©Novinium, Inc. 2019, all rights reserved. Novinium, Inc. engineering@novinium.com 22820 Russell Rd Kent, WA 98032 Revised: September 9th, 2019 (253) 395-0200

Rejuvenation Instructions

#522 – 200A Elbows – iUPR

This NRI covers the following:

• How to prepare a 200amp injection elbow for injection and installation.

• How to add the improved safety features to the injection elbow.

Trademarks: http://www.novinium.com/trademarks/

Patents: http://www.novinium.com/patents/

WARNING: It is dangerous working around energized high-voltage systems, pressurized systems, and chemicals. Always work in accordance to the Novinium Field Operations Safety Handbook (FOSH) or other local governing safety standards.

©Novinium, Inc. 2019, all rights reserved. NRI 522 – 200A Elbows – iUPR Revised: September 9th, 2019 Page 1 of 15

Table of Contents Introduction ............................................................................................................................................................................ 2

Keeping the Existing Connector ........................................................................................................................................... 2

1. Prepare the existing connector. .................................................................................................................................. 2

Replace the Connector .......................................................................................................................................................... 2

1. Determine if an extension is needed. ......................................................................................................................... 2

Selecting the URD Crimp Die ................................................................................................................................................... 3

Crimping the Connector .......................................................................................................................................................... 3

Quality Check .......................................................................................................................................................................... 4

1. Check the connector and strands. .............................................................................................................................. 4

2. Compare the cable to the template. ........................................................................................................................... 4

Preparing the Elbow ................................................................................................................................................................ 4

1. C-clip and retaining clip ............................................................................................................................................... 4

2. Reticular Flash Preventer (RFP) ................................................................................................................................... 5

Installing the Access Interface (AI) .......................................................................................................................................... 7

3. Verify the fluid injection cap (FIC). .............................................................................................................................. 7

Installing the Injection Elbow .................................................................................................................................................. 8

4. Apply lubricating grease. ............................................................................................................................................. 8

5. Install the elbow. ......................................................................................................................................................... 8

6. Connect the concentric neutrals. ................................................................................................................................ 9

7. Final elbow preparations. ......................................................................................................................................... 10

iUPR Injection ........................................................................................................................................................................ 10

8. Inject the cable. ......................................................................................................................................................... 10

9. Remove the injection equipment. ............................................................................................................................ 10

10. Using the retaining clip handling tool for submersible and low-profile transformers. ........................................ 11

Operating Instructions .......................................................................................................................................................... 12

1. Before loadmake or loadbreak operation. ................................................................................................................ 12

2. Loadmake operation. ................................................................................................................................................ 13

3. Fault close. ................................................................................................................................................................ 13

4. Loadbreak operation. ................................................................................................................................................ 14

5. Voltage test on Novinium 1-EB-15kV and 1-EB-25kV. ............................................................................................... 14

6. Injection application supplement. ............................................................................................................................ 15

©Novinium, Inc. 2019, all rights reserved. NRI 522 – 200A Elbows – iUPR Revised: September 9th, 2019 Page 2 of 15

Introduction This NRI describes how to install new 200A injection elbows for the Improved Unsustained Pressure

Rejuvenation (iUPR) process.

Keeping the Existing Connector If the existing connector and cable preparation quality are satisfactory and meet IEEE® 1816™

requirements, the existing connector may be kept with the cutbacks modified per the non-extension, or

standard templates.

1. Prepare the existing connector.

The conductor strands rotate around at a 15° angle. It is possible to create a suitable flow path into the cable

by opening the conductor strands. Prepare the strands by:

Tightening the strands by 15° in the strand lay’s direction. Then, rotate the connector back 15° to its original position.

Figure 1: Tighten by 15° then loosen the connector to open the strands.

Examine and remove any debris from the strands.

Examine for any strands that broke during the rotation steps. Re-terminate if necessary.

Skip to the Quality Check section on page 4.

