Installation Instructions

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517 Lyons Ave, Irvington, NJ 07111 Phone: 973-371-1771 Fax:

25kV Cls ed Concentric Neutral (JCN) Longitudinally Corrugated

1 517 Lyons Ave, Irvington, NJ Phone: Fax: Installation Instructions Series Cold Shrink R-800 Appli Ftener Type G Style Appli Housing Sizes O, P, & Q Appli Catalog Prefix Use With the Following Types 15kV Cls 25kV Cls ed Concentric Neutral (JCN) Longitudinally Corrugated Neutral (LC) Tape Neutral 61G 71G 91G 62G 72G 92G RP-II-G [C] Sheet 1 of 16

Appli Catalog Prefix WARNING System must be de-energized during installation or future operation of this product or its components.

Failure to follow these instructions will result in damage to the connector and serious or fatal injury.

Variations in equipment or configuration or work procedures may not be covered in these instructions. Plee contact Richards Manufacturing for any additional questions.

These high voltage accessories have internal phe to ground insulating interfaces which must be intact.

This may be the cab of an operating vehicle if no other facility resources are available.

This can incree the contact pressure between the accessory and the substrate. The heat should be applied primarily around the semicon shield cutback area.

Heat should not be concentrated but should be applied circumferentially around the product.

Check that proper ventilation is available if working in a confined space structure.

2 Appli Catalog Prefix WARNING System must be de-energized during installation or future operation of this product or its components. Do not touch or move energized connectors or components by hand. Excess distortion of the sembled connector may result in its failure. Failure to follow these instructions will result in damage to the connector and serious or fatal injury. This product should only be installed and/or operated by trained personnel in accordance with normal and safe work procedures. Variations in equipment or configuration or work procedures may not be covered in these instructions. Plee contact Richards Manufacturing for any additional questions. WARNING WARNING Guidelines for Installation in Cold Temperatures (<32 degrees F): 22 The cold shrink product must be kept and stored in a clean, dry manner. These high voltage accessories have internal phe to ground insulating interfaces which must be intact. Keep product within a warmer climate controlled environment long possible PRIOR to installation. This may be the cab of an operating vehicle if no other facility resources are available. If product h been inadvertently exposed and stored in freezing (or below) temperatures for an extended or unknown period of time: Product must warmed (41F or greater) and inspected prior to installation. If installing product in temperatures below freezing, and conducting post installation electrical testing it may be necessary to warm the interface of the accessory. This can incree the contact pressure between the accessory and the substrate. The heat should be applied primarily around the semicon shield cutback area. This can be accomplished via a space heater or hot air gun. The accessory should be gently heated so that the product becomes warm to the touch. Heat should not be concentrated but should be applied circumferentially around the product. If using a hot air gun, care must be taken not to apply the heat in a concentrated manner that could damage the or accessory. Check that proper ventilation is available if working in a confined space structure KIT CONTENTS KIT CONTENTS T KIT CONTENTS R Standard kits may include the following. Custom kits may vary. Check package contents to be sure they are complete, undamaged,and properly sized for the application. P N G Style Cold Shrink R-800 () (15kV or 25kV) M Insulating Cap 21LBICG (for 15kV Cls) 22LBICG (for 25kV Cls) L OR K J Shear Bolt Lug P6ALR-X-15/16 /16 Threaded Hole Lug P6AL-X-15/16 P7ALCU-X-15/16 P9CU-X-15/16 15 (1) Prep Pack containing: H G F Silicone Lubricant P6SL1 (1) Piece Sealing (1) Piece Stress Control (1) Piece Latex Gloves (1) Pair E Stud P625HIP-STUD P925HIP-STUD D UNLESS OTHERWISE SPECIFIED: DIMENSIONS ARE IN MILLIMETERS SURFACE FINISH: TOLERANCES: LINEAR: ANGULAR: C RP-II-G [C] DEBURR AND BREAK SHARP EDGES FINISH: SIGNATURE NAME N/A DATE CHK'D APPV'D MFG Q.A Sheet 2 of 16 MATERIAL: As Noted B DO NOT SCALE DRAWING TITLE: DRAWN WEIGHT: REVISION 15 kv Cold Shrink R800; F Style; (EXPANDED) TestA0 6FCN-01A Point - Size P DWG NO. SCALE:1:1 2 SHEET 1 OF 1 1

