Is 550601
Is 550601
Is 550601
Connectors
DTS1242 Deadbreak Bolted Tee Connector Interface C Installation Instructions For Single Core
Cable with Copper Wire Screen and Outer Sheath
Contents
Product Information 1
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation Procedure 3
Electrical Apparatus
IS550-60-1
cap moulded
semiconductive
epdm
test point
(optional)
tee connector
body
cable
adapter
Figure 1.
Line illustration of 42 kV bolted tee connector.
Product Information
Introduction
Cooper Power Systems 1250 A, 42 kV bolted tee separable
connectors are used to terminate polymeric cable to
equipment, such as transformers, switchgear, motors
etc. equipped with bushings meeting type C interface per
CENELEC EN 50180 and 50181. They are fully screened
and fully submersible when mated with the proper bushing
or plug and they meet the requirements of CENELEC HD
629.1 S2. The bolted tee connectors can be mounted
vertically, horizontally or any angle in between with proper
cable support. Each bolted tee connector is tested for AC
withstand and partial discharge prior to leaving the factory.
Additional Information
These instructions cannot cover all details or variations in
the equipment, procedures, or process described nor
provide directions for meeting every possible contingency
during installation, operation, or maintenance. For
additional information, contact your representative.
0312 New Issue
DTS1242 Deadbreak Bolted Tee Connector-Interface C Installation Instructions for Single Core Cable with Copper Wire
Screen and Outer Sheath
SAFETY
FOR LIFE
SAFETY
FOR LIFE
Cooper Power Systems products meet or exceed all applicable industry standards relating to product safety. We
actively promote safe practices in the use and maintenance of our products through our service literature, instructional
training programs, and the continuous efforts of all Cooper Power Systems employees involved in product design,
manufacture, marketing and service.
We strongly urge that you always follow all locally approved safety procedures and safety instructions when working
around high-voltage lines and equipment and support our Safety For Life mission.
SAFETY Information
The instructions in this manual are not intended as a
substitute for proper training or adequate experience
in the safe operation of the equipment described.
Only competent technicians, who are familiar with this
equipment should install, operate and service it.
A competent technician has these qualifications:
n Is
n Is
n Is
n Is
DANGER:
WARNING:
CAUTION:
Safety Instructions
Following are general caution and warning statements
that apply to this equipment. Additional statements,
related to specific tasks and procedures, are located
throughout the manual.
DANGER:
WARNING:
WARNING:
WARNING:
IS550-60-1
SAFETY
FOR LIFE
Standards
ISO 9001 Certified Quality Management System
Installation Procedure
Kit Contents
1 - Tee connector (test point optional)
1 - Cable adapter
1 - Crimp lug or mechanical lug
1 - Stud
1 - Nut
1 - Plug
1 - Rubber cap
1 - Cable sealing kit (if ordered)
Silicone lubricant, paper wipes, Iso (Isopropyl
Alcohol) wipes and installation instructions.
Cap
Plug
Nut
Stud
Tee Body
Tools Required
13 mm open end wrench
22 mm socket
Torque wrench up to 70 Nm
8 mm Allen hex key for mechanical lug (if
ordered)
Bushing
3
Crimp or
Mechanical
Lug
Adapter
Cable
1
Figure 2.
Tee connector components. Sequential order of installation
shown.
DTS1242 Deadbreak Bolted Tee Connector-Interface C Installation Instructions for Single Core Cable with Copper Wire
Screen and Outer Sheath
Step 1
Cable Preparation
1. Train the cable to the desired finished position and cut the cable. (See Figure 3.)
Note: If cable is visibly bent, it should be straightened before installation of the tee. A bent cable
will result in a loose interface and reduce the dielectric withstand of the interface, especially
for large cable sizes. Recommended method for straightening the cable: Heat up the cable
to 90 C by using a heat tape. Keep the tape on for approximately 120 minutes and then
remove the heat tape. Keep the cable straight while cooling. It may be helpful to tape a
splint to the cable while it's cooling down.
2. Remove the cable jacket for a distance of 315 mm (for crimp lug only) or 320 mm (for
mechanical lug only) from the end of the cable.
3. Pull back drain wires. Use vinyl tape to secure wires temporarily.
4. Remove 265 mm (for crimp lug only) or 270 mm (for mechanical lug only) of insulation screen.
Chamfer the sharp end at a 45 angle.
5. Remove "L" mm of cable insulation.
6. Apply three layers of vinyl tape of the end of the conductor.
315 mm
265 mm
L
50 mm
CHAMFER
Crimp Lug
320 mm
270 mm
L
50 mm
CHAMFER
Mechanical Lug
Figure 3.
Cable preparation shown for crimp lug shown at left and mechanical lug shown at right.
TABLE 2
Dimensions
Crimp Lug
Conductor
Size (mm2)
95
120
150
185
240
300
400
500
630
800
L
(mm)
Conductor Size
(mm2)
L
(mm)
With Centering Sleeve
50
95 - 300
76
73
77
105
115
-
300 - 630
800
120
-
115
123
IS550-60-1
SAFETY
FOR LIFE
7. Remove vinyl tape from the screen wires. Wrap two half-lapped layers of sealing tape over
cable sheath, then pull down the screen wires. Wrap two layers of sealing tape over screen
wires, and cover the end of cable sheath and screen wires.
