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

PRODUCT INFORMATIONIntroduction

Cooper Power Systems 1250 A, 42 kV bolted companiontee connectors 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 screened

and fully submersible when mated with the proper bushingor plug and they meet the requirements of CENELEC HD629.1 S2. The bolted companion tee connectors can bemounted vertically, horizontally or any angle in betweenwith proper cable support. Each bolted companion teeconnector is tested for AC withstand and partial dischargeprior to leaving the factory.

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

Additional InformationThese 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

IS550-61-1

Screened SeparableConnectorsDTB1242 Deadbreak Bolted Companion Tee Connector- Interface C Installation Instructions For Single CoreCable with Copper Wire Screen and Outer Sheath

10312 New Issue

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 Systems

separable connector is designed to beoperated 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 electrical

equipment. 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 with

silicone grease and assemble to the test point.The capacitive test point is not sufficiently accu-rate, nor is it intended for, actual voltage mea-surements 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 companion tee connector.

CAP MOULDEDSEMICONDUCTIVEEPDM

TEST POINT(OPTIONAL) TEE CONNECTOR

BODY

CABLEADAPTER

!

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DTB1242 Deadbreak Bolted Companion Tee Connector - Interface C Installation Instructions For Single Core Cablewith Copper Wire Screen and Outer Sheath

The instructions in this manual are not intended as asubstitute for proper training or adequate experiencein the safe operation of the equipment described.Only competent technicians, who are familiar with thisequipment should install, operate and service it.

A competent technician has these qualifications:nIs thoroughly familiar with these instructions.

nIs trained in industry-accepted high- and low-voltagesafe operating practices and procedures.

nIs trained and authorized to energize, de-energize,clear, and ground power distribution equipment.

nIs trained in the care and use of protective equipmentsuch as flash clothing, safety glasses, face shield, hardhat, rubber gloves, clampstick, hotstick, etc.

Following is important safety information. For safeinstallation and operation of this equipment, be sure to

read and understand all cautions and warnings.

Safety Instructions

Following are general caution and warning statementsthat apply to this equipment. Additional statements,related to specific tasks and procedures, are locatedthroughout the manual.

DANGER:Hazardous voltage. Contact with high voltage willcause death or severe personal injury. Follow alllocally approved safety procedures when workingaround high- and low-voltage lines and equipment.

!

WARNING:Before installing, operating, maintaining, or testingthis equipment, carefully read and understandthe contents of this manual. Improper operation,

handling or maintenance can result in death, severepersonal injury, and equipment damage.

!

WARNING:This equipment is not intended to protect humanlife. Follow all locally approved procedures andsafety practices when installing or operating thisequipment. Failure to comply may result in death,severe personal injury and equipment damage.

!

WARNING:Power distribution and transmission equipmentmust be properly selected for the intendedapplication. It must be installed and servicedby competent personnel who have been trainedand understand proper safety procedures. Theseinstructions are written for such personnel andare not a substitute for adequate training andexperience in safety procedures. Failure to properlyselect, install or maintain power distribution andtransmission equipment can result in death, severepersonal injury, and equipment damage.

!

SAFETY FOR LIFECooper Power Systems products meet or exceed all applicable industry standards relating to product safety. Weactively 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 workingaround high-voltage lines and equipment and support our Safety For Life mission.

!SAFETY

FOR LIFE

!SAFETY

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SAFETY INFORMATION

Th is manua l may con tain four types of hazardstatements:

DANGER:Indicates a hazardous situation which, if notavoided, will result in death or serious injury.

WARNING:Indicates a hazardous situation which, if not

avoided, could result In death or serious injury.

CAUTION:Indicates a hazardous situation which, if notavoided, could result in minor or moderate injury.

CAUTION:Indicates a hazardous situation which, ifnot avoided, could result in equipment damage only.

Hazard Statement Definitions

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!

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3

Acceptance and Initial Inspection

Each bolted companion tee connector is completelyinspected and tested at the factory. It is in good conditionwhen accepted by the carrier for shipment. Upon receipt

of a bolted companion tee connector, inspect it thoroughlyfor damage and loss of parts incurred during shipment. Ifdamage or loss is discovered, file a claim with the carrierimmediately.

Handling and Storage

Be careful during handling and storage of the boltedcompanion tee connector to minimize the possibility ofdamage. If the separable connector is to be stored for any

length of time prior to installation, provide a clean, drystorage area.

Standards

ISO 9001 Certified Quality Management System

Figure 2.Bolted tee connector plus bolted companion tee components. Sequential order of installation.

INSTALLATION PROCEDURE

Cap Plug Nut Stud Bushing

Tee Body

Crimp orMechanicalLug

Adapter

Cable

1

2

3

510

Crimp orMechanicalLug

Adapter

Cable

4

5

6

Stud & Rod

Tee Body

47

11121314

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Kit Content

1 - Bolted companion tee connector (test pointoptional)

1 - Cable adapter1 - Crimp lug or mechanical lug1 - Rod and stud1 - Cable sealing kit (if ordered)Silicone lubricant, paper wipes, Iso (IsopropylAlcohol) wipes and installation instructions

Note: For installation of the tee, see IS550-60-1, DTS1242 Deadbreak Bolted Tee

Connector-Interface C Installation Instructions packaged with the bolted tee connector.

