ABB Installation Products 168FLR1B0180 Molded Current Limiting Fuse Housing, Nominal Fuse Voltage Rating 8.3kV, Fuse Test Port…

Frequently Asked Questions

How to Install the 168FLR/274FLR Loadbreak Fused Elbow Connector

This guide provides step-by-step instructions for the safe installation, detailed cable preparation, and complete assembly of the 168FLR or 274FLR Loadbreak Fused Elbow Connector, including critical safety precautions and component integration.

Estimated time: 1h 30m

1. Perform Initial Inspection and Ensure Safety

   Ensure all apparatus is de-energized during installation or removal of parts. Inspect all components for any damage, verify correct ratings, and confirm compatibility with mating parts. Check the package contents for completeness and proper fit with the cable and/or mating products. If the product was supplied with a protective shipping cover, remove it and replace it with the appropriate HV insulated cap(s) or connector(s) before submerging or energizing the circuit. This product must be installed only by competent personnel trained in high voltage electrical equipment safety practices.

2. Perform Cable Training

   Using the bushing centerline as a reference, cut any excess cable off, ensuring a minimum of 20 inches beyond the bushing. If using an optional 200ECS Cold Shrink Cable Seal, slide it onto the cable now. Remove the jacket from the excess cable length remaining AND the distance of 'A' (11-1/2 inches for FLR-1, 15-3/4 inches for FLR-3) plus 7-3/8 inches from the bushing centerline. If a Cable Seal kit is used, follow its specific instructions. Otherwise, unwrap and fold the Concentric Neutral wires back over the jacket and bind them. Squarely cut off the cable a distance of 'A' from the bushing centerline, leaving a minimum of 7-3/8 inches of cable to terminate.

3. Prepare the Cable End

   Cut 1-1/8 inches from the cable end, ensuring a square cut and taking extreme care not to nick the conductor. Immediately wire brush the bare aluminum conductors and install the compression lug. Rotate the lug to spread the inhibitor. Crimp the unthreaded end of the compression lug to the conductor, referring to the crimp chart packaged with the compression lug for tool information. Start the crimp at the crimp line mark and rotate 180 degrees for each successive crimp. Carefully wipe any excess inhibitor from the outside of the lug and cable. Remove the insulation shield 5-1/2 inches from the end of the lug. Bevel the insulation end a maximum of 1/8 inch. Thoroughly clean the insulation to remove all traces of conductive residue.

4. Lubricate and Assemble Cable Half Housing

   Apply the supplied lubricant to the outside of the connector, the cable insulation, the conductive shield, and the cable entrance end of the Fused Elbow cable half. DO NOT SUBSTITUTE the lubricant. Insert the connector and cable into the cable half of the Fused Elbow until the top end of the connector protrudes beyond surface 'A'. This positioning is crucial to allow the fuse to be tightened before it bottoms out on the rubber.

5. Install the Fuse

   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 the fuse. CAUTION: The fuse stud will fracture if over-torqued. After hand tightening, pull the housing up against the bottom of the tightened fuse.

6. Assemble the Probe Connector

   Assemble the probe connector to the fuse terminal. Rotate the probe connector so that its flats are perpendicular to the bushing with which it will mate. Lock the probe connector in position by tightening 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.

7. Assemble Elbow Half Housing and Probe

   Apply lubricant to the elbow half of the fused elbow and assemble it to the cable half. The cuff of the cable half will overlap the elbow half by 3/4 inch. Ensure the probe connector faces the opening of the fused elbow half and that the two test points are in line with each other. 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. To tighten, use the special torque-limiting allen wrench supplied; insert the short end of the wrench into the hole in the probe and tighten until the wrench bends and remains bent. Position the hose clamp as shown in the product diagram and tighten it, but DO NOT OVERTIGHTEN.

8. Connect Concentric Neutral Wires

   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 the grounding eyes. If used, finish installing the 200ECS jacket seal. Twist all neutral wires, exercising care not to damage grounding eyes, and connect them to ground using an appropriate connector. Provide adequate slack in the wires to allow for elbow operation.

9. Connect Elbow to Bushing Plug (De-energized)

   Lubricate the receptacle portion of the elbow connector and the mating bushing with the supplied lubricant. IMPORTANT: Lubricate ONLY if the transformer and elbow are known to be de-energized. Operate the connection using a full insulated hotstick tool; DO NOT OPERATE BY HAND. Ensure the area is clear of obstructions or contaminants. Securely fasten a hotstick to the loadbreak connector pulling eye. 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. Immediately push the elbow home with a fast, firm, straight motion, applying sufficient force to engage the internal lock on the elbow connector and bushing interface.

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