The Elastimold® 600 Series Deadbreak Elbow system is a high-voltage, modular connector solution designed for underground cable access and maintenance in primary feeder and network circuits. This system is engineered for reliability, ease of installation, and compatibility with existing infrastructure. It is particularly valuable in scenarios requiring temporary grounding, testing, and isolation of energized or de-energized circuits. The system supports a wide range of voltage classes and is adaptable for use in 15kV, 25kV, and 35kV applications. This article provides a detailed technical overview of the components, ratings, and installation considerations based on information from the manufacturer's documentation and product specifications.
Technical Overview of the 600 Series Deadbreak Elbow System
The 600 Series Deadbreak Elbow system is a modular, bolted connection system that supports deadfront construction and is designed for high reliability and performance in underground power distribution. The system incorporates components such as elbows, receptacles, junctions, and vault stretchers that allow for the connection and isolation of equipment and cables. The modular design supports bolted connections, and the system can be operated using standard hand tools and hotstick equipment.
The system is specifically designed for de-energized operations, where connectors can be quickly and easily connected or disconnected. Optional accessories such as insulated caps, parking bushings, and grounding plugs provide additional functionality for visible separation, bypassing, isolation, and testing. These features are essential for ensuring safety and operational flexibility in high-voltage environments.
The 600 Series Deadbreak system is part of a broader range of Elastimold® products and is often used in conjunction with the Cam-Op™ system, which supports hotstick operability for de-energized circuits. This capability is particularly useful in situations where visible external separation is required for safety and compliance.
System Ratings and Specifications
The 600 Series Deadbreak Elbow system is rated for continuous current up to 600 amps, with higher 900-amp ratings available when using copper cable and copper current-carrying components. The system is designed to handle symmetrical short-circuit currents of up to 25kA for 10 cycles, making it suitable for high-demand applications in primary feeder systems.
Voltage ratings vary by class and are defined as follows:
15kV Class
- Phase-to-Ground: 8.3kV
- Phase-to-Phase: 14.4kV
- BIL (Basic Insulation Level): 95kV
- AC Withstand: 34kV
- DC Withstand: 53kV
- Corona Extinction: 11kV
25kV Class
- Phase-to-Ground: 15.2kV
- Phase-to-Phase: 26.3kV
- BIL: 125kV
- AC Withstand: 40kV
- DC Withstand: 78kV
- Corona Extinction: 19kV
35kV Class
- Phase-to-Ground: 21.1kV
- Phase-to-Phase: 36.6kV
- BIL: 150kV
- AC Withstand: 50kV
- DC Withstand: 103kV
- Corona Extinction: 26kV
These ratings ensure that the system is suitable for a wide range of underground cable applications, including primary feeders and network circuits. The system supports various configurations, including 2-point, 3-point, and 4-point junctions, as well as feed-thrus and in-line junctions.
Key Components of the 600 Series Deadbreak System
The 600 Series Deadbreak system includes a range of components that are essential for installation, operation, and maintenance. These components include:
Elbow Connectors: These are the primary connectors used in the system and are available in various configurations, including straight receptacles, junctions, and vault stretchers. The elbow connectors are designed for easy installation and removal using standard hand tools or hotstick equipment.
Compression Lugs: Used to connect the cable to the elbow connectors, these lugs are available in different styles, including threaded and unthreaded versions. The choice of lug depends on the specific application and the type of cable being used.
Cable Adapters: These are used to connect the cable to the elbow connectors and ensure a secure and reliable connection. The adapters are available in different sizes and configurations to accommodate various cable types and diameters.
Insulated Parking Bushings: These components are used to provide insulation and protection for the elbow connectors during installation and maintenance. They are particularly useful in situations where the connectors need to be temporarily grounded or isolated.
Grounding Plugs and Kits: These are used to ground the system during installation and maintenance. The grounding kits include an insulated cap, a test and ground reducing tap plug, and a compression lug. The use of these components is essential for ensuring safety during de-energized operations.
Mounting Components: These include alignment brackets, sleeves, and other hardware used to secure and align the elbow connectors during installation. The mounting components ensure that the connectors are properly positioned and securely fastened.
Retrofit Components: These are used to upgrade existing equipment to support the 600 Series Deadbreak system. Retrofit kits allow for the installation of mountable insulated bushings and other components that are not originally included in the equipment.
Test Rods and Assembly Tools: These tools are used to install and operate the elbow connectors. The test rods are used to apply pressure and ensure that the connectors are properly seated, while the assembly tools are used to connect and disconnect the components.
Installation Considerations and Best Practices
The installation of the 600 Series Deadbreak Elbow system requires careful planning and adherence to safety procedures. The system is designed for de-energized operations, and all connectors must be de-energized before installation. The connectors must also be mechanically secured with bails when connected to prevent accidental disconnection.