Tools Required

13 mm open end wrench29 mm open end wrench22 mm socketTorque wrench up to 70 Nm8 mm Allen hex key for mechanical lug (if ordered)

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 screen wires. Allow enough extra screen wires to connect to ground after installation.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.

CAUTION:Optional Capacitive Test Point Operating Instructions:Use only voltage indicating instruments specificallydesigned for test points. Use of conventional voltagesensing devices may 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.

!

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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.

TABLE 2Dimensions

Figure 4.Application of tape marker for cable adapter.

Crimp Lug Mechanical (Shear Bolt) Lug

ConductorSize (mm2)

L(mm)

Conductor Size(mm2)

L(mm)

With Centering Sleeve Without Centering Sleeve

95

5095 - 300 76 73

120150185

77240300

300 - 630 120 115400500 105630 115800 - 800 - 123

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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Step 2Adapter1. Polish and thoroughly clean the cable insulation, using sand paper, 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 insulationscreen.

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 cable screen wires. Wrap 2-3

half-lapped layers of vinyl tape over the sealing tape.7.Remove the tape from the end of the conductor.

Figure 6.Cable adapterCritical Dimension.

CriticalDimension

Crimp Lug 113 mm (+/- 5 mm)Mechanical Lug 118 mm (+/- 5 mm)

Figure 5.Crimp lug crimping sequence.

23 mm

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Step 3ACrimp Lugs

1. Wire brush conductor (aluminum only). Wipe off aluminum dust. Do not get dust on cableadapter.

2. Immediately insert the conductor into the crimping barrel as far as it will go. Ensure that the flatof the lug spade is parallel to the face of the bushing.

3. Crimp the lug starting at 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 sharpprojections.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 8for tightening sequence).

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

4 3 2 1

Figure 7.Crimp lug crimping 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 34400 CDT630U400 38

CDT1250SB630500 CDT1250U500 44

630 CDT1250U630 48

800 - - CDT1250SB800

TABLE 2Crimp Chart

Figure 8.Mechanical lug tightening sequence.

CENTERING SLEEVEBOLT 1

BOLT 2

BOLT 3

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Step 4Tee

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.

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: For installation of only a tee (DTS1242) on the bushing, proceed to Step 7. If a boltedcompanion tee (DTB1242) will be installed, proceed to Step 10.

Figure 10.Installation of stud in bushing.

Figure 9.Tee connector body installation.

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Step 7Nut

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

socket .

Step 8Plug

1. Clean the deadend plug and the tee connector interfaces with cleaning wipes. Wait for cleaningsolvent 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.

Figure 11.Installation of nut and deadend plug.

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DTB1242 DTS1242

Figure 13.Rod assembly installation.

Step 9Cap 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 the drain wire to the grounding tab of tee body as shown in

Figure 12.4. Connect drain wire on tee body to earthing system.5. Clamp the cable below cable jacket seal.

Step 10Rod and Stud Assembly

1. Install the rod and stud assembly by hand in the tee. Make sure the stud in the bushing passesthrough the hole in spade of the connector.

2. Tighten the rod and stud assembly to approximately 70 Nm, using a 29 mm open end wrench.

CAUTION:A connector/bushing mated combinationshould not be allowed to carry the full weight of thecable. Therefore it is necessary to clamp the cableas close as possible to the connector.

M5 HEX NUT

Earth Wire Attachment Detail (already assembled)

M5 x 15 mm SCREW

M5 RING TONGUETERMINAL

DRAIN WIRE

Figure 12.Cable clamp and screen wire earthing arrangement.

CableClamp

SystemEarth

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Step 11

1. Repeat Steps 1 to Step 4, prepare cable and install bolted companion tee connector.2. Clean the interface of companion tee connector and tee connector with an Iso wipe. Wait for

cleaning solvent to evaporate. Apply a thin layer of lubricant to both interfaces.3. Slide the bolted companion tee connector over the rod and stud assembly and into the tee

connector.4. Put the hex nut onto the rod and stud assembly and tighten to 70 Nm using a 22 mm socket

and a torque wrench.

Step 12

1. Clean the deadend plug and the companion tee interfaces with an ISO wipe. Wait for cleaningsolvent to evaporate. Apply a thin layer of lubricant to both surfaces.

2. Insert the deadend plug into the back of the companion tee and engage the threads of thethreaded stud.

3. Tighten the deadend plug to 55 Nm, using a 22 mm socket and a torque wrench.

Figure 14.Installation of nut and deadend plug.

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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

IS550611 Rev 0

2300 Badger DriveWaukesha, WI 53188

CAUTION: A connector/bushing matedcombination should not be allowed to carry

the full weight of the cable. Therefore it is necessaryto clamp the cable as close as possible to the

connector.

!

Step 13

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/companion teebody as shown in Figure 12 of Step 9.

4. Connect drain wire on tee body/companion tee body to earthing system.5. Clamp the cable below cable jacket seal.

Figure 15.Cable clamp and screen wire earthing arrangement.

!SAFETY

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