1221 29th St. NW, Suite D
Auburn, WA 98001
(206) 529-4828
help@novinium.com
Rejuvenation Instructions
Power Cables Installation &
Operation
Of 15kV & 25kV Injection
Elbow
1-EB-15kV & 1-EB-25kV
The contents of this document are the property of Novinium, Inc. and may not be duplicated or distributed without the
express written consent of Novinium. Novinium®, Ultrinium™, Tailored Injection™, Tailored Formulation™, Perficio™, NRex™, N-Ter™ and Single visit – single switch™ are trademarks of Novinium. Novinium has patents granted or pending
on many of the technologies described by these instructions including but not limited to:

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Ultrinium™ sustained pressure injection method (U.S. Patent 7,615,247 and 8,205,326)
Ultrinium™ formulation optimization injection method (U.S. Patent 7,611,748)
Injection Adaptor (U.S. Patents 7,195,504, 7,538,274 and 7,683,260)
Perfectium™ single visit, single switch injection (U.S. Patent 7,353,601)
Formulation of Ultrinium™ & Perficio™ components (U.S. Patents 7,658,808, 7,700,871 and 8,101,034)
Predicting performance of Electrical Power cables (U.S. Patents 7,643,977 and 7,848,912)
N-Rex™ submarine cable injection process (U.S. Patent 7,976,747)
N-Ter™ injection or Novinium thermally enhanced rejuvenation (patent pending)
Reticular Flash Preventer (RFP) provides safer operation of conventional injection elbows (U.S. patent
8,475,194)
Version 20140902
©Copyright 2014, Novinium, Inc. All rights reserved.
Installation & Operating Instructions
Novinium 1-EB-15kV & 1-EB-25kV
Loadbreak Injection Elbow Connectors
CONTENTS: Elastimold® Elbow, Probe with O-ring, Probe Wrench, Lubricant (Do Not Substitute),
Hose Clamp, Installation & Operating Instructions (NRI 36), templates (4), cable ties, Reticular Flash
Preventer™ (RFP), C-clip, retaining clip, and tags.
OTHER REQUIRED COMPONENTS: Copper-top compression lug, and, when extended length is
required, a Novinium specified splice compression lug and copper conductor.
The 1-EB-15kV and 1-EB-25kV injection elbows are designed to terminate underground distribution
cable having concentric neutral and extruded insulation shielding and provide an access port to
allow injection of Novinium® Ultrinium™ or Perficio™ rejuvenation fluid (Do not substitute). The
elbows provide operating interfaces for connecting respectively to 15kV class (8.3kV phase-toground and 14.4kV phase-to-phase) and 25kV class (15.2kV phase-to-ground and 26.4kV phaseto-phase) 200 ampere loadbreak bushing or accessory device with fault close ratings of 10,000
amperes RMS, symmetrical. 25kV class elbows may also be used on 28kV systems.
All apparatus must be de-energized during installation and removal of
part(s).
Do not energize this component before reading the entirety of this NRI 36.
DANGER
Do not touch or move energized products by hand.
Excess distortion of the assembled product may result in its failure.
Inspect parts for damage, rating and compatibility with mating parts.
All cable preparation must meet or exceed IEEE® P1816™ requirements.
This product should be installed only by qualified personnel trained in good
safety practices involving high voltage electrical equipment. These
instructions are not intended as a substitute for adequate training or
experience in such safety practices.
Direct contact with or close proximity to any of the following in an energized
system can result in electric shock, which will cause serious or fatal injury:
Uncovered elbow port, elbow with fluid access interface, fluid injection tube,
and fluid injection collection containers and fittings.
If fluid has been injected into elbow, there may be considerable pressure,
which will release when the fluid access injector or insulated cap is removed.
Always wear approved eye protection when installing or removing these
caps.
These instructions do not attempt to provide for every possible contingency.
Always exercise caution when working with electrical equipment.
Failure to follow these instructions could result in damage to the product and
serious or fatal injury
©Copyright 2014, Novinium, Inc. All rights reserved.
NRI-15-25kV (36) Page 2 of 14
Pre-Installation Instructions
IMPORTANT
1. Check Your Components
a) Check that the package is complete
and undamaged.
This component has the allowable
insulation diameter range in two units.
The top numbers are in millimeters
(mm) and the bottom numbers are in
inches.
b) Verify components properly fit the
cable and/or mating products.
