Utility Solutions BREAK-SAFE USBS-15-1-PS User manual

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101#33rd#St.#Drive#SE#
Hickory,#NC#28602#
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UTILITY#SOLUTIONS,#INC.#
Phone##(828)#323-8914#
Fax######(828)#323-8410#
[email protected]#
www.utilitysolutionsinc.com#
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The “BREAK-SAFE®”
PORTABLE LOADBREAK & LOAD PICKUP JUMPER
CLAMP
USBS-15-1-PS
USBS-15-2-PS
USBS-27-1-PS
USBS-27-2-PS
USBS-46-1-PS
USBS-46-2-PS
Operation Manual
B-00125 USBS Manual Rev. 2.2 (9-23-19)

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B-00125!USBS!(1st!Gen)!Operation!Manual! !
2!
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Contact!with!high!voltage!will!cause!death!or!grievous!personal!injury!to!the!
operator.!!Only!use!this!device!in!conjunction!with!safe!operating!practices!
around!energized!lines!and!equipment.!
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DANGER#
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Always!wear!appropriately!rated!rubber!gloves!and!personnel!protective!gear!
when!utilizing!this!product!to!prevent!electrocution.!
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DANGER#
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Carefully!read!and!fully!understand!this!manual!prior!to!operating,!
maintaining!or!testing!this!device.!!Improper!operation,!handling!or!
maintenance!of!this!device!can!result!in!death,!grievous!personal!injury!and!
or!equipment!damage.!!!
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WARNING#
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The!BREAK-SAFE®!tool!is!a!portable!switch!designed!to!perform!the!following!three!
functions:!loadbreak,!load!pickup!and!continuous!current!duty.!!It!is!intended!for!
temporary!connecting!and!transferring!of!load!and!should!not!be!used!in!a!
permanent!capacity!under!any!circumstance.!!!The!BREAK-SAFE®!is!designed!to!be!
installed!using!appropriate!rubber!gloves!and!personal!protective!equipment.!!The!
tool!is!operated!using!an!insulated!hotstick.!
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B-00125!USBS!(1st!Gen)!Operation!Manual! !
3!
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Follow!safe!work!procedures!and!practices!when!utilizing!this!product.!!
Failure!to!use!this!tool!in!a!safe!manner!can!result!in!death,!grievous!personal!
injury!and!or!equipment!damage.!
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WARNING#
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These!instructions!are!not!intended!to!replace!or!be!a!substitute!for!proper!
safety!training!procedures.!!Failure!to!select!the!proper!tool!in!regards!to!
minimum!system!requirements!can!result!in!death,!grievous!personal!injury!
and!or!equipment!damage.!
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WARNING#
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Only!trained!and!qualified!personnel!should!operate,!inspect!and!maintain!
this!equipment.!!!
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WARNING#
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B-00125!USBS!(1st!Gen)!Operation!Manual! !
4!
BREAK-SAFE®CIRCUIT#RESTRICTIONS#
BREAK-SAFE®!devices!should!not!be!used!in!situations!where!the!maximum!voltage!
and/or!amperage!rating!of!the!tool!can!be!exceeded.!!BREAK-SAFE®!tools!are!rated!
by!maximum!amperage!(A)!and!voltage!(V).!!TABLE!1!details!the!specific!ratings!of!
the!various!BREAK-SAFE®!models.!
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Cat.!#!
Maximum!
Current!
Rating!
Maximum!
System!
Voltage!
Minimum!
Conductor!Size!
Maximum!
Conductor!Size!
USBS-15-1-PS!
300!A!
15!kV!
#6!Copper!
954!ACSR!
USBS-15-2-PS!
300!A!
15!kV!
#6!Copper!
954!ACSR!
USBS-27-1-PS!
300!A!
27!kV!
#6!Copper!
954!ACSR!
USBS-27-2-PS!
300!A!
27!kV!
#6!Copper!
954!ACSR!
USBS-46-1-PS!
200!A!
46!kV!
#6!Copper!