3 LCN/ LCN/ Installation Instructions Installation Instructions Installation Instructions Installation Instructions Installation Instructions Installation Instructions TIP: 517 Lyons Lyons Ave. Ave. 517 Irvington, NJ NJ Irvington, 517 Lyons Ave. Phone (973) Phone (973) TIP: TIP: Irvington, NJ TIP: FaxTIP: (973) Fax (973) Phone (973) TIP: 0-Positioning FaxTIP: (973) the TIP: Use To-Scale Cutback Template aid to prepare. 0-Positioning 0-Positioning 0-Positioning 0-Positioning TIP: Use Use to-scale cutback template on lt page aid aid to to prepare prepare.. TIP: to-scale cutback template on lt page Certain items used, such PVC tape, may not be included. 1-Exposing 0-Positioning the the 1-Exposing 0-Positioning the the TIP: Use to-scale cutback template on lt page aid to prepare. Certain items used such mtic, PVC tape, shrink tube, etc. may not be includ Certain items used such mtic, PVC tape, shrink tube, etc. may not be includ ing the Metallic Tape /L Strap/Wire s ing Metallic /LC s the Positioning & Exposing Metallic Certain items used such mtic, PVC tape, shrink tube, etc.tape may not be includ 1 A. A. A. B. B. C. C. B. C. Straighten and and train train end. end. should should be be free free to to move move Straighten approximately 2"train either direction. approximately inin either direction. Straighten and2" end. should be free to move Cut to to dimensions dimensions Cut approximately 2" in either direction. Clean jacket approximately 24" from from end end of of.. Clean approximately Cut tojacket dimensions 24" Clean jacket approximately 24" from end of. 1-Exposing ing 1-Exposing 1-Exposing 1-Exposing 1-Exposing 1-Exposing ing 1-Exposing ing ing ing ing ing Metallic Tape /LC Sh Bushingor or Bushing Mating Part Mating Part Bushing or Metallic Metallic Tape/LC /LC Tape Mating Part Metallic MetallicTape Tape /LC /LC Metallic Tape /LC Metallic Tape /LC Metallic Metallic Tape/LC Tape/LC or Strap/Wire s Strap/Wire Strap/Wire s s s s Strap/Wire s s Strap/Wire Strap/Wire D. Strap/Wire Remove jacket to to dimensions dimensions D. Remove jacket E. Abrade area E. Abrade area D. Remove jacket to dimensions Strap/Wire s e s E. Abrade area REF. 111/1/22 REF. 1 1 /2 REF. 2 AbradedArea Area Abraded Abraded Area or Strap/Wire s 113/3/44 1 3/4 2-Applying Tape/LC 2-Applying D. Metallic Remove jacket jacket to dimensions dimensions D. Remove to E. Abrade Abrade area jacket E. D. Removearea to dimensions Metallic Tape /L Metallic Tape /LC E. Abrade area REF. 111/1/22 REF. 1 1 /2 REF /4 12 AbradedArea Area Abraded 2-Applying Abraded Area Metallic Tape /LC Shie Applying 2-Applying 2-Applying 2-Applying 2-Applying 2-Applying Metallic MetallicTape Tape/LC /LC 2-Applying Metallic Tape/LC Metallic MetallicTape Tape/LC /LC Metallic Tape /LC Strap/Wire Strap/Wire s s Strap/Wire s s Strap/Wire s s A. Apply one piece of jacket mtic at position shown by stretching and Go to Metallic Step 3 Tape /LC wrapping with light tension fully around outer jacket. mtic will be applied in Step /4 3- Exposing 3- Exposing Strap/Wire re s s 3 Exposing Strap/Wire A. B. Metallic Tape /LC Metallic Tape /LC 3- Exposing Metallic Tape/LC Fold back strap/wire shields and press firmly into jacket mtic. A. Wrap 2 layers 3- Exposing Exposing of PVC tape at dimension shown to secure metallic shield Exposing Exposing Secure strap/wire shields 3 back from jacket mtic with binding wire 3- Exposing B. Remove metallic shield up to PVC tape 3- Exposing or zip tie Strap/Wire s Binding Wire or Zip Tie Strap/Wire Strap/Wire s s s s ee Strap/Wire s e s mtic under strap/wire shield RP-II-G [C] Metallic Tape /LC 10 Metallic MetallicTape Tape/LC /LC Metallic MetallicTape Tape/LC /LC Metallic Tape /LC Metallic Tape /LC PVC Tape Metallic Sheet 3 of 16

4 Strap/Wire A. Remove semi-conductive shield to dimension Exposing Insulation Metallic Tape/LC A. Remove semi-conductive shield to dimension WARNING: Do not nick or cut the insulation.

