PATTON & COOKE CO.

INSTALLATION GUIDE
25kV CABLE COUPLERS
C250J SERIES
 PATTON & COOKE CO.

TABLE OF CONTENTS

Page 1 ............................................Installation Tools

Page 2 ............................................Installation Materials

Page 4 ............................................Insulator Installation

Page 6 ............................................Cable Jacket Removal

Page 8 ............................................Conductor Preparation

Page 9 ............................................Cable Adapter Installation

Page 10...........................................Contact Installation

Page 12 ..........................................Insulator Assembly

Page 14 ..........................................Ground, Pilot, Bonding Wire Installation

Page 15 ..........................................Final Assembly

Page 17 ..........................................Coupler Assembly Testing

Page 17...........................................Operation

Page 18 ..........................................Appendix a - Technical Data

Page 19 ..........................................Drawing of C250J2103

Page 20 ..........................................Drawing of C250J3011

High Voltage Equipment Solutions. Design and Manufacturing.

PATTON & COOKE CO. • #100-7795 128th Street, Surrey, B.C. V3W 4E6 Canada • Tel: 604.591.5374 • Toll Free: 1.866.591.5374 • Fax: 604.591.3505
Email: info@pattonandcooke.com • Website: www.pattonandcooke.com
 1. INSTALLATION TOOLS

Note: Tools and materials below are required for 25kV couplers installation. It is not recommended to
proceed with installation if you do not have all of the required items.

• Utility knife, or other means for jacket removal

• Conductor cutting tool

• Heat gun (recommended for cleaning of insulation)

• Hex keys: 6, 8, 10 mm sizes

• Wrench 17mm size

• Metal file: medium to fine

• Measuring tape

• Diameter tape or calipers

• Hydraulic crimp tool

• Crimp die set

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2. INSTALLATION MATERIALS 1 2

RECOMMENDED INSTALLATION MATERIALS:

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1. Silicone Grease

2. Semi-con tape (Scotch 13)

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3. Vinyl electrical tape

4. (1-3) Crimp ground terminals. Note: quantity dependant

on cable type

INCLUDED INSTALLATION MATERIALS:

5. Emory cloth

6. Solvent wipes

7. Bonding Straps

6
5

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8. (3) Crimp phase pins P&C Part Number: PLU-102-X

9. (3) Silicone filler seals P&C Part Number: HA-R254

10. (3) Phase retainer clips P&C Part Number: RE-025

11. (3) Cable adapters P&C Part Number: OS-W972-EE

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10

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3. INSULATOR INSTALLATION

3.1. Remove pre-installed brass retainers from front body

before beginning assembly.

3.2. Install (3) insulators into front body. Notice the

notches on the side of the insulator (Figure 1). These will
need to be lined up with the brass retainers secure
insulators.

3.3. Re-install retainer by placing the brass retainer into

notches in insulators follwed by the lock washer & hex head
bolt. Tighten hex head bolt to secure insulators in place
(Figure 2).

3.4. Repeat step 3 for second brass retainer.

Figure 1

Figure 2
4
3.5. Install insulator retainer ring on to brass stud and around
insulators. Retainer ring should be fully seated collars of
insulators.

3.6. Tighten set screw on the side of insulator retainer ring.

Insulators are now securely installed to front body.

Insulator Retainer Ring

Retainer Ring Set Screw

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 4. CABLE JACKET REMOVAL

4.1. Before proceeding with installation it is

recommended that the cable outside diameter be
measured to confirm the entrance fitting and sealing
gaskets are the appropriate size for the cable. A good
cable seal will prevent ingress of moisture and
contamination of termination compartment and provide
effective cable strain relief.

4.2. Before termination of a cable it is recommended

that the working area of the cable jacket be cleaned to
prevent contamination of the insulation. A wipe down
with clean cloth and mild cleanser solutions may be
used if necessary. Ensure there is no moisture present
in working section of cable, if moisture is present cut
back cable until there is no further evidence of
contamination.

4.3. Slide entrance fitting components, cable sealing

gaskets, adapter plate, gaskets and rear body of
coupler onto the cable. This procedure is best done
prior to any cutting or preparation of the cable jacket.

