The reliability of a 35kV electrical system often comes down to the quality of the installation. Even the most advanced Eaton Cooper Power series bushing can fail if the physical and electrical interfaces are not perfectly established. Drawing from the technical specifications of the 600A/900A 35kV Deadbreak Bushing, here are the three critical steps to ensuring a safe and leak-free installation.

1. External Clamping: Achieving a Hermetic Seal

Unlike internal-mount bushings that can be difficult to access, this 35kV bushing is designed for sidewall mounting with an external clamp.

• The Process: The bushing is inserted through the apparatus sidewall (typically a transformer or switchgear tank). A 4.50-inch square clamp is then used to secure it from the outside.

• The Gasket Factor: The use of a high-quality Buna-N gasket is essential. Because these bushings often operate in equipment filled with mineral oil or Envirotemp™ FR3™ fluid, the seal must be chemically resistant and capable of withstanding thermal expansion and contraction without weeping.

2. The Grounding Link: Connecting the Internal Shield

Safety in high-voltage components isn't just about insulation; it’s about managing electrical stress.

• Internal Ground Screen: This bushing features an integrated internal ground screen that surrounds the conductor. This screen helps eliminate voltage stress concentrations that could lead to insulation breakdown.

• The Connection: To make the system safe, the electrical connection to ground must be made via the ground clips and the bushing clamp. Failure to properly ground the bushing can lead to "floating" potentials, which cause corona discharge and eventually catastrophic failure.

3. Tool-Free Interface but Torque-Critical Assembly

One of the major advantages mentioned in the documentation is that no special tools are required for basic mounting. However, "no special tools" does not mean "no precision."

• The Threaded Stud: Depending on your current requirements (600A vs 900A), you will install either an aluminum or a copper threaded stud (such as the STUD635 series).

• The BOL-T™ Connection: When attaching the separable connector (like the BOL-T™ or T-OP™ II), achieving the correct torque is the most critical factor. A loose connection creates high resistance, leading to overheating, while over-tightening can strip the threads or damage the epoxy body.

Summary: Why Follow the S800-35-2 Manual?

Eaton provides specific service information (S800-35-2) for these bushings. Adhering to these instructions ensures that the bushing meets its tested performance of 50kV AC Withstand and 150kV BIL.

By focusing on these three pillars—Sealing, Grounding, and Precise Torquing—installers can guarantee that the "throat" of the power system remains secure for its entire 30+ year lifecycle.

Technical Reminder: Always conduct a final physical inspection to ensure the interface is clean and free of contaminants before applying silicone lubricant and mating the connectors.