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ContentsProduct Information. . . . . . . . . . . . . . . . . . . . . . . . . . . 1Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 3

PRODUCT INFORMATIONIntroduction

Cooper Power Systems 1250 A, 42 kV bolted tee separableconnectors are used to terminate polymeric cable toequipment, such as transformers, switchgear, motorsetc. equipped with bushings meeting type C interface perCENELEC EN 50180 and 50181. They are fully screenedand fully submersible when mated with the proper bushingor plug and they meet the requirements of CENELEC HD629.1 S2. The bolted tee connectors can be mountedvertically, horizontally or any angle in between with propercable support. Each bolted tee connector is tested for ACwithstand and partial discharge prior to leaving the factory.

Read This Manual First

Read and understand the contents of this manual andfollow all locally approved procedures and safety practicesbefore installing or operating this equipment.

Additional Information

These instructions cannot cover all details or variations inthe equipment, procedures, or process described norprovide directions for meeting every possible contingencyduring installation, operation, or maintenance. Foradditional information, contact your representative.

Electrical Apparatus

IS550-60-1

Screened SeparableConnectorsDTS1242 Deadbreak Bolted Tee Connector -Interface C Installation Instructions For Single CoreCable with Copper Wire Screen and Outer Sheath

10312 New Issue

CAP MOULDEDSEMICONDUCTIVEEPDM

DANGER: All associated apparatus must bede-energized during any hands-on installation

or maintenance. Failure to comply will result in death,severe personal injury and equipment damage.

!

WARNING: The Cooper Power Systemsseparable connector is designed to be

operated in accordance with normal safe operatingprocedures. These instructions are not intended tosupersede or replace existing safety and operatingprocedures. Separable connectors must bede-energized during operation or maintenance.Visible break and adequate grounding must beprovided before cable work proceeds. Ensure thatthe connector is rated for the intended applicationbefore it is installed.

Separable connectors should be installed andserviced only by personnel familiar with good safetypractice and the handling of high-voltage electricalequipment. Failure to comply could result in death,

severe personal injury and equipment damage.

!

WARNING: Optional Capacitive Test PointOperating Instructions: Use only voltage

indicating instruments specifically designed for testpoints. Use of conventional voltage sensing devicesmay provide false No Voltage indications.

The test point must be dry and free of contaminantswhen checking for voltage. After indication is taken:clean, dry, and lubricate the test point cap withsilicone grease and assemble to the test point.

The capacitive test point is not sufficiently

accurate, nor is it intended for, actual voltagemeasurements or phasing operations.

A reading of no voltage from the test pointshould not be the only indication of ade-energized circuit obtained before touchingthe connector. Other procedures can includedirect conductor voltage testing or groundingusing a live-line tool.

Failure to comply could result in death, severepersonal injury and equipment damage.

!Figure 1.Line illustration of 42 kV bolted tee connector.

!

TEST POINT(OPTIONAL) TEE CONNECTOR

BODY

CABLEADAPTER

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Acceptance and Initial Inspection

Each bolted tee connector is completely inspected andtested at the factory. It is in good condition whenaccepted by the carrier for shipment. Upon receipt of a

bolted tee connector, inspect it thoroughly for damageand loss of parts incurred during shipment. If damage orloss is discovered, file a claim with the carrier immediately.

Handling and Storage

Be careful during handling and storage of the bolted teeconnector to minimize the possibility of damage. If thebolted tee connector is to be stored for any length of time

prior to installation, provide a clean, dry storage area.

Standards

ISO 9001 Certified Quality Management System

Kit Contents

1 - Tee connector (test point optional)1 - Cable adapter

1 - Crimp lug or mechanical lug1 - Stud1 - Nut1 - Plug1 - Rubber cap1 - Cable sealing kit (if ordered)Silicone lubricant, paper wipes, Iso (IsopropylAlcohol) wipes and installation instructions.

Tools Required

13 mm open end wrench22 mm socketTorque wrench up to 70 Nm8 mm Allen hex key for mechanical lug (if

ordered)

CAUTION: Optional Capacitive Test PointOperating Instructions: Use only voltage indi-

cating instruments specifically designed for testpoints. Use of conventional voltage sensing devicesmay provide false "No Voltage" indications.

The test point must be dry and free of contaminants

when checking for voltage. After indication is taken:clean, dry, and lubricate the test point cap withsilicone grease and assemble to the test point.

!

Figure 2.Tee connector components. Sequential order of installationshown.

INSTALLATION PROCEDURE

Cap Plug Nut Stud Bushing

Tee Body

Crimp orMechanicalLug

Adapter

Cable

1

2

3

4

56789

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DTS1242 Deadbreak Bolted Tee Connector-Interface C Installation Instructions for Single Core Cable with Copper WireScreen and Outer Sheath

4

Step 1Cable Preparation1. 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 cablewill result in a loose interface and reduce the dielectric withstand of the interface, especiallyfor large cable sizes. Recommended method for straightening the cable: Heat up the cableto 90 C by using a heat tape. Keep the tape on for approximately 120 minutes and thenremove the heat tape. Keep the cable straight while cooling. It may be helpful to tape asplint 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 (formechanical 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.

