.

Q6 What Type of Metal Is Used in Making Hot Line Clamps?

                                                       Figure 4: Bronze hot line clamp

Highly conductive metal alloys are the most suitable and economically viable materials for making hot line clamps. Many manufacturers use bronze and aluminum. Likewise, some companies use copper, stainless, or forged steel for specific parts in addition to these alloys.

Bronze alloy combines the best of two separate metals, copper and tin. The metal alloy has high conductivity for electricity, vital for making connections to the hot line. The introduction of tin into the mix provides the strength needed to endure external pressure without losing its lightness.

Aluminum is a cheaper alternative that works just fine. Aluminum is the most abundant metallic element on earth. Therefore, it is easily accessible once separated from its base compounds. It offers enough conductivity needed by hot line clamps. It is also strong, light, and durable.

There is another major reason these two are the go-to metals for making hot line clamps. And that is because of their corrosion resistance capacity. Hot line clamps are exposed to the atmosphere for most of their existence without protection.

It is important to use metals that endure exposure to moisture, snow, rain, and all other atmospheric conditions. Both metals get oxidized in contact with the atmosphere to create an oxide layer. What is interesting about this is that the layer only forms on the surface. And they are highly resistant to corrosion.

Q7 How Are Hot Line Clamps Different from Stirrup Clamps?

                                                         Figure 5: stirrup clamp

Hot line clamps and stirrup clamps have a lot in common. For one, you can use both together. They are essentially made from the same materials, usually bronze, aluminum, and stainless steel. They are also both used in connection with hot lines. But they are different devices that serve varying purposes.

Stirrup clamps usually have their body (jaws) made of aluminum, with two eye stems made of either bronze alloy or stainless steel. As the name states, there is a stirrup also that is fixed on a spring. However, hot line clamps have just a single eye stem and a body, and a keeper.

Both devices work hand in hand to help electricians make tap line connections with ease. The stirrup clam is first attached to the hot line. The clip-like spring in the stirrup helps it apply sufficient pressure on the jaws when you attach it to the hot line.

The tap line is then attached to the hot line clamp and installed on the stirrup clamp using a hot stick. The stirrup’s jaws grip the hot line clamp while the electrician tightens the eye stem to the standard torque.

With the stirrup clamp on the hotline accepting a connection from the tap line via the hot line clamp, an electric connection is made in a controlled manner.

Q8 How Does Bronze Alloy Compare to Aluminum Alloy in Making Hot Line Clamps?

                                                         Figure 6: Aluminum hot line clamp

Both bronze and aluminum alloys make exceptional hot line clamps. The material you pick, however, can depend on the conductor or specific weather conditions. Other forces are considered, like the recommended standards for the particular region.

Hot line clamps made from aluminum alloys are cheaper and work as well as those made of bronze. They are both light, effective conductors with satisfactory strength that ensures durability.

Q9 Do Different Tap Connections Need Different Hot Line Clamps?

Yes, different tap connections would need different hot line clamps.

Hot line clamps come in different sizes, each with varying amp ratings and made with different materials. Using the wrong hot line clamp for a tap connection can injure the electrician or damage the tap connections themselves.

There is a standard for the hot line clamps to be used with different tap connections. Electricians or vendors should do the appropriate research and follow the standards in their vicinity. Some things to look out for are the size, the material used, the amp rating, etc.

Q10 What Are the Different Amp Ratings for Hot Line Clamps?

While there are different amp ratings for hot line clamps, each region usually has a standard with ratings listed. When ordering hot line clamps, one thing to have in mind is to use the maximum rating of the largest tap conductors in range.

Q11 How Are Hot Line Clamps Installed?

                                                   Figure 7: Installing hot line clamp

The installation of hot line clamps should be carried out by a professional with proper protection. Protections such as rubber gloves, Faraday suits, and eye protectors have to be worn. An insulated universal grip all tool is also very necessary for the installation process.

Also, you need to connect the tap line to the clamp after being cleaned with a conductor cleaning brush to rid it of conductor oxides.

Then the eye bolts are loosened to allow the wire from the tap line to fit into the tap eye hole. The eye bolts are then tightened back to the recommended torque.

The clamp is then installed on the universal grip all tool (shotgun stick), with the eye stem fixed on the stick.

The hot line clamp is then to be attached to the stirrup clamp on the distribution line. The hot line clamp should be hooked onto the stirrup bail while still on the stick. The eye stem is then to be tightened to the recommended torque value.

Q12 Is a Hot Line Clamp Suitable For Transformers?

Hot line clamp is a perfect electric transmission line attachment for transformers. Many electricians use this tool for line tap distribution connections in a distant location. Often, contractors use the clamp as a fixing tool or attachment. The hot line clamp creates a safety connection between the transformer and the hot line.

