Product Overview
The 15kV Bypass Operation Equipment — Adapter Cable (DT + Quick Plug, Adapter cable (DT+QuickPlug)) is a dedicated connection cable designed for live-line bypass operations in 10kV/15kV medium-voltage distribution systems. One end is fitted with a DT copper lug crimp terminal compatible with distribution equipment/cables, while the other end features a quick-connect/disconnect interface. This configuration enables rapid connection between bypass cables and distribution equipment to establish a temporary bypass power supply circuit, supporting live-line maintenance and retrofitting of distribution equipment. It is a critical piece of equipment for live-line operations in medium-voltage distribution systems.
Product Features
Electrical and Insulation Performance
Constructed with 15kV-rated high-strength insulated cable. The conductor consists of high-purity stranded copper wire, offering excellent conductivity and low contact resistance. The cable can carry a rated current of 200A/630A, generates minimal heat during continuous operation, and exhibits strong resistance to corrosion and oxidation.
The insulation layer is made of high-performance EPDM (ethylene propylene diene monomer) rubber, providing excellent insulation properties capable of withstanding the rated system voltage and short-duration overvoltages at 15kV, meeting the operational requirements of a maximum working voltage of 17.5kV. Partial discharge level ≤10pC (at 1.5U₀).
An integrated semi-conductive shielding layer uniformly distributes the electric field, effectively suppressing partial discharge. The design eliminates the risk of electrical erosion and dielectric breakdown during long-term operation, ensuring stable and reliable insulation performance.
The cable surface is treated with a specialized process to achieve high surface resistivity and strong hydrophobicity, effectively preventing surface flashover caused by condensation and contamination, thereby enhancing insulation reliability in harsh environments.
Structural and Safety Features
The two ends employ different interface designs. One end uses a DT copper lug crimp terminal for fixed connection to distribution equipment/cables; the other end features a quick-connect/disconnect interface for direct plug-in connection with bypass quick-plug equipment, requiring no additional tools, enabling convenient installation and significantly reducing construction time.
The integrated sealed structure uses dedicated sealing components at the interfaces, providing moisture, water, and contamination resistance with an IP67 ingress protection rating, suitable for long-term stable operation in humid, dusty, outdoor, and other harsh environments.
The cable incorporates a built-in grounding/equipotential bonding structure to ensure reliable earthing, effectively dissipating induced voltages and fault currents, thereby enhancing system safety.
The fully insulated structure features a high-strength outer insulation layer. The outer jacket may be handled directly during operation without risk of electric shock, ensuring the safety of operations and maintenance personnel.
Environmental and Weather Resistance
Excellent weather resistance across a wide operating temperature range of -40°C to +90°C. Cable insulation and conductor performance show no degradation at extreme temperatures, with no risk of cracking or embrittlement, suitable for both outdoor and indoor applications.
Resistant to moisture, water ingress, contamination, and salt spray, enabling long-term stable operation in humid, dusty, and saline environments without susceptibility to rain and condensation.
Resistant to aging, ultraviolet radiation, and ozone corrosion. Service life exceeds 10 years with maintenance-free operation, reducing long-term operational and maintenance costs.
Mechanical and Compatibility Features
High mechanical strength with resistance to tension, bending, and impact. The cable withstands pulling and bending stresses encountered during field operations without risk of deformation or damage, making it suitable for complex on-site working environments.
The quick-connect/disconnect interface design strictly conforms to industry standards, allowing universal interchangeability with mainstream bypass quick-plug equipment for strong compatibility.
Modular design enables flexible configuration to accommodate different specifications of distribution equipment and bypass cables, offering broad versatility.
