ABB Installation Products 162LR-D5270 15kV 200 Amp, Loadbreak Elbow Connector with Test Point, .890 inch - 1.220 Inch Cable…

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How to Install 161LR and 162LR Loadbreak Elbow Connectors

This guide provides step-by-step instructions for the safe and proper installation of Elastimold 161LR (without test point) and 162LR (with test point) Loadbreak Elbow Connectors on various UD cables, including cable preparation, lug installation, elbow assembly, and grounding.

Estimated time: 1h 30m

1. Perform Initial Safety Checks and Cable Training

   DANGER: De-energize all apparatus before installation or removal of parts, except for test point caps and indicators. Do not touch or move energized products in the work area. This product must be installed only by competent personnel trained in good safety practices involving high voltage electrical equipment. Inspect all parts for damage, rating, and compatibility with mating parts. Train the cable to ensure adequate slack for ease of operation. Prepare the neutral wires or grounding braid wire according to your specific cable type (non-jacketed, jacketed concentric neutral, jacketed with drain wires, or jacketed copper tape shield), following the specified lengths for removing outer jacket, unwrapping neutrals, and binding/folding wires. If using a cold shrink sealing kit (e.g., 200ECS, 200ECS-G1, G2, or G3), slide the cold shrink tube onto the cable loose end first, if applicable for your cable type.

2. Prepare Cable End and Install Compression Lug

   Remove the insulation shield and primary insulation 2-1/8 inches (55mm) from the cable end, ensuring a square cut and taking care not to nick the conductor. Thoroughly wire brush bare aluminum conductors and immediately install the compression lug onto the conductor, rotating it to spread inhibitor. Position the lug so the contact threaded hole aligns with the bushing bore. Crimp the lug according to the crimp chart provided with the compression lug, starting at the crimp line mark and rotating 180 degrees for each successive crimp. Carefully wipe off any excess inhibitor from the outside of the lug and cable. Remove the insulation shield 6-7/8 inches (175mm) from the end of the primary insulation. Bevel the end of the primary insulation a maximum of 1/8 inch (5mm). Thoroughly clean the primary insulation to remove all traces of dirt or excess inhibitor.

3. Assemble Elbow Connector

   Lubricate the cable insulation and the inside of the elbow housing with the lubricant supplied. DO NOT SUBSTITUTE other lubricants, as they may be harmful to this product or its mating product(s). Keep insulation clean of dirt and grime. Slide the elbow connector onto the cable with a back-and-forth twisting motion until it is fully seated. Wipe off all excess lubricant. Align the elbow's operating eye with the compression lug's threaded hole. Thread the probe into the lug by hand, taking care not to cross-thread. The probe must turn freely for approximately four turns before becoming snug. Tighten the probe with the supplied probe wrench until the wrench bends, indicating proper torque.

4. Ground the Elbow and Neutral Wires

   Insert one end of a separate copper wire (No. 14 AWG / 2.5mm) or equivalent through the grounding eye on the elbow. Twist the wire tightly, taking care not to damage the eye. If the elbow is preordered with a ground wire, proceed to the next step. Twist all concentric neutral wires together and connect them to ground using an appropriate connector. Provide adequate slack in the wires to allow for elbow operation. If using a cold shrink grounding kit, refer to the instructions supplied with that kit to complete the grounding installation.

5. Connect Elbow to Bushing Plug

   WARNING: CONFIRM THAT THE TRANSFORMER AND ELBOW ARE DE-ENERGIZED before proceeding with connection. Lubricate the receptacle portion of the elbow connector and the mating bushing with the lubricant supplied. Securely fasten a hotstick to the loadbreak connector pulling eye. Insert the probe tip approximately 2 inches (50mm) into the bushing (at this point the contacts are approximately 4 inches apart). DO NOT HOLD IN THIS POSITION BUT IMMEDIATELY PUSH THE ELBOW HOME WITH A FAST, FIRM, STRAIGHT MOTION. Use sufficient force to engage the internal lock on the elbow connector and bushing interface. DO NOT OPERATE BY HAND.

6. Perform Voltage Test (162LR Only)

   This step applies only to 162LR connectors equipped with an integral capacitance test point. WARNING: The voltage test point is a capacitance device and is not directly connected to the conductor. Do not use conventional voltage measuring equipment. Follow the manufacturer’s directions for the specific meter that is used. Remove the test point cap with a hotstick, peeling it off at an angle rather than pulling directly in line with the test point assembly. Test with a suitable sensing device, made for use with separable connectors manufactured with capacitive test points, to determine if the cable is energized. WARNING: 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. After voltage detection has been made, clean the inside surface of the cap, lubricate it with silicone lubricant supplied, and replace it on the test point.

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