954!ACSR!
USBS-46-2-PS!
200!A!
46!kV!
#6!Copper!
954!ACSR!
TABLE!1:!Model!Ratings!
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Outlined!below!are!some!circuit!restrictions!known!to!exist:!
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•Do!not!utilize!the!BREAK-SAFE®!tool!in!situations!where!ferroresonance!can!
produce!overvoltage!situations.!!An!example!of!this!involves!switching!
unloaded!transformers!that!are!delta-connected!three!phase!and!wye-
connected!three!phase!with!primary!neutral!ungrounded.!
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•Do!not!utilize!the!BREAK-SAFE®!to!switch!unloaded!transformers.!
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•Do!not!utilize!the!BREAK-SAFE®!to!switch!capacitor!banks.!!Capacitor!
switching!can!cause!large!over!voltage!situations!that!are!likely!to!cause!
flashover!of!the!tool.!!
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B-00125!USBS!(1st!Gen)!Operation!Manual! !
5!
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Do!not!utilize!the!BREAK-SAFE®!in!phase-to-phase!or!grounding!circuits.!
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WARNING#
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The!BREAK-SAFE®!is!to!be!used!in!a!temporary!capacity!only.!!Do!not!utilize!
the!tool!in!a!permanent!capacity!or!for!extended!periods!of!time.!!
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WARNING#
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The!BREAK-SAFE®!is!not!waterproof.!!Do!not!use!the!BREAK-SAFE®!in!wet!
conditions.!
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B-00125!USBS!(1st!Gen)!Operation!Manual! !
8!
Do!not!use!the!BREAK-SAFE®!if!the!clear!body!of!the!tool!exhibits!cracking!
(cracks!larger!than!¼”!length).!!Cracks!larger!than!¼”!are!an!indicator!that!
the!tool!was!either!dropped!or!was!cleaned!/!exposed!to!solvents.!!The!
BREAK-SAFE®!should!only!be!cleaned!with!soap!and!water.!!Also!any!thread!
lock!material!utilized!on!the!tool!must!be!dry!and!solventless.!!Contact!Utility!
Solutions!for!a!list!of!approved!thread!lock!materials.!!
WARNING#
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•Do!not!use!the!BREAK-SAFE®!if!the!internal!yellow!tube!exhibits!signs!
of!a!flashover.!!Internal!flashover!can!be!attributed!to!the!following!
situations:!!!
•The!tool!was!used!in!the!rain.!
•The!tool!was!used!to!open!capacitor!banks.!
•The!tool!was!not!reset!properly!prior!to!performing!a!loadbreak!
operation.!
•The!tool!had!accumulated!soot!/!debris!from!prior!loadbreak!
operations!that!deteriorated!the!overall!dielectric!strength!of!the!tool.!!!
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The#yellow#tube#needs#to#be#cleaned#on#a#routine#basis#to#prevent#
the#buildup#of#loadbreak#deposits.##
WARNING#
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Do!not!use!the!BREAK-SAFE®!if!the!tool!exhibits!pitting!and!or!charring!
around!the!external!brass!contacts.!!Pitting!and!or!charring!are!the!result!of!a!
tool!that!was!not!properly!reset!prior!to!performing!a!loadbreak!operation.!
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B-00125!USBS!(1st!Gen)!Operation!Manual! !
9!
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When!working!with!the!BREAK-SAFE®!always!assume!the!tool!is!energized!at!
all!times.!!Never!consider!the!tool!body!as!rated!insulation.!!
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WARNING#
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When!working!with!the!BREAK-SAFE®!always!assume!the!tool!is!energized!at!
all!times.!!Never!consider!the!tool!body!as!rated!insulation.!!
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WARNING#
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BREAK-SAFE®#LINE#AND#TOOL#PREPARATION#
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BREAK-SAFE®#FIELD#INSPECTION#PROCEDURE#(PRIOR#TO#OPERATION)#
Reference!the!accompanying!laminated!BREAK-SAFE®!Inspection!Procedure.!
