A load break tool lets a lineman open or close a circuit under load with a hot stick, without an outage. Utility Solutions makes two families. The LOAD-RANGER hooks onto the arcing horn and fuse ring of a hook-equipped switch or cutout. The BREAK-SAFE adds a portable switch to a mechanical jumper for load break, continuous current and load pick-up.
| Tool | System voltage | Current rating | Weight | Best for |
|---|---|---|---|---|
| BREAK-SAFE | 15, 27, 38 and 46 kV | 300 A (200 A at 46 kV) | 6 lb 3 oz to 10 lb 3 oz | Load break, load pick-up and continuous current in a portable jumper |
| BREAK-SAFE 600 | 27 kV | 600 A | 12 lb 3 oz | High-current jumpers, with dual conductor bars for parallel jumpers |
| LOAD-RANGER FLEX-LT | 27 and 38 kV | 900 A | 4 lb 10 oz to 5 lb 5 oz | Hook-equipped switches and cutouts, with a head that rotates 180 degrees |
| LOAD-RANGER XLT | 27 and 38 kV | 900 A | 4 lb 3 oz (XLT-1), 4 lb 12 oz (XLT-2) | Same devices, with a fixed head and machined parts |
| LOAD-RANGER (FLEX-LT and XLT) | BREAK-SAFE | |
|---|---|---|
| Connects to | Arcing horn and fuse ring of hook-equipped disconnects, cutouts, switches and power fuses | Mechanical jumper, with a floating or duckbill head |
| Rated for | Up to 34.5 kV and 150 BIL or less | 15 to 46 kV (see the catalog table) |
| Breaks | Cable charging, line charging and transformer magnetizing current (transformers over 5% load) | Load break, load pick-up and continuous current |
| Also does | Single capacitor banks, and padmount gear up to 25 kV with the -E or -P version | Takes conductors from #6 copper to 954 ACSR (1.1 in.); the 600 takes up to 3.5 in. |
| Limits | The 38 kV models should not be used inside padgear or cabinets | The 38 kV, 46 kV and 600 models need a product verification form before ordering |
The FLEX-LT head rotates, which cuts down binding positions, and it can go on either horn. The XLT has a fixed head, and Utility Solutions says to install it on the horn opposite the operator.
| Topic | What Utility Solutions says (manual B-01031, 9-18-24) |
|---|---|
| Intended use | A jumper clamp that works like a portable switch on overhead distribution lines, with an appropriately rated and approved jumper cable. It is for temporary connections only and is not a fuse. |
| Ratings | 300 A at 15, 27 and 38 kV; 200 A at 46 kV; conductors from #6 copper to 954 ACSR |
| Testing | Tested to the full voltage and amperage rating at 70% to 80% power factor, for both load break and load make |
| Voltage choice | Rated by system voltage. Use a 15, 27, 38 or 46 kV tool for system voltages at or below that class. |
| Phases | Designed for three phase systems, but used on one phase at a time. Typical three phase work needs three tools. |
| Floating head (-1) | Installed and removed with approved rubber gloves and PPE |
| Duckbill head (-2) | Installed and removed with an approved insulated hot stick |
| Load break and pick-up | All models need an approved insulated hot stick for these operations |
| Do not use it | Phase to phase, to switch unloaded transformers, to switch capacitor banks, or where ferroresonance can cause over-voltage |
| Weather | Not waterproof. Do not use it in wet conditions, and cover it with an insulating rubber blanket if bad weather is expected. |
| After each load break | Remove the tool or the jumper from the conductor bar. The tool is not rated insulation and is not a visible gap. |
| Maintenance | Service every 2 years, sooner for frequently used tools or tools used near their maximum ratings |
| Storage | Clean, dry place, in the LOCK CLOSE position, in a soft or hard case |
| Warranty | One year against manufacturing defects |
BREAK-SAFE: How It Works, a video from Utility Solutions.