4 4 Strap/Wire A. Remove semi-conductive shield to dimension Exposing Insulation Metallic Tape/LC A. Remove semi-conductive shield to dimension WARNING: Do not nick or cut the insulation. WARNING: Do not nick or cut the insulation. 9 3 / /4 Insulation Metallic Insulation 5 A. Remove insulation. Refer to instructions provided with lug for insulation cutback dimension. Cutback dimension should not exceed 4 3 /8". Exposing Conductor Insulation Cutback WARNING: Do not nick or cut the conductor strands. Insulation Conductor Confirm all dimensions with To-Scale Cutback Template before proceeding. 6 Installing Lug WARNING: Lug MUST have a 15 /16 hole. Confirm lug and hole dimension before installing lug. A. Clean conductor of any debris. aluminum conductor, wire brush and immediately insert lug onto conductor. Slide lug until the conductor is fully seated within the lug barrel. B. Rotate lug so that spade is parallel to the contact face of the bushing or mating part C. Shear Bolt Connectors: Install lug using separate instructions provided with lug. Crimp Connectors: Select correct tool and die using crimp chart supplied with lug. Crimp lug (min. number indicated in crimp chart) starting just below knurl line adjacent to pad Carefully wipe any excess inhibitor from lug and insulation. Lug Locate first crimp here Ensure surfaces are parallel before installing lug Bushing Knurl Line RP-II-G [C] Sheet 4 of 16

5 7 A. After installing lug, confirm distance from lug end to insulation cutback does not exceed dimension Checking Lug 7 1 /4 MAX WARNING: Do not exceed maximum dimension 8 Strap/Wire Applying Stress Control Metallic Tape/LC A. Clean insulation with approved cleaning wipes by wiping from lug to shielding. B. Apply supplied stress control mtic centered over edge of semiconductive shield cutback. Apply the mtic with light tension so it slightly stretches and completely wraps the. A. Clean insulation with approved cleaning wipes by wiping from lug to shielding. B. Remove PVC tape from Step 3. C. Apply supplied stress control mtic centered over edge of semiconductive shield cutback. Apply the mtic with light tension so it slightly stretches and completely wraps the. Applied Stress Control Stress Control Wipe Direction Applied Stress Control Stress Control Wipe Direction Cutback Insulation Cutback Insulation 9.1 Applying Gree A. Apply gree over exposed insulation and stress control mtic Use only supplied or approved silicone gree. Apply gree in this area RP-II-G [C] Sheet 5 of 16

6 9.2 A. Install onto until the lug is fully seated inside the housing. Installing WARNING: Confirm the lug h fully seated into housing Housing Lug fully seated within housing 15 /16" Threaded Lug RP-II-G [C] Sheet 6 of 16

7 9.3 Inserting Hex Tool A. Insert Hex tool (P620AT or equivalent 5 /16" hex tool) through loadbreak interface and engage ftener. B. Slide ftener into forward position through lug hole ( shown in detail view). WARNING: Ftener is factory-installed in a retracted position. The Ftener must be stroked into forward position. The female threaded end of Ftener will then extend into the 15 /16" Threaded hole of the Lug. WARNING: Confirm that ftener goes through lug hole shown below. Ftener Ftener in the retracted position Ftener stroked into forward position through Lug Hole Hex Tool Push Ftener through Lug Hole Lug RP-II-G [C] Sheet 7 of 16

8 9.4 A. Hand-tighten stud into the appropriate mating part or bushing. Mounting WARNING: A standard threaded stud is included in the kit. If the use of an ymmetrical threaded stud is approved, it MUST be installed with longer threaded side facing AWAY from equipment shown below. Correct Incorrect B. Clean and lubricate (using supplied or approved silicone gree) deadbreak interface of and interface of mating part or bushing. C. Place one hand on the power directly below and one hand on the body of the. Lifting together, push onto mating part, lining up the hole in the lug with the stud on the mating part. D. Insert Hex tool (P620AT or equivalent 5 /16" hex tool) into loadbreak interface and engage fter. Rotate tool 2-3 turns to start thread engagement. CHECK: Tug on power to confirm stud is through hole in lug. Only a small amount of movement should be possible. If the moves more than a small amount repeat steps above. E. Continue rotating hex tool. Torque ftener to 20ft-lb (P620AT Tool h built in 20ft-lb torque limiter.) CHECK: As a final check, tug on power. This should result in no movement at all. Clean and Lubricate (Internal Cavity) Mating Part or Bushing Clean and Lubricate Stud Torque Grp and lift from here RP-II-G [C] Sheet 8 of 16

Check that tape is broken. B. To remove core by hand: Proceed to Step D.

