Eaton 200 A 15 kV class User manual

200 A 15/25 kV class deadbreak straight connector
installationinstructions
COOPER POWER
SERIES
Deadbreak Apparatus
Connectors
MN650043EN Effective February 2017
Supersedes October 2004 (S550-12-1)

iINSTALLATION INSTRUCTIONS MN650043EN February 2017
DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITY
The information, recommendations, descriptions and safety notations in this document are based on Eaton Corporation’s
(“Eaton”) experience and judgment and may not cover all contingencies. If further information is required, an Eaton sales
office should be consulted. Sale of the product shown in this literature is subject to the terms and conditions outlined in
appropriate Eaton selling policies or other contractual agreement between Eaton and the purchaser.
THERE ARE NO UNDERSTANDINGS, AGREEMENTS, WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES
OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OTHER THAN THOSE SPECIFICALLY SET OUT IN ANY
EXISTING CONTRACT BETWEEN THE PARTIES. ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF EATON. THE
CONTENTS OF THIS DOCUMENT SHALL NOT BECOME PART OF OR MODIFY ANY CONTRACT BETWEEN THE PARTIES.
In no event will Eaton be responsible to the purchaser or user in contract, in tort (including negligence), strict liability or
other-wise for any special, indirect, incidental or consequential damage or loss whatsoever, including but not limited to
damage or loss of use of equipment, plant or power system, cost of capital, loss of power, additional expenses in the use of
existing power facilities, or claims against the purchaser or user by its customers resulting from the use of the information,
recommendations and descriptions contained herein. The information contained in this manual is subject to change
withoutnotice.

ii INSTALLATION INSTRUCTIONS MN650043EN February 2017
Contents
DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITY ....................................I
SAFETY FOR LIFE .........................................................................III
SAFETY INFORMATION ....................................................................III
Safety instructions.............................................................................. iii
GENERAL ................................................................................ 1
INSTALLATION............................................................................ 1
PREPARATION OF CONCENTRIC NEUTRAL CABLE.............................................. 2
STRAIGHT CONNECTOR AND COPPERTOP INSTALLATION....................................... 3

iiiINSTALLATION INSTRUCTIONS MN650043EN February 2017
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:
• Is thoroughly familiar with these instructions.
• Is trained in industry-accepted high and low-voltage safe
operating practices and procedures.
• Is trained and authorized to energize, de-energize, clear,
and ground power distribution equipment.
• Is trained in the care and use of protective equipment
such as arc flash clothing, safety glasses, face shield, hard
hat, rubber gloves, clampstick, hotstick, etc.
Following is important safety information. For safe
installation and operation of this equipment, be sure to read
and understand all cautions and warnings.
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.
Safety for life
!
SAFETY
FOR LIFE
!
SAFETY
FOR LIFE
Eaton’s Cooper Power series 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 Eaton 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
This manual may contain four types of hazard statements:
DANGER
Indicates an imminently hazardous situation which, if
not avoided, will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
CAUTION
Indicates a potentially hazardous situation which, if not
avoided, may result in equipment damage only.
Hazard Statement Definitions
DANGER
Hazardous voltage. Contact with hazardous voltage will
cause death or severe personal injury. Follow all locally
approved safety procedures when working around
high- and low-voltage lines and equipment. G103.3
WARNING
Before installing, operating, maintaining, or testing this
equipment, carefully read and understand the contents
of this manual. Improper operation, handling or
maintenance can result in death, severe personal injury,
and equipment damage. G101.0
WARNING
This equipment is not intended to protect human
life. Follow all locally approved procedures and safety
practices when installing or operating this equipment.
Failure to comply can result in death, severe personal
injury and equipment damage. G102.1
WARNING
Power distribution and transmission equipment must
be properly selected for the intended application. It
must be installed and serviced by competent personnel
who have been trained and understand proper safety
procedures. These instructions are written for such
personnel and are not a substitute for adequate training
and experience in safety procedures. Failure to properly
select, install or maintain power distribution and
transmission equipment can result in death, severe
personal injury, and equipment damage. G122.3

1
200 A 15/25 kV class deadbreak straight connector installationinstructions
INSTALLATION INSTRUCTIONS MN650043EN February 2017
WARNING
All associated apparatus must be de-energized during
installation, operation and/or maintenance.
General
The Eaton Cooper Power series Deadbreak Straight
Connector is a fully-shielded and insulated plug-in
termination for connecting underground cable to
transformers, switching cabinets and junctions equipped
with deadbreak bushings.
Wide cable ranges are sized to accept cables insulated at
either 175 mil or 220 mil within a given conductor size. The
wider cable ranges increase installation flexibility.
The Coppertop (bimetal) compression connector is a
standard item to transition from the cable to the bushing
contacts. An aluminum crimp barrel is inertia-welded to a
copper lug. The aluminum barrel makes the connector easy
to crimp and the copper lug ensures a reliable, tight, cool
operating connection with the bushing contacts.
CAUTION
The 200 A Deadbreak Straight Connector is designed to
be operated in accordance with normal safe operating
procedures. These instructions are not intended to
supersede or replace existing safety and operating
procedures. The straight connector should be installed
and serviced only by personnel familiar with good
safety practices and the handling of high-voltage
electrical equipment.
Installation
Cable stripping and scoring tools, available from various tool
manufacturers, are recommended for use when installing
deadbreak connectors. After preparing the cable, the
connector housing is pushed onto the cable.
Complete straight connector kit includes:
 Connector Body with Test Point
 Coppertop Compression Connector
 Bail Assembly
 Silicone Lubricant
 Instruction Sheet
Figure 1. 15/25 kV deadbreak straight connector
Tools/Accessories needed:
 Tape Measure
 Wire Brush
 Knife
 Cable Stripping Tool
 Crimping Tool
 Cable Cleaner
 Cable Cutters
 Emery Cloth
These instructions do not claim to cover all details or variations in the equipment, procedure, or process described, nor to provide
directions for meeting every contingency during installation, operation, or maintenance. When additional information is desired to
satisfy a problem not covered sufficiently for the user’s purpose, contact your Eaton representative.