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1. Do!not!exceed!the!rated!voltage!of!the!tool!(TABLE!1).!!!
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2. Do!not!exceed!the!rated!amperage!of!the!tool!(TABLE!1).!!!
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3. Insulate!the!pole!and!conductor!as!required!by!the!supervising!utility!safety!
practices.!
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4. Clean!the!conductor!at!each!location!where!the!BREAK-SAFE®!jumper!clamp!
system!will!be!attached.!
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5. If!the!BREAK-SAFE®!is!equipped!with!a!duckbill!head!(USBS-**-2-PS)!ensure!
that!all!attachment!fasteners!are!tight!and!secure.!
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BREAK-SAFE®#OPERATIONAL#INSTRUCTIONS#
The!following!procedures,!as!described,!are!intended!to!overview!a!typical!circuit!
bypass!application!and!circuit!re-energizing!application!using!the!BREAK-SAFE®!
Portable!Switch.!!Always!follow!supervising!utility!installation!and!use!procedures!
for!the!BREAK-SAFE®!jumper!clamp!system.!!!
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CIRCUIT#BREAK#APPLICATION#
1. Prior!to!securing!the!BREAK-SAFE®!to!the!line,!pull!the!Loadbreak!Ring!on!
the!BREAK-SAFE®!Black!Pull!Strap!until!the!tool!locks!in!the!open!tool!
position!(the!internal!yellow!tube!is!visible).!!!
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B-00125!USBS!(1st!Gen)!Operation!Manual! !
10!
2. Insert!the!Safety!Locking!Pin!into!the!hole!labeled!“LOCK!OPEN”!and!verify!
the!Safety!Locking!Pin!secures!the!tool!in!the!fully!open!position.!!!
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The!Safety!Locking!Pin!secures!the!tool!in!the!open!position!and!prevents!an!
accidental!load!pickup!operation.!!
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If!the!Safety!Locking!Pin!cannot!be!inserted!into!the!“LOCK!OPEN”!hole!it!
alerts!the!operator!the!tool!has!not!been!fully!extended!in!the!open!position.!!
If!necessary!pull!down!on!the!Black!Pull!Strap!Assembly!with!enough!force!so!
the!Safety!Locking!Pin!fully!seats!in!a!smooth!and!easy!manner.!!!!!!
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3. Verify!the!BREAK-SAFE®!is!in!the!open!position!with!the!Safety!Locking!Pin!
securely!fastened!to!prevent!accidental!tool!operation.!
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4. Securely!attach!the!BREAK-SAFE®!jumper!head!to!the!“SOURCE!SIDE”!or!
“LINE!POWER!SIDE“!(FIGURE!1)!using!standard!utility!safety!practices!and!
procedures.!!!
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Attaching!the!BREAK-SAFE®!to!the!“SOURCE!SIDE”!or!“LINE!POWER!SIDE”!
ensures!that!after!the!loadbreak!operation!has!been!preformed!in!STEP!(12)!
the!jumper!cable!is!entirely!de-energized.!!!
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5. Securely!attach!one!end!of!a!jumper!cable!to!the!“LOAD!SIDE”!of!the!circuit!
(FIGURE!1)!using!standard!utility!safety!practices!and!procedures.!
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6. Securely!attach!the!opposite!end!of!a!jumper!cable!to!the!Conductor!Bar!
located!at!the!base!of!the!BREAK-SAFE®.!!Do!not!allow!the!jumper!cable!to!
pull!sideways!on!the!BREAK-SAFE®.!!The!jumper!cable!should!have!enough!
slack!to!hang!straight!down.!
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7. Prior!to!performing!the!load!pickup!operation!remove!the!Safety!Locking!Pin!
from!the!“LOCK!OPEN”!position.!!!!
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8. To!pickup!load,!exert!a!steady!downward!movement!on!the!Load!Pickup!
Trigger!using!an!insulated!hotstick.!!The!Black!Pull!Strap!Assembly!should!
retract!forcefully!into!the!Clear!Tube!Assembly.!!!
