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IS---0417
IS---167/168RLR
March 2010
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Installation & Operating Instructions
167RLR (without Test Point)
168RLR (with Test Point)
Loadbreak Replacement Elbow Connectors
CONTENTS: Replacement Elbow Connector Housing, Compression Lug, Probe, Probe Wrench, Lubricant, (Do Not
Substitute), Hose Clamp, Installation/Operating Instructions.
The 167RLR (without Test Point)168RLR (with Test Point) is designed to convert a livefront termination to deadfront for UD cable
having concentric neutral and extruded insulation shielding. The elbow provides an operating interface for connecting to an
Elastimold 15kV class (8.3kV phase--to--ground and 14.4kV phase--to--phase) 200 ampere loadbreak bushing or accessory
device with fault close ratings of 10,000 amperes RMS, symmetrical. When other types of UD cable are to be terminated an
appropriate Elastimold cable shield or grounding device must be used.
DANGER
All apparatus must be de--energized during installation
or removal of part(s) except for test point caps and
indicators that can be installed and operated energized.
After installation loadbreak products can be operated
energized per operating instructions. All deadbreak
connectors must be de--energized before operating.
All apparatus must be installed and operated in
accordance with individual user, local, and national work
rules. These instructions do not attempt to provide for
every possible contingency.
Do not touch or move energized products.
“Loadbreak connectors must be operated with a full
insulated “hotstick” type live--line tool.” Consult the
company’s safe work practices for the required live--line
tool length.
FOR MORE INFORMATION ON PARTS, INSTALLATION RATINGS AND COMPATIBILITY, CALL THE NEAREST ELASTIMOLD OFFICE.
Excess distortion of the assembled product may result in
its failure.
Inspect parts for damage, rating and compatibility with
mating parts.
This product should be installed only by competent
personnel trained in good safety practices involving
high voltage electrical equipment. These instructions
are not intended as a substitute for adequate training or
experience in such safety practices.
Failure to follow these instructions will result in damage
to the product and serious or fatal injury.
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.
IMPORTANT
1. Check contents of package to ensure they are complete
and undamaged.
2. Check all components to ensure proper fit with cable
and/or mating products.
3. Check threadsby threading probe into compression lug. If
resistance is encountered prior to full assembly, check for
damage and replace damaged component.
4. Read entire installation instructions before starting.
5. Have all required tools at hand and maintain cleanliness
throughout the procedure.
CAUTION: Lubricate test point cap and assemble tightly.
IS---0417
IS---167/168RLR
March 2010
Printed in U.S.A.
8155 T&B Boulevard, Memphis, Tennessee 38125
(800) 888--0211 Fax: (800) 888-- 0690
Operating
Eye
Probe
Test Point
(168RLR ONLY)
Compression
Lug
Hose Clamp
ASSEMBLED ELBOW
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March 2010
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NEW INSTALLATION OF REPLACEMENT ELBOW HOUSING AND COMPRESSION LUG
DANGER: All apparatus must be de--energized during installation or removal of part(s).
STEP 1 LIVEFRONT REMOVAL
A. Remove the rubber cap from the terminator.
B. Cut off connector at the top of the terminator.
C. Disconnect ground lead from the base of the terminator.
D. Remove the terminator housing from the cable.
Bushing Centerline
Remove Cap
Cut and Remove
Connector
Remove Terminator
Disconnect
Ground Lead
STEP 2 CABLE PREPARATION
A. Train cables to be straight and in--line with bushing centerline.
B. The end of the cable MUST measure 10--1/2” from the bushing centerline. Cut the cable to 10--1/2”.
CHECK DISTANCE FROM END OF CUT CABLE TO INSULATION SHIELD.
1. If the insulation shield measures less than 6--1/2” continue to “C”. Insulation shield will be cut in STEP 3.
2. If the insulation shield is greater than 6--1/2”, consult your nearest ELASTIMOLD representative.
C. Remove cable insulation 1--3/8” from end of cable. Cut squarely. DO NOT NICK THE CONDUCTOR.
Bushing
Centerline
Cable
In--- Line
with
Bushing Centerline
Insulation
24”
10---1/2”
1---3/8”
Check for
6---1/2”
Insulation Shield
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IS---0417
March 2010
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STEP 3
Wire brush bare aluminum conductor and immediately 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 with compression lug for
recommendedcrimp information) Start crimp at the crimp line mark. Rotate 1800each successivecrimp. Carefullywipe excessive
inhibitor from the outside of the lug and cable.