4.4. Measure the required length of jacket to be

removed and mark clearly. Recommended jacket
cutback lengths are illustrated in Figure 1 below. For
standard cable mount coupler installation, an overall
cutback length of 14” (380 mm) is recommended. It is
recommended to start the jacket removal process at
this section of the cable. A straight, clean cut will help
ensure the coupler entrance fitting glands will provide
optimal sealing and cable strain relief.

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 14 1/2” (368.3 mm)

8 1/2” (216 mm)

Cable Jacket

Bare Conductor,
Shield & Insulation
Removed

Insulated Conductor, 1 3/8” (35 mm)

Shielded, Insulated Conductor Shield Removed
7 1/8” (181 mm )
Figure 1

4.5. Once the initial radial cut is complete, a length wise cut
to the end of the cable can be made. Pliers or vice grips can be
used to pull the jacketing away from the cores during this
process. Pulling the jacket away will help prevent accidental
damage to the cores and insulation.

Note: if using a knife or blade to cut jackets, always try to keep

the blade of the knife moving away from the cores of the cable.

4.6. If insulation is punctured, cut or damaged during the

cable jacket removal it is strongly recommended that the dam-
aged section be removed and the process restarted.

4.7. Once cable jacket has been removed, the core binding
wraps, tapes and fillers may be cut back and removed.

4.8. If phase crossing is required, add 1” to the overall cut back length of the jacket (See Figure 2). The 2
phases to be crossed can be left at their current length, the remaining phase can be shortended by 1”. Once
all the phases have been cut back, visually confirm by crossing the 2 phases that all 3 finished phases
appear of equal length. Please note that if you cut back too much, the cable sealing will not work.

14 1/2” (368.3 mm)

Cable Jacket 8 1/2” (216 mm) Bare

Conductor,
Shield &
6” (152.4 mm) 7 1/8” (181 mm) 1 3/8” (35 mm) Insulation
Removed

7” (177.8 mm) 7 1/8” (181 mm) 1 3/8” (35 mm)

15 1/2” (393.7 mm)

Shielded Insulated Conductor Insulated Conductor, Shield Removed

Figure 2 7
 5. CONDUCTOR PREPARATION

5.1. Once the jacket and wraps have been removed, any
metallic shielding can be cut or pulled back to allow semi con
to be removed and trimmed to the length prescribed in Figure
1 above. Marking the shield cutback point with a constant
force spring or electrical tape will help ensure a clean cut and
to keep the shielding in place.

• Note: When working with extruded shields, the

application of heat can assist in removing the extruded shield
layer. Once heated, the extruded shield layer can be peeled
back from the insulation.

• Important: A straight clean cut edge on the shielding

will help prevent electrical stress at the point the shield has
been removed. A file may also be used to taper the end of the
semi con.

5.2. The BRK-516C compression plate should be installed

prior to completing the cleaning stage to prevent
contamination of insulation.

5.3. Once the shield is removed and the compression plate

is in place, the insulation should be cleaned to remove any
residual semi-conductive material and contaminants that may
be present.

5.4. To clean the insulation, a combination of light sanding,

heating, and cleaning with solvent wipes will help achieve the
best results.

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• Start with a light sanding with emery cloth to remove any
surface residue.
• A light heating of the insulation will “plump” the insulating
material making sanding and cleaning easier.
Use solvent wipes periodically to remove residue.
• Note: It is important when working around the exposed
insulation to prevent further contamination. Take care when
sanding or wiping near the semi conductive shield not spread
residue or particles onto the insulation.

• Repeat above steps until insulation is clean and free of

residue. Once each phase is complete, the cable adapter may
be installed, or the insulation should be protected to prevent
contamination.

6. CABLE ADAPTER INSTALLATION

6.1. Cable adapters can be installed by sliding the

adapter over the cleaned phase insulation. A tapering
cut (penciling) the end of the insulation and a liberal
application of silicone grease will assist with this
procedure.

6.2. Repeat cable adapter steps for each phase.

Once installed, the tip of the insulation may be
removed to allow the phase pin (PLU-102-X) to be
installed on the exposed conductor.

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6.3. Measure the required cut back length as described in
Figure 1 above, remove insulation and any protective
wrappings with a utility knife. A clean straight cut is strongly
recommended.

6.4. Once the conductor has been exposed, the phase pin
(PLU-102-X) can be installed immediately. If not installing the pin
immediately it is recommended to bind the conductors with tape or tie
wrap to prevent the conductor strands from relaxing.

