EPS Magazine November 2014

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CONTENTS

PUBLISHER

Danny J. Salchert OFFICE MANAGER

Anita Salchert ASSOCIATE PUBLISHER

Bart Beason bart@epsmag.net CREATIVE DIRECTOR

Derek Gaylard

20 FEATURES 6

Versatility and Cost Savings through Commercial Solar Lighting Systems

20

UL 1008 listed Transfer Switches When Uninterrupted Power is Important

By Bhavesh Patel

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Five Considerations When Selecting a New Service Truck Body Knowing the details of service body design and construction pays off for electricians in terms of utility, durability and professional appearance.

CASE STUDY 14 What You Need to Know When Upgrading Power Transformers on Campus

DEPARTMENTS 32 Product Focus 40 Ad Index

ON THE COVER Photo provided by SEPCO — Solar Electric Power Company

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Electrical Products & Solutions • November 2014

CIRCULATION DIRECTOR

Pam Fulmer CONTRIBUTING WRITERS

Bhavesh Patel

PRESIDENT

Danny J. Salchert Executive and Advertising Offices 3591 Cahaba Beach Road Birmingham, AL 35242 toll free: 800.981.4541 phone: 205.981.4541 fax: 205.981.4544 www.epsmag.net • danny@epsmag.net Electrical Products & Solutions™ is published twelve times a year on a monthly basis by ABD Communications, Inc., 3591 Cahaba Beach Road, Birmingham, Alabama, 35242, USA. Electrical Products & Solutions™ is distributed free to qualified subscribers. Non-qualified subscription rates are $57.00 per year in the U.S. and Canada and $84.00 per year for foreign subscribers (surface mail). U.S. Postage paid at Birmingham, Alabama and additional mailing offices.

Electrical Products & Solutions™ is distributed to qualified readers in the electrical contracting industry. Publisher is not liable for all content (including editorial and illustrations provided by advertisers) of advertisements published and does not accept responsibility for any claims made against the publisher. It is the advertiser’s or agency’s responsibility to obtain appropriate releases on any item or individuals pictured in an advertisement. Reproduction of this magazine in whole or in part is prohibited without prior written permission from the publisher.

POSTMASTER: Send address changes to ABD Communications, Inc., P.O. Box 382885 Birmingham, Alabama 35238-2885 PRINTED IN THE USA

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FEATURE • SEPCO

Versatility and Cost Savings through Commercial Solar Lighting Systems

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t is estimated that lighting alone accounts for 12% of the total U.S. electrical consumption every year, using upwards of 461 billion kWh of electricity. This is a heavy cost to businesses, cities and municipalities. Solar lighting can provide both a financial relief as well as a green alternative to traditional lighting.

They are self-contained and grid free, and with LED technology, requiring almost no maintenance throughout their lifespan.

These lower installation costs compared with utility powered lighting and continue huge savings in the short and long run for most installations.

SEPCO – Solar Electric Power Company provides versatile solar lighting systems that can easily adapt to most lighting requirements.

Continued on page 8

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FEATURE • SEPCO

Continued from page 6

From large parking lots, roadways, security perimeters and such, all the way down to small sign, flag and bus stop/shelter lighting systems, each project is specified to meet the needs of the application. With over 30 years in the lighting industry, SEPCO solar lighting systems have provided illumination to thousands of projects all over the world.

Locally, we have installed a number of projects, Airport Road in Stuart, FL being one. The Martin County Project Manager Paul Bangs chose SEPCO solar lighting systems “to do something innovative” along this stretch of roadway leading into the local airport. The solar lighting systems will save the county money both in the short and long-term as there is no need to run permanent power and the lights are easy to assemble and install. These systems use efficient LED fixtures that provide even lighting along the roadway and are dark sky compliant so no light is wasted.

If a roadway is in a landmark area, more decorative and architecturally designed fixtures may be required. SEPCO’s partnership with Hubbell Lighting allows us to easily adapt almost any style fixture to our solar power systems. This allows us to provide large decorative fixtures for roadway applications without sacrificing lighting levels.

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The City of Bradenton Beach required just that. The city was looking to use renewable energy to lower the city’s electric bill and become more environmentally friendly. This coastal city has streets of beautiful architecture, homes and shops, and required something a little more than a standard street light system. Using the Urban fixture, we were able to provide a solar lighting system that matched the look of the area, and by powder coating the entire

Electrical Products & Solutions • November 2014

system, blended the solar lighting systems in well with the surrounding buildings and landscape. The lights in Bradenton Beach are a beautiful example of how solar and decorative fixtures work well together to provide the needed lighting for the area while not compromising the architectural looks of an area.