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When!load!pickup!has!been!properly!performed!the!yellow!indicator!band!
(either!yellow!paint!or!yellow!tape!on!older!models)!on!the!Black!Pull!Strap!
Assembly!should!not!be!visible.!!!
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If!the!yellow!indicator!band!is!visible!on!the!Black!Pull!Strap!Assembly!the!
tool!has!not!properly!closed!and!the!operator!should!push!the!Loadbreak!
Ring!upward!until!the!yellow!indicator!band!is!no!longer!visible!to!ensure!the!
tool!has!fully!reset.!!!!!!
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B-00125!USBS!(1st!Gen)!Operation!Manual! !
11!
The!BREAK-SAFE®!when!in!the!“OPEN!POSITION”!does!not!constitute!being!
rated!insulation!nor!does!it!provide!a!visible!gap.!!This!is!why!the!use!of!the!
Utility!Solutions!“Jumper-T”!(USJT-001)!or!equivalent!as!a!parking!stand!is!
suggested.!!
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WARNING#
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9. Insert!the!Safety!Locking!Pin!into!the!hole!labeled!“LOCK!CLOSED”!and!verify!
the!Safety!Locking!Pin!secures!the!tool!in!the!fully!closed!position.!!The!Safety!
Locking!Pin!secures!the!tool!in!the!closed!position!and!prevents!an!accidental!
loadbreak!operation.!!!!!!
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10. Following!standard!safety!practices!and!procedures!the!permanent!circuit!
can!now!be!cut!and!both!ends!isolated!and!insulated.!!
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11. Prior!to!performing!the!loadbreak!operation!remove!the!Safety!Locking!Pin!
from!the!“LOCK!CLOSED”!position.!!!
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12. With!one!steady!motion,!pull!down!firmly!on!the!Load!Break!Ring!using!an!
approved!insulated!hot!stick!until!the!tool!locks!in!the!open!position.!Do!not!
stop!or!hesitate!while!pulling.!!
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13. Insert!the!Safety!Locking!Pin!into!the!hole!labeled!“LOCK!OPEN”!and!verify!
the!Safety!Locking!Pin!secures!the!tool!in!the!fully!open!position.!!!
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The!Safety!Locking!Pin!secures!the!tool!in!the!open!position!and!prevents!an!
accidental!load!pickup!operation.!!
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If!the!Safety!Locking!Pin!cannot!be!inserted!into!the!“LOCK!OPEN”!hole!it!
alerts!the!operator!the!tool!has!not!been!fully!extended!in!the!open!position.!!
If!necessary!pull!down!on!the!Black!Pull!Strap!Assembly!with!enough!force!so!
the!Safety!Locking!Pin!fully!seats!in!a!smooth!and!easy!manner.!!!!!!
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14. Verify!there!is!NO!VOLTAGE!AND/OR!NO!AMPERAGE!present!on!the!“LOAD!
SIDE”!prior!to!removing!the!jumper!cable!end!attached!to!the!“LOAD!SIDE”!
line.!!!
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15. Place!the!unattached!“LOAD!SIDE”!jumper!cable!end!on!an!insulated!Utility!
Solutions!“Jumper-T”!(USJT-001)!or!equivalent!device!(FIGURE!2).!!This!
separation!constitutes!a!visible!gap!for!safety.!
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16. Following!standard!safety!practices!and!procedures,!work!can!be!performed!
on!the!de-energized!line.!
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B-00125!USBS!(1st!Gen)!Operation!Manual! !
12!
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CIRCUIT#MAKE#APPLICATION#
1. Prior!to!securing!the!BREAK-SAFE®!to!the!line,!pull!the!Loadbreak!Ring!on!
the!BREAK-SAFE®!Black!Pull!Strap!until!the!tool!locks!in!the!open!tool!
position!!(the!internal!yellow!tube!is!visible).!!!
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2. Insert!the!Safety!Locking!Pin!completely!through!the!hole!labeled!“LOCK!
