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IS---168/274FLR
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Installation and Operating Instructions: 168FLR or 274FLR
Loadbreak Fused Elbow Connector
CONTENTS: Cable Half Housing, Elbow Half Housing, Fuse, Compression Lug, Probe, Probe Connector, Hose Clamp,
The 168FLR and 274FLR are designed to provide an in line full range current limiting fuse while terminating UD cable having
concentric neutral and extruded insulation shielding. When other types of UD cable are to be terminated, an appropriate
Elastimold cable shield or grounding device must be used.
The 168FLR 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 rating of 10,000 amperes RMS
symmetrical.
The 274FLR elbow provides an operating interface for connecting to an Elastimold 25kV class (15.2kV phase--to--ground and
26.3kV phase--to--phase) 200 ampere loadbreak bushing or accessory device with fault close rating of 10,000 amperes RMS
symmetrical. The 274FLR elbow provides an operating interface for connecting to an Elastimold 25kV class (15.2kV
phase--to--ground and 26.3kV phase--to--phase) 200 ampere loadbreak bushing or accessory device with fault close rating of
10,000 amperes RMS symmetrical.
All apparatusmust be de--energized during installation
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.
Failuretofollowtheseinstructionswill resultin 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 intendedas a substituteforadequatetrainingor
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 P ARTS, INSTALLATION RATINGS AND COMP ATIBILITY, CALL THE NEAREST ABB OFFICE.
Limited Warranty:
1. ABB Installation Products Inc. warrants that its products will be free from defects in materials or workmanship for a period of two (2) years, except for tools
which are warranted separately (see warranty accompanying those products). Fisher PierceRproducts and ElastimoldRReclosers are warranted for three
years; and Joslynt VBT and VBU 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. In no event shall ABB Installation Products Inc. be liable for any consequential, indirect or special damages, nor will ABB Installation Products Inc. be liable
for transportation, labor, or other charges arising out of the 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,
INCLUDING BUT NOT LIMITEDTO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, WHICH ARE
SPECIFICALLY DISCLAIMED.
Probe Wrench, Allen Wrench, Lubricant, Installation/Operating Instructions.
DANGER
If this product is supplied with a protective shipping
cover(s), removethis shipping cover(s)andreplacewith
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 package to ensure they are complete
and undamaged.
2. Check all components to ensure proper fit with cable
and/or mating products.
3. Check threads by 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, V2 voltage detector
or test point fault indicator and assemble tightly.
IS--0926
IS--168/274FLR
Date: March 2019
Printed inU.S.A.
860 Ridge Lake Blvd, Memphis, Tennessee 38120
(800) 888--0211
Cable Half Housing
Test Point
Compression Lug
ASSEMBLED ELBOW
Hose Clamp
Fuse
Probe Connector
Elbow Half Housing
Test Point
Operating Eye
Probe
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End of Cable
1--1/8”
Cable Cut Back Diagram (Not to Scale)
STEP 1 Cable Training
1. Using the bushing centerline as reference,
cut excess cable off 20” minimum beyond
bushing.
2. Slide optional 200ECS Cold Shrink Cable
Seal onto cable.
3. Remove the jacket from the excess cable
length remaining AND the distance of
“A” (as defined) + 7--3/8” from the bushing
centerline.
4. If a Cable Seal kit is used, follow the
instructions provided. Otherwise, unwrap
and fold the Concentric Neutral wires
back over the jacket, and bind.
5. Using the bushing centerline as reference,
squarely cut off the cable a distance
of “A”, leaving 7--3/8” minimum of cable
to terminate. Distance “A” represents
the length of the fuse body.
STEP 2 Cable Preparation
5--1/2”
(Cable Cut Back Diagram located in the
left margin is NOT to scale and is provided
for reference only.)
1. Cut 1--1/8” from the cable end. Cut
squarely taking care not to nick conductor.
2. Wire brush bare aluminum conductors
and immediately install compression lug.
Rotate to spread inhibitor. Crimp the
7--3/8”
unthreaded end of the compression lug
to the conductor (refer to crimp chart
packaged with the compression lug for
recommended crimp tool information.)
Start crimp at the crimp line mark. Rotate
180_ each successive crimp. Carefully
wipe excess inhibitor from the outside
of the lug and cable.
3. Remove insulation shield 5--1/2” from
end of lug. Bevel insulation end
1/8” max.
4. Thoroughly clean insulation to remove
all traces of conductive residue.
Excess Cable
Bushing
Concentric Neutral
20”min + ”A”+ 7 --- 3 / 8”
Insulation Shield
Jac ket
Concentric Neutral Wire
Bind
Insulation Shield
20” Min
Excess Cable
”A”
7---3/8” Min.