Mandates that have been set forth by the US Federal Government have required federal facilities to reduce Continued on page 12

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FEATURE • SEPCO

Continued from page 8

energy and improve energy security by installing renewable energy that operates independent of the electrical grid. The US Marine Corps Bachelor Enlisted Quarters complied with this by retrofitting their current lighting systems with solar power and replacing the fixtures with LEDs to increase visibility. Their parking lots and walkways have all been fitted with solar powered LED systems replacing the old High Pressure Sodium lamps with LED fixtures, even matching the style of the old fixtures along the walkways with Beacon’s Slide fixture.

LED lights are not the only style fixtures that can be adapted. A secure US Military facility required Metal Halide fixtures to be used for their roadway and parking lot area application. We were able to adapt a standard shoebox fixture with Metal Halide lamps to provide this facility light along their roadways, entrances and parking lot areas. This helped the facility to meet its energy reduction goal and provide security through grid free lighting.

Fort McHenry has been using our solar 12

powered lighting systems for their entrance and parking lots since 2001; however, in 2009 they installed a solar lighting system to light the Star Spangled Banner flag, replacing the 400 Watt metal halide flood lights that were bulky, compromising the aesthetics of the site, and consumed unnecessary energy. They installed a 24 Watt and a 17 Watt flood fixture along with the solar power system on the rooftop of the fort, unseen from tourists. These illuminate the oversized reproduction 15-star 15-stripe original flag for all night. The switch from the metal halide fixtures to LED increased the visibility and allows the flag to show its true colors at night.

SEPCO’s founder Steve Robbins invented the first commercial solar street light over 25 years ago and has been a leader in the industry since SEPCO was founded in 1994. Systems are manufactured to specifications laid out by the project designer with help from our lighting specialists. Each system is custom built and takes into account the geographical location, available sun, light level requirements and weather of each

Electrical Products & Solutions • November 2014

installation location to determine the best system to meet the needs of the customer.

SEPCO systems provide a minimum of five nights autonomy, more in the northern areas, and have a life span of 25 to 30 years, providing long term benefit to every solar lighting system installed.

SEPCO also provides custom solar power systems for many different applications. From cameras, Wi-Fi, meters, monitoring systems, the stand alone solar power stations can provide the needed power for almost any application where grid power is not available. These types of systems have been installed all over the world and are primarily used for military and government applications.

In the end, commercial solar lighting systems can provide the necessary security and reduce our energy consumption while maintaining the architectural integrity of the project. With a wide range of choices and custom built designs, SEPCO can easily adapt to the project requirements without sacrificing the lighting level requirements of the area. ❏

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CASE STUDY • ELSCO

What You Need to Know When Upgrading Power Transformers on Campus

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f your transformers are 10-15 years old, now is the time to take proactive steps to save utility costs and prevent power outages.

On May 2, 2013, a transformer explosion caused a power outage and forced evacuations at the University of La Verne in California. The local police department closed off adjacent areas while the city fire department put out the blaze.

Power transformers seldom go down, but when they do the effects on campus operations are immediate and devastating. Beyond the lost continuity of classroom instruction, the risk of subsequent fires, fines, security lapses and lawsuits can quadruple the damages.

At the same time, legacy power transformers represent a huge money drain on an educational institution’s operating budget when they force the campus to pay a steeper price for stepped-down electricity.

With the current move by utility companies to deliver higher and higher voltages from the grid, many schools, colleges and universities must replace their transformers.

“We were looking at a multi-phase process to literally transform our entire campus from a 5KV to 15KV distribution system because our utility company would no longer supply the lower voltage,” says Ben Johnson P.E., Assistant Director of Planning, Design, and Construction at Western Kentucky University at the Bowling Green location. “Between that and the occasional failures within our system, not doing anything was no longer an option.”

Spurring the need for replacement is the aging infrastructure at many established teaching institutions.

“The units in our substation were 40-60 years old, and were operating at 120-125% of capacity,” continues Johnson. “Since the utility said they would no longer provide 5KV class service we had to change every primary transformer on campus.”

According to “An Analysis of Trans-

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Electric Service Company specializes in emergency replacement. For mission critical applications, transformers can be prepped for shipping within a matter of hours. But to ensure a rapid return to operation, any replacement transformer must duplicate “form, fit and function” as much as possible.

former Failures” by William H. Bartley, P.E., on behalf of the Hartford Steam Boiler Inspection and Insurance Company, the average age at the time of failure ranged from only 9.4 to 14.9 years.