Press handles inwards to eject core. D. Completely remove core from rubber housing by hand.

A Removal Ring B C D 10.2 Strap/ Wire Go to Step 11 Metallic Tape/LC A.

Wrap tinned copper braid around exposed metallic shield. C. Align edge of solder block with jacket cutback. D.

9 10.1 Removing Core A. Grp removal ring. Push ring against core flange and twist so that cutting teeth breaks tape on both sides. Check that tape is broken. B. To remove core by hand: Proceed to Step D. To remove core using P6AT-CS2 Tool: Insert one half of tool between removal ring and core flange. Pry core slightly away from housing. C. Insert second half of core removal tool between removal ring and core flange. Press handles inwards to eject core. D. Completely remove core from rubber housing by hand. DO NOT twist core while removing. E. Separate core into two halves and clip any pltic rings that remain on. A Removal Ring B C D 10.2 Strap/ Wire Go to Step 11 Metallic Tape/LC A. Install jacket mtic on jacket aligned with jacket cutback. B. Wrap tinned copper braid around exposed metallic shield. C. Align edge of solder block with jacket cutback. D. Secure copper braid 3 back from end of jacket mtic with zip tie or binding wire. E. Unwind constant force spring over wrapped copper braid F. Tighten constant force spring by hand and wrap two layers of PVC tape (in direction of spring) to secure. G. Press solder block into jacket mtic. Preparing Metallic Binding Wire or Zip Tie Solder Block Tinned copper braid wrapped around exposed tape shield Constant ce Spring Apply PVC tape here RP-II-G [C] Sheet 9 of 16

10 11 Strap/Wire Applying Sealing Metallic Tape/LC A. Apply sealing mtic close possible to folded back jacket seal while maintainting complete overlap of previously applied jacket mtic. sealing mtic may or may not overlap stress control mtic. A. Apply sealing mtic close possible to folded back jacket seal while maintainting complete overlap of previously applied jacket mtic. sealing mtic may or may not overlap stress control mtic. Sealing Sealing completely covered with Sealing completely covered with Sealing 12 Strap/Wire Applying Seal Metallic Tape/LC A. Apply gree over area Only use gree supplied with kit or approved silicone gree. B. Hold both tabs and pull out to completely cover sealing mtics shown below. Ensure sealing mtic is not dislodged when unfolding seal. A. Apply gree over area shown below. Only use gree supplied with kit or approved silicone gree. B. Hold both tabs and pull out to completely cover sealing mtics shown below. Ensure sealing mtic is not dislodged when unfolding seal. Lubricate Pull Pull Tab Lubricate Pull Pull Tab Pull Pull Pull Tab Pull Tab Seal Installed Seal Installed RP-II-G [C] Sheet 10 of 16

11 13 Installing Mating Component A. Clean and lubricate (using supplied or approved silicone gree) loadbreak interface of and interface of insulating cap or mating part. B. Install mating component per manufacturer instructions. Loadbreak Cap shown reference. Clean and Lubricate (Internal Cavity) Clean and Lubricate RP-II-G [C] Sheet 11 of 16

12 14 Strap/Wire Connecting Drain Wires to A. Insert one end of a piece of wire (#14 AWG copper or larger) through one of the available grounding eyes and twist to make a small loop. Be sure not to damage grounding eye. B. Connect other end of wire to shield wires. C. Ground the shield according to appropriate/approved practice. To Ground Metallic Tape/LC Ground Eye Drain Wire A. Insert one end of a piece of wire (#14 AWG copper or larger) through one of the available grounding eyes and twist to make a small loop. Be sure not to damage grounding eye. B. Connect other end of wire to copper braid. C. Ground the shield according to appropriate/approved practice. To Ground Ground Eye Drain Wire Installation Complete RP-II-G [C] Sheet 12 of 16

13 RP-II-G [C] Sheet 13 of 16

14 Strap/Wire 9 3 /4 11 Cutback Template SCALE 1:1 Conductor Conductor intentionally not shown exposed. Multiple insulation cutback lengths exist depending on lug being installed. Locate appropriate dimension within instructions (dimension should not exceed 4 3 /8"). Insulation 11 3 /4 10 Metallic Tape/LC 8 3 /4

15 RP-II-G [C] Metallic Sheet 15 of 16

16 RP-II-G [C] Sheet 16 of 16

Installation Instructions

517 Lyons Ave, Irvington, NJ 07111 Phone: 973-371-1771 Fax: 973-371-4304 Installation Instructions Deadbreak Elbow Applicable Current Ratings 600A (Aluminum) 900A (Copper) Applicable Catalog Prefix 35kV