Figure 4.
Step 2
Adapter
1. Polish and thoroughly clean the cable insulation, using sand paper provided if necessary, and
Iso wipes.
2. Wrap two turns of vinyl tape to serve as marker at a position of 23 mm from end of insulation
screen.
23 mm
Figure 5.
Application of tape marker for cable adapter.
DTS1242 Deadbreak Bolted Tee Connector-Interface C Installation Instructions for Single Core Cable with Copper Wire
Screen and Outer Sheath
Step 3A
Crimp Lugs
4 3 2 1
Figure 7.
Crimp lug crimp sequence.
1. Wire brush conductor (aluminum only). Wipe off aluminum dust. Do not get dust on cable
adapter.
2. Immediately insert the conductor into the crimping barrel as far as it will go. Ensure that the flat
of the lug spade is parallel to the face of the bushing.
3. Crimp the lug starting at the mark on the barrel of the spade end of the lug as shown in
Figure 7. Rotate the crimping tool 90 degrees for each successive crimp.
4. Remove any excess inhibitor that may have come out of the crimp lug. File off any sharp
projections. Apply a layer of vinyl tape on the barrel.
TABLE 2
Crimp Chart
Conductor
Size (mm2)
Part Number
(DIN Type)
Die
Size
120
CDT630U120
23
150
CDT630U150
25
185
CDT630U185
28
240
CDT630U240
32
300
CDT630U300
34
400
CDT630U400
38
500
CDT1250U500
44
630
CDT1250U630
48
800
Part Number
(Mechanical)
CDT630SB300
8 mm
CDT1250SB630
CDT1250SB800
Step 3B
Mechanical Lugs
1. If the lug is supplied with centering sleeves, check the chart supplied with the lug and determine
if a sleeve is required and what the correct color would be.
2. Wire brush conductor (aluminum only).
3. Immediately insert the conductor into the barrel of the lug and visually check that the lug is on
as far as possible.
4. With an 8 mm Allen hex key screw in bolt No. 1 until it breaks off smoothly. Proceed with bolt
No. 2 in a similar way. If the lug has more than two (2) bolts, continue with No. 3 (See Figure 8
for tightening sequence).
IS550-60-1
SAFETY
FOR LIFE
5. Once all the bolts have broken off, smooth any rough edges with a file and install the covering
caps. Carefully clean off any filings.
BOLT 2
BOLT 3
BOLT 1
CENTERING SLEEVE
Figure 8.
Mechanical lug tightening sequence.
Step 4
Tee
1. Clean the outer surface of the cable adapter and the interior of the cable entrance of the tee
connector with a lint-free cloth. Apply a thin layer of lubricant to both surfaces.
2. Push the tee connector body over the cable adapter as far as it will go. Ensure that the hole in
the top of the crimp connector is visible through the interface end of the tee.
Figure 9.
Tee connector body installation.
DTS1242 Deadbreak Bolted Tee Connector-Interface C Installation Instructions for Single Core Cable with Copper Wire
Screen and Outer Sheath
Step 5
Stud
Figure 10.
Installation of stud in bushing.
Step 6
Tee
1. Clean the bushing interface and the tee connector interface with an Iso wipe. Wait for cleaning
solvent to evaporate. Lubricate both interfaces.
2. Push the tee connector onto the bushing. Make sure the stud passes through the hole in spade
of lug.
Note: If a companion tee is to be installed, do not proceed any further. Follow the DTB1242
Deadbreak Bolted Companion Tee Connector Installation Instructions IS550-61-1.
Figure 11.
Installation of nut and deadend plug.
3.
Put hex nut on the stud, and tighten the nut to 70 Nm, using a torque wrench and a 22 mm
socket.
SAFETY
FOR LIFE
IS550-60-1
Step 7
Plug
1. Clean the deadend plug and the tee connector interfaces with cleaning wipes. Wait for cleaning
solvent to evaporate. Apply a thin layer of lubricant to both surfaces.
2. Insert the deadend plug into the tee and engage the threads of the threaded stud.
3. Tighten the deadend plug to 55 Nm, using a torque wrench and 22 mm socket.
Step 8
Cap and Earth wire
1. Clean the interior surface of the rubber cap.
2. Place it over the deadend plug and push it until it snaps into place.
3. If not already attached, connect drain wire to the grounding tab of tee body as shown in the
Figure 12.
4. Connect drain wire on tee body to earthing system.
5. Clamp the cable below cable jacket seal.
DTS1242 Deadbreak Bolted Tee Connector-Interface C Installation Instructions for Single Core Cable with Copper Wire
Screen and Outer Sheath
M5 HEX NUT
M5 x 15 mm SCREW
M5 RING TONGUE
TERMINAL
DRAIN WIRE
System Earth
Figure 12.
Cable clamp and screen wire earthing arrangement.
10
IS550-60-1
SAFETY
FOR LIFE
11
DTS1242 Deadbreak Bolted Tee Connector-Interface C Installation Instructions for Single Core Cable with Copper Wire
Screen and Outer Sheath
SAFETY
FOR LIFE