Besides the transformer, electricians also use the clamp with other equipment like the arresters and cutouts. The clamp maintains and adjusts the hot line’s heavy flow of current to the transformer. It controls the high flow of current with its aluminum bronze eyelets and keepers and forged stainless steel eye bolts.

Unlike other transmission line fixtures, you can disconnect the hot line clamp without affecting the main transmission line. Likewise, electricians can quickly restore the hot line clamp while leaving the main transmission line unharmed. Whether the contractor is installing or servicing the transformer, the hot line clamp keeps the electrician safe.

Also, all hot line tap clamps must be used with insulated universal grip all tools, especially on an energized conductor. Before connecting the clamp to the transformer, ensure you thoroughly clean the conductor with the conductor cleaning brush. This is to ensure that no debris or conductor oxide stays on the conductor.

Next is to attach the hoist of the universal grip all tools to the hot line clamp. Then you mount and tighten all the devices on the central conductor. If you need to connect two hot line clamps to a single transformer, follow the other clamp process.

More importantly, hot line tap clamps are ideal for all distribution tap connections to transformers or other devices. Besides having great conductor compatibility, the fixture also has high mechanical strength.

Q13 Can a Hot Line Clamp Be Used With a Shotgun Stick?

                                                              Figure 8: Shotgun stick

Hot line clamps are perfect for shotgun sticks, especially when working on high voltage transformers or cutouts. Many electricians use the attachment alongside a shotgun stick for live-line maintenance and work. One of the reasons contractors employ this tool is safety. Live electrical equipment is hazardous. So the shotgun stick ensures adequate safety for all linemen.

Likewise, the shotgun stick allows linemen to work on a high voltage transformer without turning off the power. Often, these hot sticks come with a sliding hand grip. With the handgrip, the linemen can quickly adjust the hook at the stick’s rear. Also, the sliding handgrip ensures electricians have total control while at work on live electrical equipment. One big draw of the shotgun stick is that users can easily fold them in the middle.

Attaching the hot line clamp to the shotgun stick is a piece of cake. However, you need to make sure the installation tools are at hand. Some of these tools include a glove, a standard shotgun stick, and a universal hot stick. Also, ensure you are using the accurate hot line clamp size. Next is to prepare your conductor for installation. According to CIP, you need to brush about 68 inches of the area where you want to install the clamp.

On the other hand, unscrew the hot line clamp’s bolt either by hand or with a screwdriver. Ensure that you open the clamp for enough space to work on the electrical device. Then you mount the clamp on the exact location on the conductor and release the hot stick afterward. Don’t forget to tighten the bolt so the hot line clamp stays easily on the conductor. Once you are done, ensure you remove other tools on the conductor.

Q14 What are the Components of Hot Line Clamps?

The hot line clamp comes in four major components. These parts include the body & keeper, eye bolt, eye stem, and spring. The components often include the highly conductive aluminum or bronze body, bronze keeper, stainless steel eye stems, and hard drawn copper bail for other electrical clamps.

All these parts are vital for the control and maintenance of the flow of current to the conductor.

Body & Keeper

The body and keeper components are the nuclei of the clamp. Besides aiding the connection between the transformer and the hot line, these parts also offer some important features and benefits. For instance, they ensure the clamp is compatible with so many conductors. These components also ensure that the clamp is corrosion resistant and highly sturdy.

Eye Bolt

The eyebolt is another essential hot line clamp component. While you load, the eye bolt offers uniformed expansion. Besides, it also keeps the transformer free from corrosion or other conductor oxides. The bolt ensures that the clamps stay firmly on any electrical device you connect to the clamp. Also, the amount of weight the bolt holds depends on the weight capacity.

Eye stems

The eye stems help hold the hot line clamp tightly to the conductor. However, the number of the stem in clamps varies from one model to another. For most hot line clamps, you would find two limbs. Others often come with one.

String

The string makes working on any electrical equipment easy and quick. It allows you to adjust the hot line clamp to the size of the conductor.

Q15 Are There Alternatives for Hot Line Clamps?

There are two major alternatives for the hot line clamp. These devices include the stirrup clamp and bail clamp.

Stirrup clamp         

Like the hot line clamps, manufacturers also design stirrup clamps primarily for protection. This tool protects your electrical device from arcing damage. It allows you to attach the hot line clamp to the transformer without any contact on the live line. Besides, you can set up this live-line clamp on copper and aluminum lines.

Also, you can mount stirrup clamps on transformers, arresters, and cutouts. This device has four major components: the highly conductive aluminum or bronze body, aluminum or bronze keeper, stainless steel eye stems, and hard-drawn copper bail.

The essential function of the bronze body is to ensure the clamp is immune to rust, corrosion, or any harmful substance. On the other hand, the bronze keeper house the conductor or line going to the transformer. It can be easily adjusted to accommodate the size of the conductor.