OPEN”!and!verify!the!safety!pin!secures!the!tool!in!the!fully!open!position.!!
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The!Safety!Locking!Pin!secures!the!tool!in!the!open!position!and!prevents!an!
accidental!load!pickup!operation.!!
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If!the!Safety!Locking!Pin!cannot!be!inserted!into!the!“LOCK!OPEN”!hole!it!
alerts!the!operator!the!tool!has!not!been!fully!extended!in!the!open!position.!!
If!necessary!pull!down!on!the!Black!Pull!Strap!Assembly!with!enough!force!so!
the!Safety!Locking!Pin!fully!seats!in!a!smooth!and!easy!manner.!!!!!!
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3. Verify!the!BREAK-SAFE®!is!in!the!open!position!with!the!Safety!Locking!Pin!
securely!fastened!to!prevent!accidental!tool!operation.!
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4. Securely!attach!the!BREAK-SAFE®!jumper!head!to!the!“SOURCE!SIDE”!or!
“LINE!POWER!SIDE“!(FIGURE!1)!using!standard!utility!safety!practices!and!
procedures.!!!
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Attaching!the!BREAK-SAFE®!to!the!“SOURCE!SIDE”!or!“LINE!POWER!SIDE”!
ensures!that!after!the!loadbreak!operation!has!been!preformed!in!STEP!(13)!
the!jumper!cable!is!entirely!de-energized.!!!
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5. Securely!attach!the!first!end!of!a!jumper!cable!to!the!non-energized!“LOAD!
SIDE”!of!the!circuit!!(FIGURE!2)!using!standard!utility!safety!practices!and!
procedures.!
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6. Securely!attach!the!opposite!end!of!a!jumper!cable!to!the!Conductor!Bar!
located!at!the!base!of!the!BREAK-SAFE®.!!Do!not!allow!the!jumper!cable!to!
pull!sideways!on!the!BREAK-SAFE®.!!The!jumper!cable!should!have!enough!
slack!to!hang!straight!down.!
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7. Prior!to!performing!the!load!pickup!operation!remove!the!Safety!Locking!Pin!
from!the!“LOCK!OPEN”!position.!!!
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8. To!pickup!load!exert!a!steady!downward!movement!on!the!Load!Pickup!
Trigger!using!an!insulated!hotstick.!!The!Black!Pull!Strap!Assembly!should!
retract!forcefully!into!the!Clear!Tube!Assembly.!!
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B-00125!USBS!(1st!Gen)!Operation!Manual! !
13!
When!load!pickup!has!been!properly!performed!the!yellow!indicator!band!
(either!yellow!paint!or!yellow!tape!on!older!models)!on!the!Black!Pull!Strap!
Assembly!should!not!be!visible.!!!
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If!the!yellow!indicator!band!is!visible!on!the!Black!Pull!Strap!Assembly!the!
tool!has!not!properly!closed!and!the!operator!should!push!the!Loadbreak!
Ring!upward!until!the!yellow!indicator!band!is!no!longer!visible!to!ensure!the!
tool!has!fully!reset.!
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9. Insert!the!Safety!Locking!Pin!into!the!hole!labeled!“LOCK!OPEN”!and!verify!
the!Safety!Locking!Pin!secures!the!tool!in!the!fully!open!position.!!!
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The!Safety!Locking!Pin!secures!the!tool!in!the!open!position!and!prevents!an!
accidental!load!pickup!operation.!!
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10. Verify!VOLTAGE!AND!AMPERAGE!are!present!on!the!“LOAD!SIDE”.!
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11. Following!standard!safety!practices!and!procedures,!uncover!the!permanent!
jumpers!and!reconnect!or!create!permanent!connections!!
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12. Prior!to!performing!the!loadbreak!operation!remove!the!Safety!Locking!Pin!
from!the!“LOCK!CLOSED”!position.!!!
