Tools and Hardware
MN325001EN
COOPER POWER
Effective February 2015
Supersedes S325-40-1 October 2011
SERIES
Load pickup clamp assembly for 15 kV systems, 300 A maximum
installation and maintenance instructions
DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITY
The information, recommendations, descriptions and safety notations in this document are based on Eaton Corporation’s
(“Eaton”) experience and judgment and may not cover all contingencies. If further information is required, an Eaton sales
office should be consulted. Sale of the product shown in this literature is subject to the terms and conditions outlined in
appropriate Eaton selling policies or other contractual agreement between Eaton and the purchaser.
THERE ARE NO UNDERSTANDINGS, AGREEMENTS, WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES
OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OTHER THAN THOSE SPECIFICALLY SET OUT IN ANY
EXISTING CONTRACT BETWEEN THE PARTIES. ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF EATON. THE
CONTENTS OF THIS DOCUMENT SHALL NOT BECOME PART OF OR MODIFY ANY CONTRACT BETWEEN THE PARTIES.
In no event will Eaton be responsible to the purchaser or user in contract, in tort (including negligence), strict liability or otherwise for any special, indirect, incidental or consequential damage or loss whatsoever, including but not limited to damage or
loss of use of equipment, plant or power system, cost of capital, loss of power, additional expenses in the use of existing
power facilities, or claims against the purchaser or user by its customers resulting from the use of the information, recommendations and descriptions contained herein. The information contained in this manual is subject to change without notice.
ii
Load pickup clamp assembly for 15 kV systems installation and maintenance instructions MN325001EN February 2015 www.cooperpower.com
Contents
SAFETY INFORMATION
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
PRODUCT INFORMATION
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Acceptance and Initial Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Handling and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
APPLICATION INFORMATION
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION PROCEDURE
Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Load Pickup Clamp Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL
Load Pickup Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSPECTION AND MAINTENANCE
Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DISASSEMBLY
Conductor Clamp and Upper Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Actuator Tube/Inner Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Jumper Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ASSEMBLY PROCEDURE
Jumper Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Load Pickup Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
STEPS FOR PICKUP CLAMPS WITH SLOTTED SCREWS
Pickup Clamps with Slotted Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
PARTS AND ACCESSORIES
Load Pickup Clamp Assembly Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Load pickup clamp assembly for 15 kV systems installation and maintenance instructions MN325001EN February 2015 www.cooperpower.com
iii
!
Safety for life
SAFETY
FOR LIFE
!
SAFETY
FOR LIFE
Eaton’s Cooper Power™ series products meet or exceed all applicable industry standards relating to product safety. We
actively promote safe practices in the use and maintenance of our products through our service literature, instructional
training programs, and the continuous efforts of all Eaton employees involved in product design, manufacture, marketing,
and service.
We strongly urge that you always follow all locally approved safety procedures and safety instructions when working around
high voltage lines and equipment, and support our “Safety For Life” mission.
Safety information
The instructions in this manual are not intended as a
substitute for proper training or adequate experience
in the safe operation of the equipment described.
Only competent technicians who are familiar with this
equipment should install, operate, and service it.
Safety instructions
Following are general caution and warning statements that
apply to this equipment. Additional statements, related to
specific tasks and procedures, are located throughout the
manual.
A competent technician has these qualifications:
• Is thoroughly familiar with these instructions.
• Is trained in industry-accepted high and low-voltage safe
operating practices and procedures.
• Is trained and authorized to energize, de-energize, clear,
and ground power distribution equipment.
• Is trained in the care and use of protective equipment
such as arc flash clothing, safety glasses, face shield,
hard hat, rubber gloves, clampstick, hotstick, etc.
Following is important safety information. For safe
installation and operation of this equipment, be sure to
read and understand all cautions and warnings.
Hazard Statement Definitions
This manual may contain four types of hazard
statements:
DANGER
Hazardous voltage. Contact with hazardous voltage will
cause death or severe personal injury. Follow all locally
approved safety procedures when working around highand low-voltage lines and equipment.
G103.3
WARNING
Before installing, operating, maintaining, or testing this
equipment, carefully read and understand the contents
of this manual. Improper operation, handling or
maintenance can result in death, severe personal injury,
and equipment damage.
