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5/8 kV Cable Couplers

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P&C 5/8kV Data Sheet

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The quality and durability of Patton & Cooke’s existing line of 5/8kV, 250 and 400 amp cable couplers has already been proven throughout the global mining industry. Now that we’ve added many new improvements, we’ve definitely left our competitors trailing far behind!

For quality 5/8kV couplers at competitive prices, Patton & Cooke is your only choice. For proven performance and cost effectiveness the PK and PL Series couplers are unmatched. Both 250 amp (PK/RK) and 400 amp (PL/RL) versions are among the most widely 5-8 kV couplers in the world. If a feature rich, or customized coupler is required, our C80 series can accomodate all of your specific needs – from interlocks to fiber optics.

C80 Series

5/8 kV Cable Couplers
C80 Series Applications:

  • Mining
    1. Shovels
    2. Drills
    3. Continuous Miners
    4. Converyors
  • Shore to Ship
  • Tunneling
  • Portable Power Generation

C80 Series Specifications:

  • Use C80 Series couplers when shielded cables are used
    1. SHD-GC, G-GC cables

ORDERING PROCEDURE:

1. Determine the following:

  • Current Rating, 250, 400  or 500 Amp
  • Male (plug) or Female (receptacle) contacts
  • Cable (see #3) or Equipment Mounting

2. For Equipment Mounting, select catalog number of coupler (see table below)

Coupler Rating Male / Female Mounting Options Outside Cable Diameter P & C Cat. No.
250 A M Cable Mount 20.8-47.5 mm 0.82-1.87 in C80C1003x
47.8-60.2 mm 1.88-2.37 in C80C1004x
60.5-69.9 mm 2.38-2.75 in C80C1005x
70.1-88.9 mm 2.76-3.50 in C80C1006x
250 A F Cable Mount 20.8-47.5 mm 0.82-1.87 in C80C2004x
47.8-60.2 mm 1.88-2.37 in C80C2005x
60.5-69.9 mm 2.38-2.75 in C80C2006x
70.1-88. 9mm 2.76-3.50 in C80C2007x
250 A M Equipment Mount N/A C80C1007x
F N/A C80C2003x
400 A M Cable Mount 20.8-47.5 mm 0.82-1.87 in C80D1013x
47.8-60.2 mm 1.88-2.37 in C80D1014x
60.5-69.9 mm 2.38-2.75 in C80D1015x
70.1-88.9 mm 2.76-3.50 in C80D1016x
400 A F Cable Mount 20.8-47.5 mm 0.82-1.87 in C80D2014x
47.8-60.2 mm 1.88-2.37 in C80D2015x
60.5-69.9 mm 2.38-2.75 in C80D2016x
70.1-88.9 mm 2.76-3.50 in C80D2017x
400 A M Equipment Mount N/A C80D1017x
F N/A C80D2018x
500 A M Cable Mount 20.8-47.5 mm 0.82-1.87 in C80F1030x
47.8-60.2 mm 1.88-2.37 in C80F1031x
60.5-69.9 mm 2.38-2.75 in C80F1032x
70.1-88.9 mm 2.76-3.50 in C80F1033x
500 A F Cable Mount 20.8-47.5 mm 0.82-1.87 in C80F2030x
47.8-60.2 mm 1.88-2.37 in C80F2031x
60.5-69.9 mm 2.38-2.75 in C80F2032x
70.1-88.9 mm 2.76-3.50 in C80F2033x
500 A M Equipment Mount N/A C80F1004x
F N/A C80F2004x

3. If Cable Mounting, determine outside cable diameter and select catalog number of coupler (see table above).  Clamp inserts and cable gasket must be purchased separately as a kit for the entrance fitting (see table below)

 Cable Diameter  P&C

Cat No .

