35kV 200A Loadbreak BI & Elbow Connector Design Test...

35kV 200A Loadbreak BI & Elbow Connector

Design Test Report

Report Number: Test Start Date: Test Complete Date:

RN-R7509 2017 / 05 / 08 2019 / 06 / 10

Chardon Taiwan No. 37 Min-Chie Road Tung Lo Industrial Park Miao Li, Taiwan 366

1

Copyright © 2019, Chardon Group All rights reserved

No. 37, Min-Chie Road, Tung Lo Industrial Park, Miao Li, 366 Taiwan, R.O.C. Tel: +886-37-984385 | Fax: +886-37-984770 E-Mail: [email protected]

Table of Contents

1. Sequence A: Partial Discharge Test ...................................................... 2 2. Sequence A: AC withstand Voltage Test .............................................. 4 3. Sequence A: Impulse Withstand Test ................................................... 6 4. Sequence A: Test Point Test ................................................................. 8 5. Sequence B: Accelerated Sealing Life Test ........................................ 10 6. Sequence C: Switching and Fault-closure .......................................... 16 7. Individual Test: Short-time Current Test ............................................ 19 8. Individual Test: Accelerated Thermal Test ......................................... 21 9. Individual Test: Thermal Test with off-axis Operation ...................... 30 10. Individual Test: Cable Pull-out Test ................................................... 34 11. Individual Test: Operating Force Test ................................................ 36 12. Individual Test: Operating Eye Test ................................................... 38 13. Individual Test: Test Point Cap Test ................................................... 40 14. Individual Test: Shielding test ............................................................ 42 15. Individual Test: Operating Interface AC Withstand Test ................... 45

2



1. Sequence A: Partial Discharge Test

Object

To verify the connectors that the parts meet ANSI/IEEE Standard 386-2016 35kV partial

discharge requirement of 26kV/3pC.

Testing Samples

Bushing Insert CHARDON 35-LBI200 10 PCS

Elbow CHARDON 35-LE200 10 PCS

Mating Parts

Elbow Test Rod 35kV#C Testing Rod Φ31.5mm

Procedure and Testing Spec

The test voltage shall be raised to 20% above the corona voltage level of 26kV. If corona

exceeds 3pC, the test voltage shall be lowered the corona voltage level of 26kV and

maintained at this level for at least 3 seconds but not more than 60 seconds. Corona

readings taken during this period shall not exceed 3 pC.

Results

Sample number Corona voltage level

A-1 26.6 kV / 0.5 pC

A-2 26.6 kV / 0.5 pC

A-3 26.6 kV / 0.5 pC

A-4 26.6 kV / 0.5 pC

A-5 26.6 kV / 0.5 pC

A-6 26.6 kV / 0.5 pC

A-7 26.6 kV / 0.5 pC

A-8 26.6 kV / 0.5 pC

A-9 26.6 kV / 0.5 pC

A-10 26.6 kV / 0.5 pC

3



Partial Discharge Test

Partial Discharge Testing in Progress

4



2. Sequence A: AC withstand Voltage Test

Object

To verify the connectors that the parts meet ANSI/IEEE standard 386-2016 35kV AC

withstand requirement of 50kV/ 1 min.

Testing Samples



Mating Parts



The test voltage shall be raised to the value of 50kV in 30 seconds. The test sample shall

withstand the specified test voltage for 1 minute without flashover or puncture.

Results

Sample number 50kV/1min AC withstand voltage

A-1 PASS

A-2 PASS

A-3 PASS

A-4 PASS

A-5 PASS

A-6 PASS

A-7 PASS

A-8 PASS

A-9 PASS

A-10 PASS

5



AC Withstand Voltage Test

AC Withstand Voltage Testing in Progress

6



3. Sequence A: Impulse Withstand Test

Object

To verify the connectors that the parts meet ANSI/IEEE Standard 386-2016 35kV

impulse withstand testing requirements of 1.2×50μs ±150kV wave., 3 positive and 3

negative full-wave impulses.

Testing Samples



Mating Parts

Cable Conductor Type 35kV 1/0 AWG(Aluminum)


The test voltage shall be 1.2/50µs wave having the crest value (BIL) of 150kV. The

connector shall withstand 3 positive and 3 negative full-wave impulses without flashover

or puncture.

Results

Sample number 1.2×50μs±150kV Impulse withstand voltage

A-1 PASS

A-2 PASS

A-3 PASS

A-4 PASS

A-5 PASS

A-6 PASS

A-7 PASS

A-8 PASS

A-9 PASS

A-10 PASS

7



Impulse Withstand – Positive Wave

Impulse Withstand Testing – Negative Wave

8



Sequence A: Test Point Test

Object

To verify the elbow test point meeting the ANSI/IEEE Standard 386-2016 testing

requirement.

Testing Samples


Mating Parts

LCR Meter CHENHWA 1012F

Testing Fixture


The purpose of this test is to verify that the capacitance values of the test point meet the

requirements of 6.5.1. of IEEE 386.

The connector shall be installed on a cable of the type for which it is designed to operate,

and the shielding shall be grounded in the normal manner. The capacitances from test

point to cable and test point to ground shall be measured with suitable instruments and

proper shielding techniques. The measured values shall be within the tolerances specified

in 6.5.1. of IEEE 386.