“Our 4160 volt system was in rough enough shape and fragile enough that it was not uncommon for us to have 3-6 major outages per year,” Johnson adds. “That is obviously not acceptable. Those problems extend your downtime, and when you’re in an academic setting, that’s a killer.”

Identifying a Robust Transformer Faced with massive upgrades, whether demanded by an electricity provider or for preventative purposes, many campus facility engineers are now beginning the process of acquiring newer power transformers. For

Electrical Products & Solutions • November 2014

public entities, the project must be put out to bid. But in writing the RFQ specifications for any campus distribution system, engineers can ensure that they obtain an asset that will provide cost-effective and longlived service through a basic knowledge of the design, construction and materials of power transformers.

Starting from the top, common types of power transformers found on campuses include liquid-filled (so called because they use oil, or similar, for cooling purposes), and dry- type transformers. Given that drytypes are air-cooled, they pose less chance of leakage and fire risk.

“Whether wet or dry-type, the way the coils are wound around the core of the transformer greatly affects its robustness,” says Alan Ober, Vice President of Engineering and Manufacturing Continued on page 16

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CASE STUDY • ELSCO

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for Electric Service Company (ELSCO).

Founded in 1912 by former Westinghouse engineers, ELSCO specializes in providing quality new, repaired and rebuilt transformers—under emergency conditions when necessary—from their Cincinnati, Ohio manufacturing plant.

“Because of increased axial forces acting at the corners of rectangular-wound transformers, energy gets wasted and noise is created,” continues Ober. “On the other hand, voltage stresses are halved between the discs of round-wound designs. Hence, round disc-wound transformers stay cooler, run quieter, present less risk of short circuit and are more energy efficient.”

“Beyond the improved reliability factor, the increased efficiency of the round design saves costs in real time, as the plant consumes less electricity. Some round discwound transformers even exceed the proposed efficiency standards for Energy Star compliance, drastically lowering utility costs for a plant”, according to Ober.

When it comes to the material used for the windings, copper is a superior conductor to aluminum because copper offers less resistance, hence less heat. Additionally, aluminum corrodes which generates heat and reduces lifespan while posing a fire hazard.

“If aluminum shows up in transformers at all, it’s because copper currently sells for about $6,500 per ton, whereas aluminum costs around $1,700 per ton,” notes Ober.

“Yet, any savings gain here evaporates under operating considerations.”

Even insulation plays a major part in ensuring reliability. Temperatures can reach 200 degrees C in a dry transformer on a daily basis; hence, skimping on insulation can lead to disastrous consequences. Glastic fiberglass insulation or Nomex® provide significantly greater protection from fires and short circuits than paper insulation.

Note that Nomex® is used in racing suits for Formula 1 drivers to protect them from burns.

Saving Money by Remanufacturing Similar considerations apply when purchasing a reconditioned transformer as for a new one; except that the expertise of the remanufacturer plays a greater role.

“At the bottom end of the remanufacturing scale are transformers that are brought in, fixed up just enough to be operational, superficially cleaned and then sent out the 16

Transformers seldom fo down, but when they do the effects to the bottom line are immediate and devasting. Utilizing a two-pronged approach, though, facility managers can stack the odds in their favor and prevent the loss of hundreds of thousands of dollars.

door,” notes Ober. “These won’t hold up as well as transformers that are completely refurbished, and could leave your plant vulnerable once again.”

A more completely remanufactured transformer provides far greater security against failures. There should be a complete rewinding of the primary and secondary coils along with brand new high and low voltage bus bars. While the original core can be kept 90% of the time, even it must be replaced occasionally as older steel is less energy efficient than modern core materials.

Attention to detail pays dividends in the remanufacturing process. Hand wiring ensures the highest quality. Additionally, the deburring of the copper conductor helps ensure that the insulation won’t be punctured

Electrical Products & Solutions • November 2014

and create a short circuit.

Ultimately, any remanufactured transformer must meet or exceed all NEMA, ANSI and IEEE standards.

Matching the Old with New Too often relegated to last-minute consideration is the need to ensure that any new power transformer fits into existing campus switchgear—carefully duplicating “form, fit and function” as much as possible.

“The main problem I’ve seen with some installations is adapting to existing facilities; it may seem like a small thing but it’s really huge,” cautions Johnson. “Obviously there will be mating and connectivity issues between your substation transformer and the secondary switchgear. I’ve seen cases with mass-produced Continued on page 18

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CASE STUDY • ELSCO

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transformers where at the end of the day you have to kluge it together to make it work. Sometimes it turns into a ‘beat to fit, paint to match’ sort of thing.”