17”
Align Lug Threaded
Hole to Bushing Bore
Insulation
Insulation Shield
STEP 4 ELBOW ASSEMBLY
A. Lubricate the cable insulation and inside the elbow
housing with the lubricant supplied. DO NOT
SUBSTITUTE. Other lubricants may be harmful to this
product or its mating product(s). Keep insulation clean of
dirt and grime. Do not use excess grease and do not
introduce any grease into the gap between the lug and the
insulation.
B. Slide the elbow connector onto the cable with a back and
forth twisting motion. Wipe off all excess grease.
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 becoming snug. Tighten with wrench until
wrench bends.
Start Crimp Here
Bushing
Twist
Align
Lubricate
Wrench Hole
Probe
STEP 5 CONCENTRIC NEUTRAL CONNECTION
A. Using a separate copper wire (No. 14 AWG / 2.5mm) or
equivalent, insert one end through the grounding eye on
the elbow. Twist tight taking care not to damage the eye.
B. Twist all neutral wires and connect to ground using
appropriate connector. Provide adequate slack in wires
for elbow operation.
C. Add hose clamp as shown. Tighten snugly. Do Not
overtighten.
Wrench
Provide Slack
for Operation
Grounding
Eye
Hose
Clamp
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March 2010
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STEP 6 CONNECT ELBOW AND BUSHING PLUG
A. Lubricate the receptacle portion of the elbow connector
and the mating bushing with the lubricant supplied.
LUBRICATE ONLY IF THE TRANSFORMER AND
ELBOW ARE KNOWN TO BE DE--ENERGIZED.
B. Operate per following instructions. DO NOT OPERATE
BY HAND.
Lubricate only if known to be de ---energized
Hotstick
OPERATING INSTRUCTIONS
Before Loadmake or Loadbreak Operation:
Loadbreak connectors must be operated with a full insulated “hotstick” type live--line tool. Consult the company’s safe work
practices for the required live--line tool length.
Area must be clear of obstructions or contaminants that would interfere with the operation of the connector. This position should allow
you to establish firm footing and enable you to grasp the hotstick tool securely, maintaining 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 the elbow, certain operating positions are more advantageous than others. If there is some questionas to proper
operating position, it is recommended that the connectors be operated de--energized. Do not connect two different 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
Check appropriate accessory device operating instructions to be sure that the device is rated for energized operation.
1. Area must be clear of obstructions or contaminants that would interfere with the operation of the connector.
2. In preparing 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.
3. Securely fasten a hotstick to the loadbreak connector pulling eye.
4. After establishing firm footing and positive control of the elbow connector, withdraw the elbow from the accessory device
on the apparatus parking stand with a fast, straight, firm motion being careful not to place the elbow connector near a
ground plane.
5. Place the elbow connector receptacle area over the bushing plug, inserting the elbow male contact (arc follower portion)
into the bushing until the first slight resistance is felt. Resistance is felt when the arc follower portion of the male contact first
meets the female contact of the bushing (at this point the contacts are approximately 2” apart).
DO NOT HOLD IN THIS POSITION BUT IMMEDIATELY PUSH THE ELBOW HOME WITH A FAST, FIRM, STRAIGHT
MOTION, which will engage the internal lock on the elbow and bushing interface.
Apply sufficient force to engage the internal lock on the elbow connector and bushing interface.
Fault Close
1. It is not recommended that operations be made 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. Be certain it is rated for energized operation.
2. Firmly tighten a hotstick to the loadbreak connector pulling eye.
3. Without exerting any pulling force, slightly rotate the connector clockwise in order to break surface friction prior to
disconnection.
4. Withdraw the connector from the bushing with a fast, firm, straight motion, being careful not to place the connector near a
ground plane.
5. Place connector on appropriate accessory device, following the operating instructions for that accessory.
VOLTAGE TEST ON 168RLR
ELASTIMOLD connectors equipped with an integral capacitance test point can be used to establish whether or not the circuit is
energized. When using the test point, complete the following steps:
1. Remove test point cap with a hotstick. When removing cap, PEEL OFF AT AN ANGLE rather than pulling directly in line
with the test point assembly.
2. WARNING: THE VOLTAGE TEST POINT IS A CAPACITANCE DEVICE, IT IS NOT DIRECTLY CONNECTED TO
THE CONDUCTOR. Do not use conventional voltage measuring equipment. Follow the manufacturer’s directions for the
meter that is used. Test with a suitable sensing device, made for use with separable connectors manufactured with
capacitive test points, to determine if cable is energized. Contamination, moisture, dirt, etc. around the test point or use
of the wrong measuring equipment can provide a false “no voltage” indication on an energized 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 has been made, clean and lubricate the inside surface of the cap with silicone grease and
replace it on the test point.
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