 Cable Diameter  P&C

Cat No.
 mm  in mm in
 20.8-22.1  0.82-0.87 C150F3004  51.1-53.8 2.01-2.12  C150F3016
 22.4-23.9  0.88-0.94 C150F3005  54.1-57.2 2.13-2.25  C150F3017
24.1-25.7 0.95-1.01 C150F3006 57.4-60.2 2.26-2.37 C150F3018
25.9-26.9 1.02-1.06 C150F3007 60.5-63.5 2.38-2.50 C150F3019
27.2-28.4 1.07-1.12 C150F3008 63.8-66.5 2.51-2.62 C150F3020
28.7-31.8 1.13-1.25 C150F3009 66.8-69.9 2.63-2.75 C150F3021
32.0-34.8 1.26-1.37 C150F3010 70.1-72.9 2.76-2.87 C150F3022
35.0-38.1 1.38-1.50 C150F3011 73.2-76.2 2.88-3.00 C150F3023
38.4-41.1 1.51-1.62 C150F3012 76.5-79.2 3.01-3.12 C150F3024
41.4-44.5 1.63-1.75 C150F3013 79.5-82.6 3.13-3.25 C150F3025
44.7-47.5 1.76-1.87 C150F3014 82.8-85.6 3.26-3.37 C150F3026
47.8-50.8 1.88-2.00 C150F3015 85.9-88.9 3.38-3.50 C150F3027

SELECTION REMINDERS FOR ENTRANCE FITTING GASKET KIT:   

  • Each Kit consists of 2 clamp inserts and 1 cable gasket
  • Choose the kit to fit the outside diameter of the cable
  • Make sure that the cable outside diameter (cable OD) of the kit flass within the outside cable diameter range of the selected cable mounted coupler

4. Determine the conductor size and substitute appropriate code for “x” in catalog number (see table below).

 
Max. Cable Size SHD-GC 5 or 8kv x – Cat. Sufix No. Max. Cable Size SHD-GC 5 or 8kv x – Cat. Sufix No.
21 mm2 #4 AWG D 85 mm2 3/0 AWG K
27 mm2 #3 AWG E 107 mm2 4/0 AWG L
34 mm2 #2 AWG F 127 mm2 250 MCM M
42 mm2 #1 AWG G 152 mm2 300 MCM N
54 mm2 1/0 AWG H 178 mm2 350 MCM O
67 mm2 2/0 AWG J 203 mm2 400 MCM P

C80 SERIES COMINATION GUIDE

combination guide, 5-8 kv, C80 series

EXAMPLE OF FINAL PART NUMBER:

Male plug, 8kv, 250 Amp, cable mount, #2 cable, outside cable diameter (cable OD) 2.125″

Catalogue number: C80C1004F

Entrance Fitting Gasket Kit: C150F3017

NOTES:

All couplers and junction boxes are supplied with cover, attachment chain and provision for padlocking two mated couplers and/or covers. Termination kits and potting compound can be purchased separately.

Standard Terminations for phase, pilot and ground conductors are mechanical by means of allen head screws

Potting compound is recommended for 5 and 8kV couplers and junction boxes exposed to extreme changes in temperature and humidity. Potting compound can be purchased separately.

C80 Specs

5/8 kV Cable Couplers
8kV CLASS ELECTRICAL TEST DATA:

ElectricalCharacteristics

STANDARD CONTACT ARRANGEMENT:

250 Amp Contact Structure: 3 Power + 1 Ground + 1 Pilot
400 Amp Contact Structure: 3 Power + 2 Ground + 1 Pilot
500 Amp Contact Structure: 3 Power + 1 Ground + 1 Pilot

CABLE & CONDUCTOR RANGE

#4 – 500 MCM AWG or 21 mm2 – 240 mm2

CABLE DIAMETER

0.82″ – 3.55″ or 21 mm – 90 mm

C80 SERIES 250, 400, AMP COUPLER WEIGHTS AND DIMENSIONS:

C80_CableMountMale

 
Cable Rating (A) A B C Weight
250 17″ 9 1/2″ 21″ 31.0 lb
432 mm 241 mm 533 mm 14.0kg
400 17″ 9 1/2″ 21″ 32.0 lb
432 mm 241 mm 533 mm 14.5 kg

 

C80_EquipmentMountMale

 
Coupler Rating (A) A B C D Weight
250 7 1/2″ 10 1/2″ 12″ 9 1/4″ 24.0 lb
191 mm 267 mm 305 mm 235 mm 11.0 kg
400 7 1/2″ 10 1/2″ 21″ 9 1/4″ 25.0 lb
191 mm 267 mm 533 mm 235 mm 11.5 kg