G101.0
WARNING
Indicates an imminently hazardous situation which, if
not avoided, will result in death or serious injury.
This equipment is not intended to protect human
life. Follow all locally approved procedures and safety
practices when installing or operating this equipment.
Failure to comply can result in death, severe personal
injury and equipment damage.
G102.1
WARNING
WARNING
DANGER
Indicates a potentially hazardous situation which, if
not avoided, could result In death or serious injury.
CAUTION
Indicates a potentially hazardous situation which, if
not avoided, may result in minor or moderate injury.
CAUTION: Indicates a potentially hazardous situation
which, if not avoided, may result in equipment
damage only.
iv
Power distribution and transmission equipment must
be properly selected for the intended application. It
must be installed and serviced by competent personnel
who have been trained and understand proper safety
procedures. These instructions are written for such
personnel and are not a substitute for adequate training
and experience in safety procedures. Failure to properly
select, install or maintain power distribution and
transmission equipment can result in death, severe
personal injury, and equipment damage.
G122.3
Load pickup clamp assembly for 15 kV systems installation and maintenance instructions MN325001EN February 2015 www.cooperpower.com
Product Information
Introduction
Eaton's Cooper Power™ series load pickup clamp assembly
installation instructions gives customers the ability and
guidance to replace the load pickup clamp assembly.
Read this manual first
Handling and storage
Be careful during handling and storage of the load pickup
clamp assembly to minimize the possibility of damage. If
the reversing stationary contacts are to be stored for any
length of time prior to installation, provide a clean, dry
storage area.
Standards
ISO 9001 Certified Quality Management System
Read and understand the contents of this manual and follow
all locally approved procedures and safety practices before
installing or operating this equipment.
Additional information
These instructions cannot cover all details or variations
in the equipment, procedures, or process described nor
provide directions for meeting every possible contingency
during installation, operation, or maintenance. For additional
information, contact your representative.
Acceptance and initial inspection
Each load pickup clamp assembly is in good condition when
accepted by the carrier for shipment. Upon receipt, inspect
the shipping container for signs of damage. Unpack the load
pickup clamp assembly and inspect it thoroughly for damage
incurred during shipment. If damaged is discovered, file a
claim with the carrier immediately.
Load pickup clamp assembly for 15 kV systems installation and maintenance instructions MN325001EN February 2015 www.cooperpower.com
1
Application information
Flexible jumper cable
•
WARNING
Do not use between phases or as a grounding set.
The Load Pickup Clamp assembly is intended for use as a
temporary jumper to establish a circuit between energized
and non-energized sections of a single phase.
The Load Pickup Clamp Assembly is designed to pick up
the electrical load that may be present in the non-energized
section of the line, provided that:
•
•
•
Load is within specified limits-Maximum 300 A.
Both the Load Pickup and Jumper Clamps in the set have
been installed properly on the line
Load Pickup Clamp contacts are actuated to the closed
position
WARNING
The Load Pickup Clamp Assembly is designed for use on
one phase of a distribution system in which the maximum phase-to-phase voltage is 15 kV. Maximum phaseto-ground voltage across the contacts of the Load
Pickup Assembly must not exceed 8.3 kV.
•
Construction to conform to the latest applicable IPCEA
S-19-81 NEMA® WC3 Specification
Insulation and ampacity ratings to be compatible with the
electrical circuit on which it is to be used.
WARNING
Load Pickup Clamp Assembly is not a loadbreak device.
Prior to removal from the circuit and prior to the load
pickup clamp assembly being opened, a solid parallel
current path must be established.
Table 1. Ratings
Max.
Current
Rating*
(A)
Max.
PhasetoGround
Voltage
Conductor
Range
Minimum
300 A
8.3 kV
# 6 Sol.
Conductor Range
Maximum
Jumper
Cable**
800 KCMIL Str. or 795
KCMIL
26/7 ACSR
# 2, 1/0
or
2/0
* Rating limited to the rating of cable installed.
** Use of cable not shown in table is not recommended.
Maximum current should not exceed 300 amperes. Load
Pickup Clamp Assembly is intended for use only in conjunction with and connected to a companion Jumper
Clamp by means of a suitable length of Flexible Jumper
Cable.