If practical, the insulation diameter is
20 mils larger than the chosen elbow’s
minimum allowed insulation diameter
and less than or equal to the elbow’s
maximum allowed insulation diameter.
Refer to cable measurement
instructions in NRI 10.
The manufacturer’s allowable
insulation diameter range for this
component is .880-1.110”; Novinium
recommends an insulation O.D. range
of .900-1.110” to ensure a tight fit
c) Read this entire NRI before starting
work.
d) Have all required tools and supplies on
hand and maintain cleanliness
throughout the procedure.
CAUTION
The elbow access port provides
direct access to the cable
conductor. Contact with the
uncovered port or insertion of
objects other than the insulated
cap or fluid access interface fitting
can cause serious or fatal injury.
If the cable is energized during
injection, removal of the insulated
cap and the fluid access interface
must be done with a hot stick tool
following instructions in NRI 62.
2. Initial Inspection and Diagnosis
a) Remove the elbow or other
terminations to access the cable
strands.
Use a probe wrench to remove the
probe from the elbow.
With a back-and-forth twisting motion,
pull the elbow off the cable.
Save the elbow and probe for possible
re-use if the cable has to be replaced.
©Copyright 2014, Novinium, Inc. All rights reserved.
NRI-15-25kV (36) Page 3 of 14
b) Perform the inspection and diagnosis
procedures from NRI 10 and NRI 12.
NRI12: Electronic Cable
Diagnosis & Pinpointing
NRI 10: Visual Inspection &
Measurement
Choose an elbow and connector to match the
wire size and insulation diameter.
If the existing connector and cable
preparation quality are satisfactory
and meet IEEE® P1816™
requirements, the existing
connector may be kept with the
cutbacks modified per the nonextension, or standard templates.
If preparation is not satisfactory,
remove the existing connector
according to NRI 30 steps 1 and 2.
c) Determine if extending the cable
length is desirable and if a capacitive
test point is required.
Cut back the insulation shield and
insulation per the appropriate
template.
Existing
connector
Removal of existing
connector
Removal of existing
connector: see NRI 30
Use the non-extension
template on Page 16
Use the standard
template on Page 18
Use the #2-2/0 extension Use the 3/0 & 4/0 extension
template on Page 20
template on Page 22
d) If the existing connector was kept:
Rotate the connector 30 degrees
(or 1 full hour position on a clock)
in the opposite direction of the
strand lay.
Firmly tap the top of the connector
to open the strands and improve
flow.
Rotate the connector
to open strands
allowing flow
Tap old connector towards cable
If the original connector was removed:
Prepare the strands as instructed
in NRI 30, steps 8 through 13.
The insulation cut back must
include a 7/16” gap with strands
visible to allow a flow path into the
conductor strands.
7/16”
gap
Prepare new strands per
NRI 30 requirements
©Copyright 2014, Novinium, Inc. All rights reserved.
NRI-15-25kV (36) Page 4 of 14
3. Do a Flow Test
a) Perform a level 2 flow test with a CTA.
See NRI 50: Flow and Pressure
Testing.
You can perform an integrated flow
and pressure test using the injection
hardware by installing an injection
elbow (Steps 6 through 7).
b) If a termination using the original
connector does not flow, remove the
connector and prepare the strands as
required in step 1 for new connectors.
c) If a splice does not allow flow,
consider:
Using Sustained Pressure Injection
(SPR)
Replacing the blocked splice(s) per
NRI 33.
Recommend replacement of the
cable. See NRI 60, step 3.
4. Installing a New Compression Connector
If the existing connector was not kept,
install a new connector.
a) If a standard length connector can be
used, go to step 4d.
b) If extending the length is necessary,
install a coppertop extension and
splice connector according to the
appropriate template. (Step 2c
above)
Select the proper coppertop
extension and splice connector from
the table to the right.
c) Fully insert the copper conductor into
the splice connector and then slide it
completely onto the cable’s conductor.
AWG
Splice
#2, #1
1/0
2/0
3/0
4/0
ALCR9-8-NV
ALCR9-NV
ALCR10-9-NV
ALCR11-9-NV
ALCR12-9-NV
Extension Copper
Top
1-EC-EXTENSION-UPR
1-EC-EXTENSION-SPR
Pre-crimp length
must match template
Use the template to verify the precrimp length is correct.
d) Use the crimping tools and dies
specified for the connector. See this
NRI’s crimp table or NRI 30.
Fully insert cable and extension
conductors into splice connector
e) Crimp the standard length connector or
the splice connector for the extension.