| Catalog number | Head | Voltage | Rating | Weight | Closed / open length |
|---|---|---|---|---|---|
| USBS-15-1-PS | Floating | 15 kV | 300 A | 7 lb 3 oz | 24 / 28 in. |
| USBS-15-2-PS | Duckbill | 15 kV | 300 A | 6 lb 3 oz | 28 / 32 in. |
| USBS-27-1-PS | Floating | 27 kV | 300 A | 7 lb 10 oz | 28 / 33.5 in. |
| USBS-27-2-PS | Duckbill | 27 kV | 300 A | 7 lb | 32 / 37.5 in. |
| USBS-38-1-PS | Floating | 38 kV | 300 A | 8 lb 6 oz | 33 / 41 in. |
| USBS-38-2-PS | Duckbill | 38 kV | 300 A | 7 lb 12 oz | 37 / 45 in. |
| USBS-46-1-PS | Floating | 46 kV | 200 A | 10 lb 3 oz | 42.5 / 53.5 in. |
| USBS-46-2-PS | Duckbill | 46 kV | 200 A | 9 lb 9 oz | 46.5 / 57.5 in. |
| USBS-600-1 | Floating | 27 kV | 600 A | 12 lb 3 oz | 33 / 40.5 in. |
| Catalog number | Voltage | Configuration |
|---|---|---|
| USLR-FLEX-1-H | 27 kV | Overhead arm, hard case, 900 A |
| USLR-FLEX-1-C-H | 27 kV | With counter, hard case |
| USLR-FLEX-2-H | 38 kV | Hard case |
| USLR-FLEX-2-C-H | 38 kV | With counter, hard case |
| USLR-FLEX-1-P-H | 27 kV | Padmount arm, extended hood, hard case |
| USLR-FLEX-1-C-P-H | 27 kV | Padmount arm, with counter |
| USLR-XLT-1-H | 27 kV | With counter and hard case |
| USLR-XLT-1-NC-H | 27 kV | No counter, hard case |
| USLR-XLT-1-H-E | 27 kV | With counter, hard case and extension hood |
| USLR-XLT-1-P-H | 27 kV | Counter, extension hood, padmount arm, hard case |
| USLR-XLT-2-H | 38 kV | With counter and hard case |
Using a LOAD-RANGER: hook onto the arcing horn first, then the fuse ring. Pull in a smooth, steady motion until the tool is fully extended and the load breaks. Rotate it up to release the ring, lift it off the horn, and reset it.
Utility Solutions publishes a field inspection guide (B-02364, 7-24-26) for the LOAD-RANGER FLEX-LT and XLT Gen 2. It says to run these checks before every use and to remove the tool from service right away if it fails any of them.
| Step | Check | What you should see |
|---|---|---|
| 1 | Fully extend the tool and inspect the yellow tube | No damage, cracks or discoloration |
| 2 | Check the black gasket | Fully tightened |
| 3 | Check the upper and lower conductor paths | Tight and secure |
| 4 | FLEX-LT only: pivot the flex head side to side | Rotates freely 90 degrees each way and returns to its original position |
| 5 | Work the clip assembly | All parts pivot smoothly and return fully to their original position |
| 6 | Work the arm assembly side to side, then front to back | Parts pivot smoothly and return fully to their original position |
| 7 | Press the red reset trigger, then check continuity | Continuity breaks when the tool is fully extended |
| 8 | Pull the hook loop to extend the tool 2 to 3 inches and release | The tool rebounds quickly with felt spring pressure, which shows it reset properly |
A parallel is a temporary circuit that lets a crew keep customers on while the permanent line is opened or repaired. Traditional methods use several tools and take longer. The BREAK-SAFE is a single hot stick operated tool that does the load pick-up, carries the load, and then does the load break. It is a jumper clamp that works like a portable switch, with an appropriately rated and approved jumper cable. It is for temporary connections only and it is not a fuse.
| Function | What it means |
|---|---|
| Load pick-up | Energizes the jumper circuit under load, using a hot stick |
| Continuous current duty | Carries the load while the permanent circuit is out |
| Load break | Opens the parallel circuit under load, using a hot stick |
| Check | What to do |
|---|---|
| Rating | Do not exceed the tool's voltage or current rating. Use a tool at or above your system voltage. |
| Pole and conductor | Insulate them as your utility's safety practices require |
| Conductor | Clean it at each attachment point, and clean and inspect the conductor bar before attaching the jumper |
| Duckbill head | If your model is a -2 duckbill, make sure the attachment fasteners are tight |
| Field inspection | Follow the laminated Field Inspection Procedure card before each use |
These steps follow Utility Solutions' manual B-01031. Always follow your own utility's work rules too.