2
Load pickup clamp assembly for 15 kV systems installation and maintenance instructions MN325001EN February 2015 www.cooperpower.com
Installation procedure
Step 3
Load pickup clamp assembly installation
Grip Handle of Load Pickup Clamp at "A" and turning clockwise, install the Load Pickup Clamp on the de‑energized
line. See Figure 3.
WARNING
Assure that a fault condition does not exist prior
to installation and that proper dielectric clearances
are maintained to other energized or grounded
components. Failure to comply could result in death or
personal injury.
Step 1
Set the Load Pickup Clamp in "Open" Position by gripping
Actuator Tube at "B". Pull fully down to the "Stop". Turn to
the right to the "Stop" and release. See Figure 1.
Figure 2. Unthread the load pickup conductor clamp/
contact.
WARNING
A
Do not use or hold the Actuator Tube when installing
Load Pickup Clamp on the de-energized line. The
Actuator Tube may trip the contact rod closing the
circuit to the Jumper Clamp resulting in death or
personal injury when the Jumper Clamp is installed.
B
Figure 1. Opening Load Pickup Clamp.
Step 2
A
Unthread Conductor Clamp/Contact of Load Pickup Clamp
to clear the approximate diameter of the conductor to be
installed on. See Figure 2.
Figure 3. Installing Load Pickup Clamp on De-energized
Line.
Load pickup clamp assembly for 15 kV systems installation and maintenance instructions MN325001EN February 2015 www.cooperpower.com
3
Step 4
Step 6A
Unthread Conductor Clamp of Jumper Clamp to the
approximate diameter of the conductor to be installed. See
Figure 4.
Returning to the Load Pickup Clamp, grip the Actuator
Tube at "B" then push and hold fully into the Handle to the
stop. See Figure 6. Continue the operations as described in
Step 6B.
Figure 4. Unthread Conductor Clamp of Jumper Clamp.
B
Step 5
Grip the handle of the Jumper Clamp at "A" and turning
clockwise, install the Jumper Clamp on the energized line.
See Figure 5.
Figure 6. Pushing the activator tube upward into the
handle.
Step 6B
Turn the Actuator Tube to the left (as referenced when
viewing the instruction label on the Actuator Tube) to initiate
unrestricted, automatic closing. See Figure 7.
A
Figure 5. Installing the jumper clamp on the line.
Figure 7. Initiating automatic closing.
4
Load pickup clamp assembly for 15 kV systems installation and maintenance instructions MN325001EN February 2015 www.cooperpower.com
Removal
Step 2
Load pickup assembly removal
Grip handle of the Jumper Clamp at "A" and turning
counter-clockwise, remove the Jumper Clamp from the line.
See Figure 9.
WARNING
The Load Pickup Assembly is not a loadbreak device.
Prior to removal from the circuit and prior to the Load
Pickup Clamp being opened, a solid parallel current path
must be established. Failure to comply may result in
death or personal injury.
A
Step 1
Set the Load Pickup Clamp in "Open" Position by gripping
the Actuator Tube at "B", pull fully down to the "Stop". Turn
the Actuator to the right to the "Stop" and release. See
Figure 8. Do not remove from line at this time.
CAUTION
Do not install or remove Load Pickup Clamp from
the line with the contacts closed. This will cause
unnecessary Contact and Contact Rod wear and
possible damage.
Figure 9. Removing the jumper clamp from the line.
Step 3
Returning to the Load Pickup Clamp, grip the Handle at
"A" and turning counter-clockwise, remove the Load Pickup
Clamp from the line. See Figure 10.
A
B
Figure 10. Removing the load pickup clamp from the unit.
Figure 8. Opening the load pickup clamp.
Load pickup clamp assembly for 15 kV systems installation and maintenance instructions MN325001EN February 2015 www.cooperpower.com
5
Inspection and maintenance
Eaton recommends that an inspection and maintenance
program be established.
•
•
Ensure that each Load Pickup Clamp Assembly is
thoroughly inspected after 25 operations or 90 days,
whichever comes first.
If used during adverse weather conditions, it is recommended that a full inspection is performed.
Step 2
Clean Conductor Clamp and Upper Contact with Salisbury
Solvent, #2002 or equivalent. See Figure 12.