“Our old on-campus equipment dated anywhere from the late 1920s to the 1980s,” continues Johnson. “This is where a custom-designed transformer and bus bar, like we get with the ELSCO transformers, really shines. The known reliability and track record of their transformers played a part in my selection of ELSCO. I’m an EE by trade and have been involved in electrical construction for over 25 years, so I have a respect for hardware.”

When Emergencies Do Happen For those learning institutions that can’t replace their out-dated transformers fast enough, accidents will happen, as when a blown transformer caused a power outage at Del Mar College in Corpus Christi, Texas two years ago, immediately halting classes.

To rapidly stem such losses, transformer companies exist that specialize in emergency replacement. For mission critical applications, such as on-campus medical clinics, transformers can be prepped for shipping within a matter of hours. Attention to details such as duplication of the high and low voltage bus bar spells the difference between a lengthy replacement process versus a quick, cost-effective plug-and-play solution that brings the campus back online in minimal time.

“Even though we are a public institution and must put everything out to bid, we are permitted to buy from a sole source to alleviate the emergency,” says Johnson. “Few would argue against a power outage as being an emergency.”

Going Forward As more campuses like WKU—with approximately five million square feet under roof—must switch out dozens of distribution transformers, cables and underground vaults, the process will not take place

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Electrical Products & Solutions • November 2014

overnight. Johnson recommends tackling the oldest transformers first.

“Of the 58 buildings we have on campus, I’ve still got about 18 to go so we’re still working it,” adds Johnson. “We replaced our worst equipment first to get them offline before we had more failures.

Since we’ve had two-thirds of our system already replaced, obviously our failure rate has gone way down. We’ve never had any issues out of anything we’ve ever put in.”

“For other engineers in the same situation as I’m in here at WKU, I would absolutely recommend replacing your old transformers at your university,” continues Johnson. “Especially when you’re dealing with public funding scenarios like we are.” ❏ For more information, contact: Electric Service Company (ELSCO); 5331 Hetzel Street, Cincinnati; OH 45227; 800-2329002 or 513-271-1752; FAX: 513-2710543; info@electricservice.com or www.electricservice.com.

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CASE STUDY • ASCO Power Technology

UL 1008 listed Transfer Switches When Uninterrupted Power is Important

By Bhavesh Patel

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hen uninterrupted power is essential to a customer’s business operations, reliable switchover to standby power whenever normal power is interrupted is of paramount importance. So, too, is the switch back when normal power is restored.

This transfer of power to a backup source (the backup generator) requires a transfer switch (automatic or manual) that performs as expected when called upon.

Sometimes, however, the transfer of power does not occur as expected because the transfer switch fails, explodes, or does not function properly. This is not as rare as business owners would hope.

In a recent survey sponsored by ASCO Power Technologies that queried facility executives on transfer switch failure, 20%

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had at least one failure of a transfer switch in the previous five years. In 33% of the incidents, the switch failed completely and became totally inoperative. And the majority of the switches were not even old – 54% had been in service less than ten years.

According to that same survey, failure of transfer switches can be traced to several issues, including power surge (22%), lack of maintenance (21%), age (18%), poor design (14%), poor application (7%), operator error (3%), and other reasons (31%), as well as age of the equipment.

(That adds up to greater than 100% because responders were allowed to give multiple answers.)

All transfer switches are not the same.

Indeed, some are designed with reliability and durability uppermost in mind and

Electrical Products & Solutions • November 2014

would be smart choices for installation for back-up power systems in businesses, data centers, healthcare facilities, telecom facilities, and other mission critical businesses and establishments where uninterrupted power is critical.

For most installations, a UL 1008 listed ATS would fit the bill. And here’s why. To help ensure transfer switches operate dependably when called upon, UL (Underwriters Laboratory) developed a standard, UL 1008, to which transfer switches for installation in emergency backup power systems should be certified. The standard was established to guard against transfer switch failures and potential resulting fires and is both a performance standard and design and construction standard.

Transfer switches that are UL 1008 listed have undergone Continued on page 22

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CASE STUDY • ASCO Power Technology rigorous third-party testing. A UL 1008 listed transfer switch can transfer at least 3,000 times, with at 1,000 of those times under at least 100% of rated load. If rated at lower amperes, a UL 1008 listed transfer switch must be capable of completing 6,000 transfers under 100% load or greater. (Given that a transfer switch could be tested monthly and annually, those numbers make good sense to help ensure durability over the long run of potentially many decades of operation.)