 

C80_CableMountFemale

 
Coupler Rating (A) A B C Weight
250 20″ 9 1/2″ 23″ 33.0 lb
508 mm 241 mm 584 mm 15.0 kg
400 20″ 9 1/2″ 23″ 34.0 lb
508 mm 241 mm 584 mm 15.3 kg

 

C80_EquipmentMountFemale

 
Coupler Rating (A) A B C D Weight
250 10 5/8″ 10 1/2″ 13 1/2″ 9 1/4″ 26.0 lb
272 mm 267 mm 343 mm 235 mm 12.0 kg
400 10 5/8″ 10 1/2″ 13 1/2″ 9 1/4″ 27.0 lb
272 mm 267 mm 343 mm 235 mm 12.3 kg

 

C80D_JunctionBox

 
Coupler Rating (A) A B C D Weight
250 34 1/2″ 10 1/2″ 8″ 5 1/4″ 90.0 lb
876 mm 267 mm 203 mm 133 mm 41.0 kg
400 34 1/2″ 10 1/2″ 8″ 5 1/4″ 92.0 lb
876 mm 267 mm 203 mm 133 mm 42.0 kg

 

C80 SERIES 500 AMP COUPLER WEIGHTS AND DIMENSIONS:
C80_500A_CableMountMale

 
A B C Weight
20 1/4″ 10 1/2″ 24 1/2″ 38.0 lb
514 mm 267 mm 622 mm 17.0 kg

 

C80_500A_EquipmentMountMale (2)

 
A B C D E Weight
4 3/4″ 12 1/4″ 9″ 11″ 1 1/2″ 32.0 lb
121 mm 311 mm 229 mm 279 mm 38 mm 14.5 kg

C80_500A_CableMountFemale

 
A B C Weight
24″ 11 1/2″ 27″ 38.0 lb
610 mm 292 mm 686 mm 17.0 kg

C80_500A_EquipmentMountFemale

 
A B C D E Weight
5 1/4″ 12 1/4″ 8 1/4″ 11″ 4″ 27.0 lb
133 mm 311 mm 210 mm 279 mm 102 mm 12.3 kg

 

C80_500A_junctionbox

 
A B C Weight
16 1/4″ 14 1/4″ 32″ 100.0 lb
413 mm 362 mm 813 mm 45.0 kg

P/R-K/L Series

5/8 kV Cable Couplers
P/R-K/L Series Applications:

  • Mining
    1. Shovels
    2. Drills
    3. Continuous Miners
    4. Conveyors
  • Shore to Ship
  • Tunneling
  • Portable Power Generation

P/R-K/L Series Specifications

  • Shielded cable is not used
    1. MPF, Type W, Cab Tire

NOTES:

All couplers and junction boxes are supplied with cover, attachment chain and provision for padlocking two mated couplers and/or covers. Termination kits and potting compound can be purchased separately.

Standard Terminations for phase, pilot and ground conductors are designed for soldering. Solderless stems are available as a no charge option.

Potting compound is recommended for 5 and 8kV couplers and junction boxes exposed to extreme changes in temperature and humidity. Potting compound can be purchased separately.

P/R-K/L Specs

5/8 kV Cable Couplers
8kV CLASS ELECTRICAL TEST DATA:

ElectricalCharacteristics

STANDARD CONTACT ARRANGEMENT:

  • 250 Amp Contact Structure: 3 Power + 1 Ground + 1 Pilot
  • 400 Amp Contact Structure: 3 Power + 2 Ground + 1 Pilot

CABLE & CONDUCTOR RANGE

#4 – 500 MCM AWG or 21 mm2 – 240 mm2

CABLE DIAMETER

0.82″ – 3.55″ or 21 mm – 90 mm

PK/RK 250 AMP & PL/RL 400 AMP COUPLER WEIGHTS AND DIMENSIONS:
PKPL_CableMountMale

 
Coupler Rating (A) A B C Weight
250 A & 400 A 14″ 9 1/2″ 18″ 25.0 lb
356 mm 241 mm 457 mm 11.4 kg

 