CAUTION
Do not use solvents or any type of aerosol cleaners or
lubricants on or near plastic parts. Use of solvents may
compromise the integrity of the plastic parts.
CAUTION
Do not use solvents or any type of aerosol cleaners or
lubricants on or near plastic parts. Use of solvents may
compromise the integrity of the plastic parts.
•
Conductor Clamp
During inspection/maintenance, the following parts
should be disassembled:
•
Upper Contact
•
Handle Assembly
•
Actuator Tube
•
Inner Tube Assembly
Load Pickup
Clamp Assembly
Disassembly
Conductor clamp and upper contact
Step 1
Make sure the Load Pickup Clamp is in the "Open" position.
Unthread and remove the Conductor Clamp from the Load
Pickup Clamp Assembly. See Figure 11.
CAUTION
Do not remove Load Pickup Conductor Clamp with the
contacts closed. This will cause unnecessary Contact
and Contact Rod wear and possible damage.
Figure 11. Removing the conductor clamp from the
assembly.
Conductor
Clamp
Upper Contacts
Figure 12. Cleaning conductor clamp and upper contacts.
6
Load pickup clamp assembly for 15 kV systems installation and maintenance instructions MN325001EN February 2015 www.cooperpower.com
Step 3
Step 5
Inspect Conductor Clamp and Upper Contacts for cracks or
breaks. See Figure 13.
Lubricate Multi-lam Contact with Eaton's Cooper Power
series Kearney™ Contact Lubricant, Catalog #132488. See
Figure 15.
WARNING
Conductor Clamps and Upper Contacts with cracks
or breaks should be replaced. Failure to comply could
result in personal injury or death.
Inspect for Cracks
Figure 15. Lubricate Contacts.
Step 6
Close Load Pickup Clamp Contact Assembly. See Figure 16.
Figure 13. Conductor Clamp and upper contacts.
Step 4
Use gauge to ensure proper sizing of Multi-lam Contact.
See Figure 14.
Figure 16. Closing the contact assembly.
Figure 14. Gauge Contacts.
Load pickup clamp assembly for 15 kV systems installation and maintenance instructions MN325001EN February 2015 www.cooperpower.com
7
Handle assembly
Step 9
Remove the Handle. See Figure 19.
Step 7
Remove both of the Handle Assembly screw caps. See
Figure 17.
Handle
Figure 17. Removing the screw caps.
Figure 19. Removing handle from assembly.
Step 8
Using a 5/32" (or 4 mm) hex, remove both of the Handle
Assembly hex screws. See Figure 18.
•
Hex Screw
•
Clean Handle with warm, soapy water (or mild
detergent) to remove carbon/soot and other
contaminants.
Inspect the Handle for cracks or chips.
WARNING
Extensive carbon buildup is a likely sign that the Load
Pickup Assembly has been used as a loadbreak device
and the device shall be removed from service.
CAUTION
Do not use solvents or any type of aerosol cleaners or
lubricants on or near plastic parts. Use of solvents may
compromise the integrity of the plastic parts.
Figure 18. Removing the handle hex screws.
WARNING
Handle Assemblies with cracks or chips should be
replaced. Failure to comply could result in equipment
fracture, personal injury or death.
8
Load pickup clamp assembly for 15 kV systems installation and maintenance instructions MN325001EN February 2015 www.cooperpower.com
Step 12
Actuator tube/inner tube assembly
Remove Contact Rod and Spring from the Inner Tube. See
Figure 22.
Step 10
Remove the Inner Tube Cap from the Inner Tube Assembly.
See Figure 20.
•
Inspect Contact Rod
—Plating - Ensure that the plating is still present on the
Contact Road and in good condition. If the plating is in
poor condition, the Contact Rod should be replaced.
—Scratches - If extensive scratches are present, the
Contact Rod should be replaced.
Inner Tube Cap
•
•
Inspect the Spring and measure the free length. Replace
if the Spring shows signs of damage or the free length is
not between 10.5 and 11.3 inches.
Clean the Contact Rod and the Spring with Salisbury
Cleaner, #2002 or equivalent.
CAUTION
Do not use solvents or any type of aerosol cleaners or
lubricants on or near plastic parts. Use of solvents may
compromise the integrity of the plastic parts.
Figure 20. Removing inner tube cap.