The installation process typically involves the following steps:
Preparation: Before installation, the site must be prepared to ensure that all necessary tools, components, and safety equipment are available. The cable must be de-energized and tested to confirm that it is safe to work on.
Cable Preparation: The cable must be stripped and prepped to ensure that it can be properly connected to the elbow connector. The compression lug must be installed and secured to the cable.
Connector Installation: The elbow connector must be installed and connected to the cable adapter and compression lug. The connector must be properly aligned and secured to ensure a reliable connection.
Mounting and Alignment: The connector must be mounted and aligned using the appropriate mounting components. The alignment bracket and sleeves must be used to ensure that the connector is properly positioned.
Grounding and Testing: After the connector is installed, it must be grounded using the grounding plug and kit. The system must then be tested to ensure that it is functioning properly and that all connections are secure.
Final Inspection: A final inspection must be conducted to ensure that all components are properly installed and that the system is functioning as intended.
Compatibility and Retrofitting Options
The 600 Series Deadbreak system is designed to be compatible with a wide range of existing equipment and infrastructure. Retrofit kits are available for upgrading existing equipment to support the 600 Series system. These kits include components such as mountable insulated bushings, alignment brackets, and other hardware that can be added to existing equipment to provide the necessary functionality.
The retrofitting process typically involves the following steps:
Assessment of Existing Equipment: The existing equipment must be assessed to determine whether it is compatible with the 600 Series system. In some cases, modifications may be required to support the new components.
Installation of Retrofit Components: The retrofit components must be installed and secured to the existing equipment. This may involve the installation of new bushings, alignment brackets, and other hardware.
Testing and Verification: After the retrofit components are installed, the system must be tested to ensure that it is functioning properly. This may involve testing the grounding system, verifying the insulation levels, and checking the mechanical connections.
Documentation and Training: Once the retrofit is complete, the system must be documented and the personnel must be trained on how to operate and maintain the new components. This ensures that the system is used safely and effectively.
Safety and Compliance Considerations
The 600 Series Deadbreak system is designed to meet or exceed all relevant safety and compliance standards for high-voltage electrical equipment. The system is rated for use in a wide range of environments and is suitable for both indoor and outdoor applications. The system is also designed to be compatible with existing safety practices and procedures, including those related to grounding, isolation, and testing.
The system includes a number of safety features, including:
Insulated Caps and Plugs: These components are used to provide insulation and protection for the elbow connectors during installation and maintenance. They are essential for ensuring that the system remains safe during de-energized operations.
Grounding Systems: The system includes a comprehensive grounding system that is designed to provide additional protection during installation and maintenance. The grounding system includes components such as grounding plugs, test rods, and assembly tools.
Bails and Mechanical Locks: These components are used to secure the connectors and prevent accidental disconnection during operation. The bails are particularly important in situations where the system is being used in high-risk environments.
Testing and Inspection Protocols: The system is designed to be compatible with existing testing and inspection protocols, including those related to insulation testing, grounding verification, and mechanical inspection.
Applications and Use Cases
The 600 Series Deadbreak Elbow system is suitable for a wide range of applications in high-voltage power distribution systems. Some of the most common use cases include:
Primary Feeder Circuits: The system is commonly used in primary feeder circuits where it is used to connect and isolate equipment and cables. The system's modular design and high ratings make it ideal for use in high-demand applications.
Network Circuits: The system is also used in network circuits where it is used to connect and isolate equipment and cables. The system's compatibility with a wide range of voltage classes makes it suitable for use in both 15kV and 25kV applications.
Surge Protection: The system is compatible with surge arresters, which are used to protect equipment and cables from lightning strikes and other electrical surges. The system's modular design allows for the easy integration of surge arresters into the system.
Retrofitting Existing Systems: The system is often used to retrofit existing systems to support the 600 Series Deadbreak system. This allows for the upgrading of older systems without the need for complete replacement.
Temporary Grounding and Isolation: The system is commonly used for temporary grounding and isolation during maintenance and installation. The system's grounding and isolation capabilities make it ideal for use in high-risk environments.
Conclusion
The Elastimold® 600 Series Deadbreak Elbow system is a high-performance, modular connector solution designed for use in high-voltage power distribution systems. The system is rated for continuous currents up to 600 amps and is compatible with a wide range of voltage classes, including 15kV, 25kV, and 35kV. The system includes a range of components, including elbow connectors, compression lugs, cable adapters, and grounding kits, which are essential for installation and operation.
The system is designed for de-energized operations and includes a number of safety features, including insulated caps, grounding systems, and mechanical locks. The system is also compatible with retrofitting and can be used to upgrade existing equipment to support the 600 Series system. The system is suitable for a wide range of applications, including primary feeder circuits, network circuits, and surge protection.
Overall, the Elastimold® 600 Series Deadbreak Elbow system is a reliable, versatile, and safe solution for high-voltage power distribution systems. Its modular design, high ratings, and compatibility with existing infrastructure make it an ideal choice for both new installations and retrofitting projects.