PKPL_EquipmentMountMale

 
Coupler Rating (A) A B C D Weight
250 A & 400 A 4 1/2″ 10 1/2″ 9″ 9 1/4″ 17.0 lb
114 mm 267 mm 229 mm 235 mm 7.7 kg

 

RKRL_CableMountFemale

 
Coupler Rating (A) A B C Weight
250 A & 400 A 17 1/2″ 9 1/2″ 20 1/2″ 23.0 lb
445 mm 241 mm 521 mm 7.7 kg

 

RKRL_EquipmentMountFemale

 
Coupler Rating (A) A B C D Weight
250 A & 400 A 8″ 10 1/2″ 10 5/8″ 9 1/4″ 16.0 lb
203 mm 267 mm 272 mm 235 mm 7.3 kg

JKJL_JunctionBox

 
Coupler Rating (A) A B C D Weight
250 A & 400 A 29″ 10 1/2″ 8″ 5 1/4″ 68.0 lb
747 mm 267 mm 203 mm 133 mm 31.0 kg

 

PRKL_CutOutDetailsEquipmentMountCouplers

Options

5/8 kV Cable Couplers

AVAILABLE OPTIONS AND ACCESSORIES

MECHANICAL INTERLOCKING

Benefits: One of the most effective methods to prevent decoupling of energized couplers

Mechanical interlocking is one of the most reliable means for promoting and ensuring safety around high voltage electrical equipment. By design, 5/8 kV class couplers are not intended to be disconnected when energized. There are safety features incorporated into these products to prevent disconnecting couplers under load, as well as features to limit the danger in this event. However, utilizing a mechanical interlocking arrangement in combination with the 5/8 kV design features, and safety procedures, provides further protection for personnel and equipment.

Click here for more information on interlocking

EPOXY POWDER COATING

Benefits: corrosion resistance, visual identification

Epoxy Powder coating provides a strong and corrosion resistant finish to aluminum coupler bodies and castings. While Patton & Cooke use alloys with the highest possible corrosion resistance, for corrosive environments such as heap leaching, marine, or underground mines with acidic conditions, Patton & Cooke recommend an epoxy powder coated finish to maximize the life of the project. Powder coating is also an effective visual indicator of coupler gender. To help reduce cable laying errors, a basic color coding scheme can help mine personnel easily and identify male and female couplers. Standard colors are shown below, custom colors are available upon request.

JUNCTION BOX

Benefits: Skid mounted junctions can prolong cable and coupler life and enables plug / plug cable arrangement

Incorporating a plug to plug cable arrangement is the major advantage that can be gained with a junction box. For larger cables in particular, it can take considerable time and energy to add or remove a length of cable from a mining production environment. With a plug to plug arrangement, the cable can be laid out in either direction as the connector is the same on both ends. Traditional jumper cable arrangements are plug to receptacle, like common household extension cords, and so it is possible to lay out a cable “incorrectly” with this arrangement.

Click here for more information on junction boxes

skid-mount-junction

SPLITTER BOX

Benefits: Provides power and monitoring to multiple pieces of mobile equipment with less cable

Splitter boxes are the ideal solution   for reducing cable requirements in production areas.  Splitter boxes enable 2 or more pieces of equipment   to draw power from 1 cable feed. Splitter boxes have  a wide range of options including indicator lights and  ground wire monitoring. If equipped with optional live  end covers, it is possible to energize the splitter  box with one or more unused outlets.

Click here for more information on splitter boxes

Splitter Box

SKIDS

Benefits: Skid mounted coupler can prolong cable and coupler life

The use of skids with couplers can help   to dramatically extend the life of cable and couplers   by keeping them off the ground, and increasing their   visibility to personnel and mobile equipment. For personnel,   increased visibility means a safer work environment;   and for equipment, it means less downtime.

Patton & Cooke couplers are designed   to ensure a long working life if they are left on the   ground, however skid mounting couplers will provide   added protection for the cable and couplers. And as   the real cost of coupler ownership includes installation,   maintenance, and materials, extending the life of couplers   will help to reduce these costs as well.

Extending the life of couplers means less maintenance and more machine uptime!