Replace the Connector To remove the connector for replacement, follow the steps in NRI 512 Cable Preparation.

1. Determine if an extension is needed.

If extending the length of the cable is necessary, install a coppertop extension with a splice connector according to the template for the application.

• The coppertop extension is made from a standard length 1/0 coppertop crimped on a length of 7 strand, 1/0 size copper conductor made to the length called out on the template.

Select the correct transition splice connector for the cable’s conductor size.

15°

©Novinium, Inc. 2019, all rights reserved. NRI 522 – 200A Elbows – iUPR Revised: September 9th, 2019 Page 3 of 15

Cable Conductor Size Transition Splice Connector

#2 or #1 ALCR9-8-NV

1/0 ALCR9-NV

2/0 ALCR10-9-NV

3/0 ALCR11-9-NV

Table 1: Transition splice for the cable.

Select the coppertop extension for iUPR injection for the size cable being injected.

Fully insert the copper conductor of the coppertop extension into the splice connector.

Slide the splice connector with extension onto the cable’s conductor.

Use the template to verify that the pre-crimp length is correct.

Selecting the URD Crimp Die For iUPR installations, fit as many crimps within the crimping region of the connector as possible.

• The additional crimps will improve the conductor compression and reduce resistance between the connector and conductor.

Measure the outside diameter of the connector with a digital caliper. Manufacturers have a sizing pattern to their connectors.

Use the manufacturer’s specified crimping die or refer to NRI 442 for crimp dies based on connectors with a given outside diameter.

Test the die on the connector. If the die does not appear to crimp the connector correctly, contact Engineering for assistance.

Crimping the Connector Follow IEEE® 1816™ guidelines on how to install the connector.

Begin crimping the connector at the “no crimp” line.

Rotate the crimping tool for each crimp to avoid curving the connector.

Crimp the connector as many times as possible, moving towards the cable each time.

Figure 2: Place the maximum amount of crimps possible.

©Novinium, Inc. 2019, all rights reserved. NRI 522 – 200A Elbows – iUPR Revised: September 9th, 2019 Page 4 of 15

Quality Check 1. Check the connector and strands.

Occasionally, crimped connectors will have sharp edges or “ears.” To prevent interior damage to component bodies:

• Flatten ears and smooth sharp edges with a file. 120 grit sandpaper can also be used, but is less effective.

Check for overly bent connectors. Redo as needed.

• Crimping action can bend connectors. Rotate the crimping tool 90° each time to reduce this effect.

• Bent connectors can make installing the probe more difficult.

Figure 3: Bent connector.

2. Compare the cable to the template.

Confirm that all cutbacks and post-crimp lengths are within the required ranges. Adjust or redo any, if necessary.

Figure 4: Check the cable against the template.

Check the insulation and semi-con for cracks, gouges, ripples, scratches, dirt, or other defects.

Preparing the Elbow 1. C-clip and retaining clip

Remove the insulating cap from the elbow and attach the retaining clip following Figure 6 and 7.

Store the insulating cap assembly until after the injection is complete.

©Novinium, Inc. 2019, all rights reserved. NRI 522 – 200A Elbows – iUPR Revised: September 9th, 2019 Page 5 of 15

Figure 5: Attach the retaining clip to the cap.

Figure 6: Retaining clip sitting on the cap.

Put the C-clip on the elbow, if it has not already been installed.

Press until the C-clip is fully seated and in line with the injection port on the opposite side.

Figure 7: Attach C-clip to elbow.

Figure 8: C-clip positioned below port.

2. Reticular Flash Preventer (RFP)

The RFP is a patented safety device designed to improve flashover protection from an open injection port. To

install the RFP:

Place the RFP, rigid disk first, into the RFP insertion holder.

If the RFP insertion holder is not available, do the next step by hand.

Figure 9: RFP.

Figure 10: Place the RFP in the RFP holder.

