ABB Installation Products 168FLR3A0220 Molded Current Limiting Fuse Housing, Nominal Fuse Voltage Rating 8.3kV, Fuse Test Port…

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

This guide provides step-by-step instructions for the installation and initial setup of the 168FLR or 274FLR Loadbreak Fused Elbow Connector, including cable preparation, assembly, and neutral connection. Ensure all apparatus are de-energized before beginning installation.

Estimated time: 1h 30m

1. Pre-Installation Safety and Inspection

   DANGER: De-energize all apparatus before starting installation. Inspect package contents for completeness and damage. Verify all components fit correctly with the cable and mating products. Check threads by threading the probe into the compression lug; replace damaged components if resistance is encountered. Read all instructions thoroughly and have all required tools at hand, maintaining cleanliness throughout the procedure.

2. Cable Training and Jacket Removal

   Using the bushing centerline as a reference, cut excess cable off 20 inches minimum beyond the bushing. Slide the optional 200ECS Cold Shrink Cable Seal onto the cable if used. Remove the cable jacket for the specified length (distance of 'A' + 7-3/8 inches from the bushing centerline). If not using a cable seal kit, 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 7-3/8 inches minimum of cable to terminate.

3. Conductor Preparation and Lug Installation

   Cut 1-1/8 inches from the cable end, ensuring a square cut and taking care not to nick the conductor. Wire brush the bare aluminum conductors and immediately install the compression lug, rotating it to spread the inhibitor. Crimp the unthreaded end of the compression lug to the conductor (refer to the crimp chart packaged with the lug for tool information), 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.

4. Insulation Shield Removal and Cleaning

   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.

5. Lubricate and Assemble Cable Half

   Apply the supplied lubricant to the outside of the connector, cable insulation, conductive shield, and the cable entrance end of the Fused Elbow cable half. 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 allows the fuse to be tightened before bottoming on the rubber.

6. Install and Hand Tighten Fuse

   Insert the threaded terminal end of the fuse into the cable half of the Fused Elbow and hand-thread it into the cable connector. CAUTION: HAND TIGHTEN ONLY. The fuse stud will fracture if over-torqued. Pull the housing up against the bottom of the tightened fuse.

7. Assemble and Position 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 its test point is perpendicular to the flats on the probe connector.

8. Assemble Elbow Halves and Probe

   Apply the supplied 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 that 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, inserting the short end into the hole in the probe and tightening until the wrench bends and remains bent.

9. Secure with Hose Clamp

   Position the hose clamp as shown in the documentation and tighten it. DO NOT OVERTIGHTEN the hose clamp.

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

11. Lubricate and Connect to Bushing (De-energized)

    Lubricate the receptacle portion of the elbow connector and the mating bushing with the lubricant supplied. IMPORTANT: LUBRICATE ONLY IF THE TRANSFORMER AND ELBOW ARE KNOWN TO BE DE-ENERGIZED. Operate the connection per the operating instructions using a full insulated hotstick type tool; DO NOT OPERATE BY HAND.

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