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.
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If you need assembled jumper sets, quickly, send us a message today and we can configure your insulated jumpers according to your specifications.  |
| INSULATED JUMPER CHECKLIST | |
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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. |
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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. |
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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. | |
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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 | |
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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 |
| 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.
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| 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.
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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.
| 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. |
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| 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. | |||||