With a UL 1008 listed switch, the range of tests show that the switch can operate after withstanding and closing-on a severe fault current, bolted fault, or short circuit within the electrical distribution system. This testing meets the NEC Articles 517, 700, 701, and 708.

While manufacturers may claim a transfer switch conforms to UL 1008 specifications, specifiers should not rely on that. There should be clear documentation.

Electrical manufacturers generally offer

an array of transfer switches, including those that are UL 1008 listed and not UL 1008 and it can be hard for customers (before installation) and inspectors (after in-

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Continued from page 20

Electrical Products & Solutions • November 2014

stallation) to distinguish which have undergone the rigorous third party testing that owners/managers of critical facilities Continued on page 24 would want to rely

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CASE STUDY • ASCO Power Technology on and that, in some installations, code requires.

But it is important to look closely at the literature that accompanies a transfer switch. If it merely says “as per UL standards” or “meets UL standards” the switch might not actually have been UL tested. A customer needs to look for more precise language, such as “tested and certified by UL 1008” or “UL 1008 listed” and - and this is of utmost importance – the switch should carry a UL inside a circle logo label and identification as cited in the standard as to the type of switch it is – e.g., for an automatic transfer switch it should say just that –“automatic transfer switch.”

Along the same lines, a UL 1008 listed non-automatic switch would carry the UL logo and be labeled ‘non-automatic transfer switch. Switches that come with all this documentation and labeling have been third party tested to meet those requirements. Some manufacturers certify their equipment at 480VAC only. At least one,

however, certifies their ATSs for 480 and 600VAC equipment.

For example, Emerson Network Power’s ASCO Power Transfer Switches have all passed rigorous qualification testing by a third-party testing and certification agency for 480 and 600VAC equipment.

Installing a 1008 listed switch is an excellent decision. But the buck does not stop there - maintenance and testing are critical practices that will help ensure the ATS will operate as needed when called upon.

There are several other reasons why installing a UL 1008 ATS makes sense. Be aware when recommending automatic transfer switches, specifications for some installations at critical facilities may also call for meeting the National Fire Protection Association’s (NFPA) Life Safety Code and other applicable NFPA standards, such as NFPA 99 and 110. Also, installing a transfer switch manufactured by a company that offers only transfer switches that are UL 1008 listed makes it easier for inspectors at installations where a UL 1008 listed transfer switch is required. ❏

ABOUT THE AUTHOR BHAVESH PATEL is Director of Marketing and Customer Support,

ASCO Power Technologies, Florham Park, NJ, a business of Emerson Network Power, He is an accomplished public speaker with deep expertise in power system markets and is sought by organizations for his perspectives on their future. For more information: www.emersonnetworkpower.com/asco, customercare@asco.com, 800-800-ASCO

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FEATURE • Royal Truck Body

(Top) A sturdy material like A-60 “galvanealed” steel helps support heavy loads such as generators.

(Left) An automotive-style finish maximizes gloss retention and durability. Acrylic-urethane enamels provide resistance to chipping, corrosion, UV and chemicals.

Five Considerations When Selecting a New Service Truck Body Knowing the details of service body design and construction pays off for electricians in terms of utility, durability and professional appearance.

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sk any electrician about the one thing that makes their work go easier, and they will most likely answer, their tools. Good tools make for good work. Nowhere else is this more important than when it comes to the work truck. So when it comes time to replace or step up to a new service body, quality pays for itself in terms of usability, durability, and looks.

But how do you know which truck service body to order to meet and exceed your needs? On the face of it, competitive truck bodies look very similar.

To ensure that you get what you pay for at the dealership, you have to dig deeper into the details of design, construction, the quality of materials used, and several other factors that differentiate service bodies.

Knowing this information helps you get the most for your dollar at the original time of purchase, during the entire service life of the truck body, and even when you go to sell it.

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I. Security Off all the considerations on a contractor’s mind, security must rank as the most important. Here, details spell the difference between having thieves see your truck as an easy mark, or too much trouble to try to break into.

To start, outside handles should be made of sturdy material, like hardened chrome. These should operate metal locking rods—plated with an anti-corrosive material like zinc—at each corner of the cabinet doors, as well as a center cam.

Added strength comes from welding steel brackets onto the interior of each door behind a “hinge block.” The latter securely grips the wall of the compartment so that the door can’t be pried out from the bottom. Check for steel rivets to hold all locking hardware in place.

A popular add-on for security is a master locking system. This is achieved by the use of long rods that extend inside the length of the body, one on either side.

Electrical Products & Solutions • November 2014

The rod is engaged by pulling or twisting a handle at the rear of the body, at which time a male and female stop are mated.