Results

Sample number

Test point and the

conductor shall be at

least 1.0 pF.

Test point and shield to

the capacitance between

test point and conductor

shall not exceed 12.0

Result

A1 7.69 pF 2.68 PASS

A2 7.91 pF 2.17 PASS

A3 7.57 pF 2.92 PASS

A4 7.83 pF 2.29 PASS

A5 8.14 pF 2.14 PASS

A6 8.06 pF 2.76 PASS

A7 8.16 pF 2.26 PASS

A8 7.87 pF 2.73 PASS

A9 8.11 pF 2.57 PASS

A10 7.84 pF 2.61 PASS

9



Test Point Test

10



4. Sequence B: Accelerated Sealing Life Test

Object

To verify the connector can maintain a long-tern seal at all interfaces to prevent the

entrance of moisture.

Testing Samples



Mating Parts

Cable Conductor Type 1/0 AWG(Aluminum)

Cable Insulation Thickness 345 mil

Conductor 200A Bi-Metal Lug

Equalizers Aluminum Equalizers Size：106mm(L)20mm(OD)10.1mm(ID)

Bushing Bus 356mm(L), 102mm(W),10mm(T)


The four connector assemblies shall be placed in an oven having 121 °C temperature and

remain there for three weeks.

After the time has elapsed, the four samples shall be subjected to 50 cycles of the

following sequence of operations: The assemblies shall be heated in air using sufficient

current to raise the temperature of the connector of the control cable to 90 °C ± 5 °C for 1

hour.

The assemblies shall be de-energized and within 3 min, submerged in 25 °C ± 10 °C

conductive water (5000 Ω-cm maximum) to a depth of 30 cm (1 ft) for 1 hour.

After 50th cycle, the connector and cable assembly shall withstand a design impulse test

of IEEE 7.5.3(1.2*50µS impulse wave of 125kV, 3 positive and 3 negative) and test point

voltage test.( During the impulse test, the bushing well and bushing bus were soaked into

the silicone oil.)

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Results

Sample

#

PD Testing

Before Acc

Life Sealing

Test

AC Withstand

Testing Before

Acc Life

Sealing Test

Impulse

Testing Before

Acc Life

Sealing Test

PD Testing

After Acc Life

Sealing Test

Test Point

Voltage

Testing

B-1 26.6kV0.7pC 50kV/1m Pass ±150kV

3 Shots Each,

Pass

26.4kV0.6pC 16.2kV

B-2 26.5kV0.7pC 50kV/1m Pass 26.4kV0.6pC 15.7kV



Remark

Tested with Bushing Insert and Elbow Assembly

Cable Temp：90.3~92.7

Water Temp：26.8~28.7

Resistance of Water：3392 Ω-cm

Depth of Water：30 cm

Impulse Testing Waveform before Accelerated Sealing Life Test – Positive Wave

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Impulse Testing Waveform before Accelerated Sealing Life Test – Negative Wave

Test Setup Diagram

13



Samples Assembly – Before Accelerated Sealing Life Testing

Samples in the Chamfer 121/21 days

14



Samples in the Chamfer 121/21 days

15



Impulse Testing after Accelerated Life Sealing Test

Test Point Testing after Accelerated Life Sealing Test

16



5. Sequence C: Switching and Fault-closure

Description

The purpose of these tests is to verify that the Loadbreak Bushing Insert and Elbow are

capable of closing and interrupting the rated switching current of 200A rms. Additionally,

these tests will verify the parts are capable of closing on a 10,000A rms fault current for

0.17 sec.

Requirement

The Loadbreak Bushing Insert shall withstand 10 complete switching operations without

arcing to ground or impairing its ability to meet the spec of IEE Std 386-2016. The

Loadbreak Elbow shall also withstand 10 complete switching without arcing to ground or

impairing its ability to meet the spec of IEE Std 386-2006. Failures are permitted;

however, none of the failures are permitted in 10 consecutive samples of a maximum lot

size of 30.

Procedures

1. Assemble 30 Bushing Inserts and Elbows assemblies on cable.

2 Test all samples in accordance with IEEE Standard 386-2016 sections 7.7 “Switching

Test” under the conditions described in Tables 10 and 11, Figure 28(a) of the standard.

Each sample is subjected to 10 complete switching operations at 21.1/36.6 kV, 200A

using a mechanical fixture.

3. Test all samples that successfully passed 10 switching operations in accordance with

IEEE Standard 386-2016 sections 7.8 “Fault-closure Test” under the conditions described

in Table 11 and 12, Figure 29(a) of the standard. Each sample is subjected to 1 fault-close

operation.

4. The procedure above was repeated with elbow samples from Elastimold and Cooper

Industries, in compliance with IEEE 386-2016 standard section 6.4 “Interchangeability”.

Results

Switching passed; Fault-closure passed. Testing performed at Powertech Labs Inc, Surrey

BC Canada.

Chardon – Powertech Report PL-02179 REP1

Elastimold Interchangeability – Powertech Test Report PL-02525 REP1

17



18



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6. Individual Test: Short-time Current Test

Object

To verify the connectors that the parts meet ANSI/IEEE Standard 386-2016 200A

short-time current test requirements.

