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IS--1378
IS--161/162LR
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Installation & Operating Instructions
161LR (without test point) & 162LR (with test point)
Loadbreak Elbow Connectors
CONTENTS: Elbow Connector Housing, Compression Lug, Probe, Probe Wrench, Lubricant (Do Not Substitute),
The161LR(without testpoint)and162LR(with testpoint) are designed toterminate various UDcables.Theelbow providesan
operating interface for connecting to anElastimoldR 15kV class (8.3kV phase--to--ground and 14.4kV phase--to--phase) 200
ampereloadbreakbushingor accessorydevicewith fault closeratingof10,000amperes RMS symmetrical. Whenothertypes
of UD cable are to be terminated, an appropriate ElastimoldR cable shield or grounding devices must be used.
Allapparatusmustbede--energized duringinstallation
or removal of part(s) except for test point caps and
indicators that can be installed and operated
energized.
Do not touch or move energized products in the work
area.
These instructions do not attempt to provide for every
possible contingency.
Failure to follow these instructions will result in
damage to the product and serious or fatal injury.
This product should be installed only by competent
personnel trained in good safety practices involving
high voltage electrical equipment. These instructions
arenot intendedasasubstituteforadequatetrainingor
experience in such safety practices.
All apparatus must be installed and operated in accordance with individual user, local and national work
rules and electrical standards.
FOR MORE INFORMATION ON PARTS, INSTALLATI ON RATINGS AND COMPATIBILITY, CALL THE NEAREST ABB OFFICE.
Limited Warranty:
1. ABB Installation Products Inc. warrants that its products will be free from defects in materials orworkmanship for a periodof two (2) years, except fortools
which arewarrantedseparately (see warranty accompanying those products). Fisher PierceRproductsandElastimoldRReclosers are warranted forthree
years; andJoslynt VBT andVBU capacitor switches are warranted for four years or 40,000 operations whichever occurs first. Upon prompt notification
of a warranted defect, ABB Installation Products Inc. will, at its option, repair or replace the defective product.
2. Innoeventshall ABB Installation Products Inc. be liable for any consequential, indirect or specialdamages, nor will ABB Installation Products Inc. be liable
for transportation, labor,or other charges arising out ofthe removal or reinstallation of its products. Liability for breach of warranty is limited to the cost of
repair or replacement of the warranted product only.
3. Misuse, misapplication or modification of ABB Installation Products Inc. products immediately voids all warranties.
THE WARRANTIES AND REMEDIES CONTAINED HEREIN ARE EXCLUSIVE AND ARE IN LIEU OF ALL OTHER WARRANTIES AND REMEDIES,
INCLUDINGBUT NOT LIMITEDTOANY IMPLIED WARRANTIESOF MERCHANTABILITY AND FITNESS FOR A PARTICULARPURPOSE, WHICH ARE
SPECIFICALLY DISCLAIMED.
Installation/Operating Instructions.
DANGER
If this product is supplied with a protective shipping
cover(s), remove this shipping cover(s) and replace
with the appropriate HV insulated cap(s) or
connector(s) before submerging or energizing the
circuit.
Inspect parts for damage, rating and compatibility with
mating parts.
Excess distortion of the assembled product may result
in its failure.
After installation loadbreak products can be operated
energized per operating instructions. All deadbreak
connectors must be de--energized before operating.
Connectors must be operated with a full insulated
“hotstick” type tool. Consult the company’s safe work
practices for the required tool length.
IMPORTANT
1. Check contents of packageto ensurethey are complete
and undamaged.
2. Check all components to ensure proper fit with cable
and/or mating products.
3. Check threadsby threadingprobeintocompressionlug.
If resistance is encounteredprior to fullassembly,check
for damage and replace damaged component.
4. Read entire installation instructions before starting.
5. Have allrequiredtools athandand maintain cleanliness
throughout the procedure.
IS---1378
IS---161/162LR
Date:March 2019
Printed in U.S.A.
860 Ridge Lake Blvd, Memphis, Tennessee 38120
(800) 888--0211
Pr obe
Compression
Lug
ASSEMBLED ELBOW
Operating
Eye
Test Point
162LR Only
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STEP 1 CABLE TRAINING AND PREPARATION
A. NON JACKETED CONCENTRIC NEUTRAL CABLE
1. Train cable to ensure slack for ease of operation.
2. To facilitate connection of the neutral to the tank ground
and hotstick operation, an extra length of concentric
neutral wiresor groundingbraid wireis requiredpursuant
to one of the following methods:
1. pull extra cable 24” to 36” (610--914 mm) beyond the
centerline of the bushing and bind the neutrals 7--3/4” to
8” (195 to 203mm) further back from the bushing center;
or 2. connect theneutral wiresto thetank groundusing a
jumper or braid.