Insulation Shield
1---1/8”
Cable
Insulation
= 11---1/2”for FLR --- 1
15---3/4”for FLR --- 3
7 --- 3/ 8”
End ofJacket
Conductor
5---1/2”
1/8” Max Bevel
STEP3
Apply lubricant to the outside of the connector, cable insulation and conductive shield, and the cable half of the
Fused Elbow cable entrance end. (Use lubricant supplied. DO NOT SUBSTITUTE). Insert connector and cable
intothecable half oftheFusedElbowuntil thetopend oftheconnecter protrudes beyond surface “A”. The purpose
of this is to allow the fuse to be tightened before bottoming on the rubber.
Fused Elbow -- Cable Half
Apply
Silicone
Surface “A”
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STEP 4
Insert the threaded terminal end of the fuse into the cable half
of the Fused Elbow and thread it into the cable connector.
HAND TIGHTEN. CAUTION: Fuse stud will fracture if over
torqued. Pull the housing up against the bottom of the
tightened fuse.
Fuse
Pull up against T ightened Fuse
STEP 6
1. Apply lubricant to the elbow half of the fused
elbow and assemble it to the cable half of the fused
elbow. The cuff of the cable half will overlap the
elbow half by 3/4”. Make sure that the probe connector
faces the opening of the fused elbow half. The two
test points should be in line with each other.
2. Insert the probe into the probe connector. It may
be necessary to push on the cable to get the probe
to line up with the fuse. Start the threads by hand,
taking care, not to cross thread the probe. T o tighten
use the special torque limiting allen wrench supplied.
Insert the short end of the wrench into the hole
in the probe; tighten until the wrench bends and
remains bent.
3. Position hose clamp as shown and tighten.
DO NOT OVERTIGHTEN.
STEP 5
Assemble the probe connector to the fuse terminal.
Rotate the probe connector so that the flats are
perpendicular to the bushing with which it will mate.
Lock the probe connecter in position. Tighten the setscrews
using the special torque limiting allen wrench supplied
in the fuse kit. Rotate the cable half of the Fused
Elbow so that the test point is perpendicular to the
flats on the probe connector.
Test Point
Push Cable to Align
Probe w/Fuse
Apply
Grease
Fuse
Probe Connector
Hose
Clamp
Set Screw
Flat
3/4” Overlap
Pr obe
STEP 7 Concentric Neutral Connection
1. Using a separate copper wire (No. 14 AWG / 2.5mm)
or equivalent, insert one end through each grounding
eye on the elbow housing and cable housings. Twist
tightly taking care not to damage eye.
2. Finish installing 200ECS jacket seal if used.
3. Twist all neutral wires, exercise care to not damage
grounding eyes and connect to ground using appropriate
connector. Provide adequate slack in wires for elbow
operation.
Grounding
Eyes
R
Provide Slack
For Operation
STEP 8 ConnectElbowand Bushing Plug
1. 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.
2. Operate per following instructions. DO NOT OPERATE
BY HAND.
Lubri cate only if known to be de---energized
Hotstick
R
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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 area 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
andforcerequiredtoengage or disengagethe elbow,certainoperatingpositionsare moreadvantageous thanothers. If thereis
some question as 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
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.
Check appropriate accessory device operating instructions to be sure that the device is rated for energized operation.
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 BUTIMMEDIATELY PUSH THE ELBOW HOME WITH A FAST,FIRM, STRAIGHT
MOTION. 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 closure is experienced, the elbow housing, the probe and the bushing insert 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 pullingforce, slightly rotate the connector clockwise in order tobreaksurface friction prior todisconnection.
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 168/274FLR
The ELASTIMOLD loadbreak fused elbow connector is equipped with two integral capacitance test points that can be used to
establishwhetheror notthefusehas interruptedthecircuit.For anopenfuse, thetestpoint onthe feedsidewillindicate avoltage
andthetestpoint onthe loadsidewillindicateno voltage.Ifthe fusehas notopened bothtest pointswill indicatea voltage.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 VOLT AGE 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,todetermineif cable isenergized. Contamination, moisture, dirt, etc.
aroundthetest pointor use ofthe wrongmeasuring equipmentcanprovidea false “no voltage” indication onan energized
elbow. Toprevent serious or fatal injury treat the elbow as energized until the “no voltage” test point indication is confirmed by
other means.
3. Aftervoltagedetection hasbeenmade, cleanandlubricatethe insidesurfaceof thecap withlubricantsuppliedandreplace
it on the test point.
REPLACING CLEARED FUSE
DANGER: DO NOT ATTEMPT TOREPLACE THEFUSE IF THE FUSED ELBOW IS ENERGIZED, THIS WILL RESULT
IN SERIOUS OR FATAL INJURY.
1. With the de--energized elbow removed from the bushing use the torque limiting wrench to remove the probe.
2. Loosen the hose clamp on the body of the elbow.
3. Insert a vent stick between the Fused Elbow cable half and probe half to aid separation of the halves.
4. Remove the probe connector from the fuse by loosening the allen setscrew.
5. Unscrew by hand the cleared fuse from the cable half.
6. Install new fuse as shown in STEPS 4--6 of this instruction sheet.
E 2019 ABB Installation Products Inc. All rights reserved.
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