ABB Installation Products 02500230 15-35kV 200 Amp, Loadbreak LR Long Bi-Metal Contact - Size Code 230 - #1…

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How to Install 252LR Deadbreak Elbow Connectors

This guide provides step-by-step instructions for installing Elastimold 252LR Deadbreak Elbow Connectors on UD cable with concentric neutral and semi-con shielding, connecting them to 25kV class deadbreak bushings or accessory devices.

Estimated time: 1h

1. De-energize Apparatus and Inspect Parts

   DANGER: All apparatus must be de-energized during installation or removal of parts. Do not touch or move energized products in the work area. Inspect all parts for damage, rating, and compatibility with mating parts. Ensure the elbow housing cable entrance size and compression lug size are appropriate for your cable.

2. Verify Package Contents and Test Probe Threading

   Check the contents of the package to ensure all components (Elbow Connector Housing, Compression Lug, Probe, Probe Contact, Wrench, Lubricant, Hold-down Bail, Installation Instructions) are complete and undamaged. Thread the probe into the compression lug by hand to check for damage; if resistance is encountered prior to full assembly, check for damage and replace the damaged component.

3. Install Test Point Cap (if not already installed)

   Caution: If the test point cap is not installed, lubricate the cap and the test point with the supplied lubricant and then install the cap securely.

4. Train Cable

   Train the UD cable as shown in the documentation to ease operation, ensuring a minimum of 20 inches (508.0mm) beyond the end of the cable pad mount transformer. Cut any excess cable squarely at the center line of the bushing.

5. Prepare Concentric Neutral Wires

   Unwrap and bind the concentric neutral wires 8-1/2 inches (216.0mm) back from the end of the cable. Use a cable cut back template for precise dimensional guidance.

6. Remove Shield and Insulation

   Remove the shield and insulation from the cable end, cutting squarely. Take extreme care not to nick the conductor or insulation. The insulation should be straight, smooth, and squared.

7. Install Compression Lug

   Wire brush bare aluminum conductors immediately. Install the compression lug, rotating it to spread the inhibitor. Position the compression lug so that the CONTACT THREADED HOLE ALIGNS WITH THE BUSHING BORE. Refer to the crimp chart packaged with the compression lug for recommended crimp tool information. Start crimping at the crimp line mark, rotating 180 degrees for each successive crimp. Carefully wipe excessive inhibitor from the outside of the lug and cable.

8. Remove Semi-con Shield and Bevel Insulation

   Remove the semi-con shield as shown in the cable cut back template (6-7/8 inches or 175.0mm from the end). Bevel the insulation end a maximum of 1/8 inch (3.2mm).

9. Clean Insulation

   Thoroughly clean the insulation to remove all traces of conductive residue. Maintain cleanliness throughout the procedure.

10. Lubricate Cable Insulation and Elbow Housing

    Clean and lubricate the cable insulation and the inside of 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.

11. Slide Elbow Connector onto Cable

    Slide the elbow connector onto the cable with a back and forth twisting motion. Wipe off all excess silicone lubricant from the exterior.

12. Align Elbow and Thread Probe

    Align the elbow with the compression lug’s threaded hole. Thread the probe into the lug by hand, taking care not to cross-thread. Lubricate the wrench hole on the probe. Tighten the probe with the supplied wrench until the wrench bends, indicating proper torque.

13. Assemble Hold-down Bail

    Place the hold-down bail in the hold-down bracket. Compress the bail and insert it securely into the brackets.

14. Connect Concentric Neutral Wires to Ground

    Using a separate No. 14 AWG (2.5mm) copper wire or equivalent, insert one end through the grounding eye on the elbow, twisting tightly without damaging the eye. Twist all neutral wires together and connect them to ground using an appropriate connector. Provide adequate slack in the wires for elbow operation.

15. Clean and Lubricate Mating Surfaces

    Clean the receptacle portion of the elbow connector and the mating bushing. Lubricate these surfaces with the lubricant supplied. LUBRICATE ONLY IF THE TRANSFORMER AND ELBOW ARE KNOWN TO BE DE-ENERGIZED.

16. Connect Elbow to Bushing

    DANGER: Use a fully insulated hot stick to place the elbow onto the bushing. DO NOT OPERATE BY HAND. DO NOT SEPARATE IF ENERGIZED. All 200A deadbreak connectors must be mechanically secured with bails when connected.

17. Secure Elbow with Hold-down Bail

    Pull the hold-down bail up over the crown or top of the elbow so that the eyebolt on the bail is directly over the operating eye. Tighten down on the elbow locator by turning the eyebolt in a clockwise direction. Adjust the nut on the eyebolt until it allows the eyebolt to seat securely in the locator, acting as a stop to prevent the eyebolt from applying excessive force on the elbow.

18. Perform Voltage Test (Optional)

    If performing a voltage test, remove the test point cap with a hotstick, peeling it off at an angle rather than pulling directly in line. WARNING: The voltage test point is a capacitance device; it is not directly connected to the conductor. Do not use conventional voltage measuring equipment. Use a suitable sensing device designed for capacitive test points and follow its manufacturer’s directions. Treat the elbow as energized until the 'no voltage' indication is confirmed by other means to prevent serious or fatal injury.

19. Replace Test Point Cap

    After any voltage detection has been made, clean and lubricate the inside surface of the test point cap with silicone grease and replace it securely on the test point.

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