CAUTION
Because the Contact Rod/Spring in the Inner Tube
Assembly is under tension, care must be taken to
secure the Contact Rod prior to removal of the screw to
prevent the Contact Rod and Spring from rapidly exiting
the Inner Tube Assembly.
Spring
Contact Rod
Assembly
Inner Tube
Step 11
Secure Contact Rod, and determine:
A. If the Load Pickup Clamp has a slotted screw, remove
the screw and proceed to Steps for Pickup Clamps
with Slotted Screws page 19.
B. If the Load Pickup Clamp has a screw with internal hex
use a 1/8" (3 mm) hex key, remove the screw holding
Actuator Tube and Inner Tube Assembly together. See
Figure 21.
Inner Tube
Actuator Tube
Figure 22. Inner tube assembly components.
Actuator Tube
Figure 21. Unfastening actuator tube from inner tube
assembly.
Load pickup clamp assembly for 15 kV systems installation and maintenance instructions MN325001EN February 2015 www.cooperpower.com
9
Step 13
Step 15
Slide the Actuator Tube back onto the cable. See Figure 23.
Using a 15/16" wrench and pliers, loosen the lock nut on the
ferrule. See Figure 25.
Actuator Tube
Inner Tube
Figure 23. Sliding the actuator tube onto the cable.
Figure 25. Loosening the lock nut.
Step 14
Using a 3/32" hex, remove the set screw from the
ferrule. See Figure 24.
Step 16
Unthread the Inner Tube Assembly from the ferrule. See
Figure 26.
Cable Ferrule
Figure 24. Removing the set screw from the ferrule.
10
Figure 26. Removing the inner tube from the ferrule.
Load pickup clamp assembly for 15 kV systems installation and maintenance instructions MN325001EN February 2015 www.cooperpower.com
Step 17
Step 19
Remove the Lower Contacts from the Inner Tube. See
Figure 27.
Inspect Lower Contacts. See Figure 29.
L-slot
Inner Tube
Lower Contacts
Figure 29. Inspect Lower Contacts.
Figure 27. Removing lower contact from inner tube.
•
Step 20
Use gauge to ensure proper sizing of Multi-lam Contact.
See Figure 30.
Clean the Inner Tube and Inner Tube Cap with warm
soapy water (or mild detergent) to remove carbon/soot or
other contaminants.
CAUTION
Do not use solvents or any type of aerosol cleaners or
lubricants on or near plastic parts. Use of solvents may
compromise the integrity of the plastic parts.
•
Inspect the Inner Tube and the Inner Tube cap for cracks
and chips, paying special attention to the L-slot areas. See
Figure 27 for location of L-slot.
WARNING
Inner Tubes with cracks or chips shall be replaced.
Failure to comply could result in equipment fracture,
personal injury or death.
Step 18
Figure 30. Gauge Lower Contacts.
Step 21
Lubricate Multi-lam Contact with Kearney Contact
Lubricant, Catalog #132488. See Figure 31.
Clean the Lower Contacts with Salisbury Cleaner #2002 or
equivalent. See Figure 28.
Figure 31. Lubricate Lower Contacts.
Figure 28. Cleaning Lower Contacts.
Load pickup clamp assembly for 15 kV systems installation and maintenance instructions MN325001EN February 2015 www.cooperpower.com
11
Jumper clamp
Step 22
Slide the Actuator Tube off of the cable. See Figure 32.
Step 24
Unthread and remove the Conductor Clamp from the
Actuator
Tube
Conductor Clamp
Jumper Clamp Assembly
Figure 32. Removing actuator tube from the cable.
Figure 34. Removing the conductor clamp from the
jumper clamp.
•
Clean the Actuator Tube with warm, soapy water (or mild
detergent) to remove soot and other contaminants.
CAUTION
Do not use solvents or any type of aerosol cleaners or
lubricants on or near plastic parts. Use of solvents may
compromise the integrity of the plastic parts.
•
Jumper Clamp Assembly. See Figure 34.
Step 25
Using a 1/8" hex wrench, remove the hex screw from the
Jumper Conductor Clamp. See Figure 35.
Inspect the Actuator Tube for cracks or chips.
WARNING
Actuator Tubes with cracks or breaks shall be replaced.