“Many doors on utility or service trucks lock at just one or three points,” notes Dudley DeZonia, president of Paramount, CA-based Royal Truck Body, a leader and innovator in the design and building of specialized truck bodies for contractors and tradesmen since 1971.

“We prefer to use a five point system of defense that incorporates all of the above and includes concealed access latches for added security.”

II. Design When it comes to the actual construction of the service body, the features that make a service body a success in the field begin on the drawing table or computer screen in an engineer’s office. This is because of the complexity of today’s engine and electrical systems.

Even something as simple as a brake light is now tied into the Controller Area Network of the vehicle. In certain states, diesels must utilize complex urea systems that require an extra filler neck near the back of the truck. Even crash-worthiness specifications play a part.

“Service body manufacturers have to certify that their product meets all government regulations in order to satisfy the standards that OEMs like Ford, GMC, and Dodge must adhere to,” continues DeZonia “For that reason, look for a manufacturer that is a selected partner or preferred ‘upfitter’ of the ‘big three.’”

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FEATURE • Royal Truck Body One way of ensuring that a given service body meets these standards is to check to see if the manufacturer is a member of the Service Body Institute of the National Truck Association and has attained MVP status. Also, ask about whether or not the manufacturer supplies any major fleets.

“When you first look at truck bodies, they look all the same, but when I go deeper I notice different things, like the width and length of the bed that accommodates my needs for the use we design our truck for,” Says Frank J. Hernandez, owner of Precision Electric Co. since 1982 an electrical contractor offering services for electrical design, engineering, construction and maintenance from its Irwindale-CA base.

“What’s also important to me is whether or not a manufacturer can do a design to my specifications,” continues Hernandez. “For example, Royal makes me reinforced bumpers since my electricians tow lots of heavy equipment with

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our trailers such as emergency generators, posites will not rust. Automotive style scissors lifts, fork lifts and large reels of neoprene weather stripping around shelving and cabinet doors provides resistance wire.” to water, ozone, UV degradation, freezIII. Quality of materials ing and compression.

Consider first the grade and type of “I bought a service body at a GMC metal used for the cabinets and racks. For dealership where I first learned about example, A-60 “galvanealed” steel with a some of the details of what constitutes heavy zinc coating currently represents good build quality,” recalls Deane Tompone of the best materials for keeping rust kins, owner of Bullet Electrical of Torand corrosion at bay. rance, CA. “Attention to details like How that metal gets coated is equally keeping a wide space between the bumper important. An automotive-style high gloss and the body helps prevent falling tools finish maximizes gloss retention and dura- from getting jammed down there.” bility. For example, acrylic-urethane enamels provide resistance to chipping, IV. Workmanship corrosion, UV, and chemicals. Items subThe service body should be supported ject to very heavy use, like ladder racks, by several steel crossbeams. Tailgates bedliners and bumpers, should have their should be double-paneled with heavy duty metal surfaces protected by sprayed-on machined hinges. Hinge rods with overpowder coatings which provide much sized blocks provide maximum strength. greater permanence and won’t wash away Doors should also feature strong, doublethrough usage. steel construction.

The use of composites for the fender Seams between service body parts flares is an important element, as com- should be caulked inside Continued on page 30

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FEATURE • Royal Truck Body and out. Modular wiring harnesses protected by a plastic loom or similar will help prevent water and physical damage from causing electrical shorts.

Attention to detail extends to how ladder racks are constructed. One piece, mandrel-bent legs, versus rust-prone welds, ensures that metal integrity is not compromised. Beyond visual inspection, details like internal spacers within the rack tubing strengthen the legs and prevent the tubing from collapsing as it is tightened during the manufacturing process.

Note that service body manufacturers that install the bodies on the truck frame at the plant or through company owned branches can maintain better quality control over both installation and workmanship, as opposed to third-party distributors.

Assurances like multi-year/multi-mile warranties add credence to claims of quality workmanship.

“I replace my trucks every five years, but when I sell them to the next contractor

Continued from page 28

I want them to know they are going to get at least five more years out of them,” says Hernandez. “With things like thicker metal on the end panels supporting beefier ladder racks, I have no worries of the truck body lasting that long.”

V. Convenience Large capacity shelving should be adjustable at several levels. Gas shocks account for an easier way of opening and holding vertical doors and top compartments in an open position than metal struts.

Other convenient details include rope hooks to secure items to the ladder rack and tie downs along interior walls of the truck bed to hold cargo in place. Small things like roll-out drawers and portable storage trays also help speed a job.

