Elastimold Elbow Installation Instructions and Technical Specifications for High-Voltage Power Systems

Introduction

Elastimold elbow connectors are critical components in high-voltage power distribution systems, providing reliable connections for medium- and high-voltage (MV-HV) applications. These connectors are designed for use in underground cable systems and are available in both deadbreak and loadbreak configurations. The installation process requires strict adherence to technical specifications, safety protocols, and component compatibility. This article provides a detailed overview of Elastimold elbow installation instructions, technical ratings, and system integration, based on information from official product documentation and technical manuals.

Technical Ratings and Specifications

Elastimold 200 Amp Deadbreak Elbow Connectors are engineered to meet rigorous electrical and mechanical standards. The specifications vary based on the voltage class, with distinct ratings for 15kV, 25kV, and 35kV systems. Below is a summary of the key ratings:

• Current Ratings:

  • 200A Continuous
  • 10kA Symmetrical Interrupting Capacity for 10 Cycles

• Voltage Ratings (15kV Class):

  • 8.3kV Phase-to-Ground
  • 14.4kV Phase-to-Phase
  • 95kV BIL (Basic Impulse Level)
  • 34kV AC Withstand
  • 53kV DC Withstand
  • 11kV Corona Extinction

• Voltage Ratings (25kV Class):

  • 15.2kV Phase-to-Ground
  • 26.3kV Phase-to-Phase
  • 125kV BIL
  • 40kV AC Withstand
  • 78kV DC Withstand
  • 19kV Corona Extinction

Elastimold elbows are also available with optional accessories such as test points, insulated caps, and bushing adapters, which enhance functionality and safety during installation and operation.

Installation Requirements and Safety Protocols

According to the installation instructions provided in the technical documentation, Elastimold separable elbow connectors are intended for use with copper or aluminum wire screened cable featuring an extruded semi-conductive screen and rated for up to 24 kV. The installation must be performed by qualified personnel trained in high-voltage safety practices. Key steps in the installation process include:

1. Cable Preparation:

   • Position the cable adjacent to the equipment bushing.
   • Mark the centerline of the bushing to ensure alignment.
   • Remove the outer sheath and semi-conductive screen to the specified distances.

2. Sealing and Insulation:

   • Apply water sealing mastic and adhesive tape as per the manufacturer’s guidelines.

3. Safety Compliance:

   • The cable and equipment must be de-energized, locked out, and tagged before any installation work is initiated.

These steps are essential to ensuring the integrity of the connection and the safety of the personnel involved.

Components and Accessories

Elastimold elbow connectors are designed to integrate with a variety of accessories, depending on the specific application. Some of the most commonly used components include:

• Insulated Cap: Used to isolate components and prevent accidental contact.
• Insulated Plug: Provides temporary isolation for testing or maintenance.
• Parking Bushing: Allows for temporary bypass or grounding operations.
• Bushing Adapter: Facilitates the connection between the elbow and the equipment bushing.
• Compression Lugs and Cable Adapters: These are ordered separately and must be selected based on the conductor size and insulation type.

Additional accessories, such as grounding adapters and surge protection devices, are available to support system grounding and protection against electrical surges.

Ordering and Customization

Elastimold elbow connectors and related components can be customized to meet the specific requirements of a given installation. The ordering process is based on a systematic catalog number format that includes information about the voltage class, number of connection points, and interface type. For example:

• 4-Point, 15kV Junction with 600 Series Interfaces:
  Catalog Number: J4-6226-15

• 6-Point, 25/28kV Junction with Mixed Interfaces:
  Catalog Number: J6-626626-25-SV

Custom configurations can be created by combining different spacing options (e.g., 4-inch or 6.5-inch) and selecting appropriate interface types for each connection point. The manufacturer’s documentation provides detailed instructions for constructing the correct catalog number based on the specific system requirements.

Deadbreak vs. Loadbreak Configurations

Elastimold elbow connectors are available in two primary configurations: deadbreak and loadbreak. The key differences between these configurations are outlined below:

Deadbreak elbows are typically used in applications where the system can be safely de-energized for maintenance or testing. In contrast, loadbreak elbows are designed for use in active systems where disconnection must occur without interrupting power flow.

Integration with Surge Protection and Grounding

Elastimold elbow connectors can be integrated with surge protection and grounding systems to enhance the safety and reliability of the power distribution network. Some common integration scenarios include:

• Single-Bushing Transformer Protection:
  A bushing arrester or an elbow arrester with a feed-through insert can be used to add surge protection to a single-bushing transformer.

• Two-Bushing Transformer Protection:
  An elbow arrester can be added to the unoccupied bushing, or a bushing arrester can be used to provide surge protection.

• Loop-Feed Transformer Conversion:
  A parking stand arrester and an elbow arrester with a feed-through insert can be used to convert a single-bushing transformer to a loop-feed, open-point transformer.

These configurations allow for flexible and scalable protection strategies tailored to the specific needs of the power system.

Maintenance and Troubleshooting

Proper maintenance is essential to ensure the long-term performance and safety of Elastimold elbow connectors. Routine inspections should be conducted to check for signs of wear, insulation degradation, or mechanical damage. If issues are detected, the affected components should be replaced according to the manufacturer’s guidelines.

In the event of a malfunction or failure, the following troubleshooting steps are recommended:

1. Visual Inspection: Check for visible damage, insulation cracks, or contamination.
2. Electrical Testing: Use a properly rated voltage meter and hot-line stick to perform direct conductor voltage testing.
3. Component Replacement: Replace damaged or worn components using compatible spare parts.

It is important to note that all maintenance and troubleshooting activities should be performed by qualified personnel following established safety protocols.

Conclusion

Elastimold elbow connectors are essential components in high-voltage power distribution systems, offering reliable and secure connections for underground cable applications. The installation process requires careful planning, adherence to technical specifications, and strict safety protocols. By understanding the technical ratings, component options, and customization capabilities, system designers and maintenance personnel can ensure optimal performance and longevity. Whether used in deadbreak or loadbreak configurations, these connectors provide the flexibility and reliability needed for modern power distribution networks.

Sources

1. Elastimold Deadbreak Loadbreak Connectors
2. IS97081-ENG-200SR-G-CW45-R00-Z03
3. Elastimold Elbows – 200 Amp Deadbreak Elbow Connectors