Failure to comply could result in fracture of the actuator
tube, personal injury or death.
Step 23
Inspect the cable and ferrule for cable strand damage. See
Figure 33. Cables with strand damage should be replaced.
Inspect for Cable Strand Damage
Conductor Clamp Hex Screw
Figure 35. Removing the hex screw.
Figure 33. Inspecting the cable.
12
Load pickup clamp assembly for 15 kV systems installation and maintenance instructions MN325001EN February 2015 www.cooperpower.com
Step 26
Using a 15/16" wrench and pliers, remove the Jumper
Conductor Clamp from the cable ferrule. See Figure 36.
Figure 36. Removing the conductor clamp from the cable
ferrule.
•
•
Clean the Conductor Clamp with Salisbury Cleaner #2002
or equivalent.
Inspect the Conductor Clamp for cracks or breaks.
WARNING
The Conductor Clamps with cracks or breaks shall be
replaced. Failure to comply could result in equipment
fracture, personal injury or death.
Step 27
Inspect cable and ferrule for the cable strand damage.
Cables with strand damage should be replaced. See Figure
37.
Inspect for Cable Strand Damage
Figure 37. Inspecting the cable.
Load pickup clamp assembly for 15 kV systems installation and maintenance instructions MN325001EN February 2015 www.cooperpower.com
13
Assembly procedure
Step 3
Thread the Conductor Clamp onto the Jumper Clamp
Assembly. See Figure 40.
Jumper clamp
Step 1
Thread the Conductor Clamp onto the cable ferrule and
align the hole with the flat on the ferrule. Using a 1/8" hex
wrench, install the hex set screw and tighten. See Figure
38.
Figure 40. Installing the conductor clamp onto the
jumper clamp assembly.
Load pickup clamp
Step 4
Go to the opposite end of the cable.
Figure 38. Installing the conductor clamp on the ferrule.
Slide the Actuator Tube onto the cable. See Figure 41.
Actuator Tube
Step 2
Cable
Using a 15/16" wrench, tighten the ferrule locknut and
washer against Conductor Clamp. See Figure 39.
Figure 41. Installing the actuator tube on the cable.
Figure 39. Securing the conductor clamp on the ferrule.
14
Load pickup clamp assembly for 15 kV systems installation and maintenance instructions MN325001EN February 2015 www.cooperpower.com
Step 5
Step 8
Insert the lower contact into the Inner Tube. See Figure 42.
Using a 15/16" wrench, tighten the ferrule locknut against
the bottom of the Lower Contact. See Figure 45.
Threaded End
Figure 42. Inserting the contact into the inner tube.
Step 6
Thread the Lower Contact and Inner Tube onto the cable
ferrule and align the hole with the flat on the ferrule. See
Figure 43.
Figure 45. Tightening the ferrule locknut.
Step 9
Insert the Contact Rod, Spring (large end first) and Inner
Tube cap into the Inner Tube. See Figure 46.
Small End of Spring
Figure 43. Installing the inner tube on the cable ferrule.
Step 7
Using a 5/32" hex wrench, install the hex screw and tighten.
See Figure 44.
Figure 46. Installing the contact rod, spring and inner
tube cap.
Figure 44. Installing the hex screw.
Load pickup clamp assembly for 15 kV systems installation and maintenance instructions MN325001EN February 2015 www.cooperpower.com
15
Step 10
Step 12
Apply tension to the Contact Rod/Spring and align the
threaded hole in the Contact Rod Collar with the slot in the
Inner Tube. See Figure 47.
Apply a small amount of Loctite® 242 threadlocker to the
threads of the screw.
NNote: Avoid contacting the plastic parts with Loctite. Any
deposits should be wiped up immediately.
Using a 1/8" (3 mm) hex key, thread the screw in and
tighten. See Figure 49.
Figure 47. Aligning the contact rod in the inner tube.
Figure 49. Installing and tightening the screw.
Step 11
Slide the Actuator Tube forward, lining the slot up with the
slot in the Inner Tube and threaded hole in the Contact Rod
Collar. See Figure 48.
Step 13
Install the Handle. See Figure 50.
Figure 50. Installing the handle.
Figure 48. Aligning the actuator tube with inner tube and
contact rod collar.