The connector length should grow
about ¼” during crimping.
©Copyright 2014, Novinium, Inc. All rights reserved.
NRI-15-25kV (36) Page 5 of 14
f) Orient the cable to minimize cable
strain.
Assembled length matches template
Use the template to verify the length
of the connector assembly and 7/16”
gap to the insulation are shorter than
the maximum post-swage length.
5. Prepare the Termination
7/16” gap
a) Prepare and clean the cable
termination according to IEEE®
P1816™.
Necessary steps include:
Unwrap and bind concentric neutral
wires 1” away from end of elbow.
Remove insulation shield as in
template.
Bevel the insulation end if desired,
but no more than 1/8” max.
Thoroughly clean the insulation to
remove all conductive residue.
6. Prepare the Elbow
a) Remove the insulating cap and install
the retaining clip.
Unwrap and bind neutrals 1”
(25.4mm) from end of elbow.
1/8” MAX
insulation
taper
Remove
insulating
cap
Feed the warning tag and pulling eye
through the retaining clip slot.
Store the insulating cap assembly until
installation after injection completion.
b) Put the C-clip on the elbow, if it is not
already installed.
Place the C-clip in line with the
injection port on the opposite side.
Press on until fully seated.
If your injection elbow is an Elastimold®
elbow, go to step 7. Otherwise, skip to
step 8 on page 10.
7. Install a Reticular Flash
Preventer (RFP)
RFP – NPN: 1-UP-RFP,E
RFP Insertion Tool – NPN: 0-UP-RFPe-INSRT
Foam
a) Put the RFP, rigid disk first, into the
holder.
If a holder is not available, skip to
step 7d.
Rigid disk
©Copyright 2014, Novinium, Inc. All rights reserved.
Insert RFP with
rigid disk down
RFP Insertion
Tool Holder
NRI-15-25kV (36) Page 6 of 14
b) Press the RFP inserter into the holder
until the tip goes through the RFP, and
into the small hole in the holder on
the underside.
The RFP inserter is pushed
fully into holder; tip
inserts in small hole on the
underside.
c) Remove the RFP from the holder.
d) The RFP must be fully speared on the
RFP Inserter with the rigid disk facing
out.
Verify this is done correctly.
The RFP remains
on the inserter
Correct:
The RFP is on
the inserter,
with rigid
disk facing
out
Wrong:
The rigid disk faces
the inserter handle
e) Insert the RFP into the elbow’s fluid
access port using the RFP inserter.
Push the shoulder of the RFP inserter
firmly against the face of the fluid
access port.
The RFP inserter
is pushed fully
into the access
port.
The RFP will remain correctly installed
when the inserter is removed.
The RFP will stay in place
after the inserter is removed
f) Drip 5-10 drops of Novinium Fluid
from a bottle into the access port to
soak the RFP.
Flip Top Squeeze Bottle –
NPN:
0-FH-BTTL-40Z-FLIP
The RFP may also be wetted before
inserting into the access port.
The RFP must be saturated to function
properly.
©Copyright 2014, Novinium, Inc. All rights reserved.
NRI-15-25kV (36) Page 7 of 14
8. Install the Access Interface
(AI) or Fluid Injection Cap
(FIC)
AI installs on the fluid
access port and seals
with 2 O-rings
O-ring 1
If you are using an AI, continue
to step 8a. If you are using an
FIC, skip to step 8e.
O-ring 2
Release pin
with loop
a) Verify both AI O-rings are in place and
lightly lubricated with silicone grease.
Access Interface for 15 & 25kV –
NPN: 0-UP-AI-TUBE-QD
b) Press the release pin in until it is flush
with the open end of the dust cover.
c) Feed tie-wraps through the hole and
release slot on the dust cover in
opposite directions.
Feed
another
tie-wrap
into this
slot.
Feed a
tie-wrap
into this
hole
Tie-wrap heads should look like this:
Insert the tail of each tie-wrap around
the elbow and into the head of the
other tie-wrap. Don’t tighten yet and
don’t cross the wraps.
Head 1
Head 2
Tail 2 into
head 1
Heads
adjacent AI
d) Place the AI over the end of the
injection port.
Put the tie-wrap heads next to the AI
and evenly tight both wraps until the
body of the AI rests against the elbow
exterior.
Tail 1 into
head 2
Pull tails
Check that the AI is not tilted and
both ties are evenly tight. Trim the
excess from the tie-wraps.