Press the RFP inserter into the holder until the tip goes through the RFP

Note: RFPs are compatible

with all elbows except

Cooper LE235 35kV

©Novinium, Inc. 2019, all rights reserved. NRI 522 – 200A Elbows – iUPR Revised: September 9th, 2019 Page 6 of 15

Figure 11: Pierce the RFP with the tool.

Figure 12: RFP should be on spike.

Remove the RFP from the holder.

Verify that the RFP is fully speared with the rigid disk facing outward.

Figure 13: RFP is corrector placed.

Figure 14: RFP placed upside down.

Insert the RFP into the elbow’s fluid access port using the RFP inserter.

Figure 15: RFP inserted.

Push the shoulder of the RFP inserter firmly against the face of the fluid access port.

• The RFP will remain correctly installed when the inserter is removed.

Figure 16: RFP remains in port.

©Novinium, Inc. 2019, all rights reserved. NRI 522 – 200A Elbows – iUPR Revised: September 9th, 2019 Page 7 of 15

Pre-wet the RFP by dripping five to ten drops of Novinium fluid into the access port.

• The RFP may be wetted before inserting into the access port.

Figure 17: Pre-wet the RFP.

Installing the Access Interface (AI) 3. Verify the fluid injection cap (FIC).

Check that the fluid injection cap is the correct length to accommodate the RFP. The current FIC’s stem

extends about ½” beyond the body of the cap.

If you have legacy FICs, contact Supply Chain to request replacements.

Figure 18: Current FIC compared to legacy FIC

Note: The RFP is designed to be used

saturated with fluid!

©Novinium, Inc. 2019, all rights reserved. NRI 522 – 200A Elbows – iUPR Revised: September 9th, 2019 Page 8 of 15

Installing the Injection Elbow 4. Apply lubricating grease.

Apply the supplied grease to the cable.

Keep the strands free of grease while applying.

Some components require a specific grease to function properly.

• In this case, DO NOT SUBSTITUTE THE SUPPLIED GREASE.

• Call Engineering with any questions regarding grease.

5. Install the elbow.

Install the elbow by the more stringent of manufacturer’s installation instructions or circuit owner’s

standards.

Loosely position a hose-clamp on the elbow body.

In cold conditions, gently warming components to 120°F (49°C) may ease installation.

• Example: Heat the splice body using a vehicle’s defroster ducts.

Slide the elbow onto the cable with a back-and-forth twisting motion.

• Take care not to twist the conductor strands closed.

Wipe off all excess grease.

Align the elbow with the compression lug threads.

Remove the protective cap on the probe threads and lubricate the O-ring on the probe.

• Do not use silicone on the probe threads

Thread the probe into the lug by hand.

• Take care not to cross-thread.

Tighten with the Speed Systems wrench with comes set at 120 in. lbs.

• The supplied wrench can be used by tightening the probe until the wrench bends as in Figure 21.

©Novinium, Inc. 2019, all rights reserved. NRI 522 – 200A Elbows – iUPR Revised: September 9th, 2019 Page 9 of 15

Figure 19: Using the probe wrench in the elbow kit.

Figure 20: Speed System 15/25kV probe wrench.

6. Connect the concentric neutrals.

Neutrals from the cable must extend to within 1” from the end of the elbow. The only exception is the drain wires.

Twist the neutral wires and connect to ground with the correct connector.

Provide adequate slack in wires for elbow operation.

You must thread the end of the copper bleed wire (No. 14 AWG or equivalent) through the ground eye on the elbow.

Twist tight but do not damage the eye.

Figure 21: Neutral connections.

©Novinium, Inc. 2019, all rights reserved. NRI 522 – 200A Elbows – iUPR Revised: September 9th, 2019 Page 10 of 15

7. Final elbow preparations.

Tighten the hose clamp on the elbow until the clamp’s outer surface is even with the elbow body.

• DO NOT over tighten!

For standard length elbows, install the hose clamp over the molded load-break band and secure the additional load-break band above the hose clamp.