| Step | What to do |
|---|---|
| 1 | Lift the Yellow Safety Lock to UNLOCK, pull the Load Break Ring until the tool locks open (the yellow tube is visible), then lower the lock to LOCK OPEN to prevent an accidental pick-up |
| 2 | Attach the tool, in LOCK OPEN, to the source side of the circuit using standard utility practices |
| 3 | Attach one end of an appropriately rated and approved jumper cable to the load side of the circuit |
| 4 | Attach the other end of the jumper to the tool's conductor bar. Do not let the jumper pull sideways on the tool, and leave enough slack for it to hang straight down |
| 5 | Check all connections and the placement of the tool and jumper |
| 6 | With an approved insulated hot stick, lift the Yellow Safety Lock to UNLOCK, and push down steadily on the Load Pick-up Trigger. The ring retracts forcefully and energizes the circuit. Never do this by hand |
| 7 | Push up on the Load Break Ring with the hot stick to check that the brass contacts are fully seated |
| 8 | Right away, lower the Yellow Safety Lock to LOCK CLOSE to prevent an accidental load break |
The parallel is now made. The permanent circuit can be disconnected or cut, following standard safety practices, while maintenance is done.
| Step | What to do |
|---|---|
| 1 | With a hot stick, lift the Yellow Safety Lock to UNLOCK |
| 2 | Push up on the Load Break Ring to check that the tool is reset |
| 3 | In one steady motion, pull the ring down firmly until the tool locks open. Do not stop or hesitate |
| 4 | Right away, lower the Yellow Safety Lock to LOCK OPEN |
| 5 | Check that there is no voltage and no current on the tool and the jumper |
| 6 | If the source side must stay energized, move the jumper to the conductor bar of a Utility Solutions Jumper-T (USJT-001/2) or equivalent. That makes a visible gap with rated insulation |
| 7 | To re-energize, repeat the process from attaching the jumper to the conductor bar. If not, remove the tool and the jumper |
| 8 | Store the tool in the LOCK CLOSE position |
Utility Solutions' application note "Making Parallels: Thermal Imaging vs Hot Spots" (Jon Spencer, 9-23-24) describes a crew that had cut permanent jumpers open to isolate a system in a storm and then spliced them back together. A preventative maintenance thermal scan later flagged the crimp connections as hot spots. The crew made a parallel with the BREAK-SAFE, removed and repaired the spliced jumpers without an outage, and then broke the parallel with the tool's load break. The note gives no temperatures or measurements.
Between scheduled service, Utility Solutions describes an optional resistance test with its USGT-600 Grounds Tester or an equivalent. With the tool closed and reset, and 300 A flowing, the voltage drop from the conductor hook to the parking stand should not exceed 0.220 volts. If it does, take the tool out of service. This test does not replace scheduled service.
The LOAD-RANGER is for hook-equipped devices. Tools that insert loadbreak bushings are a different product.
Utility Solutions says every 2 years, plus a check before each use. Remove the tool from service if it fails.
It is a reference only. Spring fatigue starts after roughly 1,500 to 2,000 operations.
No. Utility Solutions says not to, even with an extended hood.
A temporary circuit that keeps customers on while the permanent line is opened or repaired.
No. It is for temporary use only and it is not a fuse.
Utility Solutions says only trained and qualified personnel should operate, inspect and maintain it.
The BREAK-SAFE is not a visible gap. Move the jumper to a Jumper-T or equivalent to make one.
Contact Powertech Associates at info@powertech-upsc.com or (860) 678-8772. Tell us the voltage and current and we will match the tool.
Learn more from Utility Solutions: load break tools, BREAK-SAFE, BREAK-SAFE 600, LOAD-RANGER XLT, LOAD-RANGER FLEX-LT, operation manual C-02311, field guide B-02364, BREAK-SAFE manual B-01031 and the Making Parallels application note.
Last updated: November 2026.