“It’s really handy for an electrician to have dividers in the top bins on each side, as you can put all kinds of stuff up there,” says Tompkins.

A retractable utility bed cover greatly

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improves access to the truck bed. Extending access beyond that point are electric roll tops that telescope onto themselves for compact storage. Push-button operation helps prevent accidents since the worker does not need to climb into the bed to manually open or close the top.

Convenience should even extend to overhead racks with swing-away crossbars for easier loading and unloading of tall items, and tailgates that permit onehand operation. These should have no chains or side brackets to get in the way.

“It seems like over the past ten years manufacturers have re-engineered the service bodies to where they are more user friendly,” says Tompkins. “I’ve owned three different Royal models, and every new one I buy just gets better.” ❏ For more information, contact: Royal Truck Body; 14001 Garfield Avenue; Paramount, CA 90723; (800) 834-7692; fax (866) 397-6968; or www.royaltruckbody.com.

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Product FOCUS

TaskMaster™ – A Game-Changing Tool Innovation from ILSCO ILSCO’s new TaskMaster™ tool gives end-users unparalleled productivity, unprecedented value and unrivaled versatility by allowing users to cut, crimp and punch all with one device. TaskMaster eliminates the need to purchase, transport, maintain and grapple with three separate tool systems.

“The ILSCO TaskMaster will improve every aspect of an electrical contractor’s work,” said ILSCO Director of Marketing, Mark Rubick. “One TaskMaster tool performs the same work of what formerly required three heavy, bulky and expensive tools and accessories.”

The TaskMaster offering includes three quick-change heads. The cable-cutting head easily cuts copper or aluminum wire.

A universal, 4-indent, dieless crimping head ensures fast, precise connections. TaskMaster’s hole-punch head makes precise cable entry holes in electrical boxes. Users can easily switch between heads using TaskMaster’s quick-change collar.

TaskMaster is powered by a quick-charging 18V Advanced Lithium battery. It features a power-saving sleep mode for longer battery life, and on-board diagnostic sensors to ensure fast, full cycles every time. The tool is housed in a lightweight, impact-resistant nylon body featuring a built-in LED work light. Its ergonomic, molded rubber hand grip provides superior comfort and control.

ILSCO’s TaskMaster is UL Listed and CSA Certified with ILSCO’s line of SureCrimp® copper and aluminum compression connectors.

For more information, visit www.ilscotaskmaster.com

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Product FOCUS DEWALT® Launches New Die Grinders with Greater Durability, Performance, and Ergonomics DEWALT recently announced the launch of its new 1-1/2” Die Grinders (DWE4887 and DWE4887N), offering greater durability, power, and enhanced ergonomics for a comfortable grinding experience compared to DEWALT’s previous models DW887 and DW887N. “These new Die Grinders reset the bar to a new level of durability, performance, ergonomics, and ease of use,” said Sean Kelly, Group Product Manager. “After extensive research with pipefitters and other trades, the new die grinders were designed to offer greater durability with longer brush life, and more performance with a higher amp rating.”

“Durability in grinding is, by far, the users’ number one request,” added Kelly. The new motors in these Die Grinders offer 2X the brush life of their predecessors (DW887 and DW887N). Additionally, epoxy coatings now help to protect the motor from harmful abrasion that occurs in many applications.

With a higher amp rating of 4.2 amps, a 1.2 amp increase over the DW887, users can get through tough applications like a pipefitter de-burring pipe with a flap wheel or cone abrasive more quickly. This increase in power and speed raises the new Die Grinders to a higher performance level.

In addition to greater durability, speed and power, research revealed that ergonomics are of prime importance to the user. “The new Die Grinders are comfortable and easy to use during the long-duty cycles of grinding applications,” said Kelly.

“The circumference of the body of the grinder was reduced by 10mm, making the gripping area smaller and more comfortable to hold.”

For more information, visit www.dewalt.com

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Product FOCUS

Eaton’s New V-Spring Telescoping Light Pole System Offers Safer, Less Expensive Alternative to Lighting Installation and Maintenance Power management company Eaton today introduced the V-Spring™ Telescoping Light Pole from its Crouse-Hinds business, designed to increase safety and reduce labor costs associated with installing and maintaining lights at industrial facilities.

The controlled lowering pole features spring assistance to easily move the fixture up and down vertically. The V-Spring™ system may prevent the need for worker’s to work at heights when they need to clean or repair the light.