Skid

Click here for more information on skids

LIVE END COVER

Benefits: Enables splitter boxes to be safely energized with 1 or more circuits disconnected

Live end covers were designed for use with splitter boxes equipped with ground wire monitor protection devices. Live end covers provide incorporate protective covers, insulated phase tubes, and end of line devices which enable safe energization of a splitter box even if one or more circuits have been disconnected.

58kV Live End Cover

Click here for more information on Live End Covers

MOUNTING HARDWARE

Benefits: Simplify the installation   process for equipment mounted couplers by ordering mounting   hardware with your coupler

C80 Series Panel mount couplers are not supplied with hardware for mounting to equipment or enclosures. The size of the hardware will depend on the thickness of the enclosure wall. To mount your coupler you can obtain hardware equivalent to the sizes indicated below. Patton & Cooke can supply these as well as an optional accessory with the part number

For an enclosure with 1/8″ – 1/4″ wall thickness the following mounting hardware kit is recommended:

(8) GB-0814 : 1/2″ x 1-3/4″ Galvanized bolts

(16) GFW-08 : 1/2″ Galvanized flatwasher

(8) GLW-08 : 1/2″ Galvanized lockwasher

(8) GN-08 : 1/2″ Galvanized nut

Kit Part Number: C80F3xxx

ELBOW / MOUNTING ADAPTERS

Benefits: Reduces strain on enclosure and cable

Patton & Cooke recommend using 3/8″ hardware for gear mount couplers and 1/2″ hardware for flange mount couplers to help ensure a robust installation and to help maintain IP protection in mining, industrial, and marine environments. However incorporating elbow adapters with gear and flange mount couplers can reduce strain on the enclosure and the cable, helping to maximize the performance and service life of your equipment.

LEG MOUNTING

Benefits: Provides versatility for mounting couplers in fixed installations

For applications where a cable mount coupler can be stationary such as when mounted to a wall, an accessory, or a piece of mobile equipment, Patton & Cooke offer the leg mounting option. Leg mounts brackets are made of mild steel and are powder coated for additional corrosion protection. Brackets are provided in a standard size, but custom or modified versions are available upon request. Couplers can be mounted in vertical or horizontal orientation.

leg mount coupler for skid Leg mount coupler vertical suspension

FIBER OPTICS

Coupler Features:

  • Enhanced entrance fitting combines strain relief and cable seal
  • Solder, solderless, or crimp style contact stems
  • Standard couplers supplied with two piece contacts for ease of maintenance
  • Customizable contact arrangement
  • Individually replaceable phase tubes
  • Fully shielded phase conductors
  • Optional one piece contacts for extreme vibration resistance
  • Stainless steel quick flip coupler eye bolts
  • Heat treated, case aluminum body

Fiber Features:

  • Patton & Cooke fiber optic components are designed to exceed military specifications
  • Three times the crush resistance and twice the tensile strength of non-metallic fiber optic cables
  • Communication is not impacted, even if rolled over by a tank
  • Completely rodent proof
  • Contamination resistance – designed for field connection and disconnection
  • High performance 2.5 mm termini and a split ceramic alignment sleeve assures superior performance and low optical insertion loss even under high shock and vibration
  • Aluminum body with durable anodized finish
  • Stainless steel construction available
  • Environmental sealing to IP68
  • APC termini optional
  • Singlemode and multimode operation
  • Configuration design supports from 2-18 fiber channels per connector
Electrical Characteristics
Nominal voltage 8 kV AC
a.c. withstand voltage 26 kV dry (1 min)
Impulse a.c. withstand voltage 75 kV (10 pos, 10 neg)
Partial discharge (for high-voltage equipment) 100pC @5.5 kV*
Nominal current 250/400 Amps
Short circuit rating 38 kA
Short time short-circuit withstand capacity 13.5 kA for .2 sec
Peak withstand 28 kA
Mechanical Characteristics
Enclosure degree of protections IP67H
Acceptable cable cross-sectional area 350 MCM/120 mm max.
Construction materials Aluminum
Ambient temperature -40°C to +45°C
Shock and vibration IK10

For more information on 5/8 kV Cable Couplers, please contact:
Patton & Cooke Co.

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