16
Load pickup clamp assembly for 15 kV systems installation and maintenance instructions MN325001EN February 2015 www.cooperpower.com
Step 14
Step 16
Align the holes in the handle with the holes in the inner
tube assembly.
Place the Contact Assembly in the open position. See
Figure 53.
•
Using a 5/32" hex, install both the Handle hex screws.
Torque to 40 in-lbs maximum. See Figure 51.
Align Holes with Holes in Inner Tube Assembly


Figure 53. Opening the contact assembly.
Figure 51. Installing the handle hex screws.
Step 17
Thread the Conductor Clamp into the Handle Assembly. See
Figure 54.
Step 15
Install both Handle screw caps. See Figure 52.
Conductor Clamp
Handle Assembly
Figure 54. Installing the conductor clamp onto the
handle.
Figure 52. Installing the screw caps.
CAUTION
Do not thread or unthread the Conductor Clamp with
the Contacts in a closed position. This will cause
unnecessary Contact/Contact Rod wear and possible
damage.
Load pickup clamp assembly for 15 kV systems installation and maintenance instructions MN325001EN February 2015 www.cooperpower.com
17
Step 18
Close the Contact Assembly. See Figure 55.
Figure 55. Closing the contact assembly.
Step 19
Open and close the Contact Assembly several times to
ensure the Load Pickup Clamp is operating properly.
Step 20
Close Contact Assembly. Assure electrical continuity
through the use of an ohmmeter.
Step 21
Open Contact Assembly. With the conductor clamp fully
tightened, assure voltage withstand of 15 kV (DC Hi-Pot
test) for one minute.
18
Load pickup clamp assembly for 15 kV systems installation and maintenance instructions MN325001EN February 2015 www.cooperpower.com
Steps for pickup clamps with slotted
screws
Step 2
Step 1
Old design - Replace with a new collar by following Steps
23 through 25.
Remove Contact Rod and Spring from the Inner Tube. See
Figure 56.
•
Inspect the Contact Rod Assembly and determine if the
collar is the old or new design. See Figure 57.
New design - Proceed to Step 26 on page 13.
Inspect Contact Rod
–– Plating - Ensure that the plating is still present on the
Contact Rod and in good condition. If the plating is in
poor condition, the Contact Rod should be replaced.
–– Scratches - If extensive scratches are present, the
Contact Rod should be replaced.
•
•
Inspect the Spring for any damage and replace as
necessary.
Clean the Contact Rod and the Spring with Salisbury
Cleaner, #2002 or equivalent.
Chamfered Outer
Edges
CAUTION
Do not use solvents or any type of aerosol cleaners or
lubricants on or near plastic parts. Use of solvents may
compromise the integrity of the plastic parts.
Figure 57. New collar to the left. Note the chamfered
outer edges.
Spring
Contact Rod
Assembly
Step 3
Inner Tube
If the screw has broken off, replace the complete Contact
Rod Assembly (Catalog Number 132479CPS). See
Figure 58.
Actuator Tube
Figure 56. New collar to the left. Note the chamfered
outer edges.
Figure 58. Contact Rod Assembly with broken screw.
Load pickup clamp assembly for 15 kV systems installation and maintenance instructions MN325001EN February 2015 www.cooperpower.com
19
Step 4
Step 6
Remove one of the retainers with the help of two flat head
screw drivers as shown. If a vise is used, be sure to protect
the rod from damage by using a soft cloth or some other
protection between the jaws of the vise and the Contact
Rod surface. Remove the collar. See Figure 59.
To test the new collar and screw, insert a new screw (see
Step 14A) and tighten. If the collar spins freely on the
Contact Rod, the parts are good and the completed assembly will work correctly. Remove the screw and set it aside. It
will be used later in the Reassembly Procedure. See Figure
61.
NNote: If the collar doesn't spin freely, remove the screw
and replace it with a new screw. If it still doesn't
work, replace the collar and discard. Check the
assembly again by following the above procedures.
Figure 59. Removing the retaining ring.
Figure 61. Check the installation of a new collar and
screw.
Step 5
Slide a new Collar onto the Contact Rod and re-install the
retaining ring(s). A pair of pliers may be helpful in pushing
the retainer back into the groove on the Contact Rod. Make
sure all three tabs on the retaining ring are seated in the
groove. If the retaining ring is bent, replace it with a new
retaining ring, Catalog Number 64184-2. See Figure 60.
