11kV Bolted Mining Coupler
Most mining couplers are very old designs, especially those connecting high voltage cables. A typical coupler was made from cast iron, with many separate loose parts. They had potentially dangerous seals and flanges, with many opportunities to absorb moisture and rust. They were often filled with compounds such as coal tar pitch, which could absorb moisture and be affected by high ambient temperatures. Finally, the couplers were heavy and awkward to handle, weighing more than 40 kilograms. This made them a constant source of OH&S problems.
New Macey set out to completely re-design these couplers, with a combination of higher quality materials and modern technology. The results are shown in the enclosed photographs. Two designs were developed, a stainless steel/bronze model for underground coal mines and a lighter marine grade aluminium version for non-flameproof applications. They both have the following features:
- The new bronze coupler weighs less than 15kg, while the aluminium version weighs only 9.9kg;
- Two handles are provided to more safely handle the coupler;
- The couplers can safely deliver a continuous current of 800 amps, compared with the older versions that only used 150 to 425 amps;
- Modern termination kits mean the couplers are fully re-usable and do not have to be compound filled;
- Sockets are beryllium copper lamella designs instead of old split sockets for low heat rise and ease of insertion;
- No soldering or connection crimping is needed, so assembly can be achieved with a knife and Allen keys; and
- The couplers are waterproof to IP68, which means they can be fully submerged in water.