Testing Samples



Mating Parts



The rms value of the first major loop of a current wave shall be not less than the value

specified in Table 2 multiplied by 1.3 (X/R=6) for 200 A connectors The magnitude shall

be measured in accordance with ANSI/IEEE C37.09.

Connectors shall withstand the current without separation of interfaces or impairing

the ability to meet the other requirements of the standard.

Results

10kA/0.17sec

Sample

number

1st Cycle

Current

(peak)

1st Cycle

Current

(rms)

Current

(rms) Time Verification Result

I-1 & I-2 21.49 kA 15.20 kA 11.88 kA 0.275 sec Normal PASS


3.5kA/3sec

Sample

number

1st Cycle

Current

(peak)

1st Cycle

Current

(rms)

Current




20



Short-time Current Test Record for 10kA/0.17sec

Short-time Current Test Record for 3.5kA/3sec

21



7. Individual Test: Accelerated Thermal Test

Object

The purpose of this accelerated test is to demonstrate that 200 A insulated connectors can

carry rated current under usual service conditions. Successful completion of the test shall

be considered as evidence that the connector meets its rating.

Testing Samples



Mating Parts







7.10.1 Accelerated thermal test

A control cable, used for the purpose of obtaining conductor temperature, shall be

installed in the heat cycle loop between two equalizers. Its length shall be 183 cm (72 in).

The control cable shall be the same type and size as the cable used to join the connectors

under test.

Four connectors shall be assembled in series on AWG No 1/0 insulated aluminum

conductors having a length of 91 cm (36 in). The cable insulation thickness shall be

selected according to its voltage class (see Table 13 of IEEE 386).Equalizers used shall

be in accordance with ANSI C119.4.The bushing bus shall be a flat, rectangular, bus bar

356 mm (14 in) long, 102 mm (4 in) wide, and 10 mm (3/8 in) thick. The bushing wells

shall be mounted 31 cm (12 in) apart centered along the midline of the bus bar. The

bushing well studs shall be tightened to the bus bar using an installation torque of 9 N·m

± 1 N·m (80 lbf·in ± 10 lbf·in).

Unless otherwise specified by the manufacturers, the elbow male contact probe shall be

threaded into the elbow compression lug using an installation torque of 9 N·m ± 1 N·m

(80 lbf·in ± 10 lbf·in).

Current-cycling tests shall be conducted at an ambient temperature of 15 °C to 35 °C in a

space free of drafts.

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The current-cycle amperes shall be adjusted during the current-on period of the first five

cycles to result in a steady-state temperature rise of 100 °C to 105 °C on the control

conductor. This current shall then be used during the remainder of the test current-on

periods, regardless of the temperature of the control conductor.

The test shall consist of 50 current cycles, with the current on 4 h and off 2 h for each

cycle. At the end of each current-on cycle, the assembly shall be de-energized and within

3 min be submerged in water at 5 °C ± 5 °C for the remainder of the current-off cycle.

At the end of the 10th, 25th and 40th cycles (± 2 cycles), after the samples have returned

to room temperature, a short time ac current of 3500 A ± 300 A rms shall be applied to

each sample for a minimum of 3 s.

The temperature of at least the following current transfer points shall be measured at the

end of each cycle with the current on:

a) Probe to compression lug

b) Probe to female contact

c) Female contact structure to metallic housing (piston contact)

d) Between bushing insert and bushing well.

These temperatures shall not exceed the temperature of the control conductor.

The temperature differences between the control conductor and the connector shall show

a condition of stability from the fifth cycle to the end of the test. Stability is indicated

when the change in the individual differences is not more than 10 °C from the average of

the measured differences in this interval for this connector.

The dc resistance of the connector system shall be measured at the end of cycles 10, 20,

30, 40, and 50 (± 2 cycles). The dc resistance measurements shall be made between the

elbow cable equalizer and the bushing stud after the connector system has stabilized at

ambient temperature. Ambient temperature shall be measured by devices located within

61 cm (2 ft.) of the test loop but in a location that minimizes the effect of thermal

convection. The ambient temperature shall be recorded at the same time as each set of

resistance measurements, and the resistance shall be corrected to 20 °C. The dc resistance

shall be stable over the period of measurement. Stability is achieved when any resistance

measurement, including allowance for instrument accuracy, does not vary more than ±

5% from the average of all the measurements in this interval.