6.5. Repeat conductor cut back for each of the three phases.

7. CONTACT INSTALLATION

7.1. Once the cable adapter has been installed and

the phase conductor has been exposed, the phase pin
(PLU-102-X) can be crimped in place. Phase pins are
conductor sized specific. It is critical that the pins
have the correct bore size, before proceeding with any
installation it is strongly recommended to confirm
sizing of all materials.

7.2. Slide phase pin onto the conductor. Ensure

hydraulic crimp tool has correctly sized compression
die installed.

7.3. It is recommended to crimp each phase pin in 3

places beginning at the end of the contact that is
closest to the cable adapter. This will prevent
movement of the conductor when additional crimps
are done. It is also recommended to align the edges of
the hex crimps to aid in the final filing procedure.

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7.4. File the crimped edges of the phase pin be file to
remove any sharp points.
7.5. Once filing is complete, a semi con tape should be
applied over top of the crimp section.
• When applying a semi con tape wrap, the tape should
be stretched to approximately ½ of its original width. Wrap
the tape in an orderly manner to keep the filled area smooth
and avoid and creasing which may entrap air.

• Using the semi con tape, bring the diameter of the

crimped section to the same diameter of the flanges on the
pin.

• Repeat step for each of the three phase conductors.

7.6. Install the silicone filler seal (GA-254) over the semi
con tape. This seal will help remove any air when the
adapter is compressed in the insulator compartment.

• Repeat step for each of the three phase conductors.

7.7. Phase conductors are now prepared for installation in the phase compartment.

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8. INSULATOR ASSEMBLY

8.1. Positioning the coupler front body below the prepared

cable conductor assembly will help to align the phases into their
respective compartments. Ensure phase markings are followed
when installing the phases in the compartment to ensure proper
phase alignment.

8.2. Once cable and the coupler bodies are positioned and
aligned, a thorough coating of silicone grease on the cable
adapters and the interior of the phase insulators should be done
to ensure all air is will be expelled when the adapters are com-
pressed.

8.3. Once all phase conductors are seated in the insulator

assembly the compression plate can be slid down and the nuts
used to tighten and compress the adapters. It is strongly
recommended to evenly and uniformly tighten the nuts in a
opposed fashion (See Figure 1) to ensure compression force is
equally distributed.

8.4. Tighten the BRK-516 compression plate until the it is

engaged within the insulator tubes. The semi conductive layer
of the cable adapter module should be visible (black) and
accessible from the rear of the compression plate.
1
8.5. The semi conductive layer of the cable can now be
3
extended to the semi conductive layer of the cable adapter 6
using semi con tap.

5
4

Figure 1

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• Remove the electrical tape previously
applied to shield to hold in place. Starting at the
cable end, begin wrapping over the insulation
working up the conductor toward the cable
adapter.
• When applying a semi con tape wrap, the
tape should be stretched to approximately ½ of
its original width. Wrap the tape in an orderly
manner to keep the filled area smooth and avoid
and creasing which may entrap air.
• Repeat this step for all three phases.

8.6. Once the semi conductive layers are

connected, the earth bonding strap (bleed wire)
can be installed. Bonding straps should be
applied over the shield and will be connected to
the designated ground point on the coupler.
• A final covering of vinyl electrical tape over
both the bonding strap and all of the semi con
taped area is recommended.
• Repeat this procedure for all three
phases.

8.7. At this point the phases are fully terminated

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 9. GROUND, PILOT, BONDING WIRE INSTALLATION

9.1. The designated grounding (earthing) location on the

coupler is the brass rod located between the phase compartments
on the compression plate.

• Remove both brass nuts and flat washer from the rod.

• Ensure that the ground terminal is securely crimped or

fastened to the ground wire before securing.

• Install the terminals on the brass ground rod and secure

with the hardware supplied.

9.2. The shield bonding wires can be installed on one of the

three designated bonding locations located on the termination
compression plate. Remove the screw from the plate and install
eyelets over the screw, note that the wires may all be connected
to the same point or may be connected individually. Reinstall the
screw or screws and securely hand tighten.

9.3. The pilot wire in the cable can now be connected to the
pilot wire supplied with the coupler

• Pilot wire supplied with the coupler may be trimmed to

length.

• Connection of the pilot wires can be done in a number of

ways provided the contact is secure and reliable. Solder or crimp
connectors are both acceptable solutions for connecting the pilot
wires. A final covering with heat shrink tubing or vinyl tape must
also be done to ensure isolation of pilot wire from ground.

