DE400 Deadbreak

Elbow Connector
Electrical Apparatus

IS550-20-1

DE400 Elbow Connector

Installation Instructions

DE400
400A
24 kV

Complete connector kit includes:

1 moulded elbow connector, with test point cap
1 cable adapter
1 probe contact
1 hex key
1 bimetallic conductor contact
1 bail assembly
1 SB400 cable screen adapter
vinyl tape
sealing (mastic) tape
silicone lubricant
paper towel
installation instructions

CAUTION: All associated apparatus must be de-energized during

installation and/or maintenance.

Step 1
MASTIC TAPE
435 mm

vinyl Tape

10 mm
Insulation Screen

100 mm

1. Train the cable to the desired finished position. Be sure that the cable is long enough to permit
movement of the elbow connector from the apparatus bushing to a standoff bushing.
2. Cut the cable 100 mm past the bushing centerline. Initially, cut the cable 100 mm past the
bushing centerline.
NOTE: This is the initial length of the cable to ensure that the screen wires are long enough to
reach the system earthing point and the earthing eye on the elbow connector. The cable
will be cut to its final length below.
3. Remove 435 mm of the cable sheath.
4. Apply one wrap of mastic tape 10 mm from the end of the sheath.
5. Fold the screen wires back over the sheath and secure them with two wraps of vinyl tape. Press
the screen wires into the mastic tape.

July 1999 New Issue

DE400 Elbow Connector Installation Instructions

SAFETY
FOR LIFE

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

thoroughly familiar with these instructions.

n Is

trained in industry-accepted high- and low-voltage

safe operating practices and procedures.

n Is

trained and authorized to energize, de-energize,

clear, and ground power distribution equipment.

n Is

trained in the care and use of protective equipment

such as flash clothing, safety glasses, face shield, hard
hat, rubber gloves, 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.

Hazard Statement Definitions

This manual may contain four types of hazard
statements:

DANGER:

Indicates a hazardous situation which, if not

avoided, 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 not

avoided, could result in minor or moderate injury.
Caution: Indicates a hazardous situation which, if
not avoided, could result in equipment damage only.

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:

Hazardous voltage. Contact with high voltage will

cause death or severe personal injury. Follow all
locally approved safety procedures when working
around high- and low-voltage lines and equipment.

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.

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 may result in death,
severe personal injury and equipment damage.

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.

IS550-20-1
Step 2
225

MASTIC TAPE

vinyl Tape

77

Insulation

Conductor

25

1. Reposition the cable to its final position and cut it 25 mm from the centerline of the apparatus
bushing.
2. Remove 225 mm of the insulation screen.
3. Remove 77 mm of core insulation.
Step 3

MASTIC TAPE

1. Apply a layer of mastic tape over the screen wires and the previously applied mastic tape. Press
firmly to eliminate gaps between the tape and the screen wires.
2. Apply another layer of mastic tape over the junction of the insulation screen, the screen wires
and the previously applied mastic. Press firmly to eliminate gaps.
Step 4

vinyl Tape

1. Wrap one half-lapped layer of vinyl tape over the mastic tape, starting at the conductor end of
the mastic.
Step 5
TABS

85 mm

1. Slide the small diameter end of the sealing boot over the vinyl tape. Fold the large diameter end
over.
2. Thoroughly clean the core insulation, using a suitable cleaner and a lint free cloth.
3. Apply a thin layer of lubricant to the core insulation and the inside diameter of the cable adapter.
4. Slide the cable adapter onto the cable, black end first, until the grey end is 85 mm from the end
of the cable.
3

DE400 Elbow Connector Installation Instructions

Step 6

4 3 2 1

1. If the conductor is aluminum, thoroughly wire brush the exposed conductor.

2. Immediately insert the conductor into the crimp barrel as far as it will go. Ensure that the flat of
the copper faces the bushing.
3. Crimp the connector starting at the shoulder. Rotate the crimping tool 90 degrees for each
successive crimp.
4. Remove any excess inhibitor that came out of the crimp connector.
Step 7
CLEAN AND LUBRICATE

DE400
400A
24 kV

1. Clean the cable adapter and the interior of the cable end of the elbow with a lint-free cloth.
Apply a thin layer of lubricant to both surfaces.
2. Push the elbow connector over the cable adapter. Ensure that the threaded hole of the crimp
connector is visible through the interface end of the elbow.
Step 8

DE400
400A
24 kV

1. Insert the probe into the threaded hole of the connector, taking care to avoid cross-threading.
2. Tighten the probe with the hex key. The proper torque is reached when the hex key has bent
90 to 180 degrees.
3. Grasp the two tabs of the folded-over cable screen adapter and pull them over the bottom of
the elbow.
4. Connect two of the screen wires to the earthing eye of the elbow.
4

IS550-20-1
Step 9

DE400
400A
24 kV

CLEAN AND LUBRICATE

1. Clean the bushing interface and the connector interface and apply a thin layer of lubricant to
each.
2. Push the elbow connector onto the bushing.
Step 10

1. Hook the legs of the bail assembly into the bushing bail tabs.
2. Position the bail over the pulling eye of the elbow and turn the eye of the bail clockwise until it is
tight.

DE400 Elbow Connector Installation Instructions

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IS550-20-1

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DE400 Elbow Connector Installation Instructions

2009 Cooper Industries. All Rights Reserved.

Cooper Power Systems is a valuable trademark of Cooper Industries in
the U.S. and other countries. You are not permitted to use the Cooper
Trademarks without the prior written consent of Cooper Industries.
IS550201 Rev 00 (Replaces 50000050846 Rev 00)
8

2300 Badger Drive

Waukesha, WI 53188
www.cooperpower.com