ABB Installation Products 262LR-C5230-S 200 Amp, 25kV, Loadbreak Elbow with Test Point, Cable Insulation Diameter 0.805 inch to…

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How to Install the 262LR Loadbreak Elbow Connector

This guide provides step-by-step instructions for the safe installation and initial setup of the 262LR Loadbreak Elbow Connector, including cable preparation, assembly, grounding, and an optional voltage test for the test point.

Estimated time: 1h 30m

1. Perform Initial Inspection and Safety Checks

   DANGER: All apparatus must be de-energized during installation or removal of part(s) except for test point caps and indicators that can be installed and operated energized. Failure to follow instructions will result in 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. Inspect all parts for damage, proper rating, and compatibility with mating parts. Check contents of package to ensure they are complete and undamaged. Verify proper fit with cable and/or mating products. Thread the probe into the compression lug to check for resistance; if resistance is encountered, replace damaged components.

2. Prepare the Cable for Termination

   DANGER: Ensure the cable is de-energized before proceeding with any cable preparation. Train the cable to ensure adequate slack for ease of operation. Prepare the neutral wires or grounding braid wire according to the specific cable type (non-jacketed concentric neutral, jacketed concentric neutral, jacketed with drain wires, or jacketed copper tape shield) as detailed in the product documentation. This typically involves pulling extra cable length, binding neutrals, removing outer jacket, and cutting excess cable squarely. If using a cold shrink sealing kit, slide the cold shrink tube onto the cable loose end first at this stage.

3. Prepare the Cable End and Install Compression Lug

   Remove the shield and insulation 2-1/8” (55mm) from the cable end, cutting squarely and taking care not to nick the conductor. Wire brush bare aluminum conductors and immediately install the compression lug. Rotate the lug to spread inhibitor and position it so the contact threaded hole aligns with the bushing bore. Crimp the lug starting at the crimp line mark, rotating 180 degrees for each successive crimp. Carefully wipe excess inhibitor from the outside of the lug and cable. Remove the insulation shield as shown in the documentation, and bevel the insulation end 1/8” (5mm) maximum. Ensure the cut is straight, smooth, and squared, and do not cut or nick the insulation. Thoroughly clean the insulation to remove all traces of dirt or excess inhibitor.

4. Assemble the Elbow Connector

   Lubricate the cable insulation and the inside of the elbow housing with the supplied lubricant. DO NOT SUBSTITUTE other lubricants, as they may be harmful. Keep insulation clean. Slide the elbow connector onto the cable using a back and forth twisting motion. Wipe off all excess lubricant. Align the elbow with the compression lug’s threaded hole. Thread the probe into the lug by hand, ensuring not to cross-thread. The probe should turn freely for approximately four turns before becoming snug. Tighten with the probe wrench until the wrench bends.

5. Ground the Elbow Connector

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

6. Connect the Elbow to the Bushing Plug

   DANGER: 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” (50mm) into the bushing. Immediately push the elbow home with a fast, firm, straight motion, using sufficient force to engage the internal lock on the elbow connector and bushing interface. DO NOT HOLD IN THE PARTIALLY INSERTED POSITION. If a fault is experienced during loadmake operations, both the elbow connector and the bushing must be replaced. DO NOT CONDUCT LOADMAKE OPERATIONS ON KNOWN FAULTS.

7. Perform Voltage Test (262LR Only)

   To determine if the circuit is energized using the integral capacitance test point (262LR only), remove the test point cap with a hotstick, peeling it off at an angle. WARNING: The voltage test point is a capacitance device and not directly connected to the conductor. Do not use conventional voltage measuring equipment. Use a suitable sensing device made for capacitive test points, following its manufacturer’s directions. Treat the elbow as energized until the 'no voltage' indication is confirmed by other means, as contamination or incorrect equipment can provide a false reading. After voltage detection, clean the inside surface of the cap, lubricate with silicone lubricant supplied, and replace it on the test point.

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