9.4. Once all the wires are connected, final coupler assembly
can begin.

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 10. FINAL ASSEMBLY

10.1. To finalize coupler installation, begin by installing the rear

body. To fit the rear body over the insulator assembly, align the
rear body so the external visual bond are adjacent. This will
ensure that the rear body will be in the correct orientation.
Alternately, align the rear body casting to ensure the ground pin
cutout is aligned to with the ground pin.

10.2. The rear body casting has (8) threaded holes for
attachment of the bodies. Confirm the sealing gasket is installed
on the front body and then secure the bodies by installing the
fastening bolt through the front face of the coupler.

10.3. Tighten the bolts in a radially opposed fashion (similar to installing a car tire) to ensure compression
force is equally distributed to maximize sealing potential.

10.4. Once the rear body has been securely fastened to the front body, the entrance fitting components
can be installed.

• Attach the adapter plate by aligning the (6) bolt holes. Ensure flat gasket is present between adapter
plate and body then securely fasten the plate to the rear body with the hardware provided.

• Once the adapter plate has been secured to the rear body, the entrance fitting components can be
installed.

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• Confirm that the cable sealing gasket and the adapter plate
gasket are both installed and then fasten the thrust plate to the
adapter.

• Once the sealing gaskets and thrust plate are all in position,
slide the strain relief fitting into position and align the bolt holes. Using
the hardware provided, fasten the (6) bolts through the strain relief
fitting and the thrust plate to the adapter plate. Tighten firmly to ensure
sealing gasket will be sufficiently compressed to prevent moisture
ingress.

• Confirm that the cable strain relief inserts are installed in the (2)
strain relief ears and are sized correctly for the cable.

• Fasten the strain relief ears to the strain relief fitting with the
hardware provided. Tighten firmly to ensure any strain on the cable will
not be transferred to the contacts.

• Coupler assembly is now complete and may now proceed to

any desired testing.

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 11. COUPLER ASSEMBLY TESTING

11.1. The following tests are recommended

• Continuity check on all phases

• High voltage (DC) test at 50 kV for 5 minutes on all phases

VLF Testing may be done as an alternative to DC Hipot

• Safety Note: After performing a DC Hipot test on a cable assembly, the conductors may hold
residual current. Any residual current should be discharged to ground using a shorting cap or other
approved method.

12. OPERATION

12.1. Before energizing a mated pair of couplers ensure the following:

• Silicone Insulating pins are installed

• Combination Ground / Pilot pin is installed

• Cable is secure in entrance fitting

• All parts are clean and free of contaminants

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 APPENDIX A - TECHNICAL DATA

PRODUCT WEIGHTS & DIMENSIONS

Equipment Mount Cable Mount

Weight: 15.7 kg/34.5 lbs Weight: 22.7 kg/50 lbs

Length: 343 mm/ 13.5’ Length: 636 mm/25” (with standard cable gland)

Width: 241 mm/10.5” Width: 267 mm/9.5”

Height: 254 mm/10” Height: 254 mm/10”

Electrical Characteristics
Nominal voltage………………………………………………………….25 kV AC
A.C. withstand voltage…………………………………………………..50 kV dry (1 min)
Impulse a.c. withstand voltage………………………………………....125 kV (10 pos, 10 neg)
Nominal current…………………………………………………………..700 Amps
Short time short circuit withstand capacity………………………........25 kA for .2 seconds
Peak Withstand…………………………………………………………...65kA

Mechanical Characteristics
Enclosure degree of protection…………………………………………..IP67H
Acceptable cable cross-sectional area………………………………….500 MCM / 240 mm²
Construction materials…………………………………………………....See drawing
Ambient temperature……………………………………………………...-40ºC - +45ºC
Shock and vibration………………………………………………………..IK 10
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HOW TO ORDER

For a copy of our product catalogue, or for

further information about our growing range
of high voltage electrical equipment for the
mining industry, call or email us.

PATTON & COOKE CO.

#100 - 7795 128th Street,
Surrey, BC V3W 4E6
CANADA
PHONE: 604.591.5374
TOLL FREE: 1.866.591.5374 (N. America)
FAX: 604.591.3505
EMAIL: info@pattonandcooke.com
WEBSITE: www.pattonandcooke.com