Technical Parameters
| Parameter Category | Item | Technical Specification |
| Rated Electrical Parameters | Applicable System Voltage (Un) | 10kV/15kV |
| | Rated Voltage (Ue) | 15kV | |
| | Maximum Working Voltage (Um) | 17.5kV | |
| | Rated Frequency (fn) | 50Hz/60Hz | |
| | Power-Frequency Withstand Voltage | 42kV/5min (dry test), no breakdown, no flashover | |
| | Lightning Impulse Withstand Voltage | 95kV (peak), no breakdown, no flashover | |
| | Partial Discharge Level | ≤10pC (at 1.5U₀) | |
| | Rated Current Class | 200A/630A (selectable) | |
| | Rated Short-Circuit Withstand Current | 20kA/2s, 25kA/2s (selectable) | |
| | Contact Resistance | ≤50μΩ | |
| Structural and Material Parameters | Main Materials | Stranded copper wire (conductor), EPDM rubber (insulation layer), tin-plated copper (DT terminal/quick-plug interface) |
| | Ingress Protection Rating | IP67 | |
| | Interface Standard | One end: DT copper lug terminal; one end: quick-connect/disconnect interface; conforms to industry standards for bypass operation equipment | |
| | Compatible Equipment | 10kV/15kV bypass operation quick-plug equipment, distribution equipment/cables | |
| Environmental Parameters | Applicable Altitude | ≤2000m (high-altitude customization available) |
| | Ambient Temperature | -40°C to +90°C (operating temperature), -40°C to +70°C (storage temperature) | |
| | Relative Humidity | ≤100% (non-condensing) | |
| | Seismic Rating | Grade 8 | |
| Applicable Standards | GB/T 12706, DL/T 1476 Preventive Test Code for Electrical Safety Tools and Apparatus, DL/T 814 Distribution Automation Terminal |
Scope of Application
Applicable voltage levels: 10kV/15kV AC medium-voltage distribution systems, compatible with distribution equipment rated at a maximum working voltage of 17.5kV.
Applicable operating scenarios:
Live-line maintenance and retrofitting of 10kV/15kV distribution lines and equipment, serving as the transition connection between bypass cables and distribution equipment;
Live-line bypass operations for urban distribution cable lines, industrial and mining enterprise distribution systems, and distribution equipment at renewable energy (photovoltaic/wind power) step-up substations;
Temporary bypass power supply for distribution equipment in indoor/outdoor switchrooms, underground utility tunnels, cable tunnels, and other multi-scenario installations.
Functional purpose: Establishes insulated isolation and conductive connection between distribution equipment and bypass cables to enable live-line bypass operations, ensuring continuous power supply to end users during maintenance and retrofitting of distribution equipment, providing a safe and reliable connection solution for live-line operations in medium-voltage distribution systems.
Operating Conditions
Normal Operating Conditions
Altitude: ≤2000m;
Ambient temperature: -40°C to +90°C; equipment operating temperature complies with applicable standards;
Relative humidity: ≤100% (non-condensing);
Environmental conditions: free from corrosive gases, flammable or explosive media, and severe vibration or shock;
Installation method: DT terminal crimp-connected to distribution equipment/cable; quick-plug interface directly connected to bypass equipment; horizontal or vertical mounting is permissible, provided the installation space satisfies operational requirements.
Special Operating Conditions (Customization Required)
Altitude exceeding 2000m;
Ambient temperature outside the range of -40°C to +90°C;
Severely polluted, salt spray, or chemically corrosive environments;
High vibration or high shock conditions;
Non-standard interface specifications or special cable length requirements;
Special current ratings or current-carrying capacity requirements.
Installation and Maintenance
Installation Requirements
Before installation, inspect the product for cracks, damage, and bubbles; verify that the insulation surface is undamaged. Check that the DT terminal and quick-plug interface are intact, free from corrosion and deformation.
Clean the connection terminal surfaces of the distribution equipment/cables to remove grease, dust, and foreign matter. Ensure the mating surfaces are dry and clean. Crimp or bolt-connect the DT terminal to the equipment terminal with reliable contact; tightening torque shall conform to standard requirements.
Apply a uniform coating of dedicated silicone grease lubricant to the outer surface of the quick-plug interface to prevent damage to the insulation layer during installation.
