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S600-10-2
ii
600 A 15/25 kV class BOL-T and separable splice connector assembly installation instructions S600-10-2 July 2014 www.cooperpower.com
Contents
SAFETY INFORMATION
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
PRODUCT INFORMATION
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Acceptance and Initial Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Handling and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
EQUIPMENT REQUIRED
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
TOOLS REQUIRED
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
INSTALLATION OF CONNECTORS
Shear Bolt Installation Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Compression Connector Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
600 A 15/25 kV class BOL-T and separable splice connector assembly installation instructions S600-10-2 July 2014 www.cooperpower.com
iii
SAFETY
FOR LIFE
SAFETY
FOR LIFE
Eatons 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 Eatons 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.
Safety instructions
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
WARNING
WARNING
DANGER
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.
iv
DANGER
600 A 15/25 kV class BOL-T and separable splice connector assembly installation instructions S600-10-2 July 2014 www.cooperpower.com
DANGER
All associated apparatus must be de-energized during
any hands-on installation or maintenance.
WARNING
The 600 A BOL-T Connector System 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 elbow connector should be installed
and serviced only by personnel familiar with good
safety practices and the handling of high-voltage
electrical equipment.
WARNING
Optional Capacitive Test Point Operating Instructions:
Use only voltage indicating instruments specifically
designed for test points. Use of conventional voltage
sensing devices may 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 with silicone
grease and assemble to the test point.
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.
Standards
T-body
Product information
Unthreaded Compression
Introduction
Connector
Test Point
Cable Adapter
Neutral Wire
600 A 15/25 kV class BOL-T and separable splice connector assembly installation instructions S600-10-2 July 2014 www.cooperpower.com
Installation of connectors
IMPORTANT
Installation Instructions to be used for 600 A, 15/25 kV
Class BOL-T connector with shear bolt connector. Please
see page 6 for installation instructions using a compression
connector.
Step 1.
Train cable
Position cable vertically so that it is centered between
apparatus bushing and parking pocket, parallel to, and 6"
(152 mm) from apparatus frontplate.
Equipment provided
T-body
Cable Adapter
Insulating Plug with Cap
Shear Bolt Connector
Silicone Lubricant
Instruction Sheet
Threaded Stud
Tools required
"A"
(See Table 1)
Torque Wrench
5/16" Hex Wrench for Splice Application
Cable Stripping Tools
5 mm or 8 mm Allen Wrench
Bushing
Cable
B
C
D
600 A 15/25 kV class BOL-T and separable splice connector assembly installation instructions for S600-10-2 July 2014 www.cooperpower.com
S3
S4
Allen Wrench
(mm)
Code
Centering Ring
with or without
in (mm)
Length
Variable
Measurement Name
Tolerance
Bushing to Cable
(+/-0.25)
2.00
(50.8)
2.00
(50.8)
2.00
(50.8)
Jacket
(+/-0.25)
12.00
(304.8)
12.00
(304.8)
12.00
(304.8)
Insulation Shield
(+/-0.125)
9.38
(238.2)
9.38
(238.2)
9.38
(238.2)
Conductor
(+/-0.125)
2.75
(69.85)
3.38
(85.85)
4.00
(101.6)
Maximum
7.25
(184.1)
7.25
(184.1)
7.25
(184.1)
Concentric or
Compressed
Compact or
Solid
AWG or
kcmil
AWG
or
kcmil
mm2
mm2
No Connector
mm2
Stranded &
Compressed
AWG or Kcmil
Compression
Conductor
Code
Concentric
Compressed
Compact
00
3/0
3/0
3/0
#2
35
11
4/0
4/0
4/0
#1
1/0
50
12
250
250
250
1/0
50
2/0
70
13
350
2/0
70
3/0
14
350
350
3/0
4/0
95
15
500
500
500
4/0
95
250
120
16
600
600
600
250
120
300
17
700
300
350
18
700
700
350
400
185
19
750
750
750
400
185
450
20
800
800
450
500
240
21
900
min
max
Shear Bolt
Conductor
Code
Shear Bolt
Catalog
Number
95
150
S1
CDT630SB150
185
300
S3
CDT630SB300
S4
CDT630SB400
400
600 A 15/25 kV class BOL-T and separable splice connector assembly installation instructions S600-10-2 July 2014 www.cooperpower.com
Step 2.
