5/8 kV Cable Couplers

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P&C 5/8kV Data Sheet

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
250 A	F	Equipment Mount	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
400 A	F	Equipment Mount	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
500 A	F	Equipment Mount	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	P&C Cat No .	mm	in	P&C Cat No.
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

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:

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:

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

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

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

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

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

C80 SERIES 500 AMP COUPLER WEIGHTS AND DIMENSIONS:

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

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

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

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

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:

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:

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:

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

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
250 A & 400 A	114 mm	267 mm	229 mm	235 mm	7.7 kg

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

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
250 A & 400 A	203 mm	267 mm	272 mm	235 mm	7.3 kg

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

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