If possible, lubricate the receptacle of the elbow and mating bushing on the transformer with the supplied lubricant.

• DO NOT HANDLE THE BUSHING OR ELBOW UNLESS THEY ARE DE-ENERGIZED!

Figure 22: Hose clamp is even with the elbow body.

Figure 23: Standard length elbow with the hose clamp and additional load-break band.

iUPR Injection 8. Inject the cable.

Follow the instructions according to NRI 602 Small Diameter Cables (URD) – iUPR.

9. Remove the injection equipment.

Using a hot stick, grab the eye of the FIC.

If the FIC retaining clip was used, twist the FIC until the clip comes free from the C-Clip.

Pull the FIC free from the elbow.

Using the hot stick, remove the injection equipment from the energized environment.

©Novinium, Inc. 2019, all rights reserved. NRI 522 – 200A Elbows – iUPR Revised: September 9th, 2019 Page 11 of 15

Tightly secure the cap to the hot stick.

• The hot stick’s metal ring presses against the retaining clip during installation.

Figure 24: Grip the permanent cap with the hot stick.

Push the permanent cap onto the elbow’s injection port.

Check that both of the retaining clip’s wings snap and stay on the barbs of the C-Clip.

• If they are, the cap is fully seated now.

• If snapping the retaining clip into place is difficult, use the retaining clip handling tool in section 3 below.

Figure 25: Snap the retaining clip to the C-clip.

The cap displaces the RFP into the conductive insert of the elbow.

Figure 26: Permanent cap presses the RFP down.

10. Using the retaining clip handling tool for submersible and low-profile transformers.

For some transformer configurations, installing the retaining clip over the permanent cap can be difficult.

To help secure the retainer clip onto the C-clip, the retaining clip handling tool can be used to increase the

user’s dexterity for installation.

Using the hot stick, place the permanent cap and retaining clip into the elbow’s injection port.

Install the retaining clip handling tool and angle the forks as needed.

©Novinium, Inc. 2019, all rights reserved. NRI 522 – 200A Elbows – iUPR Revised: September 9th, 2019 Page 12 of 15

Figure 27: The handling tool attached to a hot stick

Slide the slotted end onto a universal stick and fasten.

• A shotgun stick to universal stick adapter can be used to attach the retaining clip handling tool to a shotgun stick.

Feed the tool’s fork into the shoulders of the retaining clip around the permanent cap.

Use the tool to finesse the retaining clip onto the C-clip. The tool increases the maneuverability of the retaining clip.

Check that both of the retaining clip’s wings snap and stay on the barbs of the C-Clip.

• If they are, the cap is fully seated now.

Figure 28: Use the handling tool to move the retaining clip into position.

Figure 29: The handling tool makes snapping the clip’s wings into place easier.

iUPR installation and injection are now complete.

Operating Instructions 1. Before loadmake or loadbreak operation.

Loadbreak connectors must be operated with an 8ft fully-insulated “hotstick” type of tool.

Remove fluid access interface and install the elbow cap before operating elbow

©Novinium, Inc. 2019, all rights reserved. NRI 522 – 200A Elbows – iUPR Revised: September 9th, 2019 Page 13 of 15

• For Injection use, the access interface (AI) is always installed before the elbow is put onto the bushing.

Clear the area of obstructions or contaminants that can interfere with connector operation and allow establishing firm footing and a secure grasp of the hotstick tool.

Maintain positive control over the movement of the loadbreak connector before, during, and directly after the operating sequence.

• Certain operating positions are more advantageous because of the control, speed, and force required to engage or disengage the elbow.

• If there are questions on proper operating position, it is recommended that the connectors be operated de-energized.

Do not connect two different phases of a multiple-phase system.

Before closing a single-phase loop, make sure both ends of the loop are the same phase.

2. Loadmake operation.

Check appropriate accessory device operating instructions to be sure that the device is rated for energized

operation.

Clear the area of obstructions or contaminants that can interfere with connector operation.