Skip to step 9.
Using the FIC
Pull tails
Cinch tightly
and snip off
excess
Tie wraps
do not
cross
The FIC is very similar to the permanent cap.
It is advised to use the FIC retaining clip on
the FIC when available for increased safety.
The FIC retaining clip MUST be used when
required.
e) Slide the FIC in the Fluid Injection Cap
retaining clip if used. Similar to the
permanent cap and normal retaining clip.
f) Connect the FIC to your injection tank with
tubing, if not so already.
g) Fully install the FIC onto the injection
elbow.
AI is flush and
square to elbow
FIC
The retaining
clip must be
secured to the
C-clip
The FIC installs
similar to the regular
permanent cap
h) Secure the retaining clip, if used, to the Cclip on the elbow at this time. The C-clip
would have been installed in step 6b.
©Copyright 2014, Novinium, Inc. All rights reserved.
NRI-15-25kV (36) Page 8 of 14
FIC
Retaining Clip
AI or FIC, RFP, and
retaining clip are in
place before installing
9. Install the Elbow
a) Keep the strands free of grease.
Hose clamp here
DO NOT SUBSTITUTE THE
SUPPLIED GREASE!
Some components require a specific
grease to function properly. Changing
greases can cause a failure.
Avoid grease
on strands
Lubricate O-ring
Call Engineering to check if there will be
any problems using other grease.
b) Loosely position a hose-clamp on the
elbow body.
c) Slide the elbow onto the cable with a
back-sand-forth twisting motion.
Wipe off all excess grease.
d) Align the elbow with the compression
lug’s threaded hole.
e) Remove the protective cap on the
probe threads and lubricated the Oring on the probe.
Thread the probe into the lug by hand,
taking care not to cross-thread.
Tighten with the wrench until the
wrench bends.
10. Connect the Concentric Neutrals
a) Insert an end of No. 14 AWG (2.5mm)
copper wire or equivalent through the
ground eye on the elbow.
Twist tight but don’t damage the eye.
b) Twist the neutral wires and connect to
ground with the correct connector.
The bond wire is
attached to the
grounding eye
Provide adequate slack in wires for elbow
operation.
c) Check that all cable neutrals extend to within
1” of the elbow.
1” MAX
All neutral wires must extend to
within 1” of the elbow
©Copyright 2014, Novinium, Inc. All rights reserved.
NRI-15-25kV (36) Page 9 of 14
11. Final Elbow Prep
a) Tighten the hose clamp on the elbow snugly.
Tighten the hose
clamp until snug
The clamp is correctly tightened when the
outer clamp surface is even with the elbow
body.
Do not over tighten!
b) Attach your “Novinium Certified” craft tag to
the outside of the elbow.
Cover with 2-3 wraps of clear vinyl tape.
“Novinium Certified” Craft Tag –
NPN: 1-MI-CRAFT
Attach craft tag and
cover with vinyl tape
c) OPTIONAL: Connect the elbow and
bushing plug.
DO NOT HANDLE THE
BUSHING OR ELBOW
UNLESS THEY ARE KNOW
TO BE DE-ENERGIZED!
If possible, lubricate the receptacle of
the elbow and mating bushing on the
transformer with the supplied
lubricant.
Operate as shown.
DO NOT OPERATE BY HAND.
Use a hot stick to energize the elbow.
12. Inject the cable
Follow the instructions in:
NRI 62: Unsustained Pressure Rejuvenation
13. Disconnect the Injection Equipment
Remove the Access Interface (AI) or the
Fluid Injection Cap (FIC).
Be sure all pressure has been relieved
from the cable. See NRI 62.
©Copyright 2014, Novinium, Inc. All rights reserved.
NRI-15-25kV (36) Page 10 of 14
Removing the AI
Pull the yellow
loop
Pull the yellow loop on the release
pin with a hot stick and bring the
AI away from the elbow.
Gently nudging the pull ring from
side-to-side while pulling will ease
removal.
Pulling the pin allows the ties to fall
away from the AI, which releases it
from the elbow.
Pull AI
If the ties do not release, nudge it
with the end of the hot stick.
Removing the FIC
…then move AI
away from elbow
With the hot stick, grab the eye of
the FIC.
Twist the FIC and retaining clip up
to 90 degrees, until the retaining
clip comes free from the C-clip.
Grab the eye
with a hot stick
and twist to
unhook the
retaining clip
Pull the FIC and retaining clip free
from the elbow.