Step 7
Slide the copper washer over the long end of the Contact
Rod Assembly followed by the small end of the spring. See
Figure 62.
NNote: If the spring has never been replaced or it was a long
time (five years or more) since it was last replaced,
this would be a good time to replace the spring as
well.
Spring Catalog Number: 13916-2
Figure 60. Re-installing the retaining ring.
Figure 62. Installing the spring on the Contact Rod
Assembly.
Continue the dis-assembly process in Step 13 on
Page 10.
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Load pickup clamp assembly for 15 kV systems installation and maintenance instructions MN325001EN February 2015 www.cooperpower.com
Parts and accessories
11
8
12
12
7
11
19
9
10
1
6
14
15
3
2D
2B
2A
2
16 17
5
20
21
Opposite Label
1A
2C
13
22
4
18
Figure 63. Load Pickup Clamp Assembly parts breakdown.
Load pickup clamp assembly for 15 kV systems installation and maintenance instructions MN325001EN February 2015 www.cooperpower.com
21
Table 1. Parts and Accessories
Load Pickup Clamp and Cable
1
132476-4
Inner Tube
1A
134595
Inner Tube Cap
2
132479CPS
Contact Rod Assembly Includes:
2A
134345
Contact Rod
2B
64184-2
Ring Retainer
2C
134346
Collar
2D
279634-1
Washer
3
13916-2
Spring
4
0839869A03
Set Screw with Hex
5
132499
Contact Tube Assembly
6
760401310018R
Set Screw, 10-32 x 3/16
7
132480-1
Load Pickup Handle Assembly
8
132498
Conductor Clamp with Cap
9
134598-1
Outer Handle Tube
10
16649-1
Cap Only
11
66107-2
Hole Plug
12
733601125050R
Flat Head Screw
13
134352-1
Actuator Tube
14
3806-002
Cable #2 (Specify length)
14
3806-010
Cable 1/0 (Specify length)
14
3806-020
Cable 2/0 (Specify length)
15
30365-1
Ferrule Assembly for #2 Cable
15
30365-2
Ferrule Assembly for #1/0 Cable
15
30365-3
Ferrule Assembly for #2/0 Cable
16
880615111062R
Nut, Hex Jam SS 5/8-11
17
900815062000R
Lock Washer 5/8
18
1330-263
Decal, Warning
19
1939981A01
Decal, Caution
20
1330-269
Decal, Large
21
1330-236
Decal, Small
22
1330-217
Decal, “OPEN”
Jumper Clamp* (132284)
Jumper Clamp Handle Assembly
1
132284JH
(Items 2, 3 and 4 not included)
2
16644-28
Brass Contact Body
3
16649-1
Rubber Cap
4
760415125018R
Set Screw 1/4-20 x 3/16
Not Pictured
SK31479-2
Multi-Lam Contact Gauge
Not Pictured
132488
Contact Lubricant
Accessories
* Not pictured.
22
Load pickup clamp assembly for 15 kV systems installation and maintenance instructions MN325001EN February 2015 www.cooperpower.com
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Load pickup clamp assembly for 15 kV systems installation and maintenance instructions MN325001EN February 2015 www.cooperpower.com
23
!
SAFETY
FOR LIFE
Eaton
1000 Eaton Boulevard
Cleveland, OH 44122
United States
Eaton.com
Eaton’s Cooper Power Systems
Division
2300 Badger Drive
Waukesha, WI 53188
United States
Cooperpower.com
© 2015 Eaton
All Rights Reserved
Printed in USA
Publication No. MN325001EN Rev 00
Supersedes S325401CPS Rev 04
Eaton. Cooper Power, and Kearney are
valuable trademarks of Eaton, in the U.S.
and other countries. You are not permitted
to use these trademarks without the prior
written consent of Eaton.
NEMA® is a registered trademark of the
National Electrical Manufacturers
Association.
Loctite® is a registered trademark of
Henkel Corporation.
For Eaton's Cooper Power
series load pickup clamp
assembly product
information call
1-877-277-4636 or visit:
www.cooperpower.com.