When preparing the elbow connector bushing, attach the hotstick tool to the bushing cap pulling eye.

Following the instructions for this accessory, remove the cap from bushing.

Securely fasten a hotstick to the loadbreak connector pulling eye.

Establish firm footing and positive control of the elbow connector.

Withdraw the elbow with a fast, straight, and firm motion from the accessory device on the apparatus parking stand.

Be careful not to place the elbow connector near a ground plane.

Place the elbow connector receptacle area over the bushing plug.

Insert the elbow male contact (arc follower portion) into the bushing until the first slight resistance is felt.

• Resistance is felt when the arc follower portion of the male contact first meets the female contact of the bushing (the contacts are approximately 2” apart).

• NOTE: do NOT hold in this position but immediately push the elbow home with a fast, firm, and straight motion, which will engage the internal lock on the elbow and bushing interface.

• Apply sufficient force to engage the internal lock on the elbow connector and bushing interface.

3. Fault close.

• It is not recommended that operations be made on known faults.

©Novinium, Inc. 2019, all rights reserved. NRI 522 – 200A Elbows – iUPR Revised: September 9th, 2019 Page 14 of 15

• If a fault is experienced, both the elbow connector and the bushing must be replaced.

4. Loadbreak operation.

Place the desired accessory device on the apparatus parking stand.

• NOTE: Refer to appropriate operating instructions for accessory device to be used.

• Make sure it is rated for energized operation.

Firmly tighten a hotstick to the loadbreak connector pulling eye.

Without exerting any pulling force, slightly rotate the connector in order to break surface friction prior to disconnecting.

Withdraw the connector from the bushing with a fast, firm, and straight motion, being careful not to place the connector near a ground plane.

Place the connector on the appropriate accessory device, following the operating instructions for that accessory.

5. Voltage test on Novinium 1-EB-15kV and 1-EB-25kV.

The elongated versions of the Novinium 1-EB-15kV and 1-EB-15kV loadbreak elbow connectors

manufactured by Elastimold are equipped with integral capacitance test points that can be used to

establish whether or not the circuit is energized. All test instruments, equipment, and accessories must be

the appropriate type and rating for the application they will be used for. Proper functionality must be

verified before and after an absence of voltage test, per the individual equipment instructions. When using

the test point, complete the following steps:

Remove the test point cap with a hot stick.

• When removing the cap, peel off at an angle rather than pulling directly in line with the test point assembly.

Using a suitable sensing device, proceed to determine if the cable is energized.

• Do NOT use conventional voltage measuring equipment.

• WARNING: the voltage test point is a capacitance device; it is not directly connected to the conductor.

• 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 test point and then lubricate the inside surface of the cap with silicone grease and replace it on the test point.

©Novinium, Inc. 2019, all rights reserved. NRI 522 – 200A Elbows – iUPR Revised: September 9th, 2019 Page 15 of 15

6. Injection application supplement.

The elbow is deadfront only when the following conditions exist:

• The access port is covered with the insulated cap.

• All shields are properly grounded.

When the fluid access interface (AI) is installed, the AI, elbow, injection and collection tubes, and containers are not shielded and must be treated as energized when used to inject cable rejuvenation fluid.

• During the injection process, water within the cable may be forced out the collection tube. This water may be a conductive path from the energized conductor through the unshielded fluid collection system. The tubing must be isolated from any grounded surface by a distance greater than 1 inch.

• Do NOT disconnect the elbow during the injection process with the access interface installed. The fluid access interface was designed for non-submersible application only. Water submersion can cause electrical failure of the injection or collection system resulting in an arc to ground. Call Engineering at (253) 395-0200 for information on submersible applications.

3M® is a registered trademark of 3M, Cooper® is a registered trademark of Cooper Power Systems, and

Elastimold® is a registered trademark of Thomas & Betts. Novinium is an original equipment manufacturer

and service provider, and is not affiliated with Thomas & Betts, Cooper, or 3M.