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Results

Unit

Cycle I-5 I-6 I-7 I-8

Cable Room Water

Temp a. b. c. d. a. b. c. d. a. b. c. d. a. b. c. d. Temp

6 72.3 61.4 58.9 58.4 74.1 62.2 58.6 59.1 75.4 63.6 58.9 59.7 72.5 60.3 58.4 57.9 126.8 26.4 7.2

7 72.6 61.8 59.3 58.7 74 62.6 58.7 59.1 75.4 63.6 58.9 59.7 73.1 61.3 58.2 57.7 127.6 26.8 7.4

8 72.8 62.1 59.4 58.9 74.2 62.5 58.9 59.3 75.5 63.6 59.1 59.9 73.2 61.6 59.7 57.6 127.3 26.6 7.5

9 72.6 62.1 59.3 59 74.3 62.6 59 59.4 75.6 63.5 59 59.8 73.2 62.4 60.5 59 127.6 26.5 7.7

10 73.4 63.1 59.6 59.3 75 63.4 59.3 59.7 76.1 64.3 59.6 60.4 74.2 63.5 61.6 61.1 128.0 27.1 8.0

11 73.6 63.2 59.8 59.4 75.1 63.4 59.7 60.1 76.1 64.4 59.7 60.5 74.4 63.4 61.5 61 128.5 27.2 7.8

12 74 63.5 60.1 59.7 75.2 63.9 60.1 60.5 76 64.3 59.6 59.8 74.6 63.8 61.9 61.4 128.2 27.4 7.4

13 74.4 63.7 60.4 59.9 75.6 64.4 60.5 60.9 76.4 64.7 60 59.9 75.2 64.3 62.4 61.9 128.7 27.8 7.6

14 74.4 63.7 60.7 60.2 75.1 63.9 60.2 60.6 76.6 65.1 60.4 60.1 75.1 64.3 62 61.9 128.0 27.5 7.9

15 74.7 64.1 61 60.4 75.3 64.3 60.4 60.8 76.9 65.1 60.4 60 75.4 64.3 62.5 61.9 128.7 27.7 7.7

16 74.9 64.1 61.1 60.6 75.5 64.6 60.7 61.2 76.9 65.3 60.6 60.6 75.3 64.3 62.2 61.9 128.2 27.6 7.4

17 75 64 61.1 60.7 75.9 64.7 60.9 61.4 77.2 65.5 61 61.8 75.5 64.6 62.2 62.2 128.4 27.6 7.2

18 75 64.1 61.2 60.9 75.6 64.7 61 61.5 77.3 65.4 60.9 61.7 75.4 64.6 62.5 62.2 127.6 27.3 7.5

19 75.5 64.3 61.3 61 76.2 65.3 61.3 61.8 78 66.9 62.5 63.3 76 64.8 62.5 62.4 128.4 27.8 7.8

20 75.6 64.4 61.2 61.1 76.3 65.1 61.4 61.9 78.6 67.4 62.7 63.5 76.4 65.2 62.8 62.8 129.1 28.2 7.7

21 75.7 64.5 61.6 61.1 76.5 65.4 61.6 62 78.5 67.5 62.8 63.6 76.3 65.2 63 62.8 128.7 27.9 7.6

22 76.1 64.8 61.7 61.4 76.8 65.4 61.7 62.1 78.8 68 63.3 64.1 76.7 65.5 63.6 63.1 128.6 28.1 7.4

23 76.1 64.8 61.9 61.5 76.8 65.6 61.9 62.3 78.8 68 63.3 61.8 76.5 65.1 63.2 62.7 128.5 27.8 7.5

24 76.5 65.2 62.2 61.6 77.3 65.8 61.9 62.3 79 68.2 63.5 63.4 76.9 65.6 63.7 63.2 129.6 28.4 7.8

25 76.7 65.3 62.4 61.7 77.4 65.9 62.1 62.5 79.5 68.5 63.8 63.6 77.1 65.8 63.9 63.4 129.1 28.2 8.1

26 76.8 65.5 62.6 61.9 77.6 65.9 62.3 62.7 79.8 68.9 64.2 63.7 77.5 65.9 64 63.5 129.6 28.3 7.9

27 76.7 65.3 62.7 62 77.6 65.8 62.5 62.9 79.4 68.3 63.6 64.4 77.4 65.9 64 63.5 129.5 27.9 7.6

28 77.3 65.8 63 62 78.2 66.3 62.6 63 79.9 69 64.3 65.1 77.6 66.3 64.4 63.9 129.4 28.4 7.2

29 77.6 66 63.4 62.3 78.5 66.3 62.7 63.2 80.5 69.4 64.9 65.7 78 66.7 64.8 64.3 129.4 28.5 7.5

30 77.7 66.2 63.6 62.6 78.6 66.5 62.9 63.4 80.7 69.5 65 65.8 78.4 66.9 65 63.6 129.6 28.5 7.4

31 77.9 66.5 63.9 62.8 78.8 66.6 62.9 63.3 80.8 69.6 65.1 65.9 78.5 67.1 64.9 64 129.9 28.4 7.5

32 77.7 66.4 64 63.3 79 66.8 63 63.4 80.6 69.8 65.4 66.2 78.5 67.1 65 64.2 129.9 28.1 7.9

33 77.9 66.6 64.1 63.5 79.2 67.2 63.2 63.6 80.6 69.8 65.4 66.2 79 67.7 65 64.5 129.4 28.3 8.1

34 77.8 66.5 64.3 63.6 78.8 66.7 63.2 63.6 80.6 70 65.3 66.1 78.6 67.2 65.6 65.1 128.5 27.9 8.0

35 77.6 66.3 64.4 63.8 79 66.9 63.1 63.5 80.6 69.7 65 65.8 78.8 67.3 65.4 64.6 128.5 27.6 7.7

24



36 77.8 66.6 64.4 64.1 79.3 67.2 63.4 63.8 81.3 70.1 65.4 66.2 79.1 67.6 65.7 64.7 128.5 27.8 7.5