Step 4.
Tape Marker
Insulation Shield
Insulation
"C"
(See Table 1)
1"
(25 mm)
Bushing
Step 5.
"A"
(See Table 1)
"B"
(See Table 1)
Cable
"D"
(See Table 1)
Step 3.
Insulation
Bare Conductor
Step 6.
Bevel insulation
Remove sharp edge of insulation by beveling at a 45
angle for approximately .25" (6 mm). (Refer to Figure 7.)
Bevel
.25"
(6 mm)
Insulation
600 A 15/25 kV class BOL-T and separable splice connector assembly installation instructions for S600-10-2 July 2014 www.cooperpower.com
Step 7.
Cable
Insulation
Not Straight
Wipe Insulation
Cable
Insulation
Shield
Tape
Marker
Wiping Direction
Major OD
flared out
bulge
Straight
Not Straight
Straight
Clean insulation
NNote: Do not apply solvent directly to cable.
Correct Positioning
Incorrect Positioning
Step 8.
Lubricate and install cable adapter
Lubricate exposed cable insulation.
Lubricate Insulation
Tape Marker
Lubricate
Bolt 2
Bolt 3
WARNING
Equipment Damage/Personal Injury. Improperly
positioned cable adapter may result in equipment
damage or personal injury.
St
art
Bolt 1
wi
th
Bo
lt
600 A 15/25 kV class BOL-T and separable splice connector assembly installation instructions S600-10-2 July 2014 www.cooperpower.com
Step 9.
Install shear bolt connector
NNote: Refer to the separate installation instructions
supplied with the shear bolt connector.
Step 11.
Once all the bolts have broken off, smooth any rough
edges with a file and install the covering caps. Carefully
clean off any filings.
Apparatus
Bushing
Step 10.
Check dimensions
Check length from end of compression connector to top
of cable adapter.
Lubricate
Cable Adapter
Tape Marker
Concentric Neutral Wires
"E"
See Table 1
Cable Adapter
Tape Marker
Concentric Neutral
Wires
600 A 15/25 kV class BOL-T and separable splice connector assembly installation instructions for S600-10-2 July 2014 www.cooperpower.com
Step 2.
Equipment provided
T-body
Cable Adapter
Insulating Plug with Cap
Compression Connector with 11/16" unthreaded spade
Silicone Lubricant
Threaded Stud
Instruction Sheets
Tools required
Cable preparation
Step 1
1.75" .25"
(45 mm 7 mm)
Train cable
Cable
12.75" .25"
(324 mm 7 mm)
Concentric Neutral
Wires
1.75" .25"
(45 mm 7 mm)
Existing
Bushing
Cable
Step 4.
Put tape marker in place
Measure 1" (25 mm) from end of insulation shield. (Refer
to Figure 16.)
Tape Marker
Insulation Shield
Insulation
1"
(25 mm)
9.75"
(248 mm 3 mm)
600 A 15/25 kV class BOL-T and separable splice connector assembly installation instructions S600-10-2 July 2014 www.cooperpower.com
Step 5.
Step 7.
Clean insulation
NNote: Do not apply solvent directly to cable.
4.38" .13"
(111 mm 3 mm)
Tape Marker
Insulation
Wipe Insulation
Bare Conductor
Step 6.
Bevel insulation
Remove sharp edge of insulation by beveling at a 45
angle for approximately .25" (6 mm). (Refer to Figure 18.)
Wiping Direction
Step 8.
Lubricate and install cable adapter
Lubricate exposed cable insulation.
Bevel
.25"
(6 mm)
Insulation
Lubricate Insulation
Tape Marker
Lubricate
WARNING
Equipment Damage/Personal Injury. Improperly
positioned cable adapter may result in equipment
damage or personal injury.
