655LRTP-M0380

Frequently Asked Questions

How to Install 655/675LR and K655/K675LR Deadbreak Elbow Connectors

This guide provides step-by-step instructions for the safe installation and wiring of 655/675LR and K655/K675LR deadbreak elbow connectors, including cable preparation and connection to high voltage apparatus. Ensure all safety precautions are followed.

Estimated time: 1h 30m

1. Perform Pre-installation Checks and Position Cable

   DANGER: All apparatus must be de-energized during installation or removal of parts. Do not touch or move energized products. This product should be installed only by competent personnel trained in good safety practices involving high voltage electrical equipment. Verify package contents are complete and undamaged. Check all components for proper fit with the cable and/or mating products. Have all required tools at hand and maintain cleanliness. Assemble the cable in its final position with enough slack to provide adequate clearance for removing the elbows. For concentric neutral cable, unwind the neutral wires. Cut the cable 1-3/4” (45mm) from the center line of the mating product.

2. Clean and Prepare Cable End

   Clean the outer surface of the cable for a distance of 24” (610mm) or up to the bent back concentric neutral wires. Follow the specific cable preparation instructions (A, B, or C) that apply to your cable type. This involves removing the outer jacket (if applicable) and preparing the cable insulation, semi-con shield, and shield wires to the specified dimensions using a tape marker. Refer to separate instructions for grounding devices (20MA/21MA/600ECS) or UNISHIELD/LEAD SHEATH cable (10TL adapter).

3. Install Cable Adapter and Expose Conductor

   Bevel the end of the cable insulation at a 45-degree angle, approximately 1/4” (6mm) back. Thoroughly clean and then lubricate the cable insulation, working towards the semi-con shield. Install the cable adapter, small end first, until it is flush with the edge of the tape marker. Remove the protruding cable insulation by cutting it even with the end of the cable adapter. Do not cut or nick the cable adapter or the conductor. The exposed conductor length must be between 4-1/4” and 4-9/16” (108mm-116mm). If not, redo the assembly.

4. Crimp Compression Lug

   For copper conductors, fully insert the conductor into the compression lug. For aluminum conductors, wire brush the conductor and immediately fully insert it. Measure the “Check Dimension” before crimping; this dimension must be less than 6-3/8”. Crimp the compression lug according to its supplied instructions, locating the first crimp on the end towards the cable. Wipe all excess inhibitor from the compression lug and cable adapter surface after crimping. After crimping, the distance from the end of the compression lug to the cable adapter must be between 6-3/8” to 7-1/8” (162mm-181mm). If not, redo the assembly.

5. Install Elbow onto Cable Adapter

   Lubricate the cable adapter and the inside of the elbow's cable entrance. Install the elbow onto the cable adapter until it cannot advance further. Make sure the cable adapter is still flush with the tape marker; reposition if necessary. Remove the tape marker.

6. Prepare and Connect Mating Apparatus

   DANGER: DO NOT CONNECT OR DISCONNECT MATING PRODUCTS WHILE ENERGIZED. DO NOT ENERGIZE WHILE DISCONNECTED. Remove protective caps from the elbow and the mating part. If the mating part is not equipped with a stud, hand tighten the threaded stud supplied with the elbow into it. Clean and lubricate both the elbow and the mating part with the supplied lubricant, keeping surfaces clean. Push the elbow onto the mating part, carefully aligning the hole in the compression lug with the stud on the mating part.

7. Connect Second Mating Part (if applicable)

   Clean and lubricate the mating part for the opposite end of the elbow. Insert this mating part into the elbow. Engage the threads and hand tighten. Torque the mating part according to its supplied instructions. If an insulating plug is used as a mating part, clean and lubricate the inner surface of the voltage detection cap and place it on the elbow, pushing down hard until the cap snaps into place.

8. Ground Cable Shield and Waterproof

   Insert one end of a wire with ampacity at least equivalent to No. 14 AWG Copper through the grounding eye and twist to make a small loop, taking care not to damage the eye. Connect this wire to ground using a suitable connector. The shield of the cable must be grounded; ground according to the instructions supplied with the grounding device, or through an alternate method if no device is used. It is also recommended that the jacket of the cable be waterproofed at this point to prevent moisture from entering the cable. CAUTION: When constructing 600amp L-Kits, ensure each component is tightened to the specified torque per its instructions.

9. Perform Voltage Test

   The ELASTIMOLD deadbreak elbow connector is equipped with an integral capacitance test point. Use a hotstick to remove the test point cap, peeling it off at an angle rather than pulling directly in line. WARNING: The voltage test point is a capacitance device; it is not directly connected to the conductor. Do not use conventional voltage measuring equipment. Follow the manufacturer’s directions for the meter used. Test with a suitable sensing device, made for use with separable connectors manufactured with capacitive test points, to determine if the cable is energized. Contamination, moisture, dirt, etc., around the test point or use of the wrong measuring equipment can provide a false “no voltage” indication on an energized elbow. To prevent serious or fatal injury, treat the elbow as energized until the “no voltage” test point indication is confirmed by other means. After voltage detection has been made, clean and lubricate the inside surface of the cap with silicone lubricant and replace it on the test point.

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