37 78 66.8 64.8 64.2 79.6 67.1 63.5 63.9 81.7 70.4 65.7 66.5 79.3 67.6 65.7 65 128.5 28.0 7.6

38 77.7 66.7 65 64.5 79.2 67.4 63.7 64.1 81.8 70.4 65.7 66.5 79.3 67.6 65.7 64.9 129.0 27.7 7.4

39 77.9 66.8 65.2 64.6 79.3 67.2 63.9 64.3 82 70.7 66 66.4 79.1 67.5 65.6 65.1 128.4 27.6 7.8

40 78.1 67.4 65.6 64.7 80.4 67.6 64 64.4 82.4 71 66.3 66.3 79.2 67.6 65.7 65.2 130.3 28.2 7.5

41 78.5 67.7 65.7 64.9 80.2 67.9 64.1 64.5 82.7 71.4 66.7 66 79.6 67.9 66 65.5 130.8 28.3 7.7

42 78.4 67.5 65.9 65.1 80 68.2 64.3 64.7 83.1 71.6 66.9 66.4 80.2 68.3 66.4 65.9 130.1 28.4 7.8

43 78.1 67.2 65.5 65.3 79.8 67.8 64.1 64.5 82.8 71.3 66.6 66.7 79.8 67.7 65.8 65.3 129.7 28.4 8.0

44 77.7 67 65.6 65.3 79.6 67.3 63.8 64.2 82.8 71.4 66.7 66.7 79.6 67.4 65.5 65 129.2 28.1 7.6

45 77.9 67 65.6 65.2 79.3 67.4 64.1 64.5 83.2 71.8 67.1 67.2 79.8 67.7 65.9 65.3 129.8 28.2 7.5

46 77.4 66.6 65.4 65.5 78.9 66.9 63.9 64.3 82.8 71.3 66.9 67.6 79.3 67.4 65.6 65 129.6 27.8 7.7

47 78.2 67.2 65.7 65.4 79.5 67.6 64.2 64.6 82.8 71.4 67 67.8 79.8 67.6 65.3 65.2 129.2 28.3 7.6

48 78.5 67.6 65.9 65.3 79.7 67.9 64.5 65 82.7 71 66.5 67.5 79.4 67.2 65.5 64.8 129.4 28.4 7.9

49 78.2 67.4 65.8 65.5 79.5 67.6 64.6 65.1 83 71.4 66.9 67.6 79.7 68 65.1 65.6 129.3 28.5 7.7

50 78 67.2 65.6 65.2 79.2 67.4 64.5 65 82.1 70.8 66.3 67.5 79.2 67.4 65.9 65 128.6 27.9 7.8

Avg. 76.4 65.4 62.9 62.4 77.6 65.8 62.2 62.6 79.6 68.3 63.7 64.1 77.3 65.8 63.8 63.3 128.9 27.9 7.6

Max

2.1

(41

2.3

(41

3.0

(42

3.1

(46

2.8

(40

2.4

(42

2.4

(49

2.5

(49

3.6

(45

3.5

(45

3.4

(45

3.7

(47

2.9

(42

2.5

(42

2.6

(42

2.6

(42

126.8

~

130.8

26.4

~

28.5

7.2

~

8.1

Temp

Delta

(Cycle

Remark Temp difference does not vary more than 10 , meets the requirement of the standard.

Resistance Measurement Unit：mΩ

Date Week

#

Room

Temp

Equalizers-I1 /

Bushing Well-I1

Equalizers-I2 /

Bushing Well-I2

Equalizers-I3 /

Bushing Well-I3

Equalizers-I4 /

Bushing Well-I4

5/22 9 26.5 0.65 0.75% 0.69 0.06% 0.70 1.08% 0.68 0.93% 5/24 20 28.2 0.67 1.70% 0.68 2.15% 0.71 0.98% 0.69 0.14% 5/27 28 28.4 0.66 0.11% 0.70 0.65% 0.72 2.45% 0.69 0.22% 5/30 40 28.2 0.66 0.18% 0.71 2.16% 0.73 1.81% 0.70 1.31% 6/2 50 27.9 0.65 1.24% 0.69 0.60% 0.72 0.53% 0.69 0.02%

Average 0.658 0.694 0.716 0.690

25



Short-time Current 3500A/3 sec

25kV200A Bushing Insert 2017-May-22 9th Cycle

3.5kA/3sec X/R 6

Sample

Number

1st Cycle

Current

(peak)

1st Cycle

Current

(rms)

Current




25kV200A Bushing Insert 2017-May-25 24rd Cycle

3.5kA/3sec X/R 6

Sample

Number

1st Cycle

Current

(peak)

1st Cycle

Current

(rms)

Current




25kV200A Bushing Insert 2017-May-30 40th Cycle

3.5kA/3sec X/R 6

Sample

Number

1st Cycle

Current

(peak)

1st Cycle

Current

(rms)

Current


I-5 & I-6 7.85 kA 5.55 kA 4.17 kA 3.08 sec Normal pass

I-7 & I-8 7.79 kA 5.51 kA 4.24 kA 3.07 sec Normal pass

26



3.5kA/3sec Short-time Current Test Record for 2017-May-22 9th Cycle


27




Test Setup Diagram

28



Current Cycle Test in Progress

29



Resistance Test

30



8. Individual Test: Thermal Test with off-axis Operation

Object

The purpose of this accelerated test is to demonstrate that 200 A insulated connectors can

carry rated current after being subjected to an off-axis operating force. Successful

completion of these tests shall be considered as evidence that the connector meets its

rating.