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13. With!one!steady!motion,!pull!down!firmly!on!the!Load!Break!Ring!using!an!
approved!insulated!hot!stick!until!the!tool!locks!in!the!open!position.!Do!not!
stop!or!hesitate!while!pulling.!!
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14. Insert!the!Safety!Locking!Pin!into!the!hole!labeled!“LOCK!OPEN”!and!verify!
the!Safety!Locking!Pin!secures!the!tool!in!the!fully!open!position.!!!
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The!Safety!Locking!Pin!secures!the!tool!in!the!open!position!and!prevents!an!
accidental!load!pickup!operation.!!
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If!the!Safety!Locking!Pin!cannot!be!inserted!into!the!“LOCK!OPEN”!hole!it!
alerts!the!operator!the!tool!has!not!been!fully!extended!in!the!open!position.!!
If!necessary!pull!down!on!the!Black!Pull!Strap!Assembly!with!enough!force!so!
the!Safety!Locking!Pin!fully!seats!in!a!smooth!and!easy!manner.!!!!!!
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15. Verify!there!is!NO!AMPERAGE!present!along!the!jumper!cable.!
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16. Remove!the!jumper!cable!end!attached!to!the!“LOAD!SIDE”!line.!!!
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17. Remove!the!jumper!cable!end!attached!to!the!BREAK-SAFE®.!
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18. Remove!the!BREAK-SAFE®.!
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B-00125!USBS!(1st!Gen)!Operation!Manual! !
14!
FIGURE!1:!BREAK-SAFE®!Installation!Schematic!
!
“SOURCE“!
OR!
“LINE!POWER!SIDE”!
!
“LOAD!SIDE”!
!
USJT-001!
“Jumper-T”!
!
“SOURCE“!
OR!
“LINE!POWER!SIDE”!
!
“LOAD!SIDE”!
!
FIGURE!2:!USJT-001!Visible!Gap!/!Rated!Insulation!Configuration!for!
BREAK-SAFE®!
!
USJT-001!
“Jumper-T”!
!
!
!
!
!

!
B-00125!USBS!(1st!Gen)!Operation!Manual! !
15!
Resistance#Test
An!optional!Resistance!Test!may!be!performed!in!between!scheduled!maintenance.!
This!test!DOES!NOT!replace!scheduled!maintenance!or!extend!the!time!between!
scheduled!maintenance.!
!
This!test!is!performed!using!the!Utility!Solutions!USGT-600!Grounds!Tester!w/!
REACH!Technology!or!equivalent!device.!Refer!to!the!testers’!instruction!manual!for!
proper!set-up!procedures.!
!
1. The! BREAK-SAFE®! should! be! in! the! closed! position! and! RESET! with! the!
external!brass!contacts!fully!seated.!
2. Connect!the!BREAK-SAFE®!Conductor!Hook!to!a!Current!Output!Post!on!the!
Grounds!Tester.!Position!and!support!the!BREAK-SAFE®!so!the!weight!of!the!
tool!does!not!apply!sideways!force!on!the!Current!Output!post!(a!small!block!
of!wood!should!suffice).!
3. Connect! a! standard! Mechanical! Jumper! (minimum! 6! feet,! 1/0! AWG,! 300!
AMP)! to! the! other! Current! Output! Posts! of! the! Grounds! Tester! and! the!
conductor!bar!of!the!BREAK-SAFE®.!
4. Put!the!Grounds!Tester!in!REACH!mode.!
5. Turn!on!the!Grounds!Tester!and!adjust!the!Current!Control!Knob!to!energize!
to!300!AMPS.!
6. Using! the! red! and! black! Jumper! Leads! on! the! Grounds! Tester,! measure! the!
voltage!on!the!BREAK-SAFE®!between!the!lower!jaw!of!the!Conductor!Hook!
and!the!Parking!Stand.!!
7. Voltage!drop!should!not!exceed!0.220!volts.!If!the!voltage!displayed!exceeds!
0.220!volts!the!tool!should!be!removed!from!service.!Maintenance!should!be!
performed!by!the!factory!or!by!trained!and!certified!personnel.!