K655BRLR

Frequently Asked Questions

How to Install K655/K675LR Deadbreak Elbow Connectors

This guide provides step-by-step instructions for the safe and proper installation of 655/675LR and K655/K675LR deadbreak elbow connectors, including cable preparation, component assembly, and voltage testing for 15kV and 25kV class systems.

Estimated time: 2h

1. Position and Cut Cable

   Assemble the cable in its final position, ensuring enough slack for elbow removal. For concentric neutral cable, unwind the neutral wires. Cut the cable 1-3/4” (45mm) from the centerline of the mating product. DANGER: All apparatus must be de-energized during installation or removal of parts.

2. Clean Cable Outer Surface

   Clean the outer surface of the cable for a distance of 24” (610mm) or up to the bent-back concentric neutral wires.

3. Prepare Cable Insulation and Shield

   Prepare the cable according to its type (e.g., non-jacketed, jacketed, Unishield, lead sheath). Remove the outer jacket (if applicable) and prepare the cable insulation and semi-con shield to the specified dimensions (9-3/4”, 10-3/4”, 12-3/4” from the tape marker). If using a 20MA/21MA grounding device or 600ECS Jacket Cable Seal, refer to their specific installation instructions for cable outer jacket removal, shield connection, and grounding.

4. Install Cable Adapter

   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, always working toward the semi-con shield. Install the cable adapter, small end first, until it is flush with the edge of the tape marker.

5. Prepare Conductor Length

   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 length of exposed conductor must be between 4-1/4” and 4-9/16” (108mm-116mm). If the length is outside this range, redo the assembly.

6. 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 (it should be less than 6-3/8”). Crimp the compression lug following its supplied instructions. Wipe all excess inhibitor from the lug and cable adapter surface. After crimping, verify the distance from the end of the lug to the cable adapter is between 6-3/8” to 7-1/8” (162mm-181mm); if not, redo the assembly.

7. Install Elbow onto Cable Adapter

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

8. Prepare Mating Products

   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. Hand tighten the threaded stud (supplied with the elbow) into the mating part if it is not already equipped. Clean and lubricate both the elbow and the mating part with the supplied lubricant, ensuring surfaces remain clean.

9. Connect Elbow to First Mating Part

   Push the elbow onto the mating part, carefully lining up the hole in the compression lug with the stud on the mating part.

10. Connect Opposite Mating Part

    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 the instructions supplied with that specific mating part.

11. Install Insulating Plug (if applicable)

    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. Push down hard until the cap snaps into place.

12. Ground the Cable Shield

    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 cable shield must be grounded; follow the instructions supplied with the grounding device, or use an alternate method if no device is used. It is also recommended to waterproof the cable jacket at this point to prevent moisture from entering the cable.

13. Verify Torque for L-Kits

    CAUTION: When constructing 600-amp L-Kits, ensure each component is tightened to the specified torque per its provided instructions.

14. Remove Voltage Test Point Cap

    WARNING: The voltage test point is a capacitance device and is not directly connected to the conductor. Remove the test point cap with a hotstick. When removing, peel off at an angle rather than pulling directly in line with the test point assembly.

15. Perform Voltage Test

    WARNING: Do not use conventional voltage measuring equipment. Follow the manufacturer’s directions for the specific 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, or using 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.

16. Replace Voltage Test Point Cap

    After voltage detection has been made, clean and lubricate the inside surface of the cap with silicone lubricant and replace it securely on the test point.

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