Testing Samples



Mating Parts







7.10.2 Thermal test with off-axis operation For this test, each connector shall be subjected to six cycles, each consisting of a

“mechanical operation” and “current cycling test”.

The elbow shall be assembled with a 12.7-mm (0.5-in) wide pulling band, as shown in

Figure 30, for application of an off-axis force.

Four connectors shall be assembled in series on AWG No 1/0 insulated aluminum

conductors having a length of 91 cm (36 in). The cable insulation thickness shall be

selected according to its voltage class (see Table 13 of IEEE 386).

Mechanical Operation

The elbow rotated about the probe axis of a minimum of 10° in both the clockwise and

counterclockwise directions. The connector shall be opened 5 times with the force

applied to pulling band and closed 5 times with the force applied to operating eye.

Current Cycling test A control cable, used for the purpose of obtaining conductor temperature, shall be

installed in the heat cycle loop between two equalizers. Its length shall be 183 cm (72 in).

The control cable shall be the same type and size as the cable used to join the connectors

under test.

31



The current shall be adjusted so that the temperature on the control cable is 90°C±5°C.

The current shall be applied for 8 continuous cycles, each cycle consisting 3 hours on and

3 hours off.

Current cycling tests shall be conducted at an ambient temperature of 15°C to 35°Cin a

space free of external of forced drafts.

The temperature shall be measured by thermocouples located as follows:

(a) At the compression lug

(b) At the approximate midpoint of the bushing contact or as near thereto as practical

(c) On the conductor surface at the midpoint of the control cable

The temperature at location (a) and location (b) shall not exceed the temperature of the

conductor of the cable at location (c) when measured during the final cycle of each

6-cycle set.