3. Unwrap the neutral wire to the binding.
4. Cut excess cable squarely at the centerline of the bushing.
5. Go to Step 2 to complete the installation.
B. JACKETED CONCENTRIC NEUTRAL CABLE
1. Train cable to ensure slack for ease of operation.
2. To facilitate connection of the neutral to the tank ground
and hotstick operation, an extra length of concentric
neutral wiresor groundingbraid wireis requiredpursuant
to one of the following methods:
1. pull extra cable 24” to 36” (610--914 mm) beyond the
centerline of the bushing and place a tape mark at the
centerline of the bushing. Then remove outer jacket
9--5/8” (240mm) further back from the tape mark; or 2.
connect the neutral wires to the tank ground using a
jumper or braid.
3. Unwrap the neutral wire back past the bushing centerline.
4. Cut excess cable squarely at the centerline of the bushing.
5. If using a 200ECS sealing kit, slide the cold shrink tube onto the cable loose end first.
6. Go to Step 2 to complete the installation.
Bind Wires
Insulation Shield
Jacket
T ape covering wire ends
Insulation Shield
Cold Shrink Tube
Extra lengthofwi res
24”to36”
(610 t o914mm)
7- - -3/4” to 8”
(195 to 203mm)
Bushing Centerline
24” to 36”
(610---914mm)
9- - -5/8”
(240mm)
Bushing Centerline
C. JACKETED CABLE WITH DRAIN WIRES
1. Cut the cable squarely at the centerline of the bushing.
2. Remove 9--5/8” (240mm) of the outer jacket.
Jacket
T ape covering wire ends
9- - -5/8”
(240mm)
3. Unwrap the ground wires, DO NOT CUT OFF , bind and
fold them back out of the way.Wrap a piece of vinyl tape
around the cable covering the wire ends.
Cold Shrink Tube
Insulation Shield
Bushing
Centerline
4. Ifusing a200ECS--G1 sealing kit, slide the cold shrink
tube onto the cable loose end first.
5. Go to Step 2 to complete the installation.
D. JACKETED COPPER TAPE SHIELD CABLE
1. Cut the cable squarely at the centerline of the bushing.
2. Remove 9--5/8” (240mm) of the outer jacket.
3. Remove 7--1/8” (180mm) of the copper tape shield.
7- - -1/8”
(180mm)Copper T ape
Jacket
9- - -5/8”
(240mm)
4. Wrap conductive copper tape, included with the 200ECS- -G2 or G3 kit, over the end of the copper shield to hold it in place.
5. If using a 200ECS--G2 or G3 kit, slide the cold shrink tube onto the cable, loose end first.
Wr ap copper tape, inc lu ded wi th
the ECS-- -G2 or G3 sealing kit
Cold Shrink Tube
Insulation Shield
Bushing Centerline
6. Go to Step 2 to complete the installation.
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STEP 2 CABLE PREPARATION
(Cable Cut Back Diagram located in the left margin is NOT to scale and is provided for reference only.)
A. Remove the shield and insulation 2--1/8” (55mm) from the cable end. Cut squarely taking care not to nick
conductor.
2---1/8”
2- --1/8” (55mm)
CABLE CUT BACK DIAGRAM (NOT TO SCALE)
B. Wire brush bare aluminum conductors andimmediately install compression lug. Rotate to spread inhibitor.
Position compression lug so the CONTACT THREADED HOLE ALIGNS WITH THE BUSHING BORE.
(Refer to crimp chart packaged withcompression lug for recommended crimp toolinformation.) Start crimp
at the crimp line mark. Rotate 180_ each successive crimp. Carefully wipe excess inhibitor from the
outside of the lug and cable.
Start Crimp Here
(55mm)
6- --7/8”
Jackeketed Concentri c Neutral cable only
Align lug thread
to bushing bore.
(175mm)
See Step 1 for others
9- --5/8” (240mm)
C. Remove insulation shield as shown. Bevel insulation end 1/8” (5mm) max.
6---7/8” (175mm)
Insulation Shield
1/8”(5mm)
Max. Bevel
Straight,Smooth & Squared
Do not cut of nick insulation
D. Thoroughly clean insulation to remove all traces of dirt or excess inhibitor.
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STEP 3 ELBOW ASSEMBLY
A. Lubricate the cable insulation and inside the elbow
housing with the lubricant supplied. DO NOT
SUBSTITUTE. Other lubricantsmaybeharmful to this
product or its mating product(s). Keep insulation
clean of dirt and grime.
B. Slide the elbow connector onto the cable with a back
andforth twistingmotion. Wipe off allexcess lubricant.
C. Align elbow with compression lug’s threaded hole.
D. Thread probe into lug by hand, taking care not to
cross--thread. The probe must turn freely for
approximately four turns before becomi ng snug.
Tighten with wrench until wrench bends.