600 A 15/25 kV class BOL-T and separable splice connector assembly installation instructions for S600-10-2 July 2014 www.cooperpower.com
Step 9.
Not Straight
Straight
Cable
Insulation
Major OD
flared out
bulge
Not Straight
Straight
Cable
Insulation
Shield
Tape
Marker
Correct Positioning
Incorrect Positioning
Tool
Shoulder
Crimping
Area
Cable
Adapter
600 A 15/25 kV class BOL-T and separable splice connector assembly installation instructions S600-10-2 July 2014 www.cooperpower.com
Step 10.
Check dimensions
Check length from end of com
pression connector to top
of cable adapter.
Step 11.
Compression
Connector
Cable
Adapter
Tape
Marker
600 A Interfaces
Concentric
Neutral Wires
Test Point on
Accessible
Side
T-body
Apparatus
Bushing
Lubricate
Cable Adapter
Tape Marker
Concentric Neutral Wires
10
600 A 15/25 kV class BOL-T and separable splice connector assembly installation instructions for S600-10-2 July 2014 www.cooperpower.com
Step 12.
Step 13.
Apparatus
Bushing
T-body
Apparatus Bushing
Concentric Neutral
Wires
1/2" CROWSFOOT
WRENCH
600 A 15/25 kV class BOL-T and separable splice connector assembly installation instructions S600-10-2 July 2014 www.cooperpower.com
11
Step 14.
Step 15.
If tight:
If loose:
T-body
Apparatus
Bushing
Insulating Plug
Re-torque to 55 ft-lbs.
Remove insulating plug and T-body from apparatus
bushing.
Inspect threads of the stud and insulating plug for
damage.
If damaged, replace damaged component and re-install
per previous installation instructions.
If no damage is found, re-install per previous
installation instructions.
Step 16.
Cap the insulating plug
Clean and lubricate inner surface of insulating plug cap
with lubricant supplied.
Concentric Neutral
Wires
1" Socket
Apparatus
Bushing
Complete
Threading
Concentric Neutral
Wires
Torque Wrench
Concentric Neutral
Wires
12
600 A 15/25 kV class BOL-T and separable splice connector assembly installation instructions for S600-10-2 July 2014 www.cooperpower.com
Step 17.
Ground system
Connect one concentric neutral wire to drain wire tab of
the T-body or use a separate uninsulated copper wire
(#14 AWG/2.5 mm). Refer to Figure 30.
T-body
Drain
Wire Tab
Uninsulated
Drain Wire
Concentric Neutral
Wires
Connecting
Plug
1
Socket
Wrench
600 A 15/25 kV class BOL-T and separable splice connector assembly installation instructions S600-10-2 July 2014 www.cooperpower.com
13
Insulating Plug
Connecting Plug
1" Wrench
Connecting Plug
5/16" Hex
Shaft
Connecting Plug
Socket
Wrench
Push the caps onto the insulating plugs until they snap
into place.
Connect one drain wire to the tie-off tab of each T-body
and connect the other end to a common ground point.
Drain
Wire
Drain
Wire
Torque
Wrench
Insulating
Insulating Plug Connecting Plug Plug
Drain
Wire
Torque
Wrench
Drain
Wire
14
600 A 15/25 kV class BOL-T and separable splice connector assembly installation instructions for S600-10-2 July 2014 www.cooperpower.com
600 A 15/25 kV class BOL-T and separable splice connector assembly installation instructions S600-10-2 July 2014 www.cooperpower.com
15
SAFETY
FOR LIFE
Eaton
1000 Eaton Boulevard
Cleveland, OH 44122
United States
Eaton.com
Eatons Cooper Power Systems
Business
2300 Badger Drive
Waukesha, WI 53188
United states
Cooperpower.com
2014 Eaton
All Rights Reserved
Printed in USA
Publication No. S600102 Rev 1
(Replaces S600102 Rev 0)