32



Results

Cycle I-9 I-10 I-11 I-12

Cable Room

a. b. a. b. a. b. a. b. Temp

Cycle-1

1 66.1 46.7 67.9 45.0 67.7 47.0 68.4 47.3 90.1 25.2

2 66.3 46.8 68.0 45.1 67.9 46.9 68.3 47.7 90.0 25.3

3 66.3 46.6 67.8 45.2 67.6 47.0 68.1 47.4 90.2 25.6

4 66.2 46.8 68.0 45.1 67.9 46.9 68.5 47.5 90.2 25.1

5 66.5 47.1 68.3 45.2 68.2 47.2 68.8 47.8 90.3 24.9

6 66.5 47.1 68.3 45.3 68.2 47.3 68.6 47.8 90.1 25.2

7 66.4 47.0 68.2 45.4 68.1 47.4 68.7 47.9 89.9 25.5

8 66.3 46.9 68.1 45.4 67.9 47.5 68.6 47.7 89.5 24.8

Cycle-2

1 66.6 47.1 68.3 45.3 68.1 47.1 68.6 47.9 89.8 25.0

2 66.7 47.2 68.4 45.3 68.2 47.1 68.7 48.0 88.7 25.3

3 66.8 47.1 68.3 45.5 68.2 47.5 68.8 48.0 89.3 25.1

4 67.0 47.6 68.8 45.4 68.7 47.4 69.3 48.3 89.9 24.7

5 66.8 47.4 68.6 45.6 68.5 47.6 68.9 48.1 90.0 24.9

6 66.6 47.2 68.3 45.9 68.2 47.9 68.8 47.8 90.2 24.6

7 66.9 47.5 68.6 45.8 68.5 47.8 69.1 48.1 89.8 25.0

8 67.0 47.6 68.7 45.6 68.6 47.7 69.0 48.4 90.1 24.9

Cycle-3

1 67.1 47.7 68.8 45.8 68.8 47.6 69.4 48.6 89.7 24.9

2 67.0 47.6 68.7 45.9 68.7 47.7 69.3 48.3 90.3 25.2

3 67.0 47.5 68.7 46.1 68.6 48.1 69.2 48.2 90.5 25.4

4 66.8 47.4 68.5 46.0 68.5 48.0 69.0 48.1 89.9 25.1

5 66.9 47.5 68.6 46.2 68.6 48.2 69.2 48.2 90.1 25.2

6 67.0 47.3 68.4 46.1 68.3 48.1 68.9 48.1 90.3 24.8

7 67.2 47.5 68.5 46.1 68.5 48.1 69.0 48.3 90.0 25.6

8 67.3 47.8 69.1 46.2 68.8 48.3 69.5 48.6 90.2 26.1

33



Cycle-4

1 67.6 47.9 69.2 46.3 68.9 48.3 70.0 48.7 90.3 25.8

2 67.9 48.2 69.2 46.6 69.2 48.6 69.8 48.8 90.1 25.6

3 68.2 48.8 70.1 46.9 69.8 48.9 70.7 49.4 89.9 25.5

4 68.6 49.2 70.2 47.1 70.2 49.1 71.0 49.8 89.5 25.2

5 68.8 49.4 70.7 47.2 70.6 49.2 71.5 50.2 88.9 25.4

6 68.9 49.5 70.5 47.3 70.7 49.3 71.1 50.3 89.9 25.7

7 69.2 49.5 70.8 47.2 70.7 49.2 71.4 50.3 90.4 25.3

8 69.5 49.8 70.8 47.5 71.0 49.5 71.4 50.8 90.6 25.2

Cycle-5

1 50.0 50.3 71.6 47.8 71.5 49.9 72.2 51.3 89.7 25.4

2 70.2 50.5 71.8 48.1 71.7 50.2 72.3 51.5 89.5 25.3

3 70.3 50.9 71.9 48.2 72.2 50.2 72.4 52.0 88.9 25.7

4 70.6 51.2 72.5 48.4 72.4 50.4 73 52.0 89.6 26.2

5 71.0 51.6 72.6 48.6 72.8 50.6 73.1 52.4 90.3 26.1

6 71.3 51.9 72.9 49.0 73.2 50.8 73.4 52.8 89.9 25.8

7 71.5 52.1 73.1 49.2 73.4 51.0 73.6 53.2 90.4 25.9

8 71.7 52.0 73.3 49.5 73.3 51.6 73.8 53.1 90.2 26.0

Cycle-6

1 72.1 52.4 73.7 49.9 73.7 52.0 73.8 53.3 90.3 25.9

2 72.3 52.9 74.2 50.0 73.2 51.8 74.3 53.8 90.3 25.7

3 72.6 53.2 74.2 50.3 74.4 52.1 74.3 54.2 90.1 25.8

4 72.9 53.5 74.5 50.8 74.5 52.6 74.6 54.3 90.3 25.6

5 73.0 53.6 74.7 51.0 74.6 53.1 74.8 54.4 89.8 25.3

6 73.4 54.0 74.9 51.3 74.7 53.3 75.0 54.5 89.9 25.1

7 73.2 53.5 74.8 51.7 74.8 53.7 74.9 54.6 90.4 25.3

8 73.1 53.4 74.7 51.6 74.6 53.6 74.8 54.4 90.1 25.4

34



9. Individual Test: Cable Pull-out Test

Object

To verify the compression lug and cable assembly that the parts can meet ANSI/IEEE

Standard 386-2016 Cable Pull-Out Test requirements.

Testing Samples

Elbow Compression Lug

Chardon 200A

BiMetal Connector

1/0

4 PCS

Mating Parts

Cable 1/0 AWG Aluminum Cable


The purpose of this test is to determine if the connection between the cable conductor and

compression lug of the connector is capable of withstanding a tensile force of 890 N (200

lbf).

The compression lug shall be held in a manner that will not affect the strength of the

connection. The tensile force shall be applied to the cable conductor.

The connection shall withstand the applied force for 1 minute without impairing the

connector's ability to meet the other requirements of this standard.

Results

Sample number Measurement Result

I-9 211 lbf PASS

I-10 209 lbf PASS

I-11 210 lbf PASS

I-12 213 lbf PASS

35



Cable Pull Out Test

Cable Pull Out Test in Progress

36



10. Individual Test: Operating Force Test

Object

To verify the force of the elbow connector operating force when mating with bushing

insert that the force meets NSI/IEEE Standard 386-2016 operating force requirement.

Testing Samples



Mating Parts



The purpose of this test is to demonstrate that the force necessary to operate a connector

meets the requirements of 6.2.( 222 N - 890 N (50 lbf - 200 lbf) for connectors without

hold-down bails)

The elbow shall be assembled with a probe and compression lug and the connector

system shall be lubricated in accordance with the manufacturer's instructions.

Results

Sample number Open Close Result

Room

Temperature

27

I-13 104 lbf 96 lbf PASS




-20





37



+65





Cable Pull Out Test

38



11. Individual Test: Operating Eye Test

Object

To verify the elbow operating eye that the part meet ANSI/IEEE Standard 386-2016

requirements.

Testing Samples


Mating Parts

Testing Fixture


The purpose of this test is to demonstrate that the operating eye meets the requirements of

6.2 at 25°C ±5°C.

A tensile force shall be gradually applied to the operating eye in the direction of normal

operation. The operating eye shall withstand the force for 1 minute.

A rotational force shall be applied with a suitable live-line tool to the operating eye in a

clockwise direction and in a counter-clockwise direction.

Some distortion of the operating eye is acceptable provided the connector is serviceable

after the test and meets the corona voltage-level requirement specified in Table 1 of IEEE

standard 386-2016.

Results

Sample number 500 lbf /min 120 lbf-in

rotational force PD Test

I-17 PASS PASS 26 kV / 0.8 pC




39



Operating Eye Test

Operating Eye Test

40



12. Individual Test: Test Point Cap Test

Object

To verify the test point cap of the elbow that the part meets ANSI/IEEE Standard

386-2016 requirement.