14. Install the Permanent Cap
a) Tightly secure the cap to the hot stick.
The hot stick’s metal ring presses
against the retaining clip during
installation.
b) Push the permanent cap onto the
elbow’s injection port.
Check that the retaining clip’s wings
are engaging the barbs of the C-clip.
If so, the cap is fully seated now.
The cap displaces the RFP into the
conductive insert of the elbow.
Pull cap tight to
hot stick with
retaining clip
Push cap onto
injection port
Retaining clip wings must
engage barbs of the C-clip
Cap pushes RFP
into conductive
insert.
©Copyright 2014, Novinium, Inc. All rights reserved.
NRI-15-25kV (36) Page 11 of 14
OPERATING INSTRUCTIONS
Before Loadmake or Loadbreak Operation:
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Loadbreak connectors must be operated with an eight-foot long, fully-insulated “hotstick”
type of tool.
Remove fluid access interface and install Elbow Cap before operating elbow. For Injection
use, the AI is always installed before the elbow is put onto the bushing.
Area must be clear of obstructions or contaminants that can interfere with connector
operation.
Area should 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 certain both ends of the loop are the same phase.
LOADMAKE OPERATION:
Check appropriate accessory device operating instructions to be sure that the device is rated
for energized operation.
1. Area must be clear of obstructions or contaminants that can interfere with connector
operation.
2. 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.
3. Securely fasten a hotstick to the loadbreak connector pulling eye.
4. Establish firm footing and positive control of the elbow connector. Withdraw the elbow with
a fast, straight, firm motion from the accessory device on the apparatus parking stand. Be
careful not to place the elbow connector near a ground plane.
5. 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, 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.
Fault Close:
1. It is not recommended that operations be made on known faults.
2. If a fault is experienced, both the elbow connector and the bushing must be replaced.
LOADBREAK OPERATION:
1. Place desired accessory device on apparatus parking stand. NOTE: Refer to
appropriate operating instructions for accessory device to be used. Be certain it is
rated for energized operation.
2. Firmly tighten a hotstick to the loadbreak connector pulling eye.
3. Without exerting any pulling force, slightly rotate the connector in order to break
surface friction prior to disconnection.
4. Withdraw the connector from the bushing with a fast, firm, straight motion, being
careful not to place the connector near a ground plane.
Place connector on appropriate accessory device, following the operating instructions
for that accessory.
©Copyright 2014, Novinium, Inc. All rights reserved.
NRI-15-25kV (36) Page 12 of 14
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. 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:
1. 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.
2. Using a suitable sensing device, proceed to determine if 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.
3. 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.
INJECTION APPLICATION SUPPLEMENT:
1. The elbow is deadfront only when the following conditions exist:
• The access port is covered with the insulated cap, and
• All shields are properly grounded.
2. 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.
The elbow shall not be disconnected 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 Novinium engineering at (206)
529-4828 for information on submersible application.
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.
©Copyright 2014, Novinium, Inc. All rights reserved.
NRI-15-25kV (36) Page 13 of 14
Recommended Die Types/Sizes May 19, 2014
6-ton dies
12-ton dies
Connector Size
Connector
Barrel O.D.
(inches)
Burndy W-dies
Husky HT58
dies
Greenlee Udies
Novinium
Swage
Coppertop #4 to
2/0
0.635
W-BG, W-243
HT58G, HT58DM
U-BG, U-243
-
#2 to 2/0
0.687
W-245
HT58DP
U-245, U26ART
-
3/0
0.760
W-247, W-166
HT58DT
U-247, U27ART
-
Coppertop 3/0
to 4/0
0.785
W-247, W-166
HT58DT
U-247, U27ART
-
4/0
0.850
W-247, W-660
HT58DT
U28ART
0742
250 MCM
0.910
W-249
HT58DW
U-249, U29ART
0742
300 MCM
1.095
W-251
HT58DY
U-251, U30ART
0942
350 MCM
1.125
-
-
U31ART
0995
400 MCM
1.135
-
-
U32ART
0995
500 MCM
1.320
-
-
U34ART
1152
600 MCM
1.405
-
-
U36ART
1262
750 MCM
1.590
-
-
S39ART
1382
800 MCM
1.635
-
-
S40ART
1382
1000 MCM
1.840
-
-
S44ART
1598
©Copyright 2014, Novinium, Inc. All rights reserved.
NRI-15-25kV (36) Page 14 of 14