Engage the quick-plug interface with the bypass equipment interface until fully seated. Lock the anti-withdrawal positioning mechanism. After installation, verify there is no looseness or misalignment.
Upon completion of installation, perform insulation resistance testing and power-frequency withstand voltage testing. The equipment shall not be energized until test results are satisfactory.
Maintenance Requirements
Periodically inspect the cable exterior for cracks, damage, discharge marks, and contamination buildup. Verify that the DT terminal connection is secure and free from looseness, and that the quick-plug interface is reliably connected and free from corrosion.
Periodically test insulation resistance to confirm compliance with performance requirements and to detect potential faults in a timely manner.
Clean the cable surface to remove dust and contamination. Keep the insulation surface dry and clean, and protect it from grease and chemical corrosion.
If cracks, damage, electrical discharge, overheating, or other abnormalities are observed on the cable or interfaces, immediately take the unit out of service and replace it. Operation of defective equipment is strictly prohibited.
Insertion and withdrawal of the quick-plug interface shall be performed using dedicated insulated operating tools. Direct manual contact with energized interfaces is strictly prohibited. All operations shall strictly comply with distribution system safety regulations.
Precautions
The product shall be installed, commissioned, and maintained only by qualified electrical professionals with certification for live-line operations on medium-voltage distribution systems. Operation by non-qualified personnel is strictly prohibited.
The product shall be used only with distribution equipment and bypass operation equipment of the corresponding specifications. Mismatching equipment of different voltage or current ratings is strictly prohibited and will result in insulation failure and safety incidents.
The cable shall not be disassembled or modified without authorization, as this will void the warranty and safety assurance. Use of non-dedicated tools to forcibly install or remove interfaces is strictly prohibited.
During installation, damage to the insulation surface must be avoided. Silicone grease lubricant shall be applied uniformly to avoid compromising insulation performance and sealing effectiveness. DT terminal connection torque shall comply with standard requirements to prevent contact resistance heating caused by inadequate contact.
During storage, the product shall be kept in a dry, ventilated, and cool environment, away from direct sunlight, high temperatures, moisture, and compression. Contact with sharp objects that may damage the insulation layer is strictly prohibited.
When inserting or withdrawing the quick-plug interface in an energized state, all applicable distribution system safety regulations shall be strictly observed, appropriate safety protective measures shall be implemented, and non-compliant operations are strictly prohibited.
Model Designation
| Model Identifier | Meaning |
| 15kV | Applicable system voltage class; rated voltage 15kV; maximum working voltage 17.5kV |
| DT + Quick Plug | Interface configuration: one end DT copper lug terminal, one end quick-connect/disconnect interface |
| Adapter cable | Transition cable for connection between distribution equipment and bypass operation equipment |
Applicable Standards and Certifications
International standard: IEC 60840 — Power cables with extruded insulation and their accessories for rated voltages above 30kV (Um=36kV) up to 150kV (Um=170kV) — Test methods and requirements;
National standards: GB/T 12706 — Power cables with extruded insulation and their accessories for rated voltages from 1kV (Um=1.2kV) up to 35kV (Um=40.5kV); DL/T 1476 — Preventive Test Code for Electrical Safety Tools and Apparatus; DL/T 814 — Distribution Automation Terminal;
The product has passed type testing by the National Quality Supervision and Inspection Center for Electrical Power Safety Tools and Apparatus and conforms to national electric power industry standards.
After-Sales Service
Product warranty period: 18 months from the date of manufacture, or 12 months from the date of commissioning, whichever occurs first;
Within the warranty period, product defects due to quality issues will be repaired or replaced free of charge;
Technical support, installation guidance, and customization services (special specifications, special operating conditions) are available.
Documentation Note
The technical parameters in this manual are based on standard operating conditions. Special operating conditions require customization based on actual requirements. The product technical agreement and type test report shall prevail as the final reference.
Appendix: Product Dimensional Diagram