T wist
Align
Lubricate
Wrench Hole
Pr obe
Wrench
STEP 4 GROUNDING
Insert one end of a separate copper wire (No. 14 AWG /
2.5mm) or equivalent through the grounding eye on the
elbow. Twisttightly takingcare not todamagethe eye. Ifthe
elbowis preorderedwithground wire,continueto concentric
neutral connection section.
CONCENTRIC NEUTRAL CONNECTION
Twist all neutral wires and connect to ground using
appropriate connector. Provide adequate slack in wires for
elbow operation.
IF USING A COLD SHRINK GROUNDING KIT
Refer to the instructions supplied with the grounding kit to
complete the installation.
STEP 5 CONNECT ELBOW AND BUSHING PLUG
A. CONFIRM THAT TRANSFORMER AND ELBOW ARE DE--ENERGIZED.
B. Lubricate the receptacle portion of the elbow connector and the mating bushing with the lubricant supplied.
C. Operate per following instructions. DO NOT OPERATE BY HAND.
Grounding Eye
Ground Wire
Provide slack
for operation
Lubri cate only if known to be de---energized
Hotstick
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OPERATING INSTRUCTIONS
Before Loadmake or Loadbreak Operation:
Ensureconnector is cleanandfreeof anycontaminants. Ensureworkarea is clearofobstructionsto allow installerto establish
firm footing and ensure a secure grasp on the hotstick tool. Maintain positive control over the movement of the loadbreak
connector before, during and directly after the operating sequence. Because of the control, speed and force required to
engage or disengage theelbow, certain operating positions are more advantageous than others. If there issome questionas
to proper operating position, it isrecommended thatthe connectors be operated de--energized. Donot connect twodifferent
phases of a multiple--phase system. Before closing a single--phase loop, make certain both ends of the loop are the same
phase.
LOADMAKE OPERATION
Loadbreak connectors must be operated with a full insulated ”hotstick” type live--line tool. Consult the
Utility’s safe work practices for the required live--line tool length.
1. To prepare bushing for elbow connector, remove insulated cap by attaching hotstick tool to the insulated cap pulling
eye, and following the instructions for this accessory, remove from bushing.
2. Securely fasten the hotstick to the loadbreak connector pulling eye.
3. Confirm positivecontrol ofthe elbow connector.Withdraw theelbowfrom theaccessory deviceontheapparatus parking
stand with a fast, straight, firm motion being careful not to place the elbow connector near a ground plane.
Check appropriate accessory device operating instructions to be sure that the device is rated for energized operation.
4. Insert the probe tip approximately 2” (50mm) into the bushing (at this point the contacts are approximately 4” apart).
DONOT HOLDINTHIS POSITION BUT IMMEDIATELYPUSH THE ELBOW HOME WITH A FAST, FIRM,STRAIGHT
MOTION.
Use sufficient force to engage the internal lock on the elbow connector and bushing interface.
Fault Close
1. DO NOT CONDUCT LOADMAKE OPERATIONS ON KNOWN FAULTS.
2. If a fault is experienced, both the elbow connector and the bushing must be replaced.
LOADBREAK OPERATION
1. Place desired accessory device on apparatus parking stand.
Refer to appropriate operating instructions for accessory device to be used. Confirm device is rated for energized operation.
2. Firmly tighten the hotstick to the loadbreak connector pulling eye.
3. Without exerting any pulling force, slightly rotate (clockwise) the connector in order to break surface friction prior
to disconnection.
4. Withdraw theconnector from the bushing with a fast, firm, straight motion, beingcareful not toplace the connector near
a ground plane.
5. Place connector on appropriate accessory device, following the operating instructions for that accessory.
VOLTAGE TEST
ELASTIMOLDR connectors equipped with an integral capacitance test point can be used to determine whether or not the
circuit is energized.
When using the test point, complete the following steps:
1. Removetest point cap withthehotstick. Whenremovingcap,PEEL OFFATAN ANGLEratherthanpullingdirectlyinline
with the test point assembly.
2. WARNING: THE VOLTAGE TEST POINT IS A CAPACITANCE DEVICE, IT IS NOT DIRECTLY CONNECTED TO
THECONDUCTOR. Donot useconventionalvoltagemeasuring equipment.Follow themanufacturer’s directionsfor the
meter that is used. Test with a suitable sensing device, made for use with separable connectors manufactured with
capacitivetest points,todetermine if cableisenergized.Contamination,moisture, dirt,etc. aroundthetest pointoruse of
the wrong measuring equipment can provide afalse “novoltage” indicationon anenergized elbow. To prevent serious or
fatal injury treat the elbow as energized until the “no voltage” test point indication is confirmed by other means.
3. After voltage detection hasbeen made, clean the inside surface of the cap and lubricate withsilicone lubricant supplied;
and replace it on the test point.
E 2019 ABB Installation Products Inc. All rights reserved.
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