The stainless steel eye stems work in hand with the universal grip tool. With the device, you can quickly tighten the stirrup clamp to the conductor. For hot line clamps, you often find one stainless steel eye stem. Also, the hard-drawn copper bail protects the conductor from weakening or unwanted breakdown. Manufacturers also design the part to resist rust and corrosion.

Bail Clamp

                                                                   Figure 9: Bail clamp

The bail clamp has similar features and functions as the stirrup clamp. However, its design is different. Unlike the stirrup device, it has two unequal eye stems. Likewise, the bail clamps have aluminum construction rather than the common copper material.

Q16 What Makes a Hot Line Clamp Burn?

A hot line clamp is a safe tool to use for electrical devices. However, it is with some minor flaws. For instance, the hot line clamp often burns. There are a few reasons for the clamp burn. For example, the hot line clamp can quickly burn when not well tightened to the conductor. It would be better if you hire an experienced technician to install the clamp.

Another reason the hot line clamp burns is mismatch sizes. Like other electrical accessories, hot line clamps are available in different sizes. The measures are designed with the conductor size in mind. Therefore, you must be familiar with your conductor or line size before purchasing the hot line clamp.

Furthermore, non-corrosion or rust clamps can quickly burn. Ensure your hot line clamp has high-quality material construction that makes it durable and sturdy.

Q17 How Often Do You Need to Replace a Hotline Clamp?

Hot line clamps are built to last for an extended period. Producers design the clamp to help stabilize current flow to the transformer or arrester. At least, the hot line clamp should be efficient for about 1 or 2 years. However, less durable clamps don’t last forever. Therefore, it is important to purchase hot line clamps built with superior quality material. Bronze, as well as aluminum are the two significant hot line construction materials.

You should replace your hot line clamp whenever it burns. Also, you should replace the clamp when the rate of the current flow is high.

Q18 Can Hot Line Clamps Be Used On High Voltage Power Lines?

                                                         Figure 10: High voltage line

Technicians can use hot line clamps on high voltage power lines. The device can create a safe connection between the conductor and the transformer. Also, it can regulate the high voltage power lines. However, other live-line working tools ensure technician’s safety while working on high voltage power lines. These tools include:

Live line tool or hot stick

One of the most crucial tools to use alongside the clamp is the hot stick. This stick allows you to work on the high voltage power line without coming close to it. To use the clamp, you only need to attach it to the insulating stick. Many companies consider the live-line tool a great safety device for all contractors working on live conductors.

Rubber gloves or insulating gloves

Like the hot stick, rubber gloves are also important tools to work on high voltage power lines. These insulating gloves keep you safe from having direct contact with the live conductor. Since there are different kinds of gloves on the market today, ensure you don’t purchase ordinary hand covers. For adequate safety, we recommend insulating gloves.

Q19 What are the Kinds of Hot Line Clamps by Material?

Hot line clamps are available in two major material constructions. These material constructions are copper alloy and aluminum.

Copper Alloy

Many hot line clamps on the shelves today are designed from copper alloy. One unique feature of this material is the strength. Copper alloy is not only resistant to corrosion but is also immune to rust. This material construction makes the hot line clamp durable and sturdy. Also, it makes it perfect for a wide range of applications. Hot line clamps are exceptional heat and electrical conductivity with this material.

Aluminum

Aluminum is another typical hot line clamp material construction. On the market today, it is the third most used metal. One big draw of the aluminum hot line clamp is the lightweight feature. The material construction makes the clamp simple to transport around. These tools are also solid and long-lasting. Like copper hot line clamp, aluminum tap clamps are rust and corrosion-resistant. They are also outstanding conductive material construction. These properties produce no odor or unpleasant smell. Likewise, the aluminum material helps the clamp control the current flow to the transformer.

Q20 How to Choose the Right Hot Line Clamp?

There are hundreds of thousands of hot line clamps on the market today. So, picking a suitable model for your technical assignment can be tricky. This guide will help you make the right decision. Here are some essential features and factors to consider before choosing or purchasing a hot line clamp

Material

One of the essential factors to consider is the clamp’s material construction. On the shelves, these devices are available in copper and aluminum material. Although there are other material constructions, these two are the most durable and robust.

Both material construction makes your clamp rust and corrosion-resistant. However, aluminum clamps are lightweight. On the other hand, copper hot line clamps are versatile and ideal for different applications.

Installation

No matter why you need the hot line clamp, ensure you check for the clamp that is simple to install. Likewise, it would help if you had other vital tools to make the installation simple and fast. Some of these tools include the hot stick, insulating gloves, and many more.

Conductor’s size

Ensure you consider the conductor’s size before buying your hot line clamp. Hot line clamps are often less efficient when used with the wrong conductor size. Sometimes, they burn and can easily put the technician at great risk.