Crimp Lug Mechanical (Shear Bolt) Lug

ConductorSize (mm2)

L(mm)

Conductor Size(mm2)

L(mm)

With Centering Sleeve Without Centering Sleeve

9550

95 - 300 76 73

120150185

77240

300300 - 630 120 115

400500 105630 115800 - 800 - 123

TABLE 2Dimensions

Figure 3.Cable preparation shown for crimp lug shown at left and mechanical lug shown at right.

315 mm

265 mmL

50 mm

CHAMFER

320 mm

270 mmL

50 mm

CHAMFER

Crimp Lug

Mechanical Lug

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7. Remove vinyl tape from the screen wires. Wrap two half-lapped layers of sealing tape overcable sheath, then pull down the screen wires. Wrap two layers of sealing tape over screenwires, and cover the end of cable sheath and screen wires.

Step 2Adapter1. 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.

3. Lubricate exposed cable insulation and adapter inside interface.4. Slide the cable adapter onto the cable, black end first, until the black end is flush with tape

marker. Check the Critical Dimension as shown in Figure 6 below. Then remove the marker.5. Wipe off grease from end of cable adapter preparing surface for application of tape.6. Apply 3-4 layers of semi-conductive tape over the adapter edge and cable screen wires. Then

apply 2 layers of sealing tape over the semi-conductive tape and caulk screen wires. Wrap 2-3half-lapped layers of vinyl tape over the sealing tape.

7.Remove the tape from the end of the conductor.

Figure 5.Application of tape marker for cable adapter.

Figure 6.Cable adapterCritical Dimension.

CriticalDimension

Crimp Lug 113 mm (+/- 5 mm)

Mechanical Lug 118 mm (+/- 5 mm)

Figure 4.

23 mm

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Step 3ACrimp Lugs

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.

Step 3BMechanical Lugs

1. If the lug is supplied with centering sleeves, check the chart supplied with the lug and determineif 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).

4 3 2 1

Figure 7.Crimp lug crimp sequence.

ConductorSize (mm2)

Part Number(DIN Type)

DieSize

Part Number(Mechanical) Allen Hex Key

120 CDT630U120 23

CDT630SB300

8 mm

150 CDT630U150 25

185 CDT630U185 28

240 CDT630U240 32

300 CDT630U300 34

400 CDT630U400 38 CDT1250SB630

500 CDT1250U500 44

630 CDT1250U630 48

800 - - CDT1250SB800

TABLE 2Crimp Chart

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5. Once all the bolts have broken off, smooth any rough edges with a file and install the coveringcaps. Carefully clean off any filings.

Step 4Tee

1. Clean the outer surface of the cable adapter and the interior of the cable entrance of the teeconnector 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 inthe top of the crimp connector is visible through the interface end of the tee.

Figure 9.Tee connector body installation.

Figure 8.Mechanical lug tightening sequence.

CENTERING SLEEVEBOLT 1

BOLT 2

BOLT 3

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Step 5Stud

1. Tighten the stud to 55 Nm, using a 13 mm open end wrench.

Step 6Tee

1. Clean the bushing interface and the tee connector interface with an Iso wipe. Wait for cleaningsolvent to evaporate. Lubricate both interfaces.

2. Push the tee connector onto the bushing. Make sure the stud passes through the hole in spadeof lug.

Note: If a companion tee is to be installed, do not proceed any further. Follow the DTB1242Deadbreak Bolted Companion Tee Connector Installation Instructions IS550-61-1.

3. Put hex nut on the stud, and tighten the nut to 70 Nm, using a torque wrench and a 22 mmsocket.

Figure 11.Installation of nut and deadend plug.

Figure 10.Installation of stud in bushing.

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Step 7Plug

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 8Cap 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.

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CAUTION:A connector/bushing combinationshould not be allowed to carry the full weight

of the cable. Therefore it is necessary to clamp thecable as close as possible to the connector.

!

Cable Clamp

System Earth

Figure 12.Cable clamp and screen wire earthing arrangement.

M5 HEX NUT

Earth Wire Attachment Detail (already assembled)

M5 x 15 mm SCREW

M5 RING TONGUETERMINAL

DRAIN WIRE

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2012 Cooper Industries. All Rights Reserved.Cooper Power Systems is a valuable trademark of Cooper Industriesin the U.S. and other countries. You are not permitted to use theCooper Trademarks without the prior written consent of CooperIndustries.

One Cooper | www.cooperpower.com | Online

IS550601 Rev 0

2300 Badger DriveWaukesha, WI 53188

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Is 550601

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