2
200 A 15/25 kV class deadbreak straight connector installationinstructions
INSTALLATION INSTRUCTIONS MN650043EN February 2017
8"
(203 mm)
Bend
neutral
wires down
and out of
the way
Insulation
shield
Step 1
5 3/4"
(145 mm)
Insulation
Step 2
2 1/8"
(54.0 mm) Conductor
1/8" Bevel
Step 3
Wire
brush
conductor
Jacket
seal
Step 4
Preparation of concentric neutral cable
Step 1
Measure down from top of the cable a minimum of 8”.
Remove cable jacket (if jacketed cable is used) to expose
neutral wires.
Unwind neutral wires.
ote:N If an Eaton Cooper Power series jacket seal is used,
follow instructions supplied with the jacket seal kit.
Step 2
Measure down from top of the cable 5 3/4”.
Remove the insulation shield. Take care not to nick or
gouge insulation.
Step 3
Measure down from the top of the cable 2 1/8”.
Remove the insulation and conductor shield to expose the
bare conductor. Take care not to nick the conductor.
Place a 1/8”bevel on the insulation to ease installation.
Step 4
If not already in place, apply a suitable jacket seal over the
jacket and exposed neutral wires.
Proceed to Step 5.

3
200 A 15/25 kV class deadbreak straight connector installationinstructions
INSTALLATION INSTRUCTIONS MN650043EN February 2017
Step 5
First
crimp
placed
below
shoulder
Clean
and
lubricate
Clean
excess
inhibitor
grease
Step 7
Clean and
lubricate
Step 6
Attach lead
to system
ground
Attach
ground lead
to ground
tab
Clean and
lubricate cable
entrance
Straight connector and coppertop installation
Step 5
Clean the exposed conductor using a wire brush.
Place the Coppertop (bimetal) connector on the conductor.
Crimp the connector in place using a tool and die
combination listed in Table 1. Start crimping just below
the shoulder and rotate each successive crimp to prevent
bowing. Do not overlap crimps. Place as many crimps on
the connector as will fit.
Step 6
Clean excess inhibitor grease from Coppertop connector by
wiping toward the coppertop.
Clean insulation with a lint free cloth saturated with a
cleaning solution. Wipe insulation toward insulation shield.
Apply a thin coating of grease to the insulation.
Clean and lubricate the cable entrance of the connector.
Place straight connector on cable. With a twisting motion,
push connector onto cable until it snaps into position. Attach
a ground lead to the grounding tab of the connector.
Step 7
Clean the straight connector and bushing interfaces and apply
a thin uniform layer of silicone lubricant to both interfaces.
Push the connector onto the bushing until it is fully seated.
Insert the bail rods into the bushing tabs. Slide the bail
plates around the connector and insert the threaded ends of
the rods through the holes in the plates. Engage and tighten
the knurled nuts.

4
200 A 15/25 kV class deadbreak straight connector installationinstructions
INSTALLATION INSTRUCTIONS MN650043EN February 2017
Table 1. Crimp chart
Connector 5/8” Diameter 3/4” Diameter
Conductor size NO. 4 Thru 2/0 Stranded 3/0 - 4/0 Stranded
Tool Y34 Y35 or Y39 MD6 Y34 Y35 or Y39 MD6
Burndy Die A243 U243 UBG W243 WBG U247 U247 U467 W247
A25AR U25ART U687 BG NOSE W687 A27AR U27ART
Somerset (T
and B)
Tool UT-3 UT-5 UT-15 UT-5 UT-15
Die 5/8" TV 54 H TV 66
Kearney Tool 0 H-1, H-2 0H-1, H-2
Die 5/8" NOSE 9/16" 9/16" 572 737 747 737 747
Alcoa Tool 12A 12A
Die B24 EA B39 EA
Anderson tool VC-5, VC-6 VC-5, VC-6
EEI – Reference 8A 10A
DS225
200A
15.2 kV
1
9
.
6
-
2
4
.
1
M
M
.
7
7
0
-
.
9
5
0
I
N
F3.9"
100 mm
4.0"
102 mm
4.3"
110 mm
10.0"
254 mm
Figure 2. DS225 deadbreak connector dimensional information
WARNING
This is a Deadbreak Connector System. All associated
apparatus must be de-energized before and during
installation and/or operation.

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200 A 15/25 kV class deadbreak straight connector installationinstructions
INSTALLATION INSTRUCTIONS MN650043EN February 2017
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200 A 15/25 kV class deadbreak straight connector installationinstructions
INSTALLATION INSTRUCTIONS MN650043EN February 2017
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200 A 15/25 kV class deadbreak straight connector installationinstructions
INSTALLATION INSTRUCTIONS MN650043EN February 2017
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Eaton
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Cleveland, OH 44122
United States
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Eaton’s Power Systems Division
2300 Badger Drive
Waukesha, WI 53188
United States
Eaton.com/cooperpowerseries
© 2017 Eaton
All Rights Reserved
Printed in USA
Publication No. MN650043EN Rev. 00
Supersedes 5000050922 Rev. 0
February 2017
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of their respective owners.
For Eaton's Cooper Power series product
information
call 1-877-277-4636 or visit:
www.eaton.com/cooperpowerseries.
!
SAFETY
FOR LIFE