Testing Samples


Test Point Cap 4 PCS

Mating Parts

Testing Fixture


The purpose of this test is to demonstrate that the removal force of the test point cap

meets the requirements of 6.5.2 and the cap operating eye is capable of withstanding the

maximum operating force

Results

Sample number Pull Force

(8 lbf – 49 lbf) 100 lbf Pulling Result

Room

Temperature

27

I-21 38 lbf PASS PASS




-20





65





41



Test Point Cap Test

42



13. Individual Test: Shielding test

Object

To verify the outer conductive layer of the connector that the material meet ANSI/IEEE

Standard 386-2016 requirement of shielding test

Testing Samples



Shield Resistance. The shield resistance measured between the cable entrance and the

farthest extremity of the shield from the cable entrance shall be 5000Ω or less.

The purpose of this test is to demonstrate that the shielding meets the requirements of 6.3.

Thetest procedure shall be in accordance with IEEE Std 592.

Connectors shall have an electrically conductive shield and, where required, shall have

provision for connecting an external ground to the shield. Except for non-elastomeric

components, connectors shall meet the requirements of IEEE std 592.

Results

Shielding passed. Testing performed at Powertech Labs Inc, Surrey BC Canada.

Chardon – Powertech Report PL-26365

Temperature Sample number 5000Ω max Result

27

I-25 3290Ω PASS

I-26 3412Ω PASS

I-27 3256Ω PASS

I-28 3398Ω PASS


90

I-25 2045Ω PASS

I-26 2138Ω PASS

I-27 2396Ω PASS

I-28 2247Ω PASS

43




27

(Air oven aged

for 504 h at 121

)

I-25 2842Ω PASS

I-26 2163Ω PASS

I-27 2655Ω PASS

I-28 2494Ω PASS


90

(Air oven aged

for 504 h at 121

)

I-25 1972Ω PASS

I-26 1880Ω PASS

I-27 2046Ω PASS

I-28 1938Ω PASS

Shielding Test

44



45



14. Individual Test: Operating Interface AC Withstand Test Object

To verify the connectors that the parts meet ANSI/IEEE standard 386-2016 35kV

Operating interface AC withstand requirements.

Testing Samples



Mating Parts



The purpose of this test is to demonstrate that loadbreak and livebreak separable

connectors or devices are capable of performing an opening operation under expected

field conditions without a flashover to ground. All separable connectors or devices,

designed to be operated while energized shall pass the requirements of this test. The

connector component designed to prevent partial vacuum flashovers shall also

demonstrate the ability to meet the requirements of this test when tested with mating

components from other manufacturers where applicable.

If necessary, operating interfaces under test can be cleaned with a laboratory grade of

isopropyl alcohol (2-pro-penal). After cleaning, the samples shall dry for a minimum of

15 min before assembly to allow the cleaning solvent to evaporate from the interface.

Further preparation of the samples shall follow Option A or Option B as follows:

Option A: The operating interfaces shall be free of any lubrication. Twelve separable

connectors or devices to be evaluated should have test cable installed where appropriate

and be assembled onto 12 mating connectors or components at an ambient temperature of

25 °C ±5 °C.

After Option A or Option B, chill the connector assemblies in a cold chamber at -20 °C to

-25 °C for a min-imum of 16 h. Remove one connector assembly at a time from the cold

chamber and mount the assembly to a grounded test stand. Attach ground leads to the

external shields of the connector. Adjacent grounds are not required. This conditioning

may be performed at -1 °C to +4 °C for any connector or device that is to be mated for

less than 24 h in any field applications, such as direct-test probes.

Separate the connector or device assembly from the bushing within 10 min after removal

from the cold cham-ber. The opening operation shall be performed with a positive

continuous motion applied manually or by a mechanical actuator with an average

operating speed during the initial 2.5 cm (1.0 in) of travel of 89 cm/s ±13 cm/s (35 in/s ±5

in/s). The force shall be applied to the operating eye of the connector using a suitable

live-line tool or equivalent device.

46



Results

Sample No. Wave No. VL-G IF IGround Result

C01 0010014 37.144kV 1.028A 0A PASS

C02 0010015 37.055kV 1.023A 0A PASS

C03 0010016 40.487kV 1.042A 0A PASS

C04 0010017 37.343kV 1.053A 0A PASS

C05 0010018 36.931kV 1.085A 0A PASS

C06 0010019 37.322kV 1.091A 0A PASS

C07 0010020 37.275kV 1.081A 0A PASS

C08 0010021 37.486kV 1.079A 0A PASS

C09 0010022 37.123kV 1.075A 0A PASS

C10 0010023 36.779kV 1.077A 0A PASS

C11 0010024 37.059kV 1.068A 0A PASS

C12 0010025 36.830kV 1.062A 0A PASS

Note:

XS = 3.64kΩ, RS = 0.606kΩ, RG = 28.5kΩ

1. ZS = RS + XS = 4.246 kΩ

2. XS / RS = 6

3. ZS ≧ 0.10RG = 0.149 RG

4. IF = V / (ZS + RG) ≧ 1A

47



Cold Chamber at -20 °C to -25 °C

OIACW Test

48



Test Voltage (VL-G)

Test Current (IF)

49



Face to Ground Current (IGround)

Date post:	13-May-2020
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35kV 200A Loadbreak BI & Elbow Connector Design Test...

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