“At this very moment, nearly one-third of all lights in industrial facilities are not working, leading to the fact that a staggering 34 percent of all electrical incidents at industrial facilities are related to lighting,” said Bradford Morse, industrial fittings global product line manager, Eaton’s Crouse-Hinds business. “Our newest solution allows operators to quickly and safely maintain lighting throughout a facility by bringing the light fixture to the worker rather than the other way around.”

The V-Spring™ Telescoping Light Pole enables work to be completed on the walkway or platform.

It uses spring assistance to offset the pole and the light’s weight and enables a worker to safely and easily lower or raise the light fixture. The innovative system reduces the necessary number of workers as well as the time it takes to install, clean, or repair the light fixture. By removing the need to work at heights, the V-Spring™ lowering pole can contribute to decreased regulatory costs.

The V-Spring™ is fully adjustable from five to ten feet and travels vertically as opposed to traditional solutions that follow a 45-degree rotational path. It can be locked into any height position without requiring nuts, safety pins or tethers. A sturdy 2-inch base pole comes standard on all models and is constructed to meet high structural wind ratings.

For more information, visit www.eaton.com

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Product FOCUS T&B® Fittings Non-Metallic Expansion/Deflection Coupling Improves Safety While Reducing Installation Time The new T&B® Fittings Non-Metallic Expansion/Deflection Coupling from Thomas & Betts (T&B) improves safety and reduces installation time for joining rigid polyvinylchloride (PVC) conduit that is subject to movement in any direction at structural joints.

Its design makes the T&B® Fittings Non-Metallic Expansion/Deflection Coupling up to five times faster to install, while its versatility enables a fiveto-one reduction in stock keeping units (SKUs). The T&B® Fittings Non-Metallic Expansion/Deflection Coupling is manufactured in the United States.

“The new, patent-pending T&B® Fittings Non-Metallic Expansion/Deflection Coupling provides a flexible connection of PVC conduit runs that resists moisture ingress and stress caused by movement at structural joints,” said Chad Smith, vice president, product management and marketing, at Thomas & Betts. “It safely accommodates axial or parallel deflection of up to ¾ inch, and angular deflection up to 30 degrees from the relaxed position. It can be used indoors or outdoors, for direct burial or embedded in concrete.”

The T&B® Fittings Non-Metallic Expansion/Deflection Coupling complies with 2014 National Electric Code® (NEC®) Article 300.4(H) for use where a raceway crosses a structural joint intended for expansion, contraction or deflection in buildings, bridges, parking garages, piers, hospitals, and water and waste water treatment plants. Additional features include a flexible neoprene outer jacket with tamperproof stainless steel straps for resistance to moisture and corrosion, and an inner sleeve to provide a constant and smooth inner diameter in any position to facilitate wire pulling and prevent damage to wire insulation.

For more information, visit www.tnb.com

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Advertiser INDEX This advertisers index is compiled as a courtesy to our readers. While every effort is made to provide a complete and accurate listing of companies, page numbers and reader service numbers, the publisher is not responsible for errors.

Company

PG#

RS#

40 IBC 31 38 3 18 4 19 34 21 22 22 7 32 11 15 39 38 36 7

54 2 21 52 5 42 6 15 48 16 44 43 8 47 11 13 25 53 50 8

ACSCOUT LLC AEMC INSTRUMENTS ALFRA USA, LLC BOLT STAR/CONSTRUCTION INNOVATIONS BROTHER MOBILE SOLUTIONS, INC. CABLE GLYDZ CONDUIT REPAIR SYSTEMS COPPER DEVELOPMENT ASSOCIATION DABMAR LIGHTING DH INC. E-Z METER ELECDIRECT.COM LLC GENERATOR INTERLOCK TECHNOLOGIES GENSCO HB BRACKETS HIOKI USA ITOOLCO KOLBI PIPE MARKER CO. KRENZ & COMPANY LIGHT EFFICIENT DESIGN

Company

PG#

RS#

LUMASTROBE MILLER SAFETY CONSULTANTS, LTD NORTHWEST LIGHTING SYSTEMS PHASE-A-MATIC POWER & TEL POWER-ONE RANDL INDUSTRIES ROLL-A-REEL SEPCO SIMPLY AUTOMATED INC. SMALLPC.COM STEELMAN INDUSTRIES STRIP-TEC SURGE SUPPRESSION INC. TCP THE HOME DEPOT THIRD COAST UNDERWRITERS TRIPLETT/BYTE BROTHERS UNDERGROUND DEVICES UTILITY METALS

34 IFC 37 36 23 BC, 17 29 30 27 25 30 40 24 28 33 13 9 1 35 10

49 1 24 51 17 3, 14 20 57 19 